By Jon Crowley
Our 2019 Polaris RZR XP 4 Turbo S was already one of the most capable four-seat sport UTVs of its era, but we wanted more than a fast dune machine. The objective was to create a versatile long-distance adventure build capable of crossing the desert, carrying camping supplies, tackling technical rock trails and returning to the dunes without requiring an entirely different setup.
Cognito Motorsports helped transform the 72-inch-wide RZR into a modern interpretation of the 2013 Polaris RZR XP 900 H.O. Jagged X Edition. Like that influential factory machine, our build combined the stability of a four-seat wheelbase with removable rear-seat cargo storage, added protection and the equipment needed to travel far beyond a typical day-use staging area.
Before beginning the project, we tested the RZR in stock form during our Polaris RZR XP 4 Turbo S Glamis dune review, followed it with a fully loaded Sand Mountain dune test and compared it with the Can-Am Maverick X3 MAX in our four-seat sport UTV shootout. Those trips gave us a clear understanding of the platform’s strengths and helped define what the finished build needed to accomplish.
Completed 2019 Polaris RZR XP 4 Turbo S adventure build
Why Build a Four-Seat RZR for Two People?
A four-seat UTV is not automatically the obvious choice for a two-person adventure vehicle. It is longer, heavier and takes up more room in the trailer. However, the extended wheelbase also delivers excellent stability through rough desert terrain and gives the occupants considerably more room for tools, fuel, spare parts and camping equipment.
Our original plan called for permanently removing both rear seats. That idea changed after carrying passengers during the Sand Mountain trip. We wanted to preserve the ability to return the machine to four-seat configuration when necessary.
Cognito Motorsports provided the solution with a removable rear-seat cargo and fuel-carrier system. It attaches to the factory seat bases, allowing the storage assembly to be installed or removed without permanently modifying the chassis. We could use the RZR as a dedicated two-person adventure machine for longer trips and reinstall the rear seats when we needed to carry four people.
Cognito Motorsports Protection and Chassis Upgrades
Cognito Motorsports owner Justin Lambert brought extensive desert-racing and product-development experience to the project. His team had built several vehicles for UTVGuide.net, and its combination of fabrication knowledge and real-world racing experience made Cognito a natural fit for this RZR.
The exterior transformation began with a Cognito Motorsports roll cage, full doors, front bumper and rear bumper. These parts gave the RZR substantially more protection while creating a cohesive appearance instead of making the vehicle look like a collection of unrelated accessories.
The cage included aluminum roof panels, rear grab handles, provisions for lighting and hidden wiring, and mounting points for the spare-tire carrier. Its bolt-in hood bar also allowed the dashboard to be removed without lifting the entire cage from the chassis.
Cognito’s replacement doors retained the factory latches and used lightweight tubular frames with full-coverage panels. Both bumpers were designed as functional protection rather than purely cosmetic additions, with the front bumper also providing a mounting location for auxiliary lighting.
Removable Cargo, Fuel and Spare-Tire Storage
Carrying enough equipment for a multi-day ride is one of the biggest challenges when converting a sport UTV into an adventure vehicle. The RZR XP 4 Turbo S has plenty of passenger room, but it was never designed around the cargo requirements of unsupported backcountry travel.
The Cognito rear-seat cargo carrier converts that unused passenger area into secure storage. It clips into the vehicle using the original rear-seat bases and provides room for tools, camping equipment and recovery supplies. An attached fuel carrier holds two 5.2-gallon containers, while a separate adjustable mount secures a spare axle.
This arrangement gives the build one of its most useful characteristics: modularity. We can prepare it for an extended desert trip without permanently sacrificing the ability to carry rear passengers.
Cognito Motorsports spare-tire carrier
A rear-mounted spare-tire carrier completed the storage system. Its gas-strut-assisted design lifts out of the way for access to the cargo area and holds the tire low enough to preserve visibility through the rearview mirror.
A Modern Interpretation of the Jagged X RZR
The storage concept was inspired by the 2013 Polaris RZR XP 900 H.O. Jagged X Edition. That factory four-seat model replaced the rear passenger area with removable, weather-resistant cargo boxes and combined the longer chassis with equipment developed for desert use.
The 2013 Polaris RZR XP 900 H.O. Jagged X Edition helped inspire this build
The difference in performance illustrates how quickly sport UTVs evolved. The Jagged X Edition’s 94 horsepower made it one of the strongest production machines available in 2013. Our 2019 Turbo S started with a factory-rated 168 horsepower before receiving any engine modifications.
For a broader look at the models and engineering changes that led to the Turbo S, visit our complete history of the Polaris RZR.
BoonDocker Dominator Turbo Upgrade
The stock Turbo S engine already produced excellent power, but the dunes place unusual demands on a heavy four-seat vehicle—especially one carrying additional fuel, equipment and passengers. We installed a BoonDocker Dominator turbo package to add the power needed to compensate for the build’s additional weight.
BoonDocker Double Down exhaust
The bolt-on system included a replacement turbocharger, clutching components, Dynojet tuner and calibrations for pump gas and higher-octane fuel. At the time of the build, BoonDocker rated the package at approximately 193 horsepower on pump gas and up to 210 horsepower with the appropriate race-fuel calibration.
We also installed BoonDocker head studs, a Double Down exhaust, charge tube and cold-air intake. Alpine UTV handled the turbo installation and supporting drivetrain work.
These output figures and fuel requirements reflect the package offered when this vehicle was assembled in 2019. Owners considering a similar modification should confirm current components, tuning, fuel requirements and engine safeguards directly with the manufacturer.
Cognito Replacement Suspension and Shock Tuning
The factory Turbo S combined a 72-inch stance with FOX DYNAMIX active suspension. We wanted to retain that electronically controlled shock system while improving component strength, clearance and suspension calibration.
Cognito trailing arms, engine mounts and sway-bar links
Cognito replaced the factory suspension links with its stock-width component package. The system included upper and high-clearance lower front control arms, tie rods, trailing arms, upper and lower radius rods, sway-bar mounts and billet sway-bar links. Because the components retained the factory suspension geometry and mounting locations, they worked with the original FOX DYNAMIX shocks.
The front control arms replaced the factory ball joints with 7/8-inch uniballs and hardened spindle pins. The rear received boxed trailing arms intended to better resist twisting during hard bottom-outs, along with substantially upgraded radius rods.
Cognito also recalibrated the front shocks and installed a tunable dual-rate spring package. The goal was to add bottom-out resistance and better support the additional weight without eliminating the compliant ride that made the Turbo S effective in rough desert terrain.
The Cognito suspension retained the factory-width DYNAMIX configuration
UHMW Underbody Protection
Multi-day routes can expose a vehicle to hundreds of miles of embedded rocks, ledges, wash crossings and terrain hidden by brush. A damaged floor or drivetrain component can quickly become a serious problem when the vehicle is far from the nearest paved road.
Our earlier multi-day Arizona Peace Trail ride reinforced the importance of protecting the underside of an adventure UTV. We installed a full Factory UTV 3/8-inch UHMW skid plate to shield the RZR’s chassis and drivetrain.
Factory UTV 3/8-inch UHMW skid plate
Lower Transmission Gearing for Rock Crawling
Although the Turbo S was developed primarily for fast, rough terrain, this build also needed to work in Moab and other technical rock-crawling destinations. The combination of tall factory gearing and oversized tires can make precise low-speed driving difficult while creating additional heat at the drive belt.
We previously evaluated a lower transmission gear kit in a two-seat RZR XP Turbo S while prerunning for King of the Hammers. The reduction provided better slow-speed control and helped reduce belt slippage, so we selected the same type of upgrade for the four-seat project.
Alpine UTV performed the transmission work. The lower gearing was particularly important after installing 35-inch tires, which would otherwise make the effective gearing taller.
35-Inch ITP Coyote Tires and Walker Evans Beadlocks
A set of 35-inch ITP Coyote radial tires increased ground clearance and gave the RZR a larger footprint for desert and rock use. The eight-ply-rated Coyote was designed for hardpack, rocks and rough desert terrain, making it a logical all-around choice for this multipurpose build.
35-inch ITP Coyote tire mounted on a Walker Evans Racing Legend II beadlock wheel
The tires were mounted on 15-inch Walker Evans Racing Legend II aluminum beadlock wheels. Beadlocks allowed us to reduce tire pressure for additional traction while mechanically retaining the outer bead.
SuperATV Rhino 2.0 axles transferred power to the larger tires. These were paired with the upgraded Cognito suspension components to strengthen areas exposed to the additional leverage and traction created by the 35-inch setup.
SuperATV Rhino 2.0 axle, Cognito suspension and Vision X accent lighting
Rugged Radios Communication and Helmet Air
Communication becomes more important as the distance and number of vehicles increase. A Rugged Radios intercom allowed the driver and passenger to speak without shouting over the engine, wind and tire noise. The two-way radio provided communication with other vehicles in the group.
We also installed a Rugged Radios helmet-air system to supply filtered air during dusty desert rides. It is a significant comfort improvement when following other vehicles for hours at a time.
Rugged Radios intercom and radio with XTC switches and Lowrance GPS
XTC Power Products Electrical System
Lights, radios, helmet air and street-legal equipment can create a complicated wiring system if each accessory is installed independently. An XTC Power Products 12-volt power-control system centralized the accessory connections and helped keep the installation organized.
XTC rocker switches integrated cleanly into the dashboard and controlled the Vision X lighting, Rugged Radios equipment and other electrical accessories. We also installed an XTC street-legal kit where permitted. Equipment requirements and registration laws vary by state, so owners should verify the regulations that apply where they intend to operate the vehicle.
Vision X Lighting Package
Long adventure rides do not always end before sunset. We equipped the RZR with forward, rear-facing and underbody lighting so it could continue safely after dark.
Vision X Shocker LED light bar mounted to the Cognito front bumper
The lighting package included a 12-inch Vision X Shocker bar on the front bumper and a 40-inch XPL Halo Lo-Pro mounted above the windshield for long-range forward visibility. A rear-facing 28-inch XPL Chaser helped make the vehicle visible in dust, while an XPR rock-light kit illuminated the suspension and terrain immediately around the tires.
Simpson Seats and Five-Point Harnesses
Seat comfort matters on any ride, but it becomes critical when the occupants spend several consecutive days covering hundreds of off-road miles. We replaced the factory seats with Simpson suspension seats that provided additional lateral support and helped isolate the occupants from repeated impacts.
Simpson suspension seats and five-point harnesses
Simpson five-point harnesses kept the driver and passenger securely positioned in rough terrain. Maintaining a consistent seating position also reduces the effort required to brace against the steering wheel, grab handle or footwell during a long day.
Mirrors, Whips and Fire Extinguisher
Assault Industries Bomber side mirrors improved rearward visibility, while a securely mounted fire extinguisher added an important layer of emergency protection. Sick Stick whip flags made the vehicle more visible in the dunes without adding decorative lighting that did not support the build’s function-first theme.
Assault Industries Bomber side mirror
Final Assembly
Alpine UTV completed the 12-volt wiring, BoonDocker turbo installation and transmission gear change. Once the final details were finished, we brought the RZR into a studio for photographs before beginning real-world testing.
The finished machine could still carry four occupants when needed, but its primary configuration turned the rear passenger area into a modular storage system for fuel, tools, a spare axle and camping gear. Combined with the longer wheelbase, 35-inch tires, lower transmission gearing and full underbody protection, it was prepared for dunes, desert crossings and technical rock trails.
The clean studio finish did not last long—and that was always the point. This RZR was built to travel, not remain parked at a show.
2019 Polaris RZR XP 4 Turbo S Build Specifications
- 2019 Polaris RZR XP 4 Turbo S
- Cognito Motorsports roll cage and roof
- Cognito Motorsports replacement doors
- Cognito Motorsports front and rear bumpers
- Cognito Motorsports spare-tire carrier
- Cognito Motorsports rear-seat cargo carrier
- Cognito Motorsports dual fuel-container carrier
- Cognito Motorsports spare-axle carrier
- Cognito Motorsports stock-width replacement suspension
- Cognito Motorsports front shock tuning and dual-rate springs
- Cognito Motorsports sway-bar links and mounts
- Cognito Motorsports engine mounts and engine-mount bar
- BoonDocker Dominator turbo upgrade
- BoonDocker head studs
- BoonDocker Double Down exhaust
- BoonDocker charge tube and cold-air intake
- Lower transmission gearing installed by Alpine UTV
- Factory UTV 3/8-inch UHMW skid plate
- 35-inch ITP Coyote radial tires
- 15-inch Walker Evans Racing Legend II beadlock wheels
- SuperATV Rhino 2.0 axles
- Simpson suspension seats and five-point harnesses
- Rugged Radios intercom and two-way radio
- Rugged Radios helmet-air system
- XTC Power Products 12-volt power-control system
- XTC Power Products rocker switches
- XTC Power Products street-legal kit
- Vision X 12-inch Shocker front light bar
- Vision X 40-inch XPL Halo Lo-Pro light bar
- Vision X 28-inch XPL rear Chaser light
- Vision X XPR rock-light kit
- Lowrance GPS
- Assault Industries Bomber side mirrors
- Assault Industries fire extinguisher and mount
- Sick Stick whip flags
Complete Cognito Motorsports Build Sheet
The following product numbers and specifications reflect the Cognito Motorsports components used when the vehicle was built in 2019. Availability and current specifications may have changed.
Roll Cage — SKU 360-90596
- Bolt-in hood bar allows dashboard removal without lifting the cage from the chassis
- Roof panels mounted with countersunk Dzus fasteners
- Front and rear drip rails with tank-rolled edges
- Compatible with factory doors, Cognito doors and other doors using factory mounting points
- Mounting tabs for whip flags and an optional roof rack
- Rear-passenger grab handles
- Rearview mirror
- Adhesive foam tape to reduce roof rattles
- Mounting points for several upper light-bar configurations
- Rear seat-belt-bar clevis brackets for Cognito spare-tire carrier
- Access for concealed wiring
Door Kit — SKU 360-K0358
- Factory-replacement mounting configuration
- Full-coverage panels with countersunk Dzus fasteners
- Lightweight tubular-steel frames
- Tank-rolled upper edges
- Retains factory door latches
- Tether straps limit door travel
- Foam tape reduces panel rattles
- Mounting bars for optional Cognito door bags
Spare-Tire Carrier — SKU 360-90003
- Attaches to clevis brackets on the Cognito cage
- Can attach to other cages using Cognito’s universal mounting bar
- Gas-strut assistance for lifting and cargo-area access
- Includes MAC’s Custom Tie-Downs Y-strap
- Low-profile design preserves rearward visibility
Front Bumper — SKU 360-90607
- Sheet-metal and tubular-steel construction
- Stainless-steel accents
- Mounting provisions for an LED bar or light pods
- Bolt-on chassis mounting
Rear Bumper — SKU 360-90011
- Tubular-steel construction
- Weld-on chassis bungs with bolt-on bumper attachment
- Compatible with a modified factory muffler cover
Upper Light-Bar Mount — SKU 360-90670
- Designed to mount a 40-inch Vision X XPL Lo-Pro light bar to the Cognito four-seat cage
Front Upper Control Arms — SKU 360-90611
- Formed performance-alloy-steel construction
- Replaces factory ball joints with 7/8-inch uniballs and hardened spindle pins
- Includes bushings and crush sleeves
Front Lower Control Arms — SKU 360-90609
- Tubular performance-alloy-steel construction
- Adjustable camber
- Replaces factory ball joints with 7/8-inch uniballs and hardened spindle pins
- Includes bushings and crush sleeves
Tie-Rod Kit — SKU 360-90667
- Performance-alloy-steel adjusters
- 5/8-inch outer FK rod ends with hardened spindle pins
- Replaces the factory inner ball-and-socket joints with 5/8-inch rod ends
- Billet stainless-steel steering-rack clevises
Trailing Arms — SKU 360-90620
- Boxed performance-alloy-steel construction
- Wider structure than the factory arm to resist twisting during bottom-outs
- Provisions for Cognito rock guards
Upper Radius Rods — SKU 360-90626
- Performance-alloy-steel tubing
- Adjustable length for rear camber tuning
- 3/4-inch chromoly FK rod ends
- Stainless-steel crush-sleeve spacers
Lower Radius Rods — SKU 360-90625
- Fixed-length performance-alloy-steel tubing
- 3/4-inch FK uniballs
- Stainless-steel crush-sleeve spacers
Rear Sway-Bar Links — SKU 360-90691
- Billet-aluminum construction
- 5/8-inch FK uniballs
- Stainless-steel misalignment spacers
Sway-Bar Mounts — SKU 360-90656
- Billet-aluminum replacements for the factory cast-steel mounts
Engine-Mount Bar — SKU 360-90041
- Performance-alloy-steel tubing
- Replaces the factory engine-mount bar
Billet Engine Mounts — SKU 360-90410
- Billet-aluminum construction
- Polyurethane bushings
- Three mounts replace the two front and one rear factory mounts
Rear Chaser-Light Mount — SKU 360-90671
- Designed for a 28- or 35-inch Vision X XPL Chaser bar on the Cognito four-seat cage
Front Shock-Tuning Kit — SKU 460-90681
- Revised calibration for additional bottom-out and top-out control
- Lightweight steel inner bypass bodies
- Higher-rate negative springs
- Piston-shim kits
- Reservoir end caps with Schrader valves
Front Dual-Rate Spring Kit — SKU 460-90636
- Tunable dual-rate spring configuration
- Crossover rings
Rear-Seat Cargo Carrier — SKU 360-90389
- Replaces the rear seats using the factory seat bases
- Can be removed to return the vehicle to four-seat configuration
- Includes two MAC’s continuous-loop ratchet straps
Fuel Carrier — SKU 360-90390
- Attaches to Cognito cargo carrier SKU 360-90389
- Includes two 5.2-gallon fuel containers
- Lockable upper retaining clamp
Spare-Axle Carrier — SKU 360-90391
- Attaches to Cognito cargo carrier SKU 360-90389
- Adjustable for axles used in 64- and 72-inch-wide vehicles
