2008 Polaris RZR 800 Buildup Project

Posted on November 17, 2013

The 2008 Polaris Ranger RZR 800 marked a significant breakthrough in the side-by-side market, introducing the industry’s first sport-focused UTV. With an 800cc twin-cylinder engine delivering impressive power and acceleration, the RZR 800 was designed to dominate trails and dunes with unmatched agility. Its narrow 50-inch width allowed it to navigate tighter paths that traditional UTVs couldn’t access, while its low center of gravity and long-travel suspension provided exceptional handling and stability over rough terrain. Combining speed, performance, and versatility, the 2008 RZR 800 set a new standard for recreational off-road vehicles and helped pave the way for the high-performance UTV segment we know today.

We bought a 2008 Polaris Ranger RZR 800, then jumped right in on the customization with long travel suspension, performance modifications, durability, comfort and safety.

This Polaris RZR is part of several Product Reviews and has appeared in several Side x Side Action Magazine articles.

Safety:

One of first steps is to address a few safety concerns with a stock RZR. This will include seats & harnesses, roll cage and either doors (partial or whole) . We will also need some mirrors so we can see what is behind us in the dunes. HID lights so we can see at night.

Products we used:

Seats – Premier Racing Products
Harnesses/Restraints – Hart’s Rhino Motorsports
Rear View Mirror – Machine Trix Unlimited
Side View Mirrors – Machine Trix Unlimited
Roll Cage – Hot Ride
HID/LED Lights – Baja Designs
Fuse/Relay Block – Autotrend
Bumper – Lonestar Racing
Fire Extinguisher Mount – Motorsports2

Long Travel Kit, Wheels & Tires and Other Suspension Items:

Second project will be a long travel kit (shocks, a-arms, etc.), wheels and tires.Addressing the suspension will not only make the RZR more fun to drive andmore capable, but will also make it more safe by increasing track width,wheelbase and wheel travel.

Long Travel Product Review – Side x Side Action Magazine – March 2008

Products we used:

Long Travel Kit – Fireball Racing
Shocks/Springs – Bilstein/Eibach
Axles – Fireball Racing
Tie Rods – Fireball Racing
Rear Frame Gusset – ATR
Chassis Legs – ATR
Billet Hubs – Fireball Racing
Sand Dune: Wheels & Tires – Fullerton Sand Sports
Desert: Wheels & Tires – OMF Performance

Performance:

Performance will be next up. There are several bolt-on type improvements to be made – Exhaust, Intake, Fuel Controller will be Stage One.

Stage One – Performance Products we used:

Air Filter & Intake Kit – Unique Metal Products (UMP)
Exhaust – Muzzys
Fuel Management System – Dynojet
Air Box Cover – EHS Racing

Communication and Navigation:

Since we will be doing long desert rides in large groups, we will need communication equipment and GPS so we can stay on our route and communicate with other vehicles in our group.

Products we used: