2008 Polaris RZR 800 Project Build

Posted on November 17, 2008
8:14 pm

The original 2008 Polaris Ranger RZR 800 changed the direction of the side-by-side market. Its compact 50-inch width, low seating position and performance-oriented design established the formula that would eventually grow into the modern Polaris RZR lineup.

We purchased one of the early RZR 800s and immediately began turning it into a more capable trail, desert and dune machine. The project included long-travel suspension, safety equipment, performance upgrades, communications gear, protection and comfort improvements.

This page serves as the central index for the complete build. It preserves the individual product reviews and shows how UTVGuide.net modified the original RZR during the early years of the sport UTV aftermarket.

For additional historical context, see our history of the Polaris RZR.

Safety and Driver Equipment

Safety was one of the first areas we addressed. The stock machine received upgraded seating and restraints, a replacement roll cage, mirrors, additional lighting and other equipment suited to group rides and nighttime dune use.

Safety equipment used

Suspension seats: Premier Racing Products (PRP)
Harnesses and restraints: PRP and Hart’s Rhino Motorsports
Rearview and side mirrors: Machine Trix Unlimited
Roll cage: Hot Ride
HID lighting: Baja Designs
Fuse and relay block: Autotrend
Front bumper: Lonestar Racing
Fire-extinguisher mount: Motorsports2

Long-Travel Suspension, Wheels and Tires

The suspension was one of the most important parts of the build. A Fireball Racing long-travel system increased wheel travel and track width, while supporting chassis components helped prepare the early RZR for harder trail, desert and dune use.

The complete installation and driving impressions are covered in our Fireball Racing RZR long-travel review, which also appeared in the March 2008 issue of Side x Side Action Magazine.

Suspension and chassis components

Long-travel suspension: Fireball Racing
Shocks and springs: Bilstein and Eibach
Axles: Fireball Racing
Tie rods: Fireball Racing
Rear frame gusset: ATR
Chassis legs: ATR
Billet hubs: Fireball Racing
Dune wheels and tires: Fullerton Sand Sports
Desert wheels and tires: OMF Performance

RZR 800 Performance Upgrades

The first stage of engine work focused on complementary bolt-on upgrades. The combination included an improved intake, dual exhaust, fuel controller and modified airbox cover.

Performance components

Air intake: Unique Metal Products
Dual exhaust: Muzzys
Fuel controller: Dynojet Power Commander III
Airbox cover: EHS Racing

Communications and Navigation

Because the RZR was used on long desert rides with larger groups, we added an in-vehicle radio and intercom system from Rugged Radios. This allowed the occupants to communicate inside the vehicle while also maintaining radio contact with the rest of the group.