The original Polaris RZR helped launch a new era of sport side-by-sides, but the early 800 platform also responded especially well to aftermarket upgrades. After two years of riding and testing our 2008 Polaris RZR 800, we decided it was time to give the project a second wind.
This second stage focused on reliable engine performance, better suspension control, improved occupant protection, more comfortable seats, a complete audio system and a lightweight paddle-tire setup for the dunes. The result was a thoroughly rebuilt RZR that still retained the compact, playful character of the original machine.
This was the continuation of our original 2008 Polaris RZR 800 buildup, which had already transformed the stock machine with long-travel suspension, safety equipment and trail-oriented accessories.
Polaris RZR 800 Second Wind Build Plan
The goal was to update the RZR without sacrificing reliability or turning it into a trailer queen. The primary upgrades included:
- Holz Racing Products and Kroyer Racing Engines Stage III engine package
- Muzzys dual exhaust
- SSV Works speaker pods, subwoofer enclosure and amplifier
- FOX 2.0 RC2 long-travel shocks
- PRP high-back suspension seats with heating elements
- ITP T-9 Pro Mod wheels and Sand Star dune tires
- Fullbore Innovations bodywork
- Custom chromoly roll cage
- Racer Tech A-pillar reinforcement
- Higher-capacity Odyssey battery
- 35-watt HID headlight conversion
Holz and Kroyer Stage III Engine Package
Holz Racing Products teamed with Kroyer Racing Engines to develop a comprehensive big-bore performance package for the original Polaris RZR 800. Rather than relying on a single bolt-on part, the Stage III combination addressed airflow, displacement, compression, valve control, fueling and clutch calibration as a complete system.
The package included a five-axis CNC-ported cylinder head fitted with oversized valves and upgraded springs. The head sat above a CNC-bored, Nikasil-coated big-bore cylinder with matching 11:1 compression pistons.
A billet high-lift, longer-duration camshaft worked with chromoly pushrods and hydraulic lifters. Fuel entered through a bored 46mm throttle body and billet aluminum intake manifold. The kit also included an adjustable oil-pressure relief valve, clutch components, an ECU ignition upgrade, gaskets, break-in oil, an oil filter and iridium spark plugs.
For a closer look at the installation and performance, see our Polaris RZR 800 Holz Stage III engine kit review.
Muzzys Dual Exhaust
Our RZR was already equipped with a Muzzys dual exhaust. Combined with the Holz/Kroyer engine package, it provided the additional exhaust flow needed to support the upgraded engine.
SSV Works RZR Audio System
My wife drove the RZR regularly and wanted music, so the audio system needed to sound good without looking like an improvised collection of speakers and wiring. We chose an SSV Works system built around molded enclosures designed specifically for the original RZR cockpit.
SSV Works 6×9 Speaker Pods
The molded fiberglass kick-panel enclosures positioned the 6×9-inch speakers in the upper footwell, where they stayed out of the way of the driver and passenger. Their textured finish also matched the factory Polaris interior more naturally than universal speaker boxes.
SSV Works Subwoofer Enclosure
The molded under-dash enclosure provided the correct airspace for a 10-inch subwoofer while remaining clear of the occupants’ knees and feet. It bolted into the RZR without requiring the dashboard to be cut.
EFX Four-Channel Amplifier
An EFX four-channel, 800-watt amplifier powered the system. Its channel configuration allowed it to run four speakers or a combination of two speakers and a subwoofer.
FOX RC2 Long-Travel Shocks
The existing suspension setup had been difficult to balance. Softer settings helped in light chop but allowed the RZR to use too much travel in larger g-outs. Firmer settings resisted bottoming but made the machine harsh over smaller bumps.
We switched to FOX 2.0 RC2 shocks with independently adjustable high-speed compression, low-speed compression and rebound damping. That broader adjustment range gave us more control over bottoming resistance, body movement and comfort while retaining the Fireball Racing long-travel suspension.
For more background on the suspension setup, see our Polaris RZR long-travel suspension review.
PRP High-Back Suspension Seats
The original seats were showing their age, and their adjustable headrests did not work particularly well with the new cage. We replaced them with PRP high-back suspension seats.
The PRP seats attached to the factory latches and installed in the same general manner as the stock seats. Harness slots allowed them to work with four-point restraints, while integrated heating elements made cold-weather rides more comfortable.
ITP Sand Star Tires and T-9 Pro Mod Wheels
Additional engine power only helps in the dunes if the tires can transfer it to the sand. We wanted a paddle package that provided strong acceleration without adding unnecessary rotating mass.
The polished ITP T-9 Pro Mod aluminum wheels used lightweight .190-inch-wall construction and a double-rolled lip for durability. Reducing wheel weight helped the RZR accelerate more efficiently and allowed the suspension to react with less unsprung mass.
We paired the wheels with 26×9-12 ITP Dune Star front tires and 26×10-12 Sand Star rear paddles. The front tires provided predictable steering, while the reinforced dual-depth rear paddles supplied the hookup needed by the larger engine.
Fullbore Innovations Bodywork
Fullbore Innovations bodywork gave the older RZR a much more aggressive appearance, especially when combined with the wide Fireball suspension. The replacement hood also opened the front of the machine to direct more air toward the radiator.
Custom Chromoly Roll Cage and Chassis Reinforcement
Although the previous cage was functional, we wanted a structure that extended around the rear of the vehicle and tied into the rear suspension pivot area. Roggy Enterprises fabricated a custom cage using 1.5-inch chromoly tubing, with modified cage ends supplied by Xtreme Machine and Fabrication.
Chromoly cost more than mild steel, but it allowed the cage to be built with an emphasis on strength while controlling overall weight.
Racer Tech A-Pillar Braces
Racer Tech A-pillar braces reinforced the vulnerable forward cage-mounting area. Each brace used an existing factory mounting point along with an additional drilled mounting location. The panels also acted as useful splash shields during wet or muddy rides.
Higher-Capacity Battery
The original RZR battery offered limited reserve capacity, particularly when operating the audio system with the engine off. All Terrain Research supplied a mounting system for an Odyssey PC925 battery.
The kit included a CNC-machined billet hold-down, a protective foam pad, stainless-steel hardware, brass terminal spacers and a Battery Tender connection. The larger battery provided a more appropriate electrical foundation for the amplifier and other accessories.
35-Watt HID Headlight Conversion
Electrical capacity was limited on early UTVs, and the factory halogen headlights represented a significant portion of the available load. We installed a Side x Side Customs HID conversion using waterproof 35-watt slim ballasts and 6000K bulbs.
The conversion had two practical advantages:
- Lower electrical demand than the original halogen lighting
- More usable light for nighttime driving
Polaris RZR 800 Second Wind Testing
The following full-size images document the completed build during testing at Sand Mountain. They have been expanded from the original thumbnail gallery.
How the Second Wind Build Performed
The completed combination gave our original RZR considerably more capability without erasing the qualities that made the early 800 so entertaining. The Holz/Kroyer engine supplied the extra power, the lightweight ITP dune setup helped deliver it to the sand and the adjustable FOX shocks made it possible to refine suspension behavior for different terrain.
The comfort and electrical upgrades mattered as well. PRP suspension seats, an integrated SSV Works audio system, improved lighting and greater battery capacity made the RZR better suited to full days of riding rather than short test sessions.
We continued testing the project during our February 2010 Sand Mountain trip and returned for another Sand Mountain test in April 2010. Those trips turned the Second Wind project from a collection of promising parts into a complete, proven dune build.
Editor’s note: This is a historical UTV Guide project documenting aftermarket components available for the original Polaris RZR 800. Some products or manufacturers mentioned may have changed ownership, revised their product lines or discontinued these specific parts.
