Polaris Ranger RZR

Long Travel Kits

Polaris RZR Long Travel vs. Stock
Stock RZR on the left. Long Travel RZR on the right (F ireball Racing+6")

The RZR was just released to consumers Summer of 2007, but a few aftermarket companies got pre-release units that were used for research and development. Many more followed on and I saw twelve different kits at the 2007 Sand Sports Super Show. Things are definitely moving for the Polaris RZR.

Expect long travel kits from many of the companies that are already in the mix for Rhino long travel kits.

As new products become available, we will update this page to stay current.

Stock Polaris RZR - Before Long Travel

Polaris RZR after Fireball Racing +6" Long Travel

Polaris Ranger RZR's come stock with fully independent four-wheel suspension: Double-wishbones front and rear deliver 9" of front wheel travel, 9.5" of rear wheel travel and 10" of ground clearance.

Stock RZR's have a 77" wheelbase (2" longer than a Rhino), and are 50" wide. The seat position is 7" lower, so right out of the box, you won't feel as tippy.

Polaris Ranger RZR - Width, Length and Wheelbase

Although long travel kits are far from cheap, they are the best way to improve your RZR's suspension. Approaching the goal of long travel in steps can result in more expense because stock length shocks will not work. It is a hard pill to swallow, but if you want to get to long travel, you will save money in the long run by waiting until you can buy a full long travel kit.

If a long travel kit is just out of reach, but you still want to increase your track width for more stability in the dunes, you can try offset wheels and/or wheel spacers.

Most of the long travel kits increase wheel travel, front and rear track width and stretch the wheelbase. Long travel kits will be available from several manufacturers.

What is included in a RZR Long Travel Kit?

Before you go running off to buy one of these long travel kits, it is best to understand what is included so that you can make side by side comparisons.

A-Arms - A few different types of a-arms are out there. Most are made from chromoly tubing, others are boxed, and a few are made from billet aluminum or mild steel. Each material type has pros and cons. Ask questions about why a particular material and arm design was chosen.

Some kits come powder coated in a standard color. Others come unfinished or offer custom colors.

A-Arm Hardware - Inner and outer a-arm hardware is typically replaced. The majority of long travel kits come with new bushings (Delron, Daystar, etc.) on the inner side of the a-arm, but some come with heims. On the outer or spindle side, some kits use heims, others use uni-balls, and a few reuse the OEM ball joint. There are pluses and minuses to each type of setup and quality can vary from heim to heim and bushing to bushing, so ask questions.

Axles - When you extend the wheels out, you are going to need new axles. There are two approaches to this. The cheaper route is to reuse the stock CVs and just replace the axles. The more expensive route is new axles and CVs.

Tie Rods - Some kits come with tie rod extenders. A few come with new tie rods.

Shocks - All of the kits include new coilover shocks. Several shock manufacturers have developed RZR specific shocks, so there are many options and prices out there. Long travel kit manufacturers will tend to have a favorite. If you don't want to mess around with shock valving, stick with what the manufacturer recommends. Shock selection can greatly affect not only the cost, but also the performance of the kit.

Shock Towers - Some kits come with shock towers that move the upper shock mounting location up and out. This allows the shock to be mounted in a more vertical position.

Spindles - Stock spindles aren't typically replaced, but a few manufacturers are now offering new spindles as an option. If you race or like to jump, you may want to look into new spindles.

Frame Gussets - Long travel kits put more stress on the factory mounting locations. Several manufacturers are now offering bolt-on or weld-on gussets to help beef up the stock frame in critical areas. Upper-rear shock mount is a weak point. Look carefully at additional support for this area.

Extended Brake Lines - Most if not all RZR kits need longer brake lines.

Other things to ask:

Does the kit affect ride height? This not only affects how the RZR will handle, but also if it will make it inside your toy hauler.

Find out if your kit is "bolt-on" or if any welding is required.

Will my OEM wheels will fit?

Will the OEM front and rear anti-sway bars work?

Do they recommend removal of the front or rear sway bar?

Does the kit put extra stress on OEM parts that do not get replaced?