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Polaris Ranger RZR 800 Long Travel Kits

Polaris RZR Long Travel vs. Stock
Stock RZR on the left. Long Travel RZR on the right (Fireball 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 Suspension  Stock Polaris RZR - Before Long Travel Suspension  Stock Polaris RZR - Before Long Travel Suspension  Stock Polaris RZR - Before Long Travel Suspension
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?

Polaris Ranger RZR Long Travel Kits

  • ARS-FX / ZBROZ Racing

Status: Available

A-Arm width: +4 1/2" each side
Wheelbase: 1/2" forward and 1" rearward
Wheel travel: 12"
Shocks:
Exit

ZBROZ Racing - Polaris RZR Long Travel Kit  ZBROZ Racing - Polaris RZR Long Travel Kit  ZBROZ Racing - Polaris RZR Long Travel Kit  ZBROZ Racing - Polaris RZR Long Travel Kit

Polaris RZR Long Travel Kit - ZBROZ Racing  Polaris RZR Long Travel Kit - ZBROZ Racing

  • ATVonics

A-Arm width: +6"
Wheelbase:
Wheel travel: 
Shocks: KING, FOX, ELKA or Walker Evans

  • Billet Equipped

Status: Available

A-Arm width: 
Wheelbase: 
Wheel travel: 
Shocks: Elka
Axles:

Polaris RZR Long Travel Kit - Billet Equipped

  • CST Performance Suspension

    Status: Available

    A-Arm width: +3" per side
    Wheelbase:  Stock
    Wheel travel: 12"
    Shocks: Walker Evans Racing
    Axles:

    CST Performance Suspension - Polaris RZR Long Travel Kit   CST Performance Suspension - Polaris RZR Long Travel Kit    CST Performance Suspension - Polaris RZR Long Travel  CST Performance Suspension - Polaris RZR Long Travel

    CST Performance Suspension - RZR Long Travel  CST Performance Suspension - RZR Long Travel
     

  • Direct Concept Engineering

A-Arm width:+4" per side
Wheelbase: +2 (1" forward, 1" rearward)
Wheel travel: 13"
Shocks:
 Radflo

Polaris RZR Long Travel Kit - Direct Concept Engineering  Polaris RZR Long Travel Kit - Direct Concept Engineering  Polaris RZR Long Travel Kit - Direct Concept Engineering 

  • Dragon Fire Racing

Status: Available

A-Arm width: +4 inches per side
Wheelbase: +2 inches
Wheel travel: 13 inches
Shocks: 

A-Arm width: +6 inches per side
Wheelbase: 
Wheel travel: 
Shocks: 

Dragon Fire Racing - Polaris RZR Long Travel   Dragon Fire Racing - Polaris RZR Long Travel   Dragon Fire Racing - Polaris RZR Long Travel   Dragon Fire Racing - Polaris RZR Long Travel
+4" over kit

     
+6" over kit

  • Fabtech Motorsports

Status: In Development

A-Arm width:
Wheelbase: 
Wheel travel:
Shocks: Fabtech Dirtlogic

Fabtech Motorsports - Polaris RZR Long Travel Kit  Fabtech Motorsports - Polaris RZR Long Travel Kit 

Polaris RZR Long Travel Kit - FabTech  Polaris RZR Long Travel Kit - FabTech

  • Fireball Racing

Status: Available

A-Arm width: +6"
Wheelbase: +1" front, +2" rear
Wheel travel:
Shocks: Billstein, Elka

A-Arm width: +10" (or +5" over for RZR S)
Wheelbase: +1" front, +2" rear
Wheel travel: 16"+
Shocks: Billstein

  c  Polaris RZR Long Travel Kit - Fireball Racing  Fireball Racing - Long Travel Polaris Ranger RZR

Fireball Racing - Long Travel Polaris Ranger RZR    Polaris RZR Long Travel Kit - Fireball Racing   

     

  • FST Motorsports

Status: Available

A-Arm width: +6"
Wheelbase:  +2" front and +2" rear
Wheel travel: 14 3/4"
Shocks: King (with dual rate springs)

Front and rear shock relocation towers for correct shock geometry
Front Skid plate/support brackets
Rear frame supports

FST Motorsports - Polaris RZR Long Travel Kit  FST Motorsports - Polaris RZR Long Travel Kit  FST Motorsports - Polaris RZR Long Travel Kit  FST Motorsports - Polaris RZR Long Travel Kit 

FST Motorsports - Polaris RZR Long Travel Kit  FST Motorsports - Polaris RZR Long Travel Gusset  FST Motorsports - Polaris RZR Long Travel Kit  FST Motorsports - Polaris RZR Long Travel Shocks

 FST Motorsports - Polaris RZR Long Travel Kit  FST Motorsports - Polaris RZR Long Travel Arms  FST Motorsports - Long Travel Polaris Ranger RZR   FST Motorsports - Long Travel Polaris Ranger RZR

  • HCR Racing

A-Arm width: +6"
Wheelbase: +1" forward and +1" backward
Wheel travel: 15"
Shocks: King
Axles: Summers Brothers

HCR Racing - Polaris RZR Long Travel Kit HCR Racing - Polaris RZR Long Travel Kit

  • Holz Racing Products

Status: AvailableA-Arm width: +4"
Wheelbase: 
Wheel travel: 11.75"
Shocks: Fox

A-Arm width: +6"
Wheelbase: 
Wheel travel: 13
Shocks: Fox

  Polaris RZR Long Travel Kit - Holz Racing Products   Polaris RZR Long Travel Kit - Holz Racing Products

Polaris RZR Long Travel Kit - Holz Racing Products   Polaris RZR Long Travel Kit - Holz Racing Products

  • Houser Racing

Status: Available

A-Arm width: +4"
Wheelbase: +0" front, +0" rear
Wheel travel:
Shocks: Fox, Elka, Custom Axis

Houser Racing Polaris Ranger RZR Long Travel Kit  Houser Racing Long Travel Kit - Polaris Ranger RZR  Houser Racing Polaris Ranger RZR Long Travel Kit

Houser Racing - Polaris RZR Long Travel Kit  Houser Racing - Polaris RZR Long Travel Kit

  • iShock/Hydrodynamics

Status: Available

A-Arm width: +6 inches per side
Wheelbase: 
Wheel travel: 
Shocks: iShock

Hydrodynamics - Polaris RZR Long Travel Kit

  • Lonestar Racing

Status: MTS available, XTR available, XTR for the RZR S - available

XTR Long travel (RZR & RZR S):
A-Arm width: +8" each side
Wheelbase: 
Wheel Travel: 
Shocks: Fox, Elka

MTS Mid travel:
A-Arm width:  +4" each side
Wheelbase: +1" (rear only)
Wheel Travel: 12" - 13"
Shocks: Elka, Bilstein

 

Polaris RZR - MTS Mid travel kit from LoneStar Racing   Polaris RZR - MTS Mid travel kit from LoneStar Racing   Polaris RZR - Rear Arms for mid-travel kit   Lonestar Racing - Polaris RZR Mid-Travel Kit

Polaris RZR - MTS Mid travel kit from LoneStar Racing   Polaris RZR - MTS Mid travel kit from LoneStar Racing   Lonestar Racing - Polaris RZR Mid-Travel Kit   Lonestar Racing - Polaris RZR Mid-Travel Kit
MTS - Mid Travel

Lonestar Racing - +8" Polaris RZR XTR Long Travel  Lonestar Racing - +8" Polaris RZR XTR Long Travel  Lonestar Racing - +8" Polaris RZR XTR Long Travel  Lonestar Racing - +8" Polaris RZR XTR Long Travel Lonestar Racing - +8" Polaris RZR XTR Long Travel  Lonestar Racing - +8" Polaris RZR XTR Long Travel  Lonestar Racing - +8" Polaris RZR XTR Long Travel  Lonestar Racing - +8" Polaris RZR XTR Long Travel
XTR - Long Travel

Polaris RZR S XTR +8" Long Travel Kit  Polaris RZR S XTR +8" Long Travel Kit  Polaris RZR S - XTR
RZR S XTR +8" Kit

  • Long Travel Industries

Status: In Development

A-Arm width:  +6" each side
Wheelbase:
Wheel travel: 15"
Shocks:

A-Arm width:  +4" each side
Wheelbase:
Wheel travel: 12"
Shocks:

Long Travel Industries - Polaris RZR Long Travel   Long Travel Industries - Polaris RZR Long Travel   Long Travel Industries - Polaris RZR Long Travel Kit  Long Travel Industries - Polaris RZR Long Travel Kit

Long Travel Industries - Polaris RZR Long Travel Kit  Long Travel Industries - Polaris RZR Long Travel Kit  Long Travel Industries - Polaris RZR Long Travel Kit  Long Travel Industries - Polaris RZR Long Travel Kit

  • Magnum Offroad

A-Arm width: +6" wider per side
Wheelbase: 0"
Wheel travel: 10"
Shocks:
 

Magnum Offroad - Polaris RZR Long Travel Kit  Magnum Offroad - Polaris RZR Long Travel Kit  Magnum Offroad - Polaris RZR Long Travel Kit  Magnum Offroad - Polaris RZR Long Travel Kit

  • Polaris RZR S (factory installed long travel)

A-Arm width: +5" wider per side
Wheelbase: 0"
Wheel travel: 12"
Shocks: Fox Podium

The factory Polaris +5" long travel is not available as a standalone kit.  It comes standard on the Polaris RZR S only.

2009 Polaris RZR S with Factory Long Travel, Fox Shocks and Maxxis Bighorn Tires

  • Rancho Suspension

A-Arm width:
Wheelbase:
Wheel travel:
Shocks: Rancho Suspension

Polaris RZR with Rancho  Long Travel Suspension

  • RZR Tech / Spectrum Sand Sports

Status: Available

A-Arm width: +3" per side
Wheelbase: 1" back
Wheel travel: 12"
Shocks: stock or Elka

A-Arm width: +5" per side

A-Arm width: +6" per side
Wheelbase: +2.75" (2" back)
Wheel travel: 14"
Shocks: King, Elka

Tie rod and balljoint replacement

RZR Tech - RZR Mid-Travel Suspension Kit  RZR Tech - RZR Mid-Travel Suspension Kit  RZR Tech - RZR Mid-Travel Suspension Kit

RZR Tech - +3" A-Arms RZR Mid-Travel Suspension Kit  RZR Tech - RZR Mid-Travel Suspension Kit +3" Arms
+3" A-Arms - Mid-travel

Polaris RZR S Replacement A-Arms
+5" A-Arm - RZR S Replacement

RZR Tech / Spectrum Sand Sports - Polaris RZR +6" A-Arm Long Travel Kit  RZR Tech / Spectrum Sand Sports - Polaris RZR +6" A-Arm Long Travel Kit  RZR Tech / Spectrum Sand Sports - Polaris RZR +6" A-Arm Long Travel Kit

RZR Tech / Spectrum Sand Sports - Polaris RZR +6" A-Arm Long Travel Kit  RZR Tech / Spectrum Sand Sports - Polaris RZR +6" A-Arm Long Travel Kit  RZR Tech / Spectrum Sand Sports - Polaris RZR +6" A-Arm Long Travel Kit  RZR Tech / Spectrum Sand Sports - Polaris RZR +6" A-Arm Long Travel Kit
+6" A-Arms - Long travel

  • Shaw'z Metal Fabrications

Status:  Available

A-Arm width: +6" per side
Wheelbase: 2" forward and 2" back
Wheel travel: 15" front & 14" rear
Shocks: Fox

     

  • Sniper Sand Cars

Status: Available

A-Arm width:
Wheelbase: 
Wheel travel: 
Shocks:

Sniper - Polaris RZR Long Travel Kit (UTV)   Sniper - Polaris RZR Long Travel Kit

  • SuperATV

Status: Available

A-Arm width: +6.5"
Wheelbase: 
+2" front and 2" rear
Wheel travel: 
Shocks: Titan, King

Billet Aluminum Polaris RZR Long Travel Kit 

  • Todd's Custom Billet

Status: Available

Billet aluminum 6061 control arms
A-Arm width: 13" overall wider 6.5" per side
Wheelbase: +4" total - 2" offset forward, 2" offset backwards
Wheel travel: 14"
Shocks: 

Polaris Ranger RZR - Long Travel Kit   Polaris Ranger RZR - Long Travel Kit   Polaris Ranger RZR - Long Travel Kit

Polaris Ranger RZR - Long Travel Kit  Todd's Custom Billet - Polaris RZR Long Travel Kit

  • Tower Works Fabrication

    Status: Available

    A-Arm width: +6"
    Wheelbase: 5/8" forward, +1 1/2" rearward
    Wheel travel: 15 3/4"
    Shocks: Fox

      RZR Long Travel kit with Rear bypass shocks 
     

  • Trophy Engineering

Status: Available

A-Arm width:
Wheelbase: 
Wheel travel: 
Shocks:

     

  •  XMF

Status: Available

A-Arm width: +6" each side
Wheelbase: 
Wheel travel: 
Shocks: Walker Evans

Polaris RZR Long Travel Kit - RZR Crap   Long Travel RZR - RZRCrap.com   Long Travel Polaris RZR - RZRCrap.com


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