2012 RZR XP 900 Build
 

I figured I would document my build progress here. I bought it with front and rear bumpers, doors, front windshield, rear dust shield, rear view mirror, aftermarket steering wheel, rear cargo box, and 5 point harnesses.

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I bought a full roof and an empty stereo pod so I could build my own system.

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I'm waiting on the stereo parts to come in.

For anyone using the Cooter Brown roof and a flip down windshield, be aware that the windshield will not shut against the bars as it shuts against the roof. The only issue this may cause is if it's raining, the water might roll in between the roof and the shield. You could always pop out the two mounting screws and put the shield under the roof if it is raining a lot. You would not be able to fold the shield out unless you put it back the way it was.

I ordered a new winch, and power steering. It will be here today. Should have it on tomorrow. I still need to upgrade the trailing arms and a stronger skid plate under the engine.

The power steering is killer. Glad I went ahead and put it on.

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The winch tucks in nicely so you really can't see it. All you see is the hook.

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One of the rear arms was bent, so I put some high clearance arms on.

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Put in a Kenwood marine stereo, and some 6" LED Kickers.

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There is a full cage in it's future.

Looks good. I'm leaving Thursday morning for 4 days at Royal Blue. Hit me up if you can make it down.

Sounds like a good time, but I can't make it.

Looking good!!

Did some more updates. I found one of the front a-arms bent so I put on some high clearance arms. The stocks ones are cheap compared to the new ones. Also added a little LED bar to the front.
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What brand are the arms , I've got a tweaked one and have been looking for something new.

These are the ones from super ATV. They move the axle 1.5" forward, so you can run a 30" tire without a lift. They have a lifetime warranty, and come with all new ball joints. The only thing took some time was adjusting the camber. I like them. They are beefy.

http://www.superatv.com/Polaris-RZR-...P8105C737.aspx

You'll love the 12" led. I find I use it more than my 30" or HIDs.

Yeah, it should do the job. I have it wired to my brights. I have a 32" led bar on my rig. That sucker is like the sun.

I bought a couple el cheapo shafts to try out. I'm putting one front and one rear on to see how long they last. I'll keep the factory ones as spares. They say they're 4340 steel, so hopefully they are stronger the OEM. The rear shaft was 1/8 thicker the OEM. We'll see...
https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1

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I couldn't get the axles out of the case so I hit google to see why. Saw a video of a guy trying to get one out. It was rusted in there. I didn't know they weren't sealed inside and there's no seal to keep water out. So I got out some WD industrial and sprayed all 4 axles where they enter the case and let them soak all night. Sprayed them again next day and with a little pry and pull, they came out. I recommend spraying them often to keep them from rusting. Changing a rusty one on the trail would suck. I used anti seize on the new ones.

I had been noticing some play in the wheel bearings for a while. After I took everything off the play in the bearing was scary. I guess the caliper toned the play down some. I have 4 new ones on the way. I found a cool greaser for them too. This is something I want to add to my yearly maintenance routine.

After taking everything apart I found the bearings were in worse shape that I had thought. They were dry and had a bunch of play. Got the new ones from All Balls Racing. They are good and tight now. Definitely going to keep them greased from now on.

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Added something new to the rzr, heat... My intention is to make a set of removable uppers for my lower doors to keep the heat in. Bring on the cold weather. :thumbup:
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Got some new tires too. Same size, just more aggressive. 27" ITP Blackwater

Figured you would be getting new tires after the DTOR trip. The Blackwaters are at the top of my list also.

Found out the hard way, they run small! :crying: Mine came with 26" Bighorns, the 27" Blackwaters are a tad smaller. I hear Bighorns run big. I would've got 28's if they had them in my rim size. I have 2 new 26x11x12 Blackwaters in my garage. What size do you need?

I will go with at least a 28" tire, and maybe up to a 30", when I get new ones. From what I have seen the 26" Bighorns (which I have) run big compared to many other brands. Actually I think they just run true to size and most others run small. I know my 26" Bighorns look huge compared to the different brands of 25's on my dad's Polaris Ranger and Arctic Cat ATV.

When talking about the 28's in the Blackwaters I assume you are talking about the width? I know in the 28" size for a 12" rim they only make them in the 10" width so you can't run skinnier in the front and wider in the rear like factory. I'll probably wind up just getting the same size front and rear. If I had 14" rims I would really be looking at 29's, but they don't make anything that size for 12" rims.

Yes, the width. Not sure I want a wider tire up front, and thinner out back. Bigger tires would be nice, but breaking axles all the time isn't. My rzr has survived a lot of abuse without breaking. I'd like to keep it that way.
How well will yours hold up with big tires?

I run 28x10x14's all around and love it. I like the spare working all around and being able to rotate tires is also nice.

SxS's go so good in 2wd that you'd have bald rear tires and the fronts would still be damn near full tread when you can't rotate. I bet my XP spends 90% of the time in 2wd when I'm at Rush/DTOR/Haspin/Windrock.

The Teryx's are known to be pretty beefy and breaking axles with 28-30" tires is not that common. Not trying to bash on RZR's or Polaris in general but they are not well known for durability.

Do you think a Teryx with 100hp and 30" tires would have an issue with breakage? It would if I drove it. LOL. I would say HP and aggressive driving style is what kills most RZR's. Next time around, I am getting bigger tires that are the same all around so I can rotate them.

Put on some very needed belly, trailing arm, and rocker protection. :thumbup:
The 1/2" UHMW skid should do the job. Probably should've put the trailing arm guards on a long time ago. They are hit!! :d'oh:


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Honestly I would feel comfortable with it. Obviously the chance of breaking increases, especially if you were driving it:thumbup:, but it should handle it without having to baby it everywhere. There are several Teryx's out there with engine kits or turbos that are claiming in the 100 hp range (several companies make kits for these) and never any reports of excessive breakage. CV shafts are the most common but don't think I have ever heard of a diff, trans, or anything else going out.

The guy in this video owns a well known CVT clutch, tuner, and engine performance aftermarket company for Kawasaki and Yamaha machines. This is a '14 Teryx with some engine work, clutch kit, programming, and 29" tires. It will outrun a stock Maverick 1000. This is not some sort of drag race specific build either as he takes it trailriding to a lot of big events and uses it for R&D work. He posts a lot on several boards and don't remember him ever reporting issues with anything over the last couple of years. Granted he has several grand $$ into this setup but it's mostly stuff you can buy off the shelf and bolt on minus some machine work on the engine. There is at least one other video on YouTube of a different Teryx with the same engine work beating a Mav 1000.

https://www.youtube.com/watch?v=0Gdmqij1mvg

Definitely not trying to put the Teryx in the same league as some of these other machines in regards to power or suspension.....and really wish Kawasaki would get going on an upgraded machine!

Somehow i managed to bend the front driver axle. The center shaft has a nice crown now. It's one of the new ones i put on in June. Has a 1 year warranty, so I'll see if it's covered.
I always thought the joint would fail, not the shaft bending. Supposedly it's cro-moly

For me it has always been the CV joints that explode. Have yet to trash a shaft.


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