Let’s be honest. Your trusty 2008 Polaris RZR 800 has probably seen its fair share of tight trails, mud bogs, and maybe a friendly tree or two. Those original plastics, once vibrant and glossy, are likely showing their age with deep scratches, sun-faded patches, and maybe even a few cracks held together with grit and hope.
You know that feeling of looking at your rig and wishing it had that showroom shine again. You want to feel proud when you pull up to the trailhead, not self-conscious about its battle scars.
We promise this guide will solve that problem. We’re going to walk you through everything you need to know about selecting and installing a 2008 polaris rzr 800 plastic kit. You’ll learn the benefits, how to choose the right one, a detailed step-by-step installation process, and pro tips to keep it looking great for years to come. Let’s get that RZR looking brand new again.
Why Bother Upgrading? The Real Benefits of a 2008 Polaris RZR 800 Plastic Kit
Swapping out your plastics is more than just a cosmetic fix; it’s a full-blown revival for your machine. If you’re on the fence, consider the very real advantages you’ll gain. The benefits of a 2008 polaris rzr 800 plastic kit go beyond looks.
- Instant Aesthetic Overhaul: This is the most obvious win. A new kit instantly erases years of wear and tear, making your RZR look like it just rolled off the factory floor. It’s the single most effective way to restore your machine’s appearance.
- Increased Resale Value: A clean, crisp-looking UTV will always command a higher price than one with busted, faded plastics. This upgrade is an investment that pays you back when it’s time to sell or trade up.
- Opportunity for Customization: Tired of the stock red or green? Aftermarket kits come in a huge variety of colors, from stealthy black to high-visibility orange or even carbon fiber looks. It’s your chance to make your RZR uniquely yours.
- Improved Durability: Plastic technology has come a long way since 2008. Many new kits are made from more flexible, impact-resistant materials than the original OEM plastics, which can become brittle with age and UV exposure.
Choosing the Right 2008 Polaris RZR 800 Plastic Kit for Your Rig
Diving into the market can feel overwhelming, but breaking it down makes it simple. This 2008 polaris rzr 800 plastic kit guide will help you find the perfect match for your needs and budget.
OEM vs. Aftermarket Kits
Your first big decision is whether to stick with the original manufacturer or explore the aftermarket. There’s no single right answer, just what’s right for you.
OEM (Original Equipment Manufacturer) kits offer a guaranteed perfect fit. The bolt holes will line up exactly, and the color will be a perfect match for the original. The downside? They are typically more expensive and offer limited color choices.
Aftermarket kits, from brands like Maier, UFO, or Polisport, are the popular choice for most riders. They offer a massive range of colors, often at a lower price point. While fitment from reputable brands is generally excellent, you might occasionally need to finesse a piece into place.
Material Matters: TPO vs. Polypropylene
Most UTV plastics are made from a type of thermoplastic. The most common you’ll see is TPO (Thermoformed Polyolefin). It’s known for its excellent impact resistance and flexibility, even in cold weather, which is exactly what you want on the trail.
Some kits may also use a high-grade polypropylene, which is also very durable. The key is to look for kits that advertise UV stabilization, which prevents the sun from fading and degrading the plastic over time.
What’s Included in a Complete Kit?
Before you click “buy,” double-check what’s in the box. A comprehensive 2008 polaris rzr 800 plastic kit should typically include:
- Front Fenders (Left and Right)
- Hood / Front Fascia
- Side Panels / Rocker Panels (Left and Right)
- Rear Fenders / Bed Sides (Left and Right)
Some “full” kits may also include the dash or other smaller trim pieces. Always read the product description carefully to avoid surprises.
How to Install Your 2008 Polaris RZR 800 Plastic Kit: A Step-by-Step Guide
Alright, let’s get our hands dirty! This is a straightforward job you can absolutely tackle in your garage on a weekend. Here’s how to 2008 polaris rzr 800 plastic kit installation is done right, following some simple best practices.
Tools & Prep Work
Gather your tools first to make the job go smoothly. You don’t need anything too fancy.
- Socket and ratchet set (metric)
- Torx bit set (Polaris loves Torx bolts)
- Plastic trim removal tool kit (highly recommended to avoid scratching)
- Drill with a small bit (for stubborn plastic rivets)
- A few clean rags
Pro Tip: Once you get the old plastics off, take the opportunity to deep clean the frame and components that are normally hard to reach. It makes the final result that much better.
Step 1: Removing the Old Plastics
Take your time here. Work on one section at a time and keep your hardware organized. A few magnetic trays or labeled plastic bags are your best friends.
- Start at the Front: Begin with the hood, which is usually held on by a few rubber straps or simple bolts. Then move to the front fenders. You’ll find a series of Torx bolts and plastic push-pins along the wheel wells and where they meet the frame.
- Move to the Sides: The side panels or rocker panels are next. These are typically held on with bolts along the bottom and top edge.
- Tackle the Rear: The rear fenders and bed sides are often the most involved. You’ll need to remove bolts inside the bed, along the frame, and in the rear wheel wells. The tail lights will also need to be disconnected and removed.
Be patient with stubborn push-pins. If one won’t cooperate, you can carefully drill out the center to release it.
Step 2: Installing the New Kit
Now for the satisfying part. Lay out all your new pieces to make sure you have everything.
The key here is to start all bolts by hand and leave them loose. Do not tighten anything down until all the pieces in a section are in place. This gives you wiggle room to align everything perfectly.
Work in the reverse order of removal: start with the rear fenders, then the sides, and finish with the front fenders and hood. This logical flow helps ensure panels overlap correctly.
Step 3: Final Fitment and Tightening
Once all the new plastic panels are loosely bolted on, stand back and look at the alignment. Check the gaps between panels to make sure they are even. Gently push and pull panels into their final position.
When you’re happy with the fit, go back and tighten all the bolts. Be careful not to over-tighten, as you can crack the new plastic or strip the hardware. Snug is good enough.
Common Problems with 2008 Polaris RZR 800 Plastic Kit Installation
Even the best DIY jobs can hit a snag. Knowing the common problems with 2008 polaris rzr 800 plastic kit installs can help you avoid them entirely.
- Misaligned Bolt Holes: Especially with aftermarket kits, a hole might be a millimeter off. Don’t force it. Use a small round file or a drill bit to slightly enlarge the hole on the plastic. It’s an easy fix that prevents cracking.
- Forgetting to Transfer Parts: It’s easy to forget small items attached to the old plastics, like warning labels, heat shields, or wire harness clips. Do a final check of your old pile of plastic before you dispose of it.
- Stripping Hardware: The threaded clips on the RZR frame can be delicate. Always start bolts by hand to ensure they aren’t cross-threaded, and use a ratchet, not an impact gun, for the final tightening.
The Long Haul: Your 2008 Polaris RZR 800 Plastic Kit Care Guide
You’ve done the work, and your RZR looks amazing. Let’s keep it that way. This 2008 polaris rzr 800 plastic kit care guide will protect your investment.
Cleaning and Protection
Avoid harsh degreasers or pressure washing too close, as this can damage the finish and decals. Use a quality automotive or powersports soap.
The most important step is applying a UV protectant. Products like 303 Aerospace Protectant or SC1 High Gloss Coating work wonders. They create a non-greasy finish that repels mud and dust while protecting the plastic from sun damage, which is the primary cause of fading and brittleness.
Thinking Green: Sustainable & Eco-Friendly Options
Being an off-roader means respecting the outdoors. When it comes to your old kit, look for ways to be responsible. Some plastic manufacturers are now exploring more sustainable practices.
Consider these eco-friendly 2008 polaris rzr 800 plastic kit tips:
- Recycling: Check with your local waste management facility. While not all centers accept large automotive plastics, some have programs for TPO and polypropylene recycling.
- Repurposing: Got a cracked fender? Cut out the good sections to use for DIY projects, like making small skid plates or patch panels.
- Choose Conscious Brands: Look for manufacturers that mention using recycled materials or have take-back programs. It’s a growing trend in the industry.
Frequently Asked Questions About the 2008 Polaris RZR 800 Plastic Kit
How long does it take to install a full plastic kit?
For a first-timer working at a steady pace, plan for about 4 to 6 hours. An experienced mechanic might do it in 2 to 3. The key is not to rush. Put on some music, take your time, and enjoy the process.
Can I just replace one broken piece, or do I need a full kit?
You can absolutely buy individual pieces. However, be aware that a brand-new plastic panel will likely not match the color of your other sun-faded, 10+ year-old panels. If you want a uniform, clean look, a full kit is the way to go.
Are aftermarket plastic kits as good as OEM?
Yes, and sometimes even better! Reputable aftermarket brands often use more modern, durable plastic compounds than what was available in 2008. The key is to stick with well-known brands that have positive reviews within the RZR community.
Do I need to apply new graphics, or do they come pre-installed?
Graphics are almost always sold separately. Installing new plastics is the perfect time to install a new graphics kit, as you’ll be working with a perfectly clean, fresh surface. It’s the final touch that truly personalizes your ride.
Transforming your tired 2008 RZR 800 is one of the most rewarding projects you can undertake. With a new plastic kit, you’re not just fixing what’s broken—you’re breathing new life into a machine full of memories and getting it ready for many more.
So, grab your tools, pick a color that screams ‘you’, and get to work. The pride you’ll feel seeing that restored rig in your garage is second only to the feeling of hitting the trail in it. From all of us at FatBoysOffroad, stay safe and happy wrenching!
- Polaris 50Cc Outlaw – The Ultimate Guide For Young Riders & DIY - November 6, 2025
- Polaris Rzr Yoke – Your Ultimate Guide To Driveline Inspection And - November 6, 2025
- Polaris Rzr 800 Rack And Pinion Replacement – Your Ultimate DIY Guide - November 6, 2025