You know the feeling. You’re hitting a whooped-out trail, and every bump sends a jolt straight up your spine. Your stock Polaris RZR is capable, but on truly rough terrain, it can feel like you’re riding a bucking bronco. You see other rigs floating over the same obstacles that are rattling your teeth loose, and you can’t help but wonder what their secret is.
I’m here to promise you there’s a solution that will completely transform your off-road experience. The secret is upgrading to a long travel suspension polaris rzr kit, and it’s one of the most significant performance modifications you can make.
In this complete guide, we’re going to break it all down. We’ll cover what long travel suspension actually is, the incredible benefits you’ll gain, what to expect during installation, and how to avoid common problems. Get ready to turn your RZR from a capable trail machine into an absolute terrain-devouring beast.
What Exactly is a Long Travel Suspension Polaris RZR Kit?
Before we dive into the nuts and bolts, let’s clear up a common misconception. A long travel kit isn’t just a lift kit. While it does often provide a lift, its primary purpose is to increase wheel travel—the total vertical distance a wheel can move up and down.
Think of it this way: more travel means the suspension can soak up bigger bumps, deeper ruts, and harder landings without transferring that harsh impact to the chassis and, more importantly, to you. This is achieved by replacing key factory components with parts that are both longer and stronger.
Key Components of a Long Travel Kit
A comprehensive long travel kit is more than just a set of springs. It’s a complete system designed to work in harmony. Here’s what you’ll typically find in the box:
- Wider A-Arms: These are the foundation of the kit. Longer upper and lower A-arms push the wheels further out from the vehicle’s centerline, creating a wider, more stable stance and allowing for more articulation.
- Longer Axles: To accommodate the new, wider track width, you need heavy-duty, extended-length axles. Stock axles simply won’t reach.
- Upgraded Shock Absorbers: This is where the magic happens. Long travel kits are paired with high-performance, long-stroke shocks (like those from King, Fox, or Walker Evans) that can handle the increased travel and offer adjustability for compression and rebound.
- Extended Tie Rods: To maintain steering control with the wider stance, you need longer and often stronger tie rods.
- Extended Brake Lines: Your factory brake lines won’t be long enough to reach the new wheel position safely. Stainless steel braided lines are a common and highly recommended upgrade here.
Long Travel vs. Mid-Travel vs. Stock: A Quick Comparison
To put it in perspective, a stock RZR might have around 12-16 inches of wheel travel. A mid-travel kit might push that to 15-18 inches, offering a noticeable improvement.
A true long travel suspension polaris rzr system, however, can provide a massive 18-22+ inches of usable travel. This is a night-and-day difference that allows your tires to stay planted on the ground over wildly uneven terrain, giving you unmatched control and comfort.
The Unbeatable Benefits of Long Travel Suspension for Your Polaris RZR
Investing in a quality long travel kit is a game-changer. It’s not just about looking aggressive (though it certainly does that); it’s about unlocking a new level of performance and enjoyment from your machine. Here are the core benefits of long travel suspension polaris rzr owners rave about.
Superior Ride Comfort and “Plushness”
This is the big one. The ability to absorb harsh impacts from rocks, roots, and whoops means a dramatically smoother ride. That bone-jarring chatter disappears, replaced by a feeling of floating over the trail. This is one of the best long travel suspension polaris rzr tips we can offer: if you want comfort, this is the upgrade.
Enhanced Stability and Control at High Speeds
The wider stance created by a long travel kit acts like the base of a pyramid. It dramatically lowers your RZR’s center of gravity and increases its resistance to body roll in corners. You’ll feel more planted and confident carrying speed through turns and across off-camber sections.
Increased Ground Clearance and Obstacle Capability
While not its primary goal, the geometry of long travel kits almost always results in increased ground clearance. This, combined with the massive wheel articulation, allows you to crawl over obstacles that would have high-centered or stopped a stock machine in its tracks.
Reduced Driver and Passenger Fatigue
When your body isn’t absorbing thousands of small and large impacts all day, you can ride longer and feel better doing it. A long travel setup means you’ll end a full day on the trail feeling exhilarated, not exhausted and sore.
Your Long Travel Suspension Polaris RZR Guide: The Installation Process
So, you’re sold on the benefits. The next question is, how to long travel suspension polaris rzr? This is a significant mechanical undertaking. While it’s achievable for a skilled DIYer with the right tools and patience, it’s not a simple bolt-on job. Always follow the specific instructions provided by your kit’s manufacturer. This is just a general overview.
Pre-Installation Checklist: Tools and Prep Work
Before you turn a single wrench, get organized. Having everything ready will make the process much smoother. You’ll need:
- A heavy-duty floor jack and at least four tall, sturdy jack stands.
- A comprehensive socket and wrench set (both metric and standard).
- A quality torque wrench (absolutely essential for safety).
- A ball joint press tool or separator.
- Pry bars, hammers, and snap ring pliers.
- Brake bleeding kit and fresh brake fluid.
- Plenty of shop towels and a drain pan.
Read the manufacturer’s instructions from start to finish before you begin. This helps you anticipate steps and avoid surprises.
Step-by-Step Installation Overview
- Secure the Vehicle: Park on a level concrete surface. Use the floor jack to lift the entire RZR and support it securely on jack stands, ensuring it’s stable and won’t wobble.
- Remove Wheels and Stock Components: Remove all four wheels. Then, systematically disassemble one corner at a time. This involves removing the stock shock, disconnecting the brake caliper, separating the ball joints, and removing the factory A-arms and axle.
- Install New A-Arms: Loosely install the new, longer upper and lower A-arms. Don’t fully tighten the pivot bolts yet; you’ll need some play for alignment later.
- Install New Axles and Hubs: Carefully slide the new, longer axles into the differential and hub assembly.
- Install New Shocks: Mount the new, longer shocks to the frame and the new lower A-arm.
- Reassemble and Repeat: Reconnect the hub, tie rod, and brake caliper (with the new extended line). Repeat this process for the other three corners of the vehicle.
- Bleed the Brakes: Once all new brake lines are installed, you must properly bleed the entire brake system to remove any air. Spongy brakes are extremely dangerous.
- Torque Everything to Spec: With the RZR’s weight back on its wheels, go through every single nut and bolt you touched and tighten it to the manufacturer’s specified torque value using your torque wrench. This is not an optional step.
- Get a Professional Alignment: Your RZR’s alignment (camber, caster, and toe) will be completely out of whack. A professional alignment is crucial for proper handling and to prevent premature tire wear.
Crucial Pro-Tip: When to Call a Professional
Be honest with yourself about your skill level and tool collection. If you’re not comfortable pressing ball joints, bleeding brakes, or using a torque wrench correctly, this is a job best left to a professional off-road shop. The safety of your suspension is not something to gamble on.
Common Problems with Long Travel Suspension on a Polaris RZR (And How to Avoid Them)
While the benefits are huge, a long travel conversion introduces new variables. Being aware of the common problems with long travel suspension polaris rzr setups can save you a lot of headaches and money down the road.
Premature Axle and CV Joint Wear
The Problem: The increased angles and leverage of a long travel kit put more stress on CV joints. Cheap kits or improper installation can lead to axles that bind or pop, causing rapid failure.
The Solution: Invest in a high-quality kit from a reputable brand that has engineered the proper axle geometry. During installation, ensure the axles plunge correctly and don’t bind at full droop or compression.
Shock Tuning Nightmares
The Problem: High-end shocks are infinitely adjustable, which is great… until you get it wrong. Incorrect settings for spring preload, compression, and rebound can make your expensive suspension ride worse than stock.
The Solution: Start with the manufacturer’s recommended baseline settings. Adjust one setting at a time, in small increments, and test in a familiar area to feel the difference. Don’t be afraid to ask for setup advice from the manufacturer or experienced users.
The Hidden Costs: Beyond the Kit
The Problem: The kit itself is just the beginning. Your RZR will be significantly wider, which might mean it no longer fits on your trailer. The new geometry may also require different wheel offsets to avoid rubbing, meaning you might need new wheels and tires.
The Solution: Measure twice, buy once! Before purchasing, measure your trailer’s width. Factor the potential cost of new wheels, tires, and a professional alignment into your total budget.
The Long Travel Suspension Polaris RZR Care Guide: Best Practices for Longevity
Your new suspension is a major investment. Following a proper long travel suspension polaris rzr care guide will protect it and ensure it performs flawlessly for years. Adhering to these long travel suspension polaris rzr best practices is key.
Regular Inspection Routine
After every single ride, do a quick but thorough walk-around. Look for:
- Loose or missing bolts (especially on shock mounts and A-arm pivots).
- Cracked welds on the A-arms or frame mounts.
- Leaking shock seals (a thin film of oil is normal, but dripping is not).
- Torn CV boots, which allow dirt and water to destroy the joint.
- Play or looseness in your heim joints or ball joints.
Cleaning and Lubrication
Mud, sand, and grit are the enemies of suspension components. After a muddy ride, use a pressure washer (from a safe distance) to clean your A-arms, shocks, and axles thoroughly. This prevents corrosion and allows you to spot potential issues. Lubricate any greaseable fittings (zerks) according to your kit manufacturer’s schedule.
A Note on Sustainable and Eco-Friendly Use
When we talk about a sustainable long travel suspension polaris rzr setup, we’re talking about two things. First, sustainability of your parts. A well-maintained kit built from quality materials lasts longer, reducing waste and the need for replacement parts. Second, a more capable suspension helps you be a more responsible rider. With better control and articulation, you can more easily stay on designated trails and navigate obstacles without causing damage to the surrounding environment, which is the core of eco-friendly long travel suspension polaris rzr enjoyment.
Frequently Asked Questions About Long Travel Suspension for a Polaris RZR
How much wider will a long travel kit make my RZR?
This varies by kit, but it’s a significant change. Most long travel kits will add anywhere from 6 to 10 inches to your RZR’s total width (3 to 5 inches per side). Always check the kit’s specifications and measure your trailer before you buy!
Do I absolutely need new shocks with a long travel kit?
Yes, 100%. Your stock shocks are not long enough to handle the increased wheel travel. Attempting to use them would severely limit your suspension’s performance and could be dangerous. Reputable long travel kits are designed to be paired with specific, longer shocks.
Can I install a long travel kit by myself?
If you are a confident and experienced DIY mechanic with a full set of quality tools (including a torque wrench and ball joint press), it is possible. However, it is a complex and labor-intensive job. If you have any doubts, we strongly recommend having it professionally installed for safety and peace of mind.
What’s the real difference between a long travel kit and a big lift kit?
A lift kit primarily uses bracket extensions or taller springs to raise the vehicle’s height, but it doesn’t increase wheel travel. A long travel kit uses longer A-arms to increase wheel travel and track width, resulting in a massive performance gain. While it often adds height, its main goal is ride quality and stability, not just clearance.
Upgrading to a long travel suspension is one of the most rewarding modifications an RZR owner can make. It transforms the machine’s capability and your comfort on the trail, allowing you to go faster, ride longer, and tackle tougher terrain with unshakable confidence.
It’s a big job, but the payoff is even bigger. Do your research, buy a quality kit, and take your time with the installation (or hire a pro). You won’t regret it.
Now get out there, soak up those bumps, and ride with confidence. We’ll see you on the trail!
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