Polaris Rzr 800 Doors And Windows: The Ultimate Upgrade & Care Guide

We’ve all been there. You’re tearing up a perfect trail, and suddenly a rogue mud puddle turns your cab—and you—into a Jackson Pollock painting. Or maybe it’s that biting wind on a cold morning ride that cuts right to the bone. You agree that the open-air freedom of the RZR 800 is awesome, but sometimes, you just want some protection from the elements.

I promise this guide will solve that problem for good. Here at FatBoysOffroad, we’ve installed, tested, and abused more UTV parts than we can count. We’re going to walk you through everything you need to know about choosing, installing, and maintaining the perfect polaris rzr 800 doors and windows for your rig.

In this comprehensive guide, we’ll preview the massive benefits of a full cab enclosure, help you navigate the different types of doors and windows, provide a step-by-step installation walkthrough, and even cover the common problems you might face. Let’s get your RZR buttoned up and ready for any weather.

Why Upgrading Your Polaris RZR 800 Doors and Windows is a Game-Changer

You might think doors are just for keeping mud out, but they offer so much more. Investing in a quality set of doors and windows fundamentally transforms your riding experience. It’s one of the most practical and noticeable upgrades you can make.

Here are the key benefits of polaris rzr 800 doors and windows that you’ll notice immediately:

All-Weather Comfort: This is the big one. Doors and windows provide a shield against wind, rain, snow, and dust. This extends your riding season, turning chilly fall days and damp spring mornings into prime trail time.
Enhanced Safety: A solid set of doors adds a significant layer of protection. They help keep arms and legs inside the vehicle during a rollover and offer a barrier against stray branches, rocks, and other trail debris that can fly into the cab.
Reduced Noise: A full cab enclosure dramatically cuts down on engine and wind noise. This makes for a much more pleasant ride, allowing you to have a conversation with your passenger without shouting.
Cleanliness: Say goodbye to being caked in mud and dust after every ride. Doors and windows keep the cab—and you—significantly cleaner, which means less cleanup time and more riding time.
Increased Security: While not a vault, lockable hard doors can deter casual theft of gear you might leave in your RZR when stopping for a break or bite to eat.

Choosing the Right Doors and Windows: A Buyer’s Guide

The market is flooded with options, and picking the right setup can feel overwhelming. Don’t worry, we’ll break it down. This polaris rzr 800 doors and windows guide will help you match the right products to your riding style and budget.

Full Doors vs. Half Doors: Which is Right for You?

The first big decision is door height. Both have their place on the trail.

Full doors offer the maximum amount of protection from the elements and debris. They are the best choice for riders in colder climates or those who prioritize a fully enclosed, weather-proof cab. They create a more car-like feel and offer the best safety.

Half doors (or “suicide doors”) provide a great balance. They keep mud and water from splashing in while still giving you that open-air feeling. They’re perfect for warmer climates where you want protection without feeling boxed in. They also make it easier to see your tire placement when navigating tricky rock-crawling sections.

Soft vs. Hard Enclosures: Weighing the Pros and Cons

Next, you need to decide between soft and hard materials for your doors and windows.

Soft Enclosures: Typically made from marine-grade polyester or canvas with clear vinyl windows.

Pros: More affordable, lightweight, and easily removable or rolled up for storage. Great for occasional use or for riders who want flexibility.
Cons: Less durable, offer minimal impact protection, and vinyl windows can scratch easily. They can also flap at high speeds.

Hard Enclosures: Usually constructed from aluminum, steel, or molded plastic with polycarbonate windows.

Pros: Extremely durable, offer superior protection and safety, seal better against the elements, and provide a quieter ride.
Cons: More expensive, heavier, and a more permanent installation.

Window Materials 101: Polycarbonate vs. Glass vs. Vinyl

For windshields and window panels, the material is crucial.

Polycarbonate is the most popular choice for UTVs, and for good reason. It’s incredibly impact-resistant—about 250 times stronger than glass—making it perfect for deflecting rocks and branches. Look for hard-coated polycarbonate, as it adds a layer of scratch resistance.

Laminated Safety Glass is what’s in your car. It offers perfect clarity and is highly scratch-resistant but can shatter on heavy impact. It’s a great option for riders who prioritize clarity and primarily stick to less aggressive trails.

Vinyl is found on soft enclosures. It’s flexible and cheap but scratches very easily and can yellow over time with UV exposure. It’s a budget-friendly option but requires careful handling.

How to Install Polaris RZR 800 Doors and Windows: A Step-by-Step Guide

Alright, you’ve got your new parts. Let’s get them on the rig. This section covers how to polaris rzr 800 doors and windows are installed. While specific steps vary by brand (always read the manufacturer’s instructions!), the general process is very similar.

Pro Tip: Grab a buddy. While you can do this alone, a second set of hands makes lining up doors and holding them in place much, much easier.

Tools You’ll Need

Socket and Wrench Set (Metric and SAE)
Torx Bit Set (Polaris loves Torx bolts)
Allen Wrench Set
Drill and Drill Bits (sometimes required)
Rubber Mallet
Blue Loctite (optional, but recommended for latch hardware)

Pre-Installation Checklist

Before you turn a single wrench, do this:

Unbox and Inspect Everything: Lay out all the parts and compare them to the inventory list in the instructions. Check for any shipping damage.
Read the Instructions: Seriously. Read them all the way through first. It will save you headaches later.
Clean Your RZR: Clean the roll cage and body panels where the new parts will mount. A clean surface ensures a better fit.

Installing the Doors (Step-by-Step)

Most aftermarket doors for the RZR 800 mount to the factory locations on the roll cage.

Remove Stock Nets/Doors: If you have the factory side nets, remove them. This usually involves a few Torx bolts.
Mount the Hinge Brackets: Loosely attach the hinge brackets to the roll cage. Don’t tighten them down all the way yet; you’ll need some wiggle room for alignment.
Hang the Door: With your helper, lift the door into place and slide the hinge pins into the brackets you just installed.
Install the Latch Pin/Striker Plate: Mount the striker plate to the B-pillar of the roll cage. Again, leave it slightly loose.
Align the Door: This is the most critical step. Close the door and adjust it until it sits flush with the body plastics and the gaps are even all around. The door should open and close smoothly without binding.
Tighten Everything Down: Once you’re happy with the alignment, systematically tighten all the hinge and latch bolts. Re-check the door’s operation one last time. A dab of blue Loctite on the latch bolts is a great idea to prevent them from vibrating loose.
Repeat on the Other Side: Do the exact same process for the passenger side door.

Fitting Your New Windows or Windshield

Installing a windshield or rear window is generally simpler.

Most use a clamp-style system. You’ll position the window, wrap the rubber-coated clamps around the roll cage, and tighten the bolts. The key here is to tighten them evenly, alternating from side to side, to avoid putting stress on one area of the polycarbonate.

Common Problems with Polaris RZR 800 Doors and Windows (and How to Fix Them)

Even the best parts can have issues. Here are some common problems with polaris rzr 800 doors and windows and our go-to fixes.

Solving Annoying Rattles and Squeaks

A rattling door will drive you insane on the trail. The usual culprits are a loose latch or the door vibrating against the frame.

Fix 1: Adjust the Latch. Most striker plates are adjustable. Loosen it and move it slightly inward to create a tighter seal when the door is closed.
Fix 2: Add Weather Stripping. Apply thin, self-adhesive foam or rubber weather stripping to the inside of the door frame where it makes contact with the roll cage. This dampens vibration and quiets things down.

Adjusting and Fixing Stubborn Latches

If a door is hard to close or won’t stay shut, the latch is almost always misaligned. Don’t slam it! You’ll just damage the mechanism.

Loosen the striker plate and the door hinges slightly. Close the door until the latch just catches, then re-tighten the hardware in that position. This ensures perfect alignment.

Dealing with Scratched Polycarbonate

It’s inevitable that your polycarbonate windows will get some minor scratches. For light scuffs, you can often polish them out using a dedicated plastic polish and a microfiber cloth. For deeper scratches, you may need a multi-stage scratch removal kit, but it’s best to prevent them in the first place with proper cleaning.

The Ultimate Polaris RZR 800 Doors and Windows Care Guide

You’ve made a big investment, so let’s keep it looking good. This polaris rzr 800 doors and windows care guide focuses on longevity and performance.

Best Practices for Cleaning and Maintenance

Following these polaris rzr 800 doors and windows best practices will prevent damage and keep your view crystal clear.

NEVER Dry Wipe: Wiping a dusty or muddy polycarbonate window with a dry rag is like using sandpaper. You will scratch it.
Rinse First: Always rinse the surface with plenty of water first to float away the heavy grit and dirt.
Use the Right Cleaner: Use a mild soap (like dish soap) and water solution. Avoid ammonia-based cleaners like Windex, as they can damage polycarbonate.
Use Microfiber: Use a clean, soft microfiber cloth for washing and drying. Pat dry or use gentle wiping motions.

Making Your Gear Last: A Sustainable Approach

Thinking about sustainable polaris rzr 800 doors and windows practices isn’t about being trendy; it’s about being smart. The most eco-friendly polaris rzr 800 doors and windows are the ones you don’t have to replace.

By properly cleaning, maintaining, and storing your gear, you extend its life dramatically. This saves you money and reduces waste. Repairing a latch is always better than replacing an entire door.

Frequently Asked Questions About Polaris RZR 800 Doors and Windows

Can I install doors from a different RZR model on my 800?

Generally, no. The RZR 800 has a unique roll cage and body profile. You need to buy doors and windows specifically designed for the RZR 800 (and its various sub-models like the S or 4-seater) to ensure a proper and safe fit.

Are hard-coated polycarbonate windshields worth the extra money?

Absolutely, yes. The hard coating provides a crucial layer of scratch resistance that standard polycarbonate lacks. It will keep your windshield clearer for much longer, making it one of the most valuable upgrades you can opt for.

Do I need a full windshield, half windshield, or a folding one?

This depends on your riding style. A full windshield offers max protection. A half windshield blocks wind from your chest but allows airflow. A folding windshield gives you the best of both worlds, allowing you to adapt to changing conditions on the trail. For most riders, a folding or full hard-coated poly windshield is the most versatile option.

Enclosing your RZR 800’s cab is one of the best modifications for improving comfort, safety, and year-round usability. By choosing the right components for your needs and following these installation and care tips, you’ll be ready to tackle any trail, in any weather.

Now get out there, stay protected, and have a blast. Happy trails!

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Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.