There’s no worse feeling. You’re deep on a trail, the sun is perfect, and you’ve finally escaped the noise. Then you glance down at your fuel gauge and your heart sinks. The needle is flirting with empty, and you’re miles from camp. Suddenly, the adventure turns into a stressful calculation of fuel conservation.
We’ve all been there. That range anxiety can cut a great day short and keep you from exploring that intriguing trail just over the next ridge. What if you could double your range, eliminate that worry, and have the freedom to ride wherever the trail takes you? Adding a polaris rzr extra fuel tank is the single best upgrade for unlocking your machine’s true potential.
You want the peace of mind to go further and the confidence to be the go-to rider in your group when someone else runs low. In this complete guide, we’ll break down everything you need to know. We’ll cover the types of tanks available, how to choose the right one for your rig, and walk you through the key installation steps so you can conquer any trail without fear.
Why You Need More Fuel: The Top Benefits of a Polaris RZR Extra Fuel Tank
Beyond the obvious benefit of not getting stranded, adding a secondary fuel source to your RZR brings a surprising number of advantages. It’s not just about convenience; it’s about enhancing your entire off-road experience.
Extended Range and Uninterrupted Adventure
This is the big one. An auxiliary tank can add anywhere from 4 to 10+ gallons of fuel capacity. For a machine that gets 10-15 MPG on a good day, that translates to dozens of extra miles. No more turning back early or passing up that scenic overlook because you’re worried about making it back.
Enhanced Safety and Peace of Mind
Off-roading often takes us to remote areas with no cell service. Running out of fuel isn’t just an inconvenience—it can be a serious safety issue. An extra tank is your insurance policy, ensuring you always have the fuel to get back to safety, even if you take a wrong turn or encounter an unexpected obstacle.
Group Ride Support
Be the hero of your crew. With extra fuel on board, you can help out a buddy who miscalculated their range. It fosters a better, safer group dynamic and means no one gets left behind. This is one of the key polaris rzr extra fuel tank best practices for any responsible group leader.
Types of Extra Fuel Solutions for Your RZR
Not all fuel solutions are created equal. The right choice depends on your budget, mechanical skill, and how you use your RZR. Let’s break down the most common options.
Auxiliary Fuel Tanks (Plumbed-in Systems)
These are dedicated tanks, often made of durable polyethylene or aluminum, that are permanently mounted to your RZR’s chassis. They integrate directly into your factory fuel system, usually through a transfer pump or a gravity-feed setup connected to the main tank’s filler neck.
- Pros: Seamless operation (just flip a switch or let gravity do the work), large capacity, and out-of-the-way placement.
- Cons: More complex and permanent installation, higher initial cost.
Fuel Cans and Mounting Systems
This is a modular and popular approach. Systems from brands like RotopaX or FuelpaX involve mounting rugged, sealed fuel containers to your RZR’s roll cage, bed, or roof. They are simple, effective, and don’t require modifying your fuel system.
- Pros: Easy to install, relatively inexpensive, and versatile (you can carry fuel, water, or storage boxes on the same mounts).
- Cons: Requires you to manually stop and refuel, takes up valuable cargo space, and can raise your machine’s center of gravity if mounted high.
Racing Fuel Cells
For high-performance race builds, a fuel cell is the top-tier option. These are foam-filled, puncture-resistant tanks designed for maximum safety in extreme conditions. For 99% of trail riders, a fuel cell is overkill and unnecessary, but it’s good to know they exist.
How to Choose the Right Polaris RZR Extra Fuel Tank
With different options available, picking the perfect one comes down to a few key factors. This section of our polaris rzr extra fuel tank guide will help you make the right call.
Assess Your Riding Style and Needs
Are you a long-distance desert explorer or a weekend trail rider who just wants a little extra cushion? If you’re doing multi-day overland trips, a plumbed-in auxiliary tank is a game-changer. If you just need an extra gallon or two for peace of mind, a simple RotopaX can might be all you need.
Consider Capacity vs. Weight and Space
More fuel is great, but remember that gasoline is heavy—about 6 pounds per gallon. Adding 10 gallons means adding 60 pounds of weight, which can affect your RZR’s handling and suspension performance. Balance your need for range with the impact on your machine’s dynamics.
Material Matters: Plastic vs. Aluminum
Most auxiliary tanks are made from cross-linked polyethylene, which is incredibly durable, impact-resistant, and won’t rust. Custom aluminum tanks are an option but are typically more expensive and can be prone to cracking at the welds under extreme vibration if not built properly.
Check for Model-Specific Fitment
A tank designed for a RZR Pro XP will not fit a RZR Turbo R or a Trail 900. These tanks are molded to fit specific contours of the chassis. Always double-check that the kit you’re buying is made specifically for your year and model to avoid major installation headaches.
Installation Guide: How to Polaris RZR Extra Fuel Tank
Disclaimer: Working with fuel systems is inherently dangerous. This is a general overview. Always follow the specific instructions provided by the tank manufacturer. If you are not 100% confident in your skills, have a qualified mechanic perform the installation.
Safety First: Pre-Installation Checklist
- Work in a well-ventilated area, preferably outdoors.
- Have a Class B fire extinguisher within arm’s reach.
- NO smoking, sparks, or open flames anywhere near the work area.
- Disconnect your RZR’s battery before you begin.
- Wear safety glasses and fuel-resistant gloves.
Tools and Parts You’ll Need
Your kit should come with most of the necessary hardware, but you’ll typically need:
- A good socket and wrench set (metric)
- Trim panel removal tools
- A drill with various bits
- Hose cutters
- Zip ties
- Thread sealant designed for gasoline fittings
Step 1: Mounting the Tank
First, you’ll need to remove any plastic body panels necessary to access the mounting location. The manufacturer’s instructions will show you exactly where the tank is designed to sit. Securely bolt the tank to the frame using the provided hardware. Make sure it’s snug and doesn’t vibrate.
Step 2: Tapping into the Factory Fuel System
This is the most critical step. Most kits tap into the large filler neck hose that runs from the gas cap to the main tank. You will need to carefully cut this hose and insert the supplied “Y” or “T” fitting. Secure it with the provided hose clamps. Take your time and ensure a tight, leak-proof seal.
Step 3: Running the Fuel Lines and Wiring
Route the new fuel line from the auxiliary tank to the fitting you just installed. Secure the line away from hot exhaust components, sharp edges, and moving suspension parts using zip ties. If your tank has an electric transfer pump, you’ll also need to run the wiring to a switched power source and mount the provided switch on your dash.
Step 4: Final Checks and Leak Testing
Before putting all the plastics back on, it’s time to test for leaks. Add a small amount of fuel to the new tank and check every fitting and connection point. Look and smell for any signs of fuel seepage. Once you’re confident it’s sealed, reconnect the battery and test the transfer pump if you have one. Only after a successful leak test should you re-install your body panels.
Common Problems with Polaris RZR Extra Fuel Tank Setups
Even with a perfect installation, you might run into issues down the road. Here are a few common problems and how to troubleshoot them.
- Fuel Won’t Transfer: If you have a pump, check the fuse and wiring. For gravity-feed systems, ensure the vent line isn’t kinked or clogged, which can create a vacuum and stop fuel flow.
- Leaks at Fittings: Vibration can loosen fittings over time. The solution is often as simple as re-tightening a hose clamp or re-applying thread sealant to a threaded fitting.
- Mounting Hardware Loosens: Off-roading involves constant vibration. Periodically check the bolts holding your tank to the frame and tighten them as needed. Using a thread-locking compound like Loctite during installation is a great preventative measure.
Polaris RZR Extra Fuel Tank Care Guide and Best Practices
Proper care ensures your investment lasts and performs safely for years. Following this polaris rzr extra fuel tank care guide is simple but important.
Regular Inspection
Before each big ride, do a quick visual inspection. Look at the fuel lines for any cracks or chafing. Check the mounting bolts to ensure they’re tight. Make sure the vent line is clear of mud and debris.
Fuel Treatment
If your RZR sits for extended periods, especially with a full auxiliary tank, use a quality fuel stabilizer. This prevents the gasoline from breaking down, gumming up your fuel system, and causing issues down the road.
Sustainable and Eco-Friendly Fuel Handling
Part of being a responsible off-roader is protecting the trails we love. When filling your tanks or transferring fuel, use a spill-proof funnel or nozzle to prevent ground contamination. An eco-friendly polaris rzr extra fuel tank practice is simply being mindful. If you do have a small spill, use an absorbent material to clean it up properly instead of leaving it to soak into the ground.
Frequently Asked Questions About Polaris RZR Extra Fuel Tanks
How much extra range will I get with a Polaris RZR extra fuel tank?
It depends on the tank’s capacity and your RZR’s fuel economy. A 5-gallon auxiliary tank on a RZR that gets 12 MPG could theoretically add 60 miles of range, giving you a massive boost in trail-riding freedom.
Is installing an auxiliary fuel tank difficult?
For a DIYer with moderate mechanical skills, it’s a manageable weekend project. The key is to be patient, follow the instructions precisely, and prioritize safety when working with fuel. If you’re hesitant, there’s no shame in having a professional shop handle it.
Will an extra fuel tank void my RZR’s warranty?
This is a gray area. Modifying the fuel system could give a dealer grounds to deny a warranty claim on a fuel-related component. However, it shouldn’t affect the warranty on your engine, suspension, or other unrelated parts. Check with your dealer if you have concerns.
Can I just use regular fuel cans instead of a dedicated tank?
Absolutely! Using a high-quality, secured fuel can like a RotopaX is a fantastic and cost-effective alternative. It offers many of the same benefits, just without the convenience of an integrated, plumbed-in system. It’s a great starting point for many riders.
Adding more fuel capacity to your RZR is about more than just a part—it’s about unlocking a new level of freedom and confidence on the trail. By choosing the right system and ensuring a safe, quality installation, you’re not just adding fuel; you’re adding countless miles of adventure.
Now get geared up, ride further, and stay safe out there. We’ll see you on the trail!
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