View Full Version : RZR 570 'S' build - The hybrid

08-03-2015, 10:58 PM
Here goes -

I've got a new project that has taken priority in the garage for now. I've been contemplating how to get the buggy drivetrain closer to 'stock-ish' for the last few years, but was not able to find any deals that jumped out at me and said make it happen. Not to mention everything else on the car has been through the ringer and has kind of been limping [smilie=ext_crutch.: for the last year or so. We've just had too much of -> [smilie=ext_doc.gif] lately, and not enough of ->[smilie=boogie.gif].

I have spent quite a bit of time in the last 3-4 years around production SxS vehicles.. Their reliability and capability is undeniable. If I could afford to own one, it would happen...

Well, through some key connections and some wife convincing, I had my shot..


Here's the rundown:

Chassis: 2012 RZR 570
Suspension: 800S front, Ranger 900 XP rear
Drivetrain: Hybrid of Polaris RZR 570, Ranger 900, and RZR 900 XP, I think..

This suspension combination has never come from Polaris as a whole setup, it was pieced together by the PO to focus on a lightweight short course type car. The drivetrain was never completed, the car has never run it this configuration. I picked it up, and plan to finish it along the lines of the original build intent.

It's going to take me some time to liquidate some stuff to fund the components necessary to complete. I plan to document things here. Here's to hoping it all turns out and it will be a solid runner in the end! :cool:

Garage is pretty full at the moment..


08-03-2015, 11:07 PM
I like the route you're taking. The RZR stuff has proven really reliable and easy to get.
There's something to be said about being able to just go to the dealer and get stuff.

08-03-2015, 11:11 PM
I like the route you're taking. The RZR stuff has proven really reliable and easy to get.
There's something to be said about being able to just go to the dealer and get stuff.

I'd like to think I'm learning from the best ^

08-03-2015, 11:12 PM
Ah, you're paying attention to bdkw also! :D

08-03-2015, 11:21 PM
Good to see you MH!

08-03-2015, 11:40 PM
Yeah, that will be a cool ride when finished. The 570,800 and 900 all have the same frame, right?

08-03-2015, 11:56 PM
Yeah, that will be a cool ride when finished. The 570,800 and 900 all have the same frame, right?

Sure hope so! I'm hoping to have a light ripper that can keep up with the big guys on all but the gnarliest terrain (which is somewhat rare in WI)..

They are all unique. The 570 and 800 share some features (the front half is quite similar), but the 900 is completely different.

Good to see you MH!

I'm always around and following along, but work and side projects have kept my buggy progress to a minimum.

11-06-2015, 09:25 PM
Any updates?

11-08-2015, 11:21 AM
Stuff is happening.. slowly..

Recently I pulled out the 570 trans and set in the 1k trans. Also have a 900S transmission. Learned that they all have unique input shafts, so there is no swapping without changing clutch setups as well.. Eventually the 900S box will be for sale.


Also mounted a 900XP radiator in the front of the RZR. Isn't the greatest fit, but it can work I think. Trying to avoid the rear mounted radiator if possible.

Rear suspension will go back on soon to figure rear shock setup. I'll take some pictures soon to show what I'm up against.

I've got a few irons in the fire on sourcing an engine. Trying to keep the focus on lightweight as much as possible. I've got my eye on a few 900XP/S or 1000XP/S engines due to simplicity, but have also been considering the Yamaha Phazer 500 engine.. Wondering if K, Bull, Ody, or Jerm have an engine weight for the Yamaha?

11-08-2015, 12:38 PM
Sorry, I don't have the engine weight.

11-08-2015, 05:04 PM
Seems like shipped it was 75 lbs, so maybe between 65-70.

11-09-2015, 08:03 AM
This is going to be sweet! I definitely like the idea of the phazer powerplant, those little sleds shred even with 250lbs of me tossing it around. I haven't figured out a good source to get one of those engines from though without buying the entire sled, which I suppose would be the best way.

I've also noticed on here that nobody uses anything 2 stroke - With the electric start and being able to spin the engine backwards for reverse on some of the newer ones, I'd think they would be awesome for buggies.

11-09-2015, 08:29 AM
Wonder if part of it is that snowmobiles exist up north and buggies exist down south in general. Majority of buggies/sand rails you see up here for sale are VW powered.

11-09-2015, 01:07 PM
Mine may be small and an older motor compared to most, but the old sled motor seems to be working nice in mine ;)

11-10-2015, 05:47 PM
According to the highly accurate Team OPR scales ($12 Walmart bathroom), an engine with no clutch, FI, exhaust, etc., is 76 lbs.

11-10-2015, 06:22 PM
Dang, Kfab nailed it!

11-10-2015, 08:33 PM
I just had to do a little happy dance! [smilie=mhihi.gif]

The Phazer engine is a sweet little unit. I was never let down by it. If it's any indication of what the Nytro is gonna be, I'm stoked.

11-10-2015, 08:36 PM
I just had to do a little happy dance! [smilie=mhihi.gif]

The Phazer engine is a sweet little unit. I was never let down by it. If it's any indication of what the Nytro is gonna be, I'm stoked.

Yeah, I cant imagine a bigger version of the little version!

11-11-2015, 06:38 AM
Everyone who drives the Briggs car loves the engine! The whole car, actually.

11-11-2015, 07:09 AM
Glad to hear the praise for the little 500cc ripper! I got word this morning that I should have a pair of Phazer long blocks w/ harnesses (not sure what else yet) headed my direction in a week or so.

I spent some time peaking through K's original Briggs thread on how he installed the engines, focusing on mount points. Will be using the same basic drivetrain to what he has in the Mini-Raptor. Just trying to visualize how things will fit together with the baby twin.

BTW, props to you K for documenting your builds well with pictures and text. [smilie=mhihi.gif]

11-14-2015, 12:43 PM
I scored some tires at a major deal lately. Following K-fabs lead on his rzrs and trying out the Sedona Buzz Saw tires (26x9x12 on all corners). Plan is to mount these on the stock steel rims, again, focus is to keep weight down and the steel wheels are the lightest I am aware of. Easy decision.


11-14-2015, 01:49 PM
60 bucks!

You suck!

11-14-2015, 03:38 PM
60 bucks!

You suck!

Second that ! LOL Nice find.
How many ply and what's the weight per tire?
I'm on the same path rim/tire wise. Trying to find that compromise between weight, strength and tire height at +25". Amazing how much the weight goes up in relation to tire size. Been shopping for used golf cart 12" dia ITP sets with off road tires.

11-14-2015, 05:33 PM
Those tires worked well, lasted quite a while and proved to be quite durable.
Killer find!

11-15-2015, 02:57 PM
To be fair, the tires weren't really only $60...

At the Eagle River UTV World Championship, Sedona wheel & tire was a main sponsor. I left the weekend with $500 in gift certificates (some won, some traded for).. So I was able to buy a set of tires for a net price of $65.80...

Choosing from the Sedona catalog, the only tires I was interested in were the Buzz Saw, or the Rip Saw. K-Fab ran the Buzz Saws originally on his 900XP, and they are 3 lbs lighter each for the 26x9x12 I needed.

X- weight is 29 lbs each, 6 ply. Certainly not the lightest on the market, but for Sedona it was the easy choice.
Sedona Buzz Saw (http://tiresunlimited.com/ALL%20TIRES/Sedona/sedona_buzz_saw.htm)

11-16-2015, 06:11 PM
Hey Mech I'm just catching up on this thread now, sorry I been busy buying a bigger place for all my toys :D
you will not be disapointed with that engine, 80hp from 500cc's is no slouch. When I talk to locals about this 500cc engine they say ppfft, thats for sissy's... trust me its not, once you get it running you'll know, no other way to explain it.

11-16-2015, 06:41 PM
I'll try to get you some new vids of my sissy engine in the Briggs. The only real problem with the engine is trying to stop the drift before the next turn! LOL!

11-16-2015, 06:50 PM
I hear you man. I Think the reason is because up here you're not cool until you have a 1000+cc sled, the phazers get no respect. I bought mine from a father/son, it was the 12yr old kids and it wasn't fast enough, he was upgrading to a nytro instead. [smilie=laugh.gif]

11-17-2015, 08:11 PM
Buzz Saw compared to stock RZR 570 tire:

I was planning for steel wheels, but I have a pair of OMF aluminum beadlocks around, may run these? Would just need to drill out the lug holes for the 12mm studs.

Still waiting for details on Phazer engine(s). Should send an email tomorrow..

11-23-2015, 11:25 AM
beadlocks are nice. I could have sworn I commented on those tires previously... anyways, good score!( even if it was with gift cert's) :cool:

01-14-2016, 07:55 AM
The build has been in limbo waiting for more to develop on the engine front. It's been radio silent. [smilie=thumbs_down: I've kept busy with other projects (1972 Honda CL100 & 1977 Yamaha Exciter 440).

So, I'm chasing down another option that is equally exciting. Hoping to find out this week if it's a go. I've already done a considerable amount of figuring, and I think it would make for a killer outcome. It follows in line perfectly with the Lotus mantra 'Lightness is next to Godliness'. [smilie=lipsealed.g:

01-14-2016, 08:05 AM
Still looking for the phazer?

Have to be 4 stroke?

I have a yamaha vmax 600 you can have, but its 2 stroke.

Or a cbr 600 you can have, but its carbed, but its full of HRP parts.

01-14-2016, 08:09 AM
Still looking for the phazer?

Have to be 4 stroke?

I have a yamaha vmax 600 you can have, but its 2 stroke.

Or a cbr 600 you can have, but its carbed, but its full of HRP parts.

I am still looking for a Phazer, but it isn't primary focus anymore.

I've removed the 4 stroke requirement, but I'm still holding to EFI, which leaves me with late-model sleds, still $$.

Thanks for the offers Bull! I will keep them in mind, but fingers crossed I'm right around the corner on a deal.

01-21-2016, 09:29 AM
A 2 stroke rzr, can you say BRAP??


01-21-2016, 10:59 AM
Or a cbr 600 you can have, but its carbed, but its full of HRP parts.

generous. [smilie=peace.gif]

02-03-2016, 12:31 PM
Went to UTV race last weekend in Mech's neck of the woods. Several RZR 1000's, a 900 and a few of the new Yamaha YXZ's. Excited to see this machine racing there in the future!

12-06-2016, 01:49 AM
Things have been pretty quiet on the RZR front around here, lots of looking, limited movement... Obviously haven't posted in a while cuz there was nothing going.

Been working on a few deals for a long time, and FINALLY have something to show!!![smilie=jumping.gif]

This past weekend I picked up a 2016 RZR 1k XP long block [smilie=ecstatic.gi:!! I've already started purchasing some peripheral components to go with it. I'm on the road this week, when I get home there should be a pile of parts waiting! So excited [smilie=shocker.gif]!

The plan is to run a full 1k setup, near stock. Again, focusing on reliability. Ordered a 1k chassis wire harness last week. That'll go in after the engine is mounted up.

Speaking of the engine mounts... Will be some doing, but overall fairly simple. The engine will bolt directly to the trans as stock (ref stock 1k trans mentioned earlier in the thread), the trans mounts to the chassis in the rear as stock. The front mount will require some doing, but pretty simple. Then its harness, intake, exhaust, cooling, fuel system update, clutching, etc... SOOOOO looking forward to [smilie=gun_2guns.g:some things off the list.

Pictures to come after I'm back home, progress is still a few weeks out. Hoping to put in a few good days over Christmas break.

12-06-2016, 12:32 PM
You're gonna like that power plant. We've sold both of the 900s and replaced them with Her XP1k four seater and my Mini-Raptor (when done...)

The 1k motor, bone stock, is a great power plant. Nice low end, flat torque curve and a good power spread with a really good throttle response.

Having a stock harness is a perfect plan. It will have all the accessory lines and lighting and a pigtail for power steering. You'll have to get an ECU.

The stock mounts are beefy and isolate the drive system very well. I'm using the stock rear trans mounts in the Mini-Raptor and the Yamaha isolators on the engine.

12-06-2016, 01:07 PM
Cool build. I'm using the drive train from a 2009 RZR 800 in my latest build. Can't wait to finally have 4wd!

12-08-2016, 10:30 PM


12-08-2016, 10:37 PM
Have to go relearn how to post pics with Tapatalk... please hold.

Sent from my iPhone using Tapatalk

12-08-2016, 10:40 PM

12-08-2016, 11:18 PM


12-09-2016, 02:00 AM
Heck yeah!

12-29-2016, 08:19 PM
Things are moving forward slowly.. However, the money has been flowing out quickly!

Had to source the engine mount pieces, Intake plenum, exhaust, wire harness, clutch covers.. There are parts piled up everywhere!

Yesterday moved the car over to my buddies shop (with heat [smilie=non_banana1:), will start bolting some parts together soon!

Also spending time getting the winter toys ready for the season. Built a new Vanguard v-twin, hoping we'll pick up a little extra POWAHH!

12-30-2016, 11:51 PM
Only had a few minutes in the shop today, but start with the little things and keep moving forward, [smilie=gun_gun.gif]things off the list.

The beauty of the OE UTV stuff is commonality! Part of the swap from the RZR 570 engine into the RAGER 1000 involves changing out the stock cable throttle for the ETC setup (throttle by wire).

The ETC setup bolted right up, fits the floor pan, brake pedal, all good..

Original cable throttle:

ETC throttle setup temp mounted:

(Having troubles posting pictures.. I guess I'll have to succumb to the Photobucket evil... I was trying to use Imgur, but getting to Imgur from MBN inspired the malware page [smilie=wacko.gif])

For K-fabs reference if it matters: http://www.minibuggy.net/forum/redirect-to/?redirect=http%3A%2F%2Fimgur.com%2FmtsAASl

12-31-2016, 12:25 AM
That's cool.

01-03-2017, 04:51 PM
Made more progress yesterday [smilie=jumping.gif]

Here's a partial pile of parts waiting to go on.. [smilie=wacko.gif] There are quite a few more at home and more in the mail...

First on the list was to pull out the RZR 570 wire harness. I've got a 1k wire harness that will lay in once the engine fitment is more settled. Until then it would be in the way. Peeling the harness out is kind of a pain. Big pieces (fuse block, etc) on both ends of the harness, so removing most floor interior body panels was required, plus the skid plate. It was a pain solo, but I was enjoying it. [smilie=smackbottom:


Next I bolted a partial rear engine mount bracket to the engine (still waiting on pieces, maybe today) and hoisted it into the car. The engine is heavier than I should have tried to lift, but I'm young and [smilie=loser.gif] so... we go for it..

Somehow I avoid the [smilie=ext_doc.gif] and get it kind of into place. Apply spider web of straps and jockey into position and it kind of fits!



At this point it kind of looks like the stock 1k clutch box may fit? I have fears that it would interfere with the rear A-arm chassis mount structure, but seems OK-ish so far..


Once the rear mounts are all together this week, I'll be able to get a good figure on what the front mount plates will look like. In the picture below the black tube will mount to pillow block type rubber mounts at the ends, and 4 steel plates will connect it to the lugs on the front of the engine block (1 currently used by green ratchet strap). Not sure yet if I will be able to use the stock 1k mount plates, or if these will be custom to this chassis.

The pillow block mounts on the frame will also need to change slightly. The 1k front mount tube is maybe 1" wider than the current pillow block positions allow. The chassis will get drilled to accommodate.


FYI - I hate Photobucket.. It is the slowest, worst website ever... And the edit feature sucks.

01-03-2017, 05:45 PM
" I hate Photobucket.. It is the slowest, worst website ever... And the edit feature sucks. "

Yeah it does/is! Doesn't make sense, shouldn't it have gotten better as it got bigger/more popular? It got way worse.

I heard its owned by google (or something) and they don't GAC?

01-04-2017, 04:08 PM
As I had hoped, the UPS guy showed up yesterday and left a pile of parts at the front door! [smilie=non_banana1:

One of the main ones was the transmission-engine joint. Was able to get this bolted together so I could remove the ratchet strap spider web. Will still need to set the crank-input shaft C2C before I torque it down, but its together for more figuring.


I tossed on the throttle bodies and tried installing the intake plenum.

MAJOR PROBLEM. The stock XP 1k intake plenum wants to co-exist with the frame...


Lots more figuring to do, I ordered another OE intake plenum to stare at, but will likely have to go a different direction..

In other news: The Exhaust looks like it will be workable with some cutting/hacking, and the clutch box will all fit without mods! No idea how I will fit the clutch intake/exhaust... but that will come later.


01-07-2017, 11:40 PM
Spent some more time on the RZR today. Limited progress, but did a bit of figuring. Will have to follow up with pictures later. [smilie=sorry.gif]

The Intake plenum that I fitted earlier this week was a RZR XP1k. When that didn't work I ordered up a Ranger 900/1000 intake plenum. It's a different setup (single throttle body vs. dual). It showed up Friday, and it fits!

(plenum is upside down in this picture)


This means more figuring. In order to run a stock calibration, that will mean running full Ranger 1000 setup. The primary differences between the RZR and Ranger setup are the intake plenum, injectors, throttle bodies, and cams (as far as I know). Generally speaking, this means giving up some hp :(. More figuring to do [smilie=alright.gif].

Also started looking at cooling system hoses, fuel line, etc.. Nothing to show really. Doesn't look overly complicated. Most of the 570 stuff is pretty close to working it seems.I am concerned about air box intake plumbing, clutch intake/exhaust plumbing, etc.. There just isn't a whole lot of space below the bed. We'll do more noodling on that later...

01-19-2017, 02:08 AM
Been consistently doing some figuring on the RZR, but not much to show for it.

Still trying to figure out how to make the intake plenum situation work. Last night we tried a few different things:
- If you cut up the stock xp1k intake plenum until it fits, is it possible to plastic weld back together???
- If you make an intake plenum out of cardboard and duct tape, will it last???


Please tune in to next weeks episode for more! [smilie=lipsealed.g:

01-19-2017, 02:15 AM
I had to make a long plenum to get the airbox out from behind the firewall/seat on the Briggs, then put the air filter at the end.

I was afraid it would starve the engine, but it seems to pull just fine. I don't do any long top speed stuff though.

01-19-2017, 11:38 PM
Sitting in the truck going north to go snowmobiling, figured I might as well put together a post!

The plenum I previously posted a picture of is a Ranger XP 900/1000 setup. Single throttle body up stream of the plenum, rather than the dual throttle body down stream RZR XP1k plenum I previously tried.

After waiting for the Ranger plenum, it was pretty much a bolt on setup. I didn't bother to buy a throttle body with it right away since I wasn't sure if it would even fit or not. Seems there would be some packaging challenges in getting the air into the throttle body, but for the most part it would have worked well. The TB mount surface is on the left side in this picture:


Problem was.. I just couldn't bring myself to give up MIN 10hp and go with the Ranger setup (plus Ranger cams, plus different calibration)... So more figuring ensues.. [smilie=mhihi.gif]

If only I could get a dual throttle body plenum setup to work..

This inspired a few options as previously posted:
- Cut up the stock XP1k plenum until it fits, then plastic weld back together.
- Fabricate a plenum.

After debating which option would be better we challenged each other to do both methods.. Mike started cutting up the XP1k plenum, and I started hacking together some cardboard to mock up an aluminum version.

Mike started with this:

I started with this (I've found Amazon boxes to work well for cardboard mock-ups. The cardboard is not too thin, not too thick, and at the rate my wife purchases things, available at endless supply.):

After lots of sketchy cutting with the angle grinder and jig saw, mike came up with this. It sorta fit in the frame (without any running clearance), and is pretty much not plastic weld salvageable:

After some cutting and taping, I ended up with this (front open gap is now filled in):


It became evident that the fabricated plenum setup was the way to go. I'm not sure where the volume is at relative to the stock one, but it will aim to be the same. I'll be modeling the Cardboard plenum in CAD to create panel cut pieces for the plenum that can be welded together. This will allow me to easily measure inside volume and re-size accordingly.

Next week I've got a few other distractions, but will try to keep things moving forward. I'm hoping to keep working on the plenum a bit. Also still working to finish the engine mounts. May order a few different pieces to determine what the best mount setup is.

Once the engine is mounted:
- Finish plenum
- test fit and mod exhaust header
- mount muffler
- install wiring harness
- plumb cooling system
- swap fuel pump setups
- braap.

01-20-2017, 12:34 AM
Looking good.
I did the same. I cut the plastic section off that fit the TBs and screwed and glued it to the aluminum box. I think I used black RTV non smelly stuff.
I will say, your cardboard patterns are seriously lacking for an engineer of your caliper!

01-24-2017, 05:16 PM
I was wrong..

I spent the weekend in the Upper Peninsula of MI snowmobiling - technically snow biking...

KTM 500 XC-W with Timbersled MH LT kit. WOW. [smilie=bs_offtopic:

Meanwhile, Mike kept working on the plastic RZR intake plenum. See previous post doubting that we would be able to stitch the stock RZR XP1k intake plenum back together after cutting it up to fit the chassis. I was wrong. [smilie=sorry.gif]


Using a standard solder gun and left over pieces as filler rod he was able to get the intake plenum welded up and fitting awesome in the chassis. [smilie=shocked.gif] There is a tight spot on the passenger side up against the frame rail near the shock mount, I think we'll trim the corner of the frame and weld a cap in for added clearance.


Also, yesterday the front mount plates arrived. Time to find out if the whole thing fits together as I envisioned! [smilie=dunno.gif]

First we bolt the mount plates (yellow zinc) to the front of the engine block and to the front mount tube. Set in place and note that the pillow block mounts are too narrow for the mount tube. Engine is centered and aligned as it should be.


Measure RZR 570 front mount tube = 21" wide
Measure RZR XP1k front mount tube = 22" wide

Simple math says move the mount block holes out 0.5" per side and try again.


After reassembly, presto fit-o!! [smilie=shocked.gif][smilie=gun_gun.gif][smilie=ecstatic.gi:[smilie=shocker.gif]


List is getting shorter!
DONE - Finish mounting engine
DONE - Finish plenum
- test fit and mod exhaust header
- mount muffler
- install wiring harness
- plumb cooling system
- swap fuel pump setups
- braap.

01-24-2017, 05:46 PM
That plastic welding looks fantastic! TALON quality, if you will.

I had a plastic welder years ago that never even got taken out of the box - it got taken by an employee when he left the premises. I've always wondered how well they work.

BTW - the snowbike looks sweet!!! Only issue I have with it is the snow... damn cold crap... LOL! I'd throw a leg over that thing in a heart beat.

01-24-2017, 07:04 PM
How the filter gonna work in that modded box? I woulda thought picking up a couple filters with anged neck would have been easier fit. The plastic tig work is awesome! You can also try melting the same plastic, small bits, in acetone to use as filler.

01-24-2017, 07:04 PM
First, you suck, for getting to ride the snowbike!

3rd, I did some plastic welding with an industrial version in college. Was really cool and worked great. Id say your dude did a fantastic job with a soldering iron!

01-25-2017, 12:33 AM
That plastic welding looks fantastic! TALON quality, if you will.

I had a plastic welder years ago that never even got taken out of the box - it got taken by an employee when he left the premises. I've always wondered how well they work.

BTW - the snowbike looks sweet!!! Only issue I have with it is the snow... damn cold crap... LOL! I'd throw a leg over that thing in a heart beat.

For sure! Mike really killed it on the intake plenum. Don't tell him, but I was expecting a kindergarten elmers glue and popsicle stick project... [smilie=lipsealed.g:

He used a straight up electric soldering iron. I guess it had a nice round blade type tip that helped.. Used cut out pieces for filler. Will be doing a pressure/leak test at some point to make sure it is air tight.

The snow bike was amazing. It was really my first time riding one, rode it all day Friday and Saturday. I tipped over many times (not much taller than the K-man). But also pulled some of the most amazing lines through the back country trees. I was blown away by the capability. Looking forward to the next time I get to ride it.

The snow wasn't even bad! It was like 40ish all weekend! A little rain on Saturday kept things soggy...

01-25-2017, 12:39 AM
How the filter gonna work in that modded box? I woulda thought picking up a couple filters with anged neck would have been easier fit. The plastic tig work is awesome! You can also try melting the same plastic, small bits, in acetone to use as filler.

There will be a separate filter box up stream of the intake plenum (see top right in parts pile in post #48). This is how the RZR XP1k and newer stuff is set up. The RZR XP900 and 570 both have a panel filter in the intake plenum (these didn't fit where I needed to go). Once I get the bed over there to figure with I'll be able to see if there is any chance hiding the filter box below the bed.

Great idea on the acetone melted filler. May use this as a leak-filler if any issues pop up in pressure/leak test.

01-25-2017, 01:00 AM
Coat it with bedliner?

01-25-2017, 01:23 AM
Coat it with bedliner?

To seal any potential leaks in the intake plenum?

01-25-2017, 02:15 AM
Well, the air box, yeah, the plenum too I guess. Plus it would look "factory" ?

01-25-2017, 10:37 AM
Very jealous of the snowbike. Always wanted to try one. But I haven't even been able to take my own old snowmobile out of my yard in the past two or three years from a combination of being busy and having crappy winters. It's been foggy and drizzling here for the past week

01-30-2017, 04:11 PM
Spent a bunch of time on the RAGER this weekend, but not a whole lot to show for it.

Went to the local Polaris/BRP/Kawasaki/Honda dealer on Saturday morning to do some fiche-ineering. Got a few ideas and identified a few parts that should work for me. But, I'm too cheap to pay service retail, so eBay and wait...

We spent most of the time this weekend looking at intake & exhaust & clutch ducting details.

- Intake stuff: Trying to determine a good spot to mount the filter box without having to carve up too much of the box area. Noticed at the dealer that the General / RZR S filter box is smaller, so ordered one of those and will eventually cut that into the box. Then need to determine where the dirty air inlet goes for the filter box.

- Exhaust stuff: Trying to fit the 1k muffler where the 570 muffler used to go... Except it's twice as big... The header seems as though it will fit with clearance to the rear shock, but needs to be longer to reach the muffler. We ended up cutting up the 570 muffler/bumper mount hanger and plan to use some of that, with mods of course. The alignment isn't as bad as the picture shows, this picture was early rough placement. O yea.. and it definitely goes exactly where the sway bar goes... So that's cool.


- Clutch ducting stuff: This was one of the primary reasons for going to the dealer to check out vehicles. Unfortunately, they didn't have either a RZR 900XP or XP1k there at the time to reference. So we look at the RZR 900S and General instead. With the XP1k clutch cover there are 3 tubes (2 in, 1 out). The out tube will be same as stock, it curves and points the air at the exhaust header with a cheese grater to catch any flammable rubber bits. The intakes will be the challenge. The front tube points immediately at the cab wall. My fiche-ineering says I might be able to swap with one from a RZR 900S? Need to order. I'm still figuring what these tubes will go to. Maybe the stock 570 bed-side intake piece?? TBD.


02-13-2017, 04:11 PM

Is the clutch cover sealed to the backing plate.

AKA if you drove it though water would the belt stay dry?

02-13-2017, 04:19 PM
Is the clutch cover sealed to the backing plate.

AKA if you drove it though water would the belt stay dry?Yes

03-02-2017, 01:37 PM
Wish the Odyssey had some sort of a water repelling device for the CVT. Secondary is right next to the rear wheel and unshielded, likes to slip driving though water and light fluffy snow.

03-02-2017, 09:36 PM
I didn't really have too many issues with the buggy when we raced it. When you go through a big puddle or creek, be nice to it for a bit.. But those things are spinning real fast and the water slings off pretty quick. We didn't have any issues with snow when we ran it in the winter.

03-05-2017, 08:30 PM
Haven't had any problems with water on mine, but I've found that when the line from the two stroke oil tank comes un zip tied and dips down and gets cut open on the secondary clutch and leaks oil all over the belt and clutches, yeah that makes it kind of hard to get anywhere...

03-05-2017, 10:15 PM
Haven't had any problems with water on mine, but I've found that when the line from the two stroke oil tank comes un zip tied and dips down and gets cut open on the secondary clutch and leaks oil all over the belt and clutches, yeah that makes it kind of hard to get anywhere...

O yea... I learned that lesson plenty of times with the buggy as well....

03-06-2017, 10:45 AM
I can verify that when a CV boot band lets go, axle grease does nothing for forward motion with a CVT!

03-11-2017, 11:14 PM
I've been sidetracked with a few different projects recently, but things are still moving forward on the RAGER.

After a little act of stupidity, I had to pull the engine to change the engine-trans mount out. After that I was able to get the C2C set on the clutches and get the engine-trans torqued in place. That means the clutch cover can go back on, it fits properly this time.

Then start figuring plumbing for the clutch cover. The XP1k clutch cover has 2 air inlets, 1 air outlet. The outlet is easy, it dumps out and blows over the exhaust header, with a small cheese grater that catches any belt chunks from landing on the header... For the inlets I decided to use the stock 570 clutch/air intake box for the 570. It mounts in the box side. There are 2 chambers within the intake box, one for air intake, one for clutch. I've decided that I will use both sides as clutch intakes. A few cuts and splices to some hoses and we're getting close to having the clutch ducting done.

The intake plumbing is still TBD. I'm still trying to figure where the intake filter box will go. I've got a few options - RZR1k or RZR 900 S/General filter box. The RZR1k box would likely flow better, but it's just twice as big so it doesn't fit real great anywhere.. Also need to figure out where the air comes from going into the filter box. Don't really want to suck dirty air from the fenderwell ya know?

Also did a little fitting of the ECM, using the stock 570 mount and some dremel work got it to fit properly.

Also ordered all the Polaris parts I could think of that I needed this past week. Probably won't show up until next weekend, so until then I'll be working on other projects and doing some imagineering...

I know, I know... No pictures... Maybe next week.

03-12-2017, 12:25 AM
Thing is gonna rip!

03-22-2017, 05:00 PM
Still making progress. Been a game of order and wait recently. And distracted by other toys (1982 Kawasaki AR80, 1981 Yamaha Exciter 440, 1974 Honda CT90...) The RZR has been [smilie=poked.gif] at my mind though.

I had a bunch of parts show up this past week [smilie=ecstatic.gi:, now working to get them on the car!

Last night was work on getting the muffler mounted. I had bolted the 1k header in place, no issues (although VERY close to the cabin wall). I had started with a RZR570 exhaust mount and cut it apart to fit a 1k muffler in place kind of.


To get the header to line up and the muffler to be in position where I wanted it to be I had to massage the muffler hangers down an inch or so. Bent the mounts down, then tacked it down and bent it back up to be level.


Next was to come up with a hanger plan. I dug around the pile of parts and came up with the stock 570 muffler hangers. Standard issue car exhaust hanger looking things. They were longer than I could fit with the muffler mounts I had, so I improvised. Cut them open and only used one side of the mount, the other got bolted to the muffler frame. Two top hangers and now the muffler hangs in place.



Next step is to get the bottom of the muffler placement correct and it will be set in place. Then I'll know how much to extend the header. Have some SS tube ready for that.

I also plan to tie the muffler mount cage to the frame down below the muffler somewhere. Also considering how to put the sway bar back in there. It used to go exactly where the muffler is now.... [smilie=wacko.gif]

04-13-2017, 07:27 PM
Been all over the place in the last few weeks. Work, play, other projects (mine and friends). Life is just so distracting...

Still moving things forward, albeit slower than I'd like. I've got thoughts that I'd like to be running first weekend in May??? Idk.. Depends if I can stay focused and get dedicated time in the garage.

Exhaust is mounted and welded up. Decided to TIG the new section in, my MIG just didn't have the heat setup I wanted (either too hot or too cold). So I went over to a coworkers to use his TIG (just right). Haven't touched one since like '12... I didn't bother to practice, just went for it and it worked out pretty well! Pictures will be forth coming.

I also spent time de-tabbing some things on the rear of the frame and the muffler cage. Not what I needed to do, but it had to be done and was bothering me.

Messed with the wire harness some more, working to swap in a fuel pump that has the correct fuel pressure regulator for the 1k engine. The 800 / 570 fuel pump setup is 3 Bar, the 1k setup needs 4 Bar fuel pressure. This is nearly finished, should work out pretty good. The coolant temp sensor has a separate lead from the harness, hoping this includes the correct adapter to fit the thermistor in the engine.

I don't remember if I mentioned before, but the harness I bought ended up not being the one I want. It's a '14 XP1k harness, does not include the O2 sensor. This was added for '15+. Eventually I'll probably swap it out, but it's kind of a PITA in how it routes between the floor plan and the skid plate. And I'll have to weld in an O2 bung.

Rough list to get the engine started:
- finish fuel pump setup
- fuel line from pump to fuel rail
- seal up air plenum (found a few leaks with water test)
- assemble primary clutch
- finalize coolant lines
- intake plumbing from plenum to filter box
- brake pressure switch in MC

After that to get it drivable:
- Secondary clutch refresh
- Filter box figment
- Rear shock spring replacement
- Put the new shoes on
- Finish clutch intake ducting
- Finish muffler mount cage / rear bumper
- shift cable

After that there are lots of final details to get it setup the way I want. It's never really done is it?

Sorry for the lack of pictures, I just despise Photobucket, and I haven't figured out how to do it from the iPad yet.

04-17-2017, 11:46 PM
Jeze... I don't include any pictures and I get the cold shoulder... We get hollow promises of progress from the K-man [smilie=poked.gif] and people beg for updates?? [smilie=dunno.gif][smilie=bs_quesexcl:

I kid of course... Pictures coming soon.

04-18-2017, 01:28 AM
Catching up on pictures -

Coolant plumbing is all finished. I used some copper plumbing tube to butt join the coolant tubes I had to splice. I was just one hose shy of having the full setup, so I took a form of what I needed to the local Advance Auto. After the [smilie=wacko.gif] dude behind the counter offered no help in finding a hose for something that doesn't have a year, make, model, color, A/C or not, I went in the back and searched until I found something close.

For the sake of documentation, this hose is useful for going from the water pump to the coolant tube, minus about 1.25".

Things are starting to get busy under the bed!




Here's a comparison of the fuel pumps involved:
Left is the 4 bar reg unit we'll be using with a slight modification. I'm not sure what it's from.
Right is stock 800 I think

In this picture, a piece of highly engineered plastic was added in a very specific place. Can you find it? It serves to space the fuel pump down a smidge to make sure that the pump is in contact with the bottom of the fuel tank, ensuring we can achieve full suck from the fuel tank.

I also did some cutting and fitment to get the front nose piece to fit with the larger radiator, but it seems I forgot to take pictures of that. Nothing special, but when I add the 900XP winglets on the front nose, the cuts get conveniently covered up. I'll try to take pictures this week.

04-18-2017, 11:19 AM
Please tell me that's piece of a free pen from the local bank or pet food store!

This things gonna rip!

04-18-2017, 03:31 PM
Yessir, standard issue BIC pen tube!

04-19-2017, 03:02 PM
Make sure that "well Engineered" plastic can stand being submerged in fuel.......some plastics will dissolve

04-21-2017, 02:30 AM
two different times i used the ol bic pen body to bail out plugged fuel filters on stranded cars. one was the wife's when i first met her---her dad was Shell's fleet mechanic at the NJ refinery lol.

04-25-2017, 12:35 AM
Looks like my dropbox pictures crapped out. Someday I'll try to get back in and replace them. Seriously, anybody have a suggestion for an option other than Photobucket??

Anyways.. Things are still progressing on the RZR. Mostly in the details currently, so not much to show.

I did, however, try to start the RZR yesterday. Unsuccessfully. Had a few wiring things to sort before it was ready to try. Then had to make a jumper for the brake pressure switch since that has to be tripped to crank over the engine. Issue is, I seem to be missing some of the electro-pixie dust at the ECU. Without it, the ECU doesn't send signals to the right places. SO, the fuel pump isn't lighting off, the ignition coil isn't getting the triggers it needs, the injectors aren't firing.

Unfortunately, I ran out of time yesterday.. And probably won't be able to get any time on it until next week!! :(

04-25-2017, 11:51 AM
Modern wiring. Over-complicated by half. :(

Just a quick aside. I own a home that was built in the late '70's and it still has the original furnace and air conditioner (that's another story). It acted up about two years ago and I had a technician look at it. The fix was a quick recharge on the freon.

I asked him how long I could expect this old air conditioner to last (new furnace + new air conditioner = big bucks!!!). He told me that modern air conditioners typically fail in their electronics. The basic cooling mechanics are actually quite reliable and almost never fail. Since my air conditioner lacked those modern components and was virtually all mechanical, he was confident that the old beast would continue running for many more years.

05-03-2017, 03:56 PM
Had some travel for work, then play in the last week so I've been distracted from progress on the RZR.

Monday I spent another night trying to figure the wiring issues I was having. I'm confident that I can solve wiring issues, but I'm slow. My co-worker came over to work through it with me. After a few hours of tracing and probing, we believe that the harness is providing power as it should, and that the ECU may be the issue. I've got another ECU on it's way and will try again soon.

For now I've moved onto other items from the list.
- Last night finally got the shifter bracket that I needed (after trying 3 others, no success... Finally settled on the RZR 900S / General shift bracket)
- Started laying out where the filter box will go in the bed and ordered silicone tube to plumb. Need to cut up the bed soon for the filter box.
- Working on getting the shocks setup as they should be, however found that the bushings are incorrect for the mount bolt size... Need to order correct bushings/spacers.
- Starting to put the interior back together after having it out to lay the wiring harness in
- Disassembled the secondary clutch to clean and verify bushing condition. Looks good, will assemble and have clutching completed soon.
- Tonight will be doing leak testing and sealing of the plenum

05-08-2017, 12:40 AM
Saturday was a good day. I had an open schedule to work on whatever I wanted. I spent some time in the morning getting my Kawasaki AR80 running, it all worked out and now I'll be able to ride it to work this week!

After that I ran around to get some stuff I needed and started working on the RAGER, long list of things accomplished:
- Shock springs swapped and shocks, a-arms bolted in place
- Rear A-arm swapped with good replacement
- Air intake system assembled
- Plenum was leak tested and re-welded earlier this week.
- Brake master cylinder installed
When I added the XP1k brake banjo pressure switch, it didn't fit. Both brake circuit outlets aimed directly at a frame member so the switch wouldn't fit.
I changed to a bottom port style MC which allowed me to install the pressure switch out the bottom.
- Lines re-routed to work with new MC
- Secondary clutch cleaned, reassembled
- Filter box cut into bed, hose ordered, cut, fit, installed
- Installed headlights. I only have a LH LED light, so the RH gets a halogen for now(need to make jumper for it)
- Removed prop shaft to the front diff
I'm 100% certain I would damage the front diff if I don't upgrade. Don't have time or $$ to do immediately, so will run 2wd for a bit.

- Set rear valance in place with taillights

I know you like pictures:

Front end prior to headlight install

Lower right side valance is cut to clear the bottom of the radiator

In order to remove the prop shaft I had to unbolt the engine front mount tube, jack the front of the engine up like 6", then snake the shaft out the back.

Plan for the plenum was to set it back inside the front wall of the bed as much as possible to maintain bed space. This was the layout for for the first cut. The elbow off the plenum is beneath the hose to the filter box. Notice the tape lines on the front of the bed, that's where I started with the cut.


This is after the cuts were made to the front of the box. The filter box moved forward about 4", this allowed for a nice joint between the plenum/filter box (hose clamps still loose in picture).


Next I cut out the floor pan for the bed to clear the hose



The filter box inlet will be getting a pod type filter to prevent the nasty stuff from getting into the filter box and spoiling the filter. The filter box isn't mounted yet, but it won't take more than a few aluminum straps to attach to the remaining front bed wall.

** I switched from Photobucket to IMGUR for these pictures, hope it works OK! Also updated pic links at the beginning since the dropbox links died.

05-08-2017, 01:05 AM
Whats the plenum box out of?

I could use one of those, close to what I was going to make out of aluminum.

Lookin good!

05-08-2017, 11:57 AM
The filter box that is in the bed is from a RZR XP1k. I think the inlet & outlet are 3.25" OD. The filter inside is pretty large.

I also have a filter box from a Polaris General 1000 that I was thinking of using, it's got smaller inlet/outlet, smaller filter, and smaller box. Going to be for sale with the rest of the stuff I'm not using if you're interested.

05-08-2017, 06:48 PM
Yeah throw up a pic when you can, I might be interested. That's one is little big.

05-09-2017, 04:08 PM

The inlet & outlet are 2.5" OD


Ignore the RTV, it had a bad seal so the PO did that. I've got a new seal for the cover.

05-09-2017, 04:25 PM
More progress last night:

- Secondary clutch installed
- Clutch cover ducting assembled
- Installed skid plate
- Installed center console

This is the first time the seats have been back in it since probably January.. Definitely felt good to sit in it and make braap music!



05-09-2017, 06:25 PM
Ill take some measurements, thanks.

This things gonna rip!

05-11-2017, 12:57 AM
More work on the RAGER again last night.
- Got the front of the cage bolted in with the door frame
- Installed the roof, nice to have this attached and not taking up space in my garage
- Nearly finished the front clutch box intake to the bed side
- Trial fit the filter box inlet filter, decided to order a different one. I had ordered a K&N type cone, but now ordered a "ball type" foam filter hoping it will package better and not interfere with the bed-frame mount
- Finished the muffler mounting. Added barbs to the rubber hanger tabs to keep them engaged in the rubber hanger, finish welded the tabs to the muffler in their new bent state
- Added 2 springs to the muffler so it is properly secured
- Started to mount the XP1k rear muffler heat shield. This will mesh in with the rear valance for a decent rear setup I hope. Eventually I'll finish the muffler cage so it is mounted to the frame down by the A-arm pivot. That will act as the rear bumper.

05-17-2017, 03:05 PM
Things are still progressing!

Last night I finished mounting the muffler heat shield. Stock lower XP1k mounts go to the square chassis frame tubes, upper mounts get chopped up and welded to what I call the muffler cage. Turned out very solid and looking good. Like I said, will eventually finish the muffler cage down to the chassis below the muffler, but not now.

After that, cut and fit the rear valance to fit with the muffler heat shield. Turns out they look like they were meant to be together!

Here's a pic of a stock 570 rear valance setup, which includes the muffler guard. It is very common for them to deform and melt on the muffler.

Here's a pic of my new setup, mid process, shouldn't be any melting, I hope.

05-17-2017, 03:10 PM
Also got to spend some time exploring a few new areas in the MI UP this past weekend.

WOW as always.




05-18-2017, 02:58 PM
New ECM shows up today!! Sent the other one back to get it checked out.

Really hoping this fixes it!

05-22-2017, 01:01 AM
This weekend was a blur. I stood in my good friends wedding on Saturday, so wedding events dominated the weekend. The wedding reception was at the Harley Davidson museum, very cool. Today my wife was nursing a wicked hangover so I stayed around home.

BUT - I had like 3 minutes on Friday before the rehearsal so I plugged in the new ECM and turned the key. Stuff happened! The fuel pump fired up, the gauge was alive, and the LED dash light came on. None of these were functional before. Turned the key and it cranked over and fired [smilie=thumbs_up.g:, then died [smilie=banghead.gi:.. Multiple attempts ended in the same result.

Only other time I was able to fit in was going back to pull the check engine codes:

520279 31 = Throttle Body Control - Adaptation Aborted
520207 5 = All Wheel Drive Control Circuit
520230 31 = IC CAN Communication with EPS

The second and the third I'm not concerned with. Neither would have any impact on the car starting and running. Both are inspired by not having things hooked up currently. The front diff is disconnected (and prop shaft removed), and the power steering box is currently sitting on the shelf. The first one I believe is the issue. Tells me something is goofed in the ETC. I'm not sure yet if it is a pedal issue or a throttle body issue, will do some more figuring in the next few days.

06-05-2017, 12:27 AM
I'm in the rut now of the final build details.. I've been doing lots of tidying, tucking, and detailing. Lots of fiddling, nothing to show for it.

I'm currently waiting for another ECM. We believe the issue on the last one was the calibration. It was calibrated for a 1000 S, not a 1000 XP. The biggest difference being the throttle body. XP1k is a dual throttle body, 1k S is a single throttle body. Hence the ECM engine code... I had previously considered running this setup, that would have been ironic..

Another thing I had to do was add a few pins to the wire harness, I have a '14 XP1k harness. 2 things missing: the exhaust o2 sensor and the seat belt safety switch. I want to run the o2 for safety sake, and those calibrations make a little more power. I plan to run harnesses, so the seat belt switch is just to trick the ECM. It has to see 12V to not go into limp mode. Thankfully I have a spare junk harness, so I stole a few like-colored pins out of it. That was the tricky part. Inserting them into the ECM plug wasn't as bad as I thought. First, remove the piece that captures all the pins, then remove each individual small dummy pin, insert the new wire until you get a satisfactory snap. Now I've got a few wires hanging out of the ECM connector that will need to get run accordingly.

Also finished more trimming and prepping, lots of zip-tying.. I'll be traveling to Montreal for work this week, hopefully the ECM is on the door step by the time I get back!! Hurry up brown Santa!

06-07-2017, 09:38 PM
It's alive!!! Confirmed that the ECM calibration was the issue!

The new ECM showed up yesterday, had a few quick minutes to install and try it, cranked and fired right up! Will still have to do cooling system bleed and burb, but it's ready to drive around the back yard as is.

Hopefully I'll be able to make tracks somewhere this weekend!

06-07-2017, 10:51 PM

06-08-2017, 12:16 AM
Good news!

Cant wait to see it rip!

This things gonna rip! Did I mention this things gonna rip!

06-12-2017, 03:47 PM
The RAGER drove under it's own power for the first time on Saturday!

Did a couple cooling system heat cycles, then drove it around the yard and onto the trailer. Headed to a co-workers friends property that has a small moto type track on it. I just needed some space that I could drive around and see how things would react. I also got to drive his buddies YXZ on the track, it was awesome.

Overall, it was a highly successful first run. The only issue that I had was a cracked intake plenum. It cracked probably 6" along one of the main welds that we had stitched together. We knew this part was a risk, but now know that we need to go another direction. I've got a significant list of to-dos before the next outing, but I'm very happy with how things went on Saturday.

As Bull predicted, this thing rips! Before I even had it loaded on the trailer in the morning I left a couple witness lines on the street in front of his house during a quick roll-on of the throttle. These little tires are greasy in the grass with only 2wd, need to get the other meats mounted up.

For now, summers here, it's hot, and the jet-ski hasn't been in the water yet.. That's the focus for this week!

I've got more pictures and some videos that will get posted, but this will have to do for now:

Loaded up before the ride:

Loaded up after:

06-13-2017, 03:07 PM
Congrats on its maiden voyage! I bet it felt awesome to get it out and stretch its legs a bit.

06-19-2017, 11:22 PM

First part of the video is the first run of the RAGER! Nothing too exciting, but I was warming up to things, and still taking it easy. I got into it more throughout the day.

After that a section of drone footage from my buddy, it was super windy so he didn't move around much.

Then, as I mentioned, I also got the chance to drive a YXZ at the track! He had it setup with a Weller suspension kit and harnesses. It handled his moto type track pretty well, but with some kicks for sure on the shorter stutter-doubles. I rode with him for a bunch of laps, learned what he was doing in each part of the track then I took over. He kind of coached me through the first few jumps, then I just went for it. I hit everything on the track but the big 65-70 ft step down. After, we kind of stopped and he says "So, have you like raced before?" I just laughed and said yea, I've got some seat time in Autumn our old SAE Baja buggy racing and other stuff. He says he was a little worried when I just kept ripping around the track and hitting more and more jumps. [smilie=tr_sorry.gi: Haha, ooops I guess I should have said something to make him more comfortable... HOLD ON BUD!

06-20-2017, 01:01 AM
Congrats dude, lookin good!

I bet the new xyz with the paddles is a blast! He should have got the Johnny Greaves package instead!

06-20-2017, 03:10 PM
This one was actually a stick shifter car. He was disappointed to see the SS released for year 2, I think he'd prefer that one. He says he'll keep messing with this one until Yamaha comes out with a factory Turbo/SC car, then he'll buy that and be good.

It was a ton of fun to drive, but it definitely demands to be driven hard. It's not interested in any trail cruising, it's too lazy below 6k RPM. Also with that suspension setup, it won't be nearly as comfortable, it's fairly harsh to soak the bigger stuff. He said it was WAY harsh when he received it the first time and had to send it back to soften a bit so he could manage on his rough track and trails.

Idk why he didn't do the Greaves package. Probably because that isn't as publicly available? He doesn't plan to race so he's not in the know on those options?

06-20-2017, 03:16 PM
Here's the rough list for Phase 2 items:

Intake plenum replacement
Mount air filter box
More header heat shield, especially towards filter box
O2 sensor
Install harnesses
Install power steering
Seat belt safety switch loop to remove dash warning
Winch mount & install
Front shock bushings -> mount 800S FOX shocks
Swap to Sedona tires
Finish crankcase breather to air intake tract
Change Engine oil
Make Speedo work
Sway bars Front and Rear
Finish muffler cage / rear bumper
LED head light passenger side

06-25-2017, 11:42 AM
Sweet Mech, killer package you've put together, good luck with the iron-out of the small stuff.

09-24-2017, 12:27 AM
It's been 3 months since my last update. Progress has been minimal... Spent some time working on a ATV project to flip, took longer than expected. Also took time to enjoy the summer. Didn't put nearly enough gas through the jet ski.. Hoping for another few rides now that fall is here.

Things completed on the list above:
- Power steering installed, not fully operational. 900XP EPS not identical to XP1k. Might need recalibration?
- Bought another pair of steel front wheels at Haydays, mounted Sedona Buzzsaw tires.
- Installed XP900 int'l front sway bar. Technically it's 4" too wide, but should work ok.
- Bought and installed passenger side LED light to match driver side LED I found in swamp at Badlands Off-road in Indiana 1.5 years ago.
- Brought the RAGER out to our work car show, that's the only other Braaaaping it's seen so far.

Now as most forum builds go, we're starting the new house search. That will probably distract things. Hoping I can put together a real shop at the new place though!!

09-24-2017, 12:33 AM



10-30-2017, 03:56 PM
I've continued to pick away at the RAGER now that summer is done. A few other distractions kept me busy this year, and now my wife and I just bought a house so things will be hit/miss until I am able to settle into the new shop. Yes, I have my own 3 car garage that will become a dedicated work space! Of course I'll have to manage the new house honey-do list before I can spend too much time out there... Then I'll need to insulate and find a heat source for the K-Fab forsaken midwest winters...

List of things that have progressed since last update

Headlight wiring - quite a while back I had found a RZR XP LED headlight in the swamp at Badlands park in Indiana, brought it home and it still worked! For a while I had 1 halogen, and 1 LED. Let it be known, the stock halogen RZR headlights are absolutely terrible. Found a deal on the other side LED on eBay, had to extend the harness wiring to reach. Now have 2 decent headlights.


It's great to have extra scrap wire harnesses around to steal colored wire and connectors from: https://imgur.com/COmKr7W


O2 sensor wiring - I got dupe'd on eBay when I purchased the RZR 1k harness, listed as a '15, actually a '14. There are 2 main differences: '14 did not have an o2 sensor, and '14 did not have a seat belt safety switch (limiter). I chose the difficult path and added pins to the ECM plug for both. After a bonehead move both the o2 and the seatbelt safety bypass are now wired in.
Seat belt safety bypass - As mentioned above the '15+ RZR 1k has a seat belt safety limiter. The limiter has been turned off in my ECM, but without the bypass it still would show on the gauge cluster. Simple ECM pin to 12v+ and it's settled.
Filter box mount in bed - last time I ran the RZR the filter box was pretty much just hanging out in the bed. Now I've got it mounted between the 'harness bar' of the cage down to the top of the firewall with some steel strap. Much better.
Front sway bar mounted - As is with boring base model RZR/Ranger shocks it was pretty bad. Lots of wallow. I mounted up an international XP900 front sway bar and driveway feel seems to be improved. Hoping to add a rear sway in the future when I finish the rear muffler cage.
New tires/wheels - Back earlier in the thread I scored some better tires for a screaming deal. I just needed to get them mounted up. I ended up buying another stock set of RZR 50" wheels at Haydays, using only the fronts, and mounted the other set on old OMF beadlocks that were on Autumn for a while. Had to drill out the lug holes and taper drill them. Thankfully I was able to borrow the correct bit from work. This isn't a finished hole BTW...


Power steering - I have had a few EPS setups around. I installed a full XP900 EPS setup. Was plug n play with everything, except I currently have an error with the speed sensor, which causes an error with the EPS. It functions, I believe at a fixed speed assist level?
Heat shield installed between header and filter box - last time out I noticed significant heat from the header on the bottom of the filter box. I took a scrap muffler shield I got for free and shaped it to mount on top of the firewall to protect the filter box from radiant header heat. Also added heat shielding tape to the bottom of the filter box.

This past weekend I joined a ride with some buddies in NW Wisconsin. Based out of Winter, WI. Funny thing, this weekend was the first sighting of Winter for us this year. Friday night there were some flurries and Saturday we woke to like 1" of snow on the grass. Ground isn't really frozen yet so it didn't stay long. Temperature was between 35-40 F. I'm not sure, but I think we put on about 60 miles. Everything that was supposed to be working on the RZR worked great! No issues which was awesome. It was a great opportunity to identify the needed improvements to focus on over the winter.

Mid ride:

Post ride:

10-30-2017, 04:12 PM
O, and last Friday I weighed the RAGER on our chassis scales. This is as-is currently, accs included include doors, roof, tires, EPS, and seats.


Front left 268
Front right 276
Rear right 344
Rear left 343

Total = 1231 lbs, 3.7 gal short of a full tank of gasWet Total = ~ 1254 lbs full up

10-30-2017, 09:17 PM
Chamfer looks like crap!

11-02-2017, 10:50 AM
that drill bit looks super beefy... dang. Rim/tire combo looks great on there!