The RZR Pro XP platform is gaining in popularity. They are being built up for everything from high-speed racing action to fun, family adventures. We like the great new features of this RZR, including more cockpit room and storage, along with a better powerplant and cool new look. In addition to a long-travel option, the other thing Polaris didn’t give you is a good toolkit. While they provided a little one, it doesn’t even have a socket or wrench to fix or change a tire. By going over this ride with a fine-tooth comb, we have developed our own list of the exact tools you need to make a RZR Pro XP toolkit to bring along with you on every ride in case of a breakdown. You can always add to this list or modify it if you are installing an accessory that uses a different-sized fastener. For us, we like keeping our toolkit complete yet compact; here’s what you need to do the same.

Harbor Freight sells this affordable tool bag for less than $10. You can also find all the tools needed to fill it up there, too.
The list of tools needed to work on every part of the Pro XP is pretty extensive. Instead of building your own, you can save time by picking up a fully equipped Assault Industries On-the-Go tool roll.



3mm: Primary clutch

5mm: Caliper

6mm: Oil drain, driveshaft

8mm: Trans/diff drain


T25: Sensors, electrical

T27: Plenum bracket, electrical

T40: Bodywork, cargo, valve cover, lights, dash, roof

T55: Primary clutch

Flat: Hose clamps, hub caps

Phillips: Dash


8mm: Belt cover, stator cover, coil pack

10mm: Throttle body, skid plate, body, frame,  exhaust, front diff, seats, seat belt, clutches, battery, ground wire

11mm: Throttle body, airbox

12mm: Transmission, brake lines, timing chain, engine breather

13mm: Shift linkage, exhaust, master cylinder, brake lines, seats, frame, ground wire

15mm: Roll cage, engine, sway bar, shocks, spindle, hubs, calipers, frame, steering, ball joints

16mm: A-arms, steering, seat belt

17mm: Steering, seat belt

18mm: Roll cage, engine, radius rods, sway bar, trailing arms, shocks, A-arms steering front diff, seat belt,

19mm: Lug nuts, shift linkage

21mm: Steering

22mm: O2 sensor

23mm: Tie-rods, steering

30mm: Front and rear axle nuts


Stock pliers: Cotter pins, push pins

Stock belt tool or 1/4-20-bolt, 3 inches long

Keep: Small 5-, 7.5- and 10-amp fuses and possibly carry more

Snap-ring pliers: Ball joints

16mm socket: Spark plug

Adjustable wrench: Can take care of 21mm, 22mm, 23mm and other sizes

Drill: Brake lines

Rivet gun: Brake lines

See UTV Action’s full shootout between the RZR Pro XP and the Can-Am X3 Turbo RR here:

clutch toolEMERGENCYlug nutsMAKE A RZR PRO XP TOOLKITPolarispush pinsRZR Pro XP 4tire tooltrail repairs