Make Your Own Polaris RZR Pro XP Tool Kit

The Polaris 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 power plant and cool new look. In addition to a long travel option, the other thing Polaris didn’t give you is a good tool kit. While they provided a little one, it doesn’t even have a socket or wrench to 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 bring along with you on every ride incase of a break down. 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 tool kit complete yet compact, here’s what you need to do the same.

LIST OF TOOLS NEEDED

ALLEN HEADS

3mm: Primary clutch,

5mm: Caliper

6mm: Oil drain, driveshaft

8mm: Tans/diff drain

DRIVERS:

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,

SOCKETS/WRENCHES

8mm: Belt cover, stator cover, coil pack 

10mm: Throttlebody, skidplate, body, frame,  exhaust, front diff, seats, seat belts, clutches, battery, ground wire

11mm: Throttlebody, airbox 

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

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

15mm: Rollcage, engine, swaybar, shocks, spindle, hubs, calipers, frame, steering, ball joints 

16mm: A-arms, steering, seat belt

17mm: Steering, seat belt

18mm: Rollcage, engine, radius rods, swaybar, trailing arms, shocks, A-arms steering front diff, seat belt,

19mm: Lugnuts, shift linkage

21mm: Steering 

22mm: O2 sensor

23mm: Tie-rods, steering

30mm: Front & rear axle nuts

EXTRAS

1/4, 3/8, 1/2-inch drive ratchets

1/4, 3/8, 1/2-inch drive extensions

Stock Pliers: Cotter pins, push pins

Stock Belt Tool: Or 1/4-20 bolt 3 inches long

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

SnaprIng Pliers: Ball joints

16mm Spark plug socket: Spark plug

Drill: Brakelines

Rivet Gun: Brakelines

Hammer: You never know

Ratchet Strap: You break stuff

Tape: Electrical/duct

Adjustable Wrench: Can take care of 21mm, 22mm, 23mm and others

Harbor Freight sells this affordable tool bag for less than $10. You can also find the tools needed to fill it there too.

For the most part we pack one socket and one combination wrench.

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 buy picking up a fully equipped Assault Industries On The Go tool roll. Order at (714) 799-6711
DIYRZRTOOL KIT