i recently found out the hardway how weak some of the Polaris welds are. while racing at a track my upper front a-arm rear tab pulled off the frame. i was comming fast into a right turn and the right side of the car came off the ground, i quickly turnned into it and the left front upper arm ripped off the frame. and i landed on my drivers side while the other racers went on by. i was helpless and felt like a ID10T for going so fast into the turn.

upon inspection i found out the upper rear arm tab pulled off the frame and the car drove over the wheel.

when i got home a tore apart the car to fix this issue i found even more damage. a broken hub,

mushroomed spindle,

bent tierod end,

plus a bent bolt and tore boot on balljoint.
now for the fix and beefing up.


this is a complete Polaris RZR weld on gusset kit from LONESTAR that corrects all of the weak points of the RZR. now we can go out and beat on the RZR without worry. it a complete weld on kit and takes some time to install but will be worth every minute it takes to remove the paint off the frame.

so save yourself some money on replacement parts and install one of these kits. hope you can learn from my incident and keep you RZR on the trails longer by not doing what i did. im sure LSRGREG will post a link and pricing for this kit. but i thought i would throw it out there and get some info out that will help all.

How long did it take you to tear it down and do all of the welding?

Nice weld job, damn I'll have to order one up.

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My RZR Project

Keep It Wet and Dirty!

it takes some time to tear down the RZR. i have about 2 hours on the front and i am 75% done with the install.

link to instructions

http://www.lsracing.com/img/Guide_74.pdf

That gusset kit is cool, get that and the tubes from UTV Crap and your set..

Is this necessary if you don't have the long travel kit?

I got the hubs for ya buddy!!!

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Phoenix, AZ 85015 www.unleashedutv.com
602-246-4011

I am suprised you did not automatically put that gusset kit in when running a +8 kit. I Just kinds assumed +6 or more should have a gusset kit atleast you got the fix for it should be back outthere in no time

So is the gusset kit nessecary if you not using long travel

I would say no to respond to your question ACSRACING: unless your doing some super intense rock crawling or something. The reason it is needed for the long travel kits is because the longer you extend the arms out the more leverage it has on the frame and mounting points sometimes causing them to bend or break as we have seen above. If your word some companies also provide support kits kinda like the one above but in bolt on fashion not weld in. Obviously i would assume the Weld in ones will be the strongest though. But to respond to your question with out Long Travel you should not need the gusset kit.

i dont think you would need a gusset kit if you have stock suspension, but i could not hurt to have the extra support.

remember my breakage was due to a tab pulling off the frame. if you look close at the tab the weld pulled off the frame, the poor quality weld did not penetrate the frame tube. when that failed it let the RZR run over the front wheel which broke the hub and pulled the balljoint out of the spindle.

i have raced in 3 races and 6 practice sessions with stock tabs and bolt on gussets that come with the XTR kit.

were racing but its cross country racing!!

gotta ask because I have full doors also. How you get it. LOL
and on rear tire and step onto my seat