Been screwing around off-road and etc for 45 years now. As a rule tools per say are rarely needed. I'd think a different way. Consider this list:

1. Spare belt and tools to change it. Practice it at home!
2. Battery booster
3. Tow strap
4. 1 gallon of water
5. Ratchet strap
6. Snatch block and long tow rope
7. Really good flashlight
8. 12V air compressor
9. Tire plugs
10. Hatchet
11. Hand saw
12. Rubber bungee assortment
13. Fire extinguisher
14. Moderate first aid kit

You are far more likely to need some or all of those before you'll need to do a major trail side repair.

 

Amen on the belt change practice, the 800 belt is difficult to get to.

 

Depends on where you are gonna put your tool kit. I have a bed box I had from like 1990 that fit on all my ATVs and now my RZR. I carry everything in there on long cruises. Weighs me down though lol, but it has saved me in the past.

 

I would carry a belt and axles (If you only going to carry 1 I would get a rear axle cuz if you brake the front you can throw it in 4WD and be on your marry way) Those are the 2 things you are going to need the most.
I don't know what size sockets and other tools you will need cuz I have a XP1K but that should be easy to figure out.

 

Cell phone to call for a tow
You won't be doing many field repairs with a basic tool set. You'll always need that tool you didn't bring.
I would think along the lines of what you use at home and spare parts,
Volt meter, wire, sperk plug, fuses, electric tape, lug nut wrench etc

 

I carry very little tools, because I don’t take parts with me. I keep a spare belt, and the tools to change it, and tools to repair a tire or install my spare. I have done axles and ball joints in my repair shop. It’s not a repair I plan to do on the trails.

I always have two machines with winches, a tow rope, snatch block and tree saver. I have plenty of tools at the truck if need be.

 

A tow strap to tow the guys back that can’t control they’re right foot, or run out of talent before they run out of “hold my beer and watch this”

In all seriousness, I carry a tow strap with soft shackles, small socket set, a spare belt on the trails, two on the sand. Not sure why I’ve never had to change one 🤷🏻‍♂️. 12 volt compressor, tire plug kit, vice grips and a crescent wrench.

 

Thanks guys. I have a first aid kit that I can throw in there as well as a 12V air compressor and flat tire repair kit. I will look into the spare belt and tools. I like the idea of a tow strap and shackles. I've been stuck enough times in my truck that I can see how that would be useful.

 

Theres other threads on here with lots of posts as well. I know this bc I done one on a custom kit, listing the tools and what all could be done with them if needed. Just took a couple minutes to jog my memory but I found it.

RS1 Specific Tool Kit & Storage

RS1 Specific Tool Kit & Storage So here is my take on a tool kit based on the RS1. I had pitched the idea to SATV to do molded tool kits for machines and their needs. So polaris would have all similar sizes etc, yamaha, can-am, etc. but that took a turn to left field. So I went ahead with...

www.rzrforums.net

It’s a bit of a read but it saves me retyping it lmao. It says rs1 specific but it applies regardless since it’s polaris. Same tool kit started with my 15’ 900.


Sent from my iPhone using RZRForums.net

 

The 800 had a mixture of SAE and Metric wrenches. Have to take the seat support apart to change belt. this takes several wrenches. Belts don't break very often in 800 trail riding. Neither do axles. Just not enough power to stress them that much. These are not fiddly motorcycles that need light weight tool sets to keep the motor running. These cars need big tools to render them towable.

The real thing to do on a 800 is change the air filter like every weekend or better put in one of these air filters. DO NOT USE a foam oil air filter on a 800 or you will rebuilt the top of engine.

Ump Polaris RZR 800 Superfilter Kit

UMP now has its race wining designed Superfilter Kit for the Polaris RZR. (Part # 10937) - A bolt on kit that eliminates the problems of the stock system with UMPs race wining designed Superfilter. -Draws air from stock airbox, the cleanest place on the car. (Some minor mods of airbox...

www.sidebysidesports.com

 

for sockets and wrenches I have a https://www.amazon.com/DeWalt-DWMT7...vqmt=e&hvbmt=be&hvdev=c&hvlocint=&hvlocphy=&hvtargid=pla-4584345017367385&psc=1

along with an extra drive belt belt changer tool tow strap and a few others tools that me and the group I go with have needed on a few times going out.

 

Trail tool kit for 800S

What tools do all of you take with you on the trail? I just finished mounting up my toold box in the bed of my 2012 800S and so far I loaded up my spare axles, belt, tow rope, recovery strap and plan on adding my air compressor with patch kit, and my rain gear. I started a list of tools that I...

www.rzrforums.net

 

In my opinion ratchet straps, ratchet straps and more ratchet straps. Broken arm? Strap it back on. radius rods? Strap it on. Broken axle? Depending how it breaks, might need to strap it out of the way to keep it from doing further damage while you limp home. Can be used in a pinch to aid for recovery and winching. Use em for rope. Everything.
Belt, belt change tools, tire plugs, air compressor, jumpers (or jump box if riding alone) and like 90 million ratchet straps and you good to go.
If you break axles, just limp home in 3wd and change it at home. The first time I swapped my rears, they were so stuck, the ole cup stuck in the diff happened… It would be nearly impossible to do trail side unless you had a 27mm socket, huge 1/2” breaker bar, 10lb slide hammer, 3vise grips, etc etc that’s just unrealistic.

 

In my opinion ratchet straps, ratchet straps and more ratchet straps. Broken arm? Strap it back on. radius rods? Strap it on. Broken axle? Depending how it breaks, might need to strap it out of the way to keep it from doing further damage while you limp home. Can be used in a pinch to aid for recovery and winching. Use em for rope. Everything.
Belt, belt change tools, tire plugs, air compressor, jumpers (or jump box if riding alone) and like 90 million ratchet straps and you good to go.
If you break axles, just limp home in 3wd and change it at home. The first time I swapped my rears, they were so stuck, the ole cup stuck in the diff happened… It would be nearly impossible to do trail side unless you had a 27mm socket, huge 1/2” breaker bar, 10lb slide hammer, 3vise grips, etc etc that’s just unrealistic.

I've swapped 3 rear axles in the woods on our 800 S, takes around 20 min. 2 times were early in the ride around 10 miles from the truck, the other time we were 2 minutes from the truck, we had just started the ride too much right foot on a rocky hill in 2wd.

 

I will most definitely not be attempting to swap an axle on the trail. My intent with the tool kit is to tighten up anything that rattles loose on the trail. Or duct tape it, ratchet strap it, etc. If it breaks, it will likely be well beyond my skills to actually fix it.

 

I highly recommend having a Sidewall slug in your tool kit. They are great for fixing a sliced tire sidewall. You can use discount code: SLUGME10 for 10% off and free shipping from out site.

Sidewall Slug Tire Repair

 

Question: how appropriate would a kit like this be for basic field repairs: RZR Roll-Up Tool Bag with 36pc Tool Kit | PRP Seats

This is WAY overpriced of course but I can replicate it for pretty cheap. I can get a rolling tool bag off Amazon and I have most of the tools already. I would just need the following:

1/4" flex extension bar
T27 x 1/4"
8mm Allen head socket x 3/8" (I have 5/16" x 3/8", close enough?)
27mm socket x 1/2" (I have a 1 1/16" x 1/2" socket, close enough?)
Belt changing tool (I would just get one off Amazon like this: https://www.amazon.ca/KEMIMOTO-Belt.../dp/B07KBWHMN3/ref=sr_1_7?dchild=1&keywords=rzr+belt+tool&qid=1632281789&sr=8-7)

Besides the belt tool, how important are the other pieces that I am missing?