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Has anybody out there figured out all the tool sizes (Ie; sockets,wrenches,screwdrivers,torx) required to completely work on your RZR.

Im trying to get a road trip tool kit made up so I dont have to pack my tools from home.

A list would be freaking awsome.
 

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Has anybody out there figured out all the tool sizes (Ie; sockets,wrenches,screwdrivers,torx) required to completely work on your RZR.

Im trying to get a road trip tool kit made up so I dont have to pack my tools from home.

A list would be freaking awsome.
I have wanted to do the same thing. It would be nice to know the lug size, star bits, hex head both metric and standard, also it would be nice to know of any funky tools that work better for certin things like a T handle thing-a-mawich for changing the belt or a long neck do-hicky for adjusting the muffler belt or chain depending on which model year you have. I have not done any work on mine yet so I have no idea.
 

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I just wanna ride
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Polaris is all over the place. I got a metric and standard dog bone wrench and one of those folding pocketknife like torx tools and a few others. I hope for the best. I figure if Macgyver can build/fix anything with a paperclip, chewing gum, and a pickle I should be able to get a RZR off the trail with my tools.
 

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Polaris is all over the place. I got a metric and standard dog bone wrench and one of those folding pocketknife like torx tools and a few others. I hope for the best. I figure if Macgyver can build/fix anything with a paperclip, chewing gum, and a pickle I should be able to get a RZR off the trail with my tools.
Good idea with the dog bone, that covers a bunch.
 

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Here's a basic list

5/16 3/8 7/16 1/2 9/16 5/8 11/16 3/4
9/16 deep socket 5/8 deep socket

METRIC
8mm(same as 5/16) 10mm 11mm(same as 7/16) 12mm 13mm 14mm(same as 9/16) 15mm 17mm 19mm(same as 3/4)

TORX
#25 or #27(one thread said the 27 fits better)

ALLEN WRENCHES
4mm 5mm 6mm 8mm

3/8" rachet with 6" extension
3/8" swivel
Flat Screw Driver and #2 Phillips
 

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De Oppresso Liber
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Has anybody out there figured out all the tool sizes (Ie; sockets,wrenches,screwdrivers,torx) required to completely work on your RZR.

Im trying to get a road trip tool kit made up so I dont have to pack my tools from home.

A list would be freaking awsome.
Yes, some people have created a list of all the required tools. I think I saw it over on PRC but I am not 100% positive. What I have found to be a good kit is one of those small 100+ tool kits you can pick up in a small plastic case for anywhere from $20-$50. Granted they aren't the best tools but they do the job and you have a large variety of sockets, wrenches,hexes and there is usually a 50/50 assortment of standard/metric sizes. With that I added one of those $10 multi tip ratchet screwdrivers that has the different sized bits to include the torx and other weird types of screws out there. I've also thrown in a set of allen wrenches that are all attached like a swiss army knife for good measure. As far as I can tell, this set up will cover most trail side repairs that require tools, to include removing lug nuts or changing a belt.

You can carry less, but the footprint of these tools is small enough that it just makes sense to have them with you. Below are just examples of what I am talking about to give you a general idea. Choose a kit that has the tool assortment you think you'll need.



 
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I have the one below...Craftsman 42 piece.
I added the Torx bit and a 5/8 wrench(rear seat bar removal on the 4 to get the clutch cover out) and a 6" 1/4 extension to make getting to the clutch cover bolts easier. In another little bag I also carry a knife,pliers,misc hose clamps,safety wire,zip ties,gorrilla tape, a small air compressor and tire kit..probably some other stuff in there I'm forgetting lol.
I've often thought if someone came up with a specific RZR set up to sell I bet they could sell a boat load of them.
Sears sells an ATV/UTV specific tool kit ( Sears: Appliances, Tools, Electronics, Apparel and more from Craftsman, Kenmore, Diehard and other Leading Brands )
But the ATV isn't Crafstman,looks cheap like the crap that comes in the Polaris tool kits..and I've learned the hard way not to buy junk tools..they will fail at the worst possible time. JMO



 

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everything mentioned above and dont forget to bring a socket to remove the spindle nut (cant remember the size) but its nice to remove a broken CV. and just put the outer cup and spindle back on. tie wraps (zip ties). vise grips and channel locks, and a hammer. even a punch or two. (if its broken and your on the trail chances are its not going to come apart nice)

oh and i also bring a multimeter/amp clamp. everything is electrical so you never know
 

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AKA: blinginvic
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1 1/16" socket for the axle nut....

...speaking of booster cables, can the RZR be boosted by putting the positive cable to the starter terminal and ground the negative on the chassis? The reason I ask, is because I can't easily get to my battery because of the bench seat.
 

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I'm in the garage with the computer to type the list of what i've got...

Here's what I carry...not sure that it is complete, but so far I haven't needed something I didn't have - some of these tools aren't needed for the rzr but since I ride with a lot of different bikes, I try to have anything we might need.

I have 2 50cal ammo cans mounted in the bed, the following lives in the right hand one

Sockets:
1/4" Drive: 6mm-12mm, 5/16-9/16
3/8" Drive: 10mm-17mm, 3/8-5/8, T27
1/2" Drive: 14mm-18mm, 22mm and 27mm for axle nuts, 1/2"-7/8"
(you don't need a 22mm for anything on the rzr, but some of the sportsmans I ride with use a 22mm for an axle nut so I pack one in case they need it...)

At first, I just had the sockets dumped in the can, but I couldn't ever find what I was looking for - especially in the dark. I went to wal-mart and bought a couple of those cheap metal socket holders and cut them down short enough to fit in the box. Now they stay much more organized and it's easier to find them.

Ratchets:
(1) 1/4" drive
(2) 3/8" drive
(2) 1/2" drive

Extensions, adapters etc:
2", 3", 6" in all 3 drive sizes, and an additional 8" in 3/8" drive
Wobble (or swivel, or ujoint or whatever ya wanna call it) in all 3 drive sizes
adapters up and down for drive sizes to allow different size ratchets to drive different size sockets...

Wrenches:
8, 10, 11, 12, 13, 14, 15, 17, 19mm
5/16, 3/8, 7/16, 1/2, 9/16, 5/8"

I keep the wrenches together with a 4" x 1/4" bolt with fender washers on either end and a wing nut. I run this through the box ends of the wrenches. One bolt for standard, the other for metric.

Pliers:
Vise Grip pliers
Vise Grip crescent wrench (yup, it clamps down just like the pliers! - perfect for grabbing the flat spot on a tie rod)
needle nose pliers
channel locks

Screwdrivers, etc:
#1,2,3 Phillips
big and little flat head
Screwdriver style T-27 Torx driver
Short snap on pry bar
Cheap pocket knife
Brass hammer (with wood handle cut down just a bit so it will fit!)
Three fold up hex key sets (one standard, one metric, one torx)
8" Drift punch

In the left one:

Flashlight
Tire inflator
Starting fluid (ether) for resetting a tire bead
Matches
A couple of rags
hose clamps of assorted sizes
zip ties
silicone sealant
dielectric grease
tire plug kit
spare belt
spare tie rod end
spare valve stem
2 decent used spark plugs
electrical tape (used it up this weekend so it's not actually in there but it's SUPPOSED to be!)

It might be overkill but since all this fits in the 2 ammo boxes it's worth carrying it for peace of mind!
 

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rzr4mud
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I dont even try to carry it all with me but I have found a Bell bicycle multi tool that is pretty handy to have. Really compact with flat & phillips screwdivers, a few torx heads, and box end wrenchs. Found it at Walmart for around $15.
 

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Two crescent wrenches, phillips, straight and torque screwdrivers, pliers and *****. For the ride
Then you keep a rollaway in the trailer.
 
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