Upgrading your Polaris RZR S 800 suspension is one of the most effective ways to improve ride quality, handling, and durability. Whether you're replacing worn components or building a custom setup for your riding style, understanding the available parts and how they work together is essential. This guide covers the key suspension parts for the 800 RZR S, their functions, and what to consider when choosing upgrades.
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Understanding Your Polaris RZR S 800 Suspension
The factory suspension on the RZR S 800 is designed for a balance of comfort and off-road capability, but it has limits. The stock setup uses dual A-arms front and rear with coil-over shocks. While adequate for casual trail riding, it can feel soft in aggressive terrain or when carrying heavy loads. Aftermarket parts allow you to tune travel, damping, and geometry.
Stock vs. Upgraded Suspension
The stock suspension uses 10 inches of travel front and rear. The shocks are basic emulsion-type units with limited adjustability. Upgraded parts often provide more travel, better damping control, and stronger materials. Common upgrades include longer-travel A-arms, high-performance shocks, and sway bars. These changes can reduce body roll, improve wheel articulation, and increase bottom-out resistance.
Key Components
The suspension system consists of several parts that work together:
- Shocks: Control compression and rebound damping.
- A-Arms (control arms): Connect the wheel hub to the frame and determine travel and geometry.
- Sway bars (anti-roll bars): Reduce chassis lean during cornering.
- Tie rods: Steer the front wheels.
- Radius rods / trailing arms: control rear axle movement.
- Springs: Support the vehicle's weight and absorb impacts.
Top Suspension Upgrades for 800 RZR S
When shopping for suspension parts, focus on quality and compatibility. Here are the most common upgrades and what they offer.
Shocks
Aftermarket shocks are the single biggest improvement you can make. Options range from rebuildable coil-overs like Fox or Walker Evans to fully adjustable shocks with remote reservoirs. For the RZR S 800, a popular upgrade is the Fox 2.0 or 2.5 Podium series. These shocks offer improved damping and heat dissipation. If you run hard in rough terrain, consider shocks with piggyback reservoirs to prevent fade.
Key considerations:
- Check if shocks are direct bolt-on or require modifications.
- Consider dual-rate springs for progressive spring force.
- Adjustable compression (high/low speed) gives fine-tuning control.
A-Arms
Stock A-arms are steel and offer limited travel. Upgraded A-arms (often in chromoly or aluminum) increase travel to 12-14 inches, improve ground clearance, and allow better suspension geometry. Brands like HCR Racing and SuperATV make tubular A-arms for the RZR S 800 that are stronger and lighter.
Things to watch:
- Long-travel A-arms may require longer shocks.
- Some A-arms come with pre-installed ball joints and bushings.
- Look for caster/camber adjustability to dial in alignment.
Sway Bars
A sway bar reduces body roll but can also limit articulation. If you want a flatter ride in corners, an aftermarket sway bar with adjustable stiffness is a good choice. For rock crawling or rough trails, disconnecting sway bars temporarily improves wheel travel. Quick-disconnect end links are available for the RZR S 800.
Tie Rods
Factory tie rods are prone to bending in hard impacts. Upgraded tie rods (often made of 4130 chromoly) are stronger and have replaceable rod ends. Brands like Rhino Axle and Rugged Radios offer heavy-duty options. Replacing tie rods when you notice steering slop or after hitting a rock is wise.
Choosing the Right Parts for Your Riding Style
Your upgrade choices should match how and where you ride. A desert runner needs different parts than a rock crawler.
Trail Riding
For moderate trails, a good set of adjustable shocks (like Fox 2.0) and quality tie rods suffice. You don't need to max out travel; focus on comfort. Consider adding a sway bar if you want less body lean. Stick with stock A-arms unless you need more ground clearance.
Dune and Desert
High-speed desert riding demands more travel and better heat management. Long-travel A-arms (12+ inches) with 2.5-inch shocks and piggyback reservoirs are ideal. Stiffer springs prevent bottoming on jumps. A sway bar helps stability in the whoops. Upgrade tie rods and radius rods for durability.
Rock Crawling
In slow, technical terrain, articulation matters most. Remove or disconnect the sway bar for maximum wheel flex. Use 2.0 shocks with soft springs. Heavy-duty A-arms withstand impacts. Skid plates protect suspension components. Consider limit straps to prevent over-extension.
Installation Tips and Considerations
Installing suspension parts yourself is doable with basic mechanical skills, but some jobs require alignment or pressing. Here are practical tips:
- Always use new hardware, especially nuts and bolts.
- Torque all fasteners to manufacturer specs.
- Get a professional alignment after significant suspension changes (especially with adjustable A-arms).
- Bleed brakes if you disconnect brake lines.
- Grease all pivot points during reassembly.
- Test ride and adjust shock settings (clickers) for your weight and terrain.
If you're not comfortable, have a reputable shop do the installation. Improperly installed parts can be dangerous.
Final Recommendation
For most RZR S 800 owners looking for a balanced upgrade, start with a set of quality shocks (Fox 2.0 series or similar) and heavy-duty tie rods. This combination dramatically improves ride quality and durability without breaking the bank. If you ride aggressively in rough terrain, add long-travel A-arms and a sway bar. For rock crawling, prioritize articulation with a disconnect sway bar and soft springs.
Always verify part compatibility with your specific model year (some years have minor differences). Stick with established brands known for off-road suspension. A well-thought-out suspension upgrade will transform your RZR S 800 into a more capable and enjoyable machine.