Complete Guide to Suspension Parts for a 2012 Polaris RZR 800

If you own a 2012 Polaris RZR 800, you know that the suspension plays a critical role in how your UTV handles trails, rocks, and rough terrain. Over time, stock suspension parts wear out or simply don't deliver the performance you need for aggressive riding. Upgrading or replacing suspension components can transform your RZR's ride quality, stability, and durability. This guide covers the essential suspension parts for the 2012 RZR 800, what each does, and how to choose the right ones for your riding style.

Understanding the 2012 Polaris RZR 800 Suspension System

The 2012 RZR 800 features a double A-arm front suspension with 10 inches of travel and a trailing arm rear suspension with 9.5 inches of travel. It comes with preload-adjustable shocks, but the damping is basic. The suspension geometry is well-balanced for trail riding, but serious off-roaders often find it lacking in harsh terrain. Key components include shocks, springs, control arms, sway bars, and bushings. Each part works together to absorb impacts, maintain tire contact, and keep the vehicle stable.

Common Suspension Parts That Need Replacement or Upgrade

Shocks and Struts

Shocks are the heart of the suspension. The stock shocks on the 2012 RZR 800 are twin-tube gas-charged units that work fine for moderate use, but they fade quickly during high-speed runs or heavy loads. Upgraded shocks, such as those from Fox, Elka, or Walker Evans, offer adjustable compression and rebound damping. For the 2012 RZR 800, the front shock length is around 17.5 inches and the rear is 18.5 inches (approximate; always check your model). When choosing shocks, consider your terrain: softer valving for rocks and trails, firmer for desert whoops.

Fox 2.0 and 2.5 Shocks

Fox shocks are a popular upgrade. The 2.0 series offers a good balance of performance and cost, while the 2.5 series adds more damping oil volume and adjustability. Both are bolt-on for the 2012 RZR 800, but you may need to reorient the reservoirs for clearance.

Elka Stage 1, 2, 3, 4, and 5

Elka offers shocks tuned specifically for the RZR 800. Stage 1 is entry-level with preload and rebound adjustability, while Stage 5 includes dual-speed compression adjusters and a piggyback reservoir. For trail riding, Stage 2 or 3 is recommended; for racing, consider Stage 4 or 5.

Springs

Springs support the vehicle's weight and absorb initial impacts. The stock springs are progressive rate, which are forgiving on small bumps but can bottom out on big hits. Many riders switch to straight-rate springs matched to their weight. For the 2012 RZR 800, common front spring rates range from 125 to 200 lbs/in, and rear from 150 to 250 lbs/in. Heavier riders or those with accessories need stiffer springs. Eibach and Teryx manufacturers make springs specific to this model.

Control Arms and A-Arms

Control arms connect the suspension to the chassis. The stock stamped steel arms are strong but heavy and prone to bending in severe impacts. Aftermarket A-arms, such as those from SuperATV, High Lifter, or HCR, are made from chromoly or aluminum. They correct geometry issues, increase clearance, and allow more caster or camber adjustment. For the 2012 RZR 800, you can find long-travel kits that push travel beyond 14 inches. However, longer arms may require shock relocation brackets or longer shocks.

Front A-Arms

Stock front A-arms give about 10 inches of travel. Upgraded arms with high-clearance designs move the ball joint lower to reduce the chance of hitting rocks. Brands like Double Take and S3 Power Sports offer bolt-on options with greasable bushings.

Rear Trailing Arms

The rear uses a trailing arm setup. Stock arms are steel tubes. Aftermarket options offer increased strength and a few more inches of wheel travel. Look for arms with replaceable heim joints or urethane bushings for less flex.

Sway Bars (Stabilizer Bars)

Sway bars reduce body roll during cornering. The 2012 RZR 800 has a front sway bar; the rear is often absent or minimal. Upgrading to a thicker sway bar or adding a rear sway bar can dramatically improve handling in high-speed turns. However, a stiffer sway bar can reduce articulation on rocks. If you crawl over obstacles, consider disconnecting the sway bar. Brands like JMM Offroad and S3 Power Sports make sway bar kits for the 2012 RZR 800.

Bushings and Ball Joints

Suspension bushings wear out, causing squeaks and sloppiness. Polyurethane or Delrin bushings provide tighter control at the cost of more vibration transmitted to the frame. Greasable ball joints extend service life. For 2012 RZR 800, the upper and lower ball joints are common wear items. Upgrade to Moog or OEM replacement if just replacing, but seek quality greasable units for longevity.

Shock Tuning and Setup Tips

Even with the best parts, proper setup is key. Start by setting ride height: measure from the wheel center to fender edge with no load. For the front, aim for 1-2 inches of sag (difference between full droop and resting ride height). Adjust preload collar accordingly. Rebound damping should be set so the suspension returns quickly but doesn't top out. Use the "roll-down test": push down on the bumper and release; if it bounces up more than once, slow rebound. For compression, start at a standard setting and adjust based on how the vehicle feels on impact.

Recommended Suspension Upgrades by Riding Style

Trail Riding and Slow Speed

• Soft-valved shocks (Fox 2.0 or Elka Stage 2)
• Stock springs or slightly stiffer (about 150 lb/in front, 175 rear)
• High-clearance A-arms to avoid rock damage
• Retain stock sway bar for light body roll control
• Polyurethane bushings for durability

Dune and High-Speed Desert

• Stiff-valved shocks with cooling reservoirs (Fox 2.5 DSC or Elka Stage 5)
• Heavy springs (200 lb/in front, 250 rear)
• Long-travel control arms (14+ inches travel) for stability
• Thicker sway bars to prevent roll at speed
• Heim joint bushings for precision

Rock Crawling and Technical Terrain

• Soft progressive shocks (Fox 2.0 with custom valving)
• Light springs (125-150 lb/in all around) for maximum articulation
• Stock or mild control arms with +2 width for stability
• Disconnect sway bar or use quick-disconnect links
• Rubber bushings to allow flex

Budget Considerations

Suspension upgrades can range from a few hundred dollars for bushings and springs to several thousand for a full long-travel kit. If you are on a budget, focus on shocks and springs first; they make the biggest difference. A quality set of shocks (around $800-$1,200) can transform the ride. Control arms are best left until you need replacement or want more travel. Sway bars are relatively cheap ($100-$300) and improve handling. Always factor in alignment costs and potential need for wheels with different backspacing to clear larger arms.

Installation Considerations

Many suspension parts are bolt-on, but some require welding or fabrication. Shocks, springs, and sway bars are typically direct replacements. Control arms may require drilling for bolt holes or modifying factory mounts. If you’re not comfortable, have a professional install. After installation, get a full alignment: set toe to 1/8 inch toe-in, camber as needed (usually 0 to -1 degree), and caster around 4-6 degrees. Some aftermarket arms have built-in adjustments.

Final Recommendation

For the most practical upgrade to your 2012 Polaris RZR 800, start with a set of adjustable shocks like Fox 2.0 or Elka Stage 3. Pair them with springs matched to your weight (usually 25-30% stiffer than stock). Then, replace worn bushings with polyurethane. This combination provides a noticeable improvement in ride quality and control without a huge investment. If you ride hard or carry heavy loads, add a thicker front sway bar. For serious off-roaders, consider a long-travel kit but plan for the extra cost and installation complexity. Always buy parts designed specifically for the 2012 RZR 800 to ensure proper fitment. With the right suspension setup, your RZR will handle better and last longer, giving you more confidence on every ride.