How to Find your Polaris RZR Roll Bar Size and Style

May 12th 2020

Stock Polaris RZR roll cages are really only meant for a single roll. And for this reason, a lot of Polaris RZR owners have installed either custom or aftermarket Polaris RZR roll cages on their machines. Baja roll cages are popular, and DOM tubing is a common material used to create custom Polaris RZR roll bars and cages. But regardless of the model and edition of your rig, be it an RZR RS1, an RZR Turbo, or an RZR 4-door, knowing the dimensions of your Polaris RZR roll bars and crossbars is important. 

If you’re looking to install aftermarket Polaris RZR accessories like windshields, doors, and roofs, knowing the width, diameter, and perimeter distance of your roll cage tubes will help you avoid getting the wrong accessories.

Factory Polaris RZR Cage Sizes

The cages on the Polaris RZR Pro two-seat and four-seat vehicles have 2-inch roll bars, while the Turbo S, Turbo XP, XP4 Turbo, XP 1000, and XP4 1000 all have 1.75-inch roll bars. The 2015 and newer RZR 900s also have 1.75-inch roll bars, and so do all the RZR models that came before 2014. However, not all aspects of the pre-2014 roll cages are the same size. The harness bar and rear bumper crossbars on the RZR, RZR S, and RZR XP are 1.5 inches, with the rear top crossbars being only 1.25 inches on the four-seat versions. Meanwhile, the youth-size Polaris RZR 170 has a roll cage that measures 1.25 inches. 

Polaris RZR Roll Bar Size by Vehicle

  • XP 900 (2015+) - 1.75"
  • XP 1000 & XP 4 1000 - 1.75"
  • XP Turbo & XP 4 Turbo - 1.75"
  • Pro 2 seat and 4 seat - 2.0″
  • 170 - 1.25"
  • RZR's 2014 & Older - 1.75"

It should also be noted that the size of Polaris RZR roll bars and cross members aren't always congruent throughout. For example, while the Polaris RZR 900 has a 1.75-inch roll cage, the horizontal tube behind the seats is only 1.5 inches. 

In addition to the size of the Polaris RZR roll bars, it is also helpful to know the size of the hardware used to secure the connection between bars. For example, 3/8-inch standard thread bolts are used in the rear ROPS extension housing for any 16+ 900S or 1000S RZR. In many cases, paint will prevent you from easily threading bolts. If this is the case, you might have to tap the hole beforehand so that it accepts the bolt thread. 

Aftermarket Polaris RZR Cage Sizes

Although there are a variety of possible sizes for custom and aftermarket Polaris RZR roll cages, most use either .095-inch or .120-inch tubing. The wall thickness of a factory RZR roll cage is only .065 inches, so aftermarket RZR rollover protection structures (ROPS) are generally heavier than OEM RZR cages. 

As we mentioned earlier, many aftermarket Polaris RZR cages are made from DOM (drawn-over-mandrel) tubing. However, such electrical-resistance-welded (ERW) tubing is far from popular among racing organizations, and many riders would argue that sewer pipe should only be used for sewers, and the good stuff should be used when your life's on the line.  

One problem with factory Polaris RZR cages is that they are bolted together using thin-walled tubing with no supports. Sure they can take a good shot in the A-pillar, but roll them once and they’ll crumple, usually breaking in the main frame section. Unfortunately, most OEM Polaris Rzr cages barely meet defined legal specs, and they are designed to absorb impacts by crumpling up and deforming. 

The more rigid the cage, the harder the impact is on your body. If you look at Formula One or NASCAR, you’ll notice that they use soft-wall cages to cushion the driver from blows. And while the same concept is true with UTVs, if you’re in a multiple-roll situation -- which is common on steep and hilly terrain -- you’re going to want a Polaris RZR roll cage that can withstand multiple blows without deforming. 

In Closing

Whether you have the stock Polaris RZR roll cage, an aftermarket Polaris RZR roll cage, or a custom-built Polaris RZR cage, knowing the size and weight dimensions of your ROPS is helpful for a number of reasons. If your cage is heavy, for example, you might want to adjust your suspension to be stiffer. If your cage isn’t stock, you might experience difficulties finding windshields, doors, mirrors, and cage mounts that fit properly. Whatever the case may be, the more info you have about your cage, the better you'll be!