How to Lower the Roll Cage on Rzr 800

I've heard lots of folks talk about chopping the roll cage on a Rzr 800 for better looks and strength.  Having a Rzr 800 for testing recently we decided to give the roll cage chop a try ourselves.  After doing some research into the modification I grabbed a tape measure, saw-saw and made the first two cuts!  After the first two cuts were made we were at the point of no return and we pushed forward.  The video overview of the cage chop can be watched below or on our website.

If you're considering this modification remember that a factory roof will still fit the cage afterward.  We completed this chop with rather basic garage tools and the list of tools and materials is listed.

TOOLS & MATERIAL NEEDED:

• tape measure
• masking tape to mark cuts
• saw-saw with good metal cutting blade
• grinder
• ratchet straps
• 8mm allen wrench to loosen roll cage
• mig welder (stick welder could be used)
• 41 inches of 1 3/4 tubing
• two inserts made of 1 1/2 O.D. tubing approx 2.5 inches each.

1. Begin the cage chop by removing the seats and liberally loosening all eight 8mm allen head cage bolts.

2. Next decide how much you want to lower the Rzr 800 cage.  We removed 5 1/2 inches from the rear of the cage and that provided enough head room for a 6'2" person with helmet to sit in the cab comfortably.

3. Mark the first cut with tape as pictured below (measure from the lower horizontal side support at approx. 5 1/2 inches up)

4. Next mark the upper cut by measuring from the initial mark.

5. After removing the two pieces of tubing (5 1/2 inches in our project) it's time to modify the upper horizontal support cage bar. Either cut it in the middle or completely remove it by grinding off the welds.  It will eventually need to be completely removed by grinding off the welds on the tubing and support brackets, but can be done after the cage is pulled down and back together.

6. Next weld the inserts into the lower section of the cage or where the initial cut was made.

7. Now it's time to spread the upper rear part of the cage to fit into the inserts.  We used large ratchet straps secured to pillars on either side of the cage.  We had to really crank on the straps in order to achieve the desired spread.

8. With the straps pulling the cage a part still attached attach another set of ratchet straps to the top of the cage and to the lower horizontal support.  Tightening the straps will bring the cage down and into the desired location.

9. After the Rzr 800 cage is pulled back together and set into the inserts weld it up.

10. To complete the project the upper horizontal cage support and brackets will have to be completely removed and the existing cage ground smooth.  It is possible to remove the support brackets from the existing cage and upper horizontal for reuse.  To rebuild the upper horizontal support you will need approx. 41 inches of 1 3/4 O.D. tubing.  Grind both ends of the upper horizontal support brace to the contour of the existing cage.  Take you're time here and get the best fit possible.  Once fit, weld it into place and reinstall the two cage supports.

What is the Difference in Demand Drive Fluid and Angle Drive Fluid: Polaris Front Gearcase Noise After Oil Change

Recently we were changing the front differential fluid on a 2012 Polaris Sportsman 800.  Some folks suggested using Angle Drive Fluid and that it replaced Demand Drive Fluid.  The Owner's Manual makes no mention of this fluid, so after much research and looking at the fluids, it's apparent that these two oils are different in every way.  Watch the Comparison.

Polaris Angle Drive Fluid is made for the earlier model Polaris 4x4 ATV's that have the electrically actuated hub assembly.  This means the AWD system engages at the hub assembly or similar to a old pick-up truck that you have to get out of and lock the 4wd system in at the center of the front wheels.  The front diff on these style quads use the Angle Drive Fluid, which appears to be the same consistency and very similar to a gear oil.

Polaris Demand Drive Fluid is formulated for (approximately) 2004 and newer Sportsman's that the AWD (4x4) system engages in the front differential.  This fluid is much thinner and resembles hydraulic fluid.  The Demand Drive Fluid is clear and very thin as you can see in the video.  Some folks have ran Angle Drive Fluid in the newer center actuating front differentials with no issues, while others report the fluid made their front gearcase make a loud popping noise and ultimately break down.