A SOLID BASE

We started out with a machine we already liked. How well did we like it? You can read about in the very pages of this magazine in our review of the 2018 ZFORCE 1000 EPS LX. It is a great machine and a basis for our project. We knew we could take things a bit more extreme, so after we did our initial impressions of the machine, we got to work tearing it down and starting from the very basics.

We stripped the unit down and sent out many of the parts of the base machine to be powder coated. This included the ROPS cage, the front and rear bumpers, the rock sliders, and the spare tire rack. Power coating these parts again required sand blasting them down to bare steel, recoating them and applying new powder coat, and then heat-treating the finish for a glossy, factory look.

STAGE ONE – A-ARMS AND SUSPENSION

When we started to actual build process, we wanted to add ground clearance without adding a lift to the machine. To get this, we went to SuperATV for a set of their High-Clearance front A-arms for the CFMOTO ZFORCE, and a set of their rear Offset High Clearance A-arms out back. These A-arms gave us an extra 1.5-inches of ground clearance in an A-arm that is 25-percent thicker tubing than stock. It creates a highly functional piece that adds to the trail agility of the machine and looks seriously cool too. The rear arms have an additional 1.5-inches of offset, too, giving the ZFORCE a little better trail manners and stability, along with a different look.

With the upgraded A-arms, we knew we needed premium shocks, and where better to go than ELKA? We added Stage 5 UTV shocks all the way around for the most adjustability and precise action possible. These shocks are legendary for their superb action with high- and low-speed compression, rebound and preload adjustment. If we stopped right here, you’d still think this was an amazing upgrade to the ZFORCE, but you know we did more.

STAGE TWO – CAGE AND ELECTRONICS

After we had our new suspension system in place, we set our newly powder coated roll cage back in place. With the cage back on, it was really starting to take shape and what we saw in our minds when we started, was actually looking more like a real machine.

With the cage back on, we started in with the electronics. We knew we were adding in a stereo system, so we started that with a completely sealed and weatherproof, 360-watt amplifier from the experts at SSV Works. This amp is plug-and-play and designed for UTVs, making it the logical choice. We also added their Bluetooth panel-mount media controller. This way, we aren’t relying on the radio for tunes, but can link our phone and use downloaded music.

For speakers, we added SSV Works’ 120-watt 6-1/2-inch pod speakers in the rear of the cage, and adapted their 6-1/2 inch, 120-watt RZR speaker pods for the front speakers. Overall, we are very pleased with how the sound system turned out.

From there, we decided that our custom-built ZFORCE needed to communicate better, so we tapped the pros at Rugged Radios for some assistance. Their ABM25 25-watt weatherproof, dual-band radio is a great way to communicate with other machines in your group. Plus it looks cool, and is as durable as they come.

We also want to be able to communicate inside the ZFORCE with the person in the passenger seat, so while we were at it, we had Rugged Radios set us up with the RRP660 2-place intercom system with helmet kits. This system works with your helmet and is dash-mounted so you can easily talk to the person sitting next to you, without having to try to shout over the engine, trail and sound system.

Now that we had tunes and communication chores taken care of, there was one other electrical thing to add – lighting. There were a lot of options for lighting, but we went to where we knew we’d find just the right stuff – Rigid Lighting. We added a 30-inch Radiance Plus LED light bar that is 30-percent brighter than the previous model. We also added Radiance POD lights from Rigid and topped it off with their Rock Light kit that mounts small LED light pods under the chassis for letting the immediate terrain show up, perfect for rock crawling after dark. There are several option for colors for the LEDs, but for practicality and actual use in the dark, we chose the Amber colored lights for best night vision.

To add to the safety factor as well as the coolness factor, we went back to SuperATV for a set of five-foot LED Whip lights. These flexible LED whips really show up well after dark and are a great safety feature for remaining visable after the sun goes down. You can program the LED colors yourself, too, which is a fun and custom look.

While we were at SuperATV, we opted for some of their excellent 12-volt Off-Road Rocker Switches to control all of the lighting options we added to the ZFORCE. Using all of the same switches gives our machine a uniform look and ups the cool factor, plus we know that these are durable switches that won’t fail on us.

STAGE 3 – BODYWORK

Once we had all the electrical stuff back in place, it was time to start getting more of the bodywork back on the machine. We had our cage back on, and now we were able to get the matching rock sliders back on that we had powder coated too. We also had the front and rear bumpers ready to go back on and the whole unit was really coming together well.

We reinstalled the stock plastics, but we had removed all of the stock graphics. You can’t just have a stock-looking machine with the amount of custom work we had into our ZFORCE! Kuvek-Amerika created a special, custom full body wrap for our CFMOTO monster that really popped with the custom powder coating. If you’ve never installed a wrap on a machine before, oh man is it a lot of work. You have to go slow and meticulous, working ever last bit of air out of the adhesive and stressing to make sure everything lines up right and goes in perfect. A wrap costs hundreds of dollars, and if you screw it up, you can’t just go and redo it. You have to start over. Luckily this wasn’t our first rodeo, and we knew what we were getting in to. A piece of advice on wraps. If you’ve never done one before, and aren’t sure what you’re doing, it is worth it to pay to have an expert install it for you.

STAGE 4 – SEATING FOR TWO

Once we had the plastic back on and looking fly, we bolted our powder-coated spare tire carrier back on. The machine was really coming together now. It was time to add some seats. We could have put the stock seats back in, but that wouldn’t be our style. Besides, we plan to serious drive this machine, so we knew we wanted a little more serious of a seating platform. PRP set us up with their new XC suspension seats. These are custom made seats that PRP makes specifically to order. They are originally designed for the Polaris RZR, but we were able to easily adapt them for our CFMOTO ZFORCE. These seats have extra bolstering to provide more support for your legs, back and butt, plus they are suspension seats, so you had added comfort from impacts and rough driving. As an added bonus, we were able to color match them to our build, for a classy look.

While we were at it, we decided to bump up the protective factor of the seat belts. The PRP seats will work fine with the stock seatbelts, but they also make a sweet four-point harness. We went with their color-matched 4.3 System, which mates a four-point harness with a three-inch wide belt for optimal comfort and security. They have EZ-adjusters to quickly set up the fit and get you secured in the machine, even when they are covered in mud.

STAGE 5 – WHEELS AND TIRES

Once we had everything done, the last step was one of the easiest. We chose to upgrade the stock wheels to MSA M31 Lok2 wheels. These are heavy-duty aluminum wheels that are as sturdy as they are beautiful. They are finished in a satin black that is baked on and extremely durable. The wheels are made even more stylish and rugged with the addition of a matte grey finished bead lock rim. MSA bead locks are nice because they design cleaning holes into the bead lock ring that helps with cleaning and movement of mud and debris out of the rim. That can be a problem with bead locks, but not with the MSA rims. Plus, they look amazing.

For tires, we went with something that could handle extreme terrain. EFX Tires makes some of the most rugged and durable tires on the market today. Their new Motovator UTV competition tire was designed for hard core competition. It has deep, siped tread with a broad contact patch to keep you digging in on everything from slick rocks to hard packed dirt, to loose soils. Deep sidewall tread helps pull you out of ruts and up inclines and the steel belted construction has more in common with light truck tires than it does with traditional ATV-type tires. You want extreme, we give you extreme.

SO, THERE IT IS.

We give you the 2019 CFMOTO ZFORCE 1000 SE as we envisioned it. We are unbelievably proud of this build and how well it came together. We’d like to thank each company involved for their help with making it all blend into one seriously awesome machine, and special thanks to CFMOTO for having the faith in us to make it happen, and for letting us put our stamp on a machine that you can go to your dealership and buy. If you’re lucky enough to buy one, we’d love to see picture or video of you enjoying it, and by all means, let us know what you think. We’re happy with how well it turned out and know you will be too.

Special Thanks to the following Build Partners:

CFMOTO Canada – EFX Tires – Elka Suspension – MSA Offroad Wheels – Kutvek Amerika – PRP Seats – Rigid Industries – Rugged Radios – Super ATV – SSV Works – Soucy International

The post Building The 2019 CFMOTO ZFORCE 1000 SE appeared first on UTV Planet Magazine.

Not long ago, we got invited to Brimstone Off-Road Park in Tennessee to ride new Polaris machines, including the new ACE 900. It didn’t take long for all of the UTV media in attendance to realize there was a problem. While we loved the ACE with the 570 engine, the 900 was too much of a good thing. It didn’t take long at all for the power of the ProStar 900 engine to surpass the abilities of the suspension and handling of the ACE chassis. Polaris figured this out too and made some changes that completely reversed the course for the machine. They pulled another card out of the deck and borrowed technology from the RZR lineup, bringing in the suspension system and a few other key parts from the RZR S line. This gave the ACE 900 a whole new life and the ACE 900 XC was born.

The ACE 900 XC is a completely different animal compared to the machine it replaced. Where the original felt under suspended and had poor handling, the new wider, better suspended XC eats up terrain like a RZR, but with a great center of gravity feel. When we got a test unit, we really enjoyed the machine. Of course, being the fun-loving guys we are, we couldn’t help but think it’d make a really fun project to build one of these machines into a truly amazing machine. Challenge accepted, it’s time to get to work.

Deconstruction

With any build project, once you have all the parts lined up that you’re going to use, you need to prep the machine for the build. I can speak from experience here when I tell you that something you need to do with any build, be it a complete custom project like we did with the ACE, or if you’re just installing a few parts on your own machine – start with a clean machine. Do a very thorough washing and be sure you have all the dirt, mud and gunk off before you get started. It just makes everything go smoother.

ROPS it up

With any UTV, the ROPS roll cage is very important. To be approved for use, the ROPS has to meet certain criteria for roll-over protection. The stock ROPS design from Polaris is based on the RZR lineup as opposed to what they use on the Ranger and General lines. It is round-tubing steel and does a decent job of protection. However, for serious off-road use, there is room for improvement.

Concept Distributing is a British Columbia-based business that designs and creates custom UTV parts. Known mostly for their work with RZRs, they were the place to go to for a very trick custom cage for our ACE project. Made from heavy-wall steel tubing, the cage is gusseted for additional strength and completely power coated in a slick neon color that matched the graphics on the ACE. The cage fit right into the stock mounting points so it was truly a bolt-on addition. We opted for an aluminum roof as part of the cage. Concept Distributing offers several roof options as well as a wide range of other colors.

Polaris supplied the front bumper. Part of their own Pure Polaris accessory line, the bumper added an extra level of protection up front and being designed alongside the ACE, it was as simple of a bolt-on product as it gets. While it is nice to see what the aftermarket is doing, there is definitely something to be said about using some of the factory-designed accessory parts. For the sheer simplicity of the installation. As a plus, if you add them on at time of purchase of the machine, they can be included with the loan if you’re financing the unit.

Exhausting stuff

The stock exhaust on the ACE 900 XC is very similar in design to the Ranger lineup. It is a large muffler that does a great job of quieting the machine. Let’s face it, Polaris units have a great reputation for being quiet-running machines. But sometimes you want to change the tune, and a machine like our ACE 900 XC screams for a little more sportier exhaust note. But how do you do that without making it too loud?

The answer is the Titan QS exhaust system from HMF Racing. The Titan QS drops a whopping five pounds from the weight of the stock exhaust and with ECU tuning that HMF suggests, adds three to four additional horsepower to the power output. The best part? The HMF Titan QS only adds one additional decibel level to the sound output, making it still very quiet. The installation is very easy being a simple bolt-on product. We were very impressed with this product for sure.

Winching duties

Adding a winch to your UTV has almost become a vital part to any unit, as they have a ton of uses as well as being a bit of insurance that you’ll make it back home at the end of the day. There are several brands available for this type of machine, but again, sometimes it’s easier to just go with the factory option. Luckily for us, the Pure Polaris accessory winch is a really good, high-quality unit comparable to anything else out there.

Our 2,500-pound winch came with everything needed for installation, including a wired remote control, a nice feature for when you’re trying to get your ride out of the mud. Being a factory option, the winch itself was pretty much plug and play to get it wired into the power source. The trickiest part was actually running the wires, as there’s not a lot of extra room for working in those smaller areas. Still the payoff for the winch was well worth it.

Sound duties

Let’s face it, there are definitely times when you want to just kick back and enjoy some music while on the trail. We decided for this project that we wanted to add a sound system to our ACE 900 XC, so we went looking for something that fit the overall built theme, meaning we wanted it to be rugged and compact.

SSV Works is a company that specializes in building sound systems and other accessories for side-by-side vehicles. Their sound systems work exceptionally well and are extremely rugged. Our system consisted of two speaker pods that mounted on the backside of the roll cage, and a dash-mounted control panel. The system has an input jack, a USB input and is fully Bluetooth compatible, so it will work with just about any form of device you want to hook up to it. Installation requires a few hours of work. All of the directions are pretty clear, but this is one of those accessories that if you don’t feel comfortable, you should really take it to a dealership.

CBin’ ya later

Communication is important. If you’re on the trail, it is a good thing to be able to communicate with your buddies, especially if you’re riding in strange terrain, or you can’t see everyone. In an emergency situation, being able to communicate is vital, and as we all know, you can’t always rely on having a cell phone signal on the trail. A CB radio seemed like a good idea for a true cross-country build.

Rugged Radios supplied most of the communications equipment for the off-road racing world. Their products are built to take on the harshest environments and still work, so we were confident that they could help. Boy, did they. Their CB radio system installed very easily with a simple connection to the power source and running a wire for an antenna. Rugged Radios has amazing customer support too, so if you ever need help, or have a question, they are available with advice and technical support.

Lighting it up

What build project would be complete without additional lighting? The stock headlights do an adequate job of providing illumination, but there’s always room for more, especially when you’re getting into technical sections. For our lighting solutions, we went to Rigid Industries for a couple of reasons. For one, they have some of the brightest, most compact lights available. And they offer something that not many other companies do – a lifetime warranty.

We mounted their Dually Sideshooter light pods on the front of the cage. These compact pods offer a ton of bang for the buck in terms of cost and space for the amount of light you get. We also mounted a set of the Rigid Reflect light, side-mounted mirror combos. These amazing products have a rearview mirror on one side and a LED light mounted on the front, adding light to the side of your vision range. We also added Rigid’s Rocklight kit, which mounts up under the wheel wells to shed light on trail around the tires. This is a big help when you’re riding at night in tricky areas or picking your way up a rocky section. Installation of the Rocklights can be tricky and time consuming, but for the most part, it’s pretty easy. We also added the Chase light on the rear of the cage. This is a rear-facing, multi-function light that adds illumination, brake lighting and other options for use when trail riding to keep you highly visible. You can even select which functions you want to connect by following the easy-to-use directions.

Sit down!

We finished off the interior of the ACE 900 XC with several products from PRP Seats. We added their Door Bags. These cool products bolt on in minutes and add extra storage in the doors along with adding a knee protector pad to cure the dreaded RZR Knee that can happen when you bang your knees into the metal door frame while hammering on the trail.

To keep our butts firmly planted, we added a PRP four-point Safety Harness. This also installed quickly, as Polaris has made adding safety harnesses easy, knowing that it is a popular option with their machines. For a seat, we chose the PRP GT S.E Suspension seat. Not only are these extremely comfortable seats, but you get to custom designed your own seat right through their website. We color matched ours to our project and even had the option to include our own Raven Media logo to make it look extra sweet. Installation was easy and the seat simply bolted in.

Wheels and tires

You didn’t think we’d do a build project and just reinstall the stock tires and wheels, did you? We went to the folks at Wheel Pros for some options and they talked us into mounted EFX Tires MotoMTC rubber. These 6-ply tires have 1.25-inch deep lugs and are an outstanding all-around performance tire with a smooth ride over intense terrain. We mounted them to KMC XD-Series wheels. The KMC wheels not only look great with some really aggressive styling, but they are super strong, making them a great choice for where we plan to hammer this machine in the future.

The payoff to this entire project is now we have a single-seat machine capable of traversing extreme terrain with ease. The roll cage and seating system work together to give us an extremely confident feel when we get into some truly challenging terrain. The tire and wheel combo hook up great and the lights from Rigid illuminate the trail completely. If we get in over our heads, there is a winch to pull us out and a radio to call for help if we need it. Overall, this is a highly rewarding build project and we can’t wait to start on the next one.

Videos

A special thank-you to all the partners involved in making this project possible!

The post Polaris Ace 900 XC Build Project appeared first on UTV Planet Magazine.

When it came time for parts and accessories selection for this project, we wanted to do something different. In our previous builds we used after-market parts from various manufacturers and vendors. For our Expedition build, when possible we used Can-Am OEM parts and accessories.

We decided to go this route because of the sheer quantity of OEM parts that were readily available for the Defender. We felt that the PAC division of Can-Am excelled at their parts and accessories offerings for our model year Defender. So simply put, some of the parts/accessories deserved recognition and needed to be included in this build project.

Using OEM parts however also added an extra challenge for our team. How can we assemble a unique build and stand out from the masses using mostly OEM parts? That was indeed the big question. However, we remained confident that with some creative ingenuity we would deliver an awesome looking ride!

THE BUILD PHASE

For those of you unfamiliar with the Can-Am Defender XT CAB package, the vehicle comes stock with a full cab enclosure which features: plastic roof and cab liner, 3-postion glass windshield, back glass, full hard doors with powered windows and a heater kit. Not only was the XT CAB package the ideal canvas for us to start our build project, but also the ideal setup for any backcountry explorer.

Since the Defender boasts one of the best interiors in the industry, the only add-on modification we made here was the addition of some serious tunes. For this we installed the Complete Overhead Audio System (OEM part #715002019). The audio system features: a rugged waterproof Jensen Bluetooth Stereo that offers multi-source inputs, a powerful 4x40W amplifier and 4 ultra-sturdy outdoor speakers. Installation is straightforward and well documented, but some time-consuming assembly is required.

Before completing the installation of the audio system, and since we had the interior roof liner removed, we proceeded to install a 15” (38 cm) LED Light Bar (OEM part #715002934). The light bar was installed on the roof of the unit using the Light Rack (OEM part #715002456). Power was supplied to the light bar using the Roof Power Cable (OEM part #715003094). Once we did all the necessary connections and tested the LED light functionality, we re-installed the roof liner and completed the audio system installation.

The audio system not only sounds great but also blends well with the Defender Cabs interior. The LED light bar mounted on the light rack compliments the roof design and contributes to the unit’s rugged exterior. Plus the extra lighting power is a definite must-have when venturing throughout the remote backcountry at night.

To increase all-round visibility and to make the unit trail compliant in our area, we installed a Panoramic Center Mirror (OEM part #715002512) and a set of Side Mirrors (OEM part #715002459). The installation of the mirrors was child’s play and complimented the unit nicely.

To protect the Defender’s front end, we added the following accessories: Front Bumper (OEM part #715002418), Front Corner Protectors (OEM part #715002833) and the Xtreme Front Bumper Plates (OEM part #715003005). Once again the installation was simple and well outlined in the installation instructions. Once installed, the combination of these 3 accessories not only added the protection element that we required for our build, but also added to the aggressive styling we were seeking.

To the front bumper we also installed and mounted 2 lights: Rear Cargo Light (OEM part #715002422). As the name implies, these lights are obviously intended to be used to illuminate the cargo bed area. However, we felt they looked awesome sitting on the front bumper. We connected the lights with the included wiring, ensured they were operational and move on with the rest of the build.

Since the Defender Expedition Build would be venturing on some tough terrain, we wanted to add as much protection to the body and the rear of the unit as possible. This was accomplished by installing the Body Side Protectors (OEM part #715003055) and the Rear Bumper (OEM part #715002419). These accessories were quick and simple to install and contributed to the unit’s assertive appearance.

One of the key features of the Defender is its versatile cargo box. We wanted to take full advantage of this customizable area and to do so, we installed the following accessories: Bed Wall Extender (OEM part #715002421), Headache Rack (OEM part #715002423) and the Gear Rail (OEM part #715003391). To the gear rail, we also installed a Kolpin Fuel Can with the following mount accessories: Gear Rail Mount by Kolpin (OEM part #715001422) and Fuel Pack Bracket by Kolpin (OEM part #715001427). With these accessories installed, we could now configure the cargo box to suit our needs based on the expedition and gear we needed to carry.

For complete installation instructions on all the parts mentioned above, please visit: instructions.brp.com and enter the mentioned part number.

STANDING OUT FROM THE MASSES

At this stage, the Defender Expedition was starting to take shape. We had now completed installing all the OEM accessories and we were starting to achieve the bold assertive look we were going for. However to make this build unique we now had to turn on our creative juices if we wanted the end result to stand out from the masses.

The Defender Expedition needed a lift kit and it also needed to sit on a new set of tires and rims. For this, we turned to our friends at SuperATV.

First, we installed the SuperATV lift kit, which would give a full 3” lift to the front and rear of the unit. The kit is quality construction and consists of 4 spring spacers. The kit comes with precise installation instructions and is easy to install. It’s important to note that a spring compressor is highly recommended for this type of lift kit installation.

Once the lift kit was installed we proceeded to install the SuperATV wheel spacers. After the quick installation of the wheel spacers was complete, we were now ready to install the tires.

For the tires, we selected a set of SuperATV 32” Intimidator All-Terrain tires. The Intimidator has a 6-ply construction and is designed for ultimate off-road performance. This tire is a versatile mud tire with a unique footprint that provides greater surface contact for maximum traction. We mounted the Intimidator tires on a set of 14” Healy Fast (HF) Rims. The HF rims are cast aluminum construction and come in a black satin finish.

The Intimidator Tires and HF Rim combination added the final touch of boldness, which would complete our assertive design.

As I mentioned at the beginning, the Expedition Build was to be employed for remote backcountry exploration and adventure. Obviously this meant we needed to find a way to account for overnight (or longer) stays in the great outdoors. Sure we could have went the traditional route of lugging tents around, but our friends at Podium Trailers had a better idea.

Luggcamper, a division of Podium Trailers, is already manufacturing a trailer/camper roadster edition, which is primarily used by motorcycle or Spyder enthusiasts. The luggcamper is a dual-purpose unit: the bottom half of the unit serves as a trailer (storage) and the top half serves as a popup tent.

After several discussions with Claude Mayer, owner of Podium Trailers, it was decided that his team would come up with a prototype off-road trailer/camper for our build project. We supplied the wheels/tires and some basic dimensions and his team quickly went to work on the prototype unit. It should be noted that the trailer/camper uses the same tires/rims as the Defender, 32” Intimidators mounted on 14” Healy Fast (HF) Rims.

After several months, we finally received the call that the Luggcamper Off-Road Edition was ready. This unit was a beast and it was built for battle. The unit featured: high ground clearance, swivel coupler and retractable safety chains allowing it to tackle any obstacles on the trails. The base of the unit offered ample storage and was also use to transport the plush removable mattress. The popup tent was of quality robust construction that featured interior lighting, powered by the solar panels on the roof of the unit.

The prototype Luggcamper Off-Road Edition was functional, robust and could easily navigate any trails. Plus lets not forget to mention that it looked awesome, especially sitting on the 32” Intimidator tires mounted on 14” Healy Fast (HF) Rims.

Now that all the pieces of our build were assembled, there was just one element missing: a custom wrap. For this we could think of no other than our friends at Affichage.ca.

Affichage.ca does wraps and graphic design work for multiple large-scale companies. From commercial trucks to race team, boats and even planes! No job is too big or too complex for the team at Affichage.ca. As we had done with our other build projects, I reached out to Jonathan Gagné, president of Affichage.ca.

During my conversation with Jonathan, he quickly realized that we weren’t sure which direction we wanted to go with the wrap design. He also realized that this wrap had to be as unique just as the build was. We discussed some basic color themes and his design team immediately got to work.

After a few days of reviewing samples and making modifications, the design was finally ready to go to print. The design is printed on a 3M vinyl adhesive paper and then is laminated with a 3M UV protection film. What is also unique about the approach used by Affichage.ca is that they do not use templates. They print out square section based on measurement and apply the wrap to the unit.

The time had finally arrived to apply the final touch on our Defender Expedition. We delivered the Defender and Luggcamper to Affichage.ca and watched the master technicians painstaking apply the wrap to the units. I have said these exact words in previous write-ups about Affichage.ca and I will never hesitate to repeat them. The guys over at Affichage.ca are true professionals in the art of wrap design and installation. Watching these guys create and install the wrap was like watching an artist paint on a virgin canvas: totally mind-blowing!

We are very proud of our Defender Expedition build and we consider this build to be our best one yet.

A very special thank-you to Can-Am Off-Road and Can-Am PAC division for the help with the Defender HD10 XT Cab and Accessories

PARTNERS BUILD LIST

We would like to thank all these partners for contributing to our build, without them this project would have been impossible. We invite you to visit their websites for more information on the products and services mentioned throughout this article.

The post Can-Am Defender Expedition Build appeared first on UTV Planet Magazine.

This year we wanted to repeat the experience, so we immediately contacted our friend Ken McDonald from Lucas Production. Without a moment of hesitation, Ken once again decided to join our build project team. Our friend the television producer however had a hidden ace up his sleeve and he felt it was the right time to drop the news on us. This time around not only would this build be featured in his French television series “Histoires de Sentiers” but it would also be showcased in his new and upcoming English series “Off-Road Zone”.

This news was huge, especially for us here at UTV Planet. Our readers would get to experience the evolution of our build not only in print but also via “Off-Road Zone” this fall on Wild TV. Now with all the media elements in place, we could start to conceive our next build project.

THE CONCEPTION PHASE

If you are in the market for a new UTV right now, you realize as we do that there are many good units on the market these days. We are fortunate to practice a sport that is evolving to the point that a consumer has a vast variety of units to choose from, based on his/her riding style and preference. So once again we were faced with the tough choice of vehicle selection.

However, one unit that was released in early January of 2015 drew our attention. It was introduced as one of the most versatile multi-passenger side-by-sides available: the Polaris RZR 4 900 EPS. It’s no secret the love we have for the Polaris RZR S 900, as it was one of our top-3 picks for 2015. The Polaris RZR 4 900 shares many of the same attributes as the RZR S 900; 75 horsepower, ProStar 900 EFI engine, Dual A-Arm Front and Rear Suspension, High-Performance All Wheel Drive (AWD) and a 60 in/152.4 cm width. This unit was perfect for the type of build we wanted to achieve, so Polaris was contacted for a loaner vehicle. When Polaris accepted to loan us the unit, we could finally apply a “check mark” against vehicle selection on our long to-do list.

Since we wanted this build to be bigger and badder that last year, we had to find a location for our build project that would reflect this. Our search stopped once we were introduced to Luc Cuillerier, the President of GarageBox. GarageBox is a leader in the field of residential garage organization, ranging from storage units to flooring and accessories. Basically if you want to “Pimp out” your Garage, this is the place to go-to! Luc graciously loaned us one of his demo garage units for our build and also for the shooting sessions.

The next several weeks were spent by our team communicating with some of the biggest names in the UTV aftermarket parts industry. As we had a particular look and feel we wanted to accomplish, parts selection was crucial and many big names stepped up to help us realize this build.

With the parts selection completed, one item remained for this build to be unique: a custom wrap. For this special job we turned once again to our friends from affichage.ca. We reached out to Jonathan Gagné, President of Affichage.ca with a very basic color idea (3 colors in fact) and his team immediately started masterminding a new unique concept for us.

The conception phase of our Polaris RZR 4 900 build project was now concluded and what follows led to the birth of the “Trail Warrior” (#trailwarrior).

THE DECONSTRUCTION PHASE

We took the stock unit and started breaking it down by removing the stock seats and belts, tires and rims, front and rear shocks, rear axles and exhaust. The rear passenger back panel along with the entire cargo bed was also temporarily removed. Finally, some factory plastics and cockpit paneling also needed to be provisionally removed to facilitate the passing of wiring for certain electrical components.

THE BUILD PHASE

After months of logistics, the almost bare unit now stood firmly up on support stands and the transformation was ready to begin.

Since we knew this unit would face some harsh trail conditions in its near future, we started with SUPERATV 3” (inch) lift kit. The kit includes: heavy-duty front and rear shock relocating brackets and two Rhino Brand axles. Installation is made easy as the kit is 100% bolt-on and provides for a full 3” (inch) of front and rear lift. The lift kit is designed to prevent CV binding or damage, this is accomplished by using upper shock relocating brackets instead of the traditional lower brackets. This method improves ride quality, axle angles and steering geometry.

With the lift kit and rear axles installed, we now turned to the installation of the BARKER’S PERFORMANCE full dual exhaust system. This system is quality crafted from premium materials and methodically hand welded. The exhaust pipe section is made of (304) stainless steel that is TIG-welded with seam-reduced interior surfaces for smooth flow and the cans are comprised of (6061) aircraft grade aluminum. Swapping out an exhaust may seem like an extensive chore, however the installation process is made easy with clear and simple to follow instructions. With the new exhaust system now installed, we test fired the unit. The room immediately filled with a deep, throaty rhythm of raw power and now the Trail Warrior would be heard prior to being seen. According to Barker’s DYNO test you can expect a horsepower increase of 6 (HP Gain) and also a weight savings of 5 lbs.

Now that the under carriage work was completed, we could reassemble the rear cargo box and proceed to the installation of the spare tire carrier and the front bumper. For the spare tire carrier we decided to go with a POLARIS genuine accessory. The Polaris spare tire carrier is made of strong tube-steel construction with a black powder-coat finish that is a breeze to install (bolt-on). This spare tire carrier doesn’t occupy any of the cargo bed space; great for those who carry lots of gear when they ride.

For the front bumper we installed a HMF “IQ Equipment” U4 Winch Front Bumper. The U4 winch front bumper is constructed from .095” wall steel tubing and, as the name implies, it can house standard winches. We chose the (Red) finish to match the look of our unit and it was once again super easy bolt-on installation. The bumper not only offers an increased form of protection but also adds an aggressive look to the front of the unit.

To finish off the front-end, we installed a SUPERATV 4500 lbs Synthetic Rope Winch (with Wireless Remote). This kit comes with the 4500 lbs synthetic rope winch (obviously!), an aluminum hawse fairlead, a dash mount control and a wireless remote. We drew power direct from the battery so this was a tedious process of running wiring, however the install process itself is easy and very well documented in the installation manual. This winch also offers some nice features: brakes to hold on inclines, weather proof seals and a reliable smooth running electrical system for sustained battery life.

With some of the more labor-intensive add-ons installed, we now started to move towards the interior of the cab. The next items on the menu and probably one of my personal favorites: the sound components. I truly do enjoy listening to my tunes while riding and I could think of no better company to turn to for this than SSV WORKS. We started by installing the SSV WORKS (WP-RZ3O4) overhead weatherproof audio system. The installation of the WP-RZ3O4 is simple: the unit clamps in overhead to the stock cage and has an easy 2-wire hook up. Like all SSV Works systems, the enclosure is constructed of fiberglass for maximum durability and the best sound quality.

The WP-RZ304 unit has an intensive and impressive set of features: Bluetooth connectivity with over 30′ of range, weatherproof docking station, water tight locker with slam-latch polycarbonate door, charging capabilities, internal 50 watt x 4 ultra-efficient amp, waterproof marine 2-way 6.5″ speakers, 4 LED dome light, on board bezel mounted rubberized controls, iPod control (volume, track fwd/bck, play/pause), 3.5mm aux input for MP3 or SAT radio and FM tuner with backlit display with external antenna.

Since we wanted to go big on sound, we also installed the optional (WP-RZ3O+2) 2-speaker add-on unit. This unit is installed overhead to the stock cage as well and connects to and draws power from the (WP-RZ3O4). The amplifier in our main unit (WP-RZ3O4) is 50 watts x 4 and this add-on utilized the 2nd half of that amplifier. As I mentioned, we really love our tunes!

With the sound components installed and firmly in place, we now proceeded to install the rear net and half windshield. For the rear net, we opted to go with the POLARIS (Racing Rear Panel). This rear netting not only provides outstanding protection at the rear of the cab but also delivers rearward visibility & airflow. The rear net is constructed from ultra-strong & durable fabric and it attaches to the vehicle framework. For the half windshield we once again turned to SUPERATV. We installed the non-tinted version that is constructed from super strong, scratch resistant 1/4” thick AR Makrolon with a bottom seal that contours the unit’s design. The kit comes with all necessary hardware and instructions to allow for fast and simple installation.

Prior to completing the rest of the interior, the roof needed to be installed. We decided to go with the POLARIS Aluminum Roof, as we liked the way the roof sat on the cage and complemented the unit. It is constructed from strong and durable (5051) aluminum and this model came with a white powder coat finish. The roof installs quickly with the supplied hardware in the designated mounting positions. Not only does this roof provide outstanding overhead protection but it’s also sealed to eliminate vibrations.

A few more electrical components needed to be installed prior to applying the finishing touches. Since we frequently trail ride at night, we decided that we needed to install LEDs on the inside portion of the rear roof tail. These lights would assist to illuminate the trail when backing up or to possibly assist others. For this we turned to WICKEDBILT and installed two 3″ LED Square. Each light features four 3w Epitar LED bulbs for a total of 12 watts and can pump out 950 lumens of illumination, perfect for our needs. We mounted the light with the included hardware and ran the wiring for the electrical connection, easy but once again wiring can be tedious. Because being seen is important, especially at night, we also installed a 72″ Kool Whip from WICKEDBILT. These whips are available in a variety of colors and standing at 6 feet tall it will definitely help show others where you are on the trails at night.

The vehicle was finally starting to take shape and we were very eager to start applying the finishing touches. Comfort and especially safety were a big priority for us; we had already installed some add-ons which heightened creature comforts, however the most important were to follow. With the driver and passengers in mind, we wanted to improve not only their comfort and safety levels but also their overall ride experience, so for this we turned to PRP SEATS. First we installed 4 GT S.E suspension seats from PRP Seats, which we deem to be the most comfortable seat on the market today. PRP Seats are constructed from premium quality materials and PRP is always listening to its customer base and is constantly developing seats that are in demand. The installation calls for removal of the seat support rack from under the stock seats and mounting them back on the PRP seats. Once the hardware is mounted, simply re-install the seat in its original mounting location. I can assure you that once you ride seated in a PRP seat, you will never want to ride in a stock seat again!

To complement the seats and to specifically increase driver and passenger safety, we installed 4 sets of 5.2 safety harness from PRP SEATS. This 2”, 5 point seat belt has sewn in pads for comfort, all black hardware for cool styling and quick adjusters on the shoulders. The new quick adjusters fix a problem that has been an issue with off road seat belts for years. Once a belt gets some dirt and water in the webbing they become very difficult to adjust, these new adjusters will always provide a quick easy to use seat belt.

To further enhance the comfort level of the vehicle occupants, we also installed PRP SEATS lower door extension and a set of door bags with kneepad. The lower door extensions are made of aluminum and they simply bolt on to existing holes in the stock RZR door. We all realize the benefits acquired from a set of full doors, this simple and cost effective add-on turns your half doors into a set of stylish full doors.

When we ride, we all have the tendency to rest our knee onto the door panel. We also all are aware what happens to said knee when we hit an obstacle on the trail – ouch! Solution: the PRP SEATS door bag with kneepad. Not only does this add-on provide convenient extra storage, but it also provides a comfortable location to rest your knee. We installed one set for the driver and front passenger and the doors bags simply install onto the doors using the factory screws.

Enzo Ferrari once said and we quote “What’s behind you doesn’t matter” but in our case this wasn’t necessarily true. Being safety conscious we needed to install mirrors, but not just any mirrors, this unit deserved some bling! For this we turned to AXIA ALLOYS and we installed a 17″ Billet Panoramic Rearview Mirror and a set of 5″ Round Convex Glass Billet Arm Side Mirrors. The 17″ billet panoramic rearview mirror offers the widest non-distorted viewing angle of any mirror on the market. This mirror is very slightly curved only in the horizontal direction so that you get a nice wide view of what is behind you without distortion. The 5″ convex side mirrors feature a fully adjustable billet arm so that they can be mounted on both horizontal and vertical bars of any angle. These mirrors definitely complemented our unit and had the desired effect we were looking for.

One more safety item needed to be installed, one that no vehicle should be without: a fire extinguisher. Many fire extinguishers are available on the market, however the one from AXIA ALLOYS is best suited for our needs and it matches our thematic perfectly. The billet fire extinguisher mount is aircraft grade 6061 aluminum and the stainless steel components are precision machined for a perfect fit. Most important, all contact points are o-ringed so that it will not wear or rattle in even the most demanding off-road environments. We mounted the fire extinguisher on the spare tire carrier and if/when you need to use it, just pull the red quick release handle and the 2 lb fire extinguisher is ready to go.

We could finally see the transformation start to materialize; however a few more items needed to be installed before this unit could earns its name of the “Trail Warrior”. The same way a good pair of shoes completes any attire, we needed an awesome set of tires and rims. We could think of only one company to help us with this, COLORADO COMPONENTS. We turned to COLORADO COMPONENTS, the manufacturer of MSA WHEELS and EFX TIRES to help us complete our unit’s attire.

We decided to install a set of 30” MOTOHAMMER tires from EFX TIRES mounted on a set of 15” M21 LOK (Red) beadlock rims from MSA WHEELS. In our opinion, the MOTOHAMMER tire is the single best hard pack tire on the market, boasting the best contact patch, superior traction control, rugged 8-ply carcass and Radial DOT rated performance. Trail riders will appreciate the 8-ply carcass and completely re-engineered soft compound that conforms to your terrain.

The 15” M21 LOK rims not only looks amazing but also drastically enhanced the look of the unit. Each M21 LOK rim comes with all of the necessary parts to professionally lock any tire to your wheels to ensure a safe and quality ride. The “gunmetal” finish used on this rim is actually a dark tinted clear-coat that is overlaid on top of the micro-machined wheel face adding depth, charcoal highlights and it is a completely new industry option. The Gunmetal finish is accentuated with gloss black automotive grade paint, only offered by MSA WHEELS and currently only offered on the M21 LOK in this combination. The unique LOK rim design repels dirt, mud and debris fast making clean up a snap.

We lowered the unit to the ground, removed the support stand and took our first good look at our almost completed project. At this point a boasting session was definitely in order, the unit looked awesome! However the last vital piece of the puzzle remained to be professionally installed: the custom wrap.

We loaded the unit into our closed trailer and set-off to our final destination for this build project, AFFICHAGE.CA. Upon our arrival Jonathan, who was eager to show us several wrap samples he and his team had put together, greeted us. Once we selected our design, Jonathan proceeded to take some unit measurements and started to print out our design. The design is printed on a 3M vinyl adhesive paper and then is laminated with a 3M UV protection film. What is also unique about the approach used by AFFICHAGE.CA is that they do not use templates. They print out square section based on measurement and painstaking apply the wrap to the unit.

I will repeat word for word what I wrote about AFFICHAGE.CA in a previous article, as I can’t find better words to describe the company or their process. The guys over at affichage.ca are true professionals in the art of wrap design and installation. Watching these guys create and install the wrap was like watching an artist paint on a virgin canvas, totally mind-blowing!

Once the last section of the wrap was applied, we all stood back and gazed upon our completed build project. We are all overwhelmed by a proud sense of accomplishment as this build exceeded our every expectation. The combination of all the high-end quality parts and accessories, time and energy and logistics all resulted in this awesome unit we proudly nicknamed: Trail Warrior.

During the course of this article, we briefly mentioned many aftermarket parts manufacturers and their respective products and/or service. We would like to thank all these partners for contributing to our build, without them this project would have been impossible. We invite you to visit their websites for more information on the products and services mentioned throughout this article.

A very special thank-you to POLARIS INDUSTRIES for loaning us the Polaris RZR 4 900 EPS

PARTNERS BUILD LIST

The post Polaris RZR 4 900 EPS – Trail Warrior Build appeared first on UTV Planet Magazine.

The Conception Phase

Now we were faced with “the question”: what kind of build project should we undertake? Do we go with a “go-fast” race build? Or maybe a mud machine would be interesting? What about the ultimate crawler? The more we debated, the more uncertainties set in. After weeks of reflection and discussions, we decided to tackle a trail specific build. Now all that remained was to define our project scope: “what do we exactly want to accomplish with this build”?

In a nutshell our project scope boiled down to this:

Target audience: the consumer who utilizes his/her UTV primarily for trail riding. We wanted to present this audience a unique build using after-market parts and accessories beyond those offered by the OEMs. In other words be unique, be different and define your ride!

Now came the hard part: which UTV should we use in our build project? With so many great units on the market today, we decided to focus our attention on units that are being sold/marketed towards the trail rider. We wanted a unit that had enough horsepower and torque to concur anything we threw at it, great factory suspension and a trail friendly width. One unit stood out above the rest for our particular requirements, the Maverick X xc from Can-Am. The Maverick X xc grabbed our attention last year when we had a chance to ride it at the 2014 product launch, so we were very eager to work with this unit. We immediately contacted CAN-AM and they graciously loaned us a unit for our build project.

With a company slogan of “Define Your Ride”, it was evident that we needed to turn to our partner UTV Canada for help with this build. We already had a good idea in the direction we wanted to take with this project, however we also needed the experience and network of UTV Canada to get there.

Andy Ogg from UTV Canada jumped on this build to turn it from mild to wild! If the name sounds familiar to you there is a good reason: prior to joining the UTV Canada team, Andy built a reputation for himself working at Pro Armor for many years. During his career Andy has worked on many build projects and his experience proved vital for this venture. We gave Andy the scope of the build and it was put into motion! Several weeks were spent lining up the necessary parts and accessories for this Maverick build and nearly all of the manufacturers carried by UTV Canada stepped up for this awesome opportunity.

With the UTV and parts selection completed, only one aspect remained to make this ride totally unique; a custom wrap. For this we contacted a company, which has already provided us with excellent service: affichage.ca. We gave Jonathan Gagné (co-owner of affichage.ca) the color scheme that we wanted to see on the unit and his design team immediately started working on a concept for us.

The Deconstruction Phase

This phase of the project was quite simple in fact, and only required the removal of the stock seats, tires and rims, front bumper and side safety nettings. Some factory plastics and cockpit paneling also needed to be temporarily removed to facilitate the passing of wiring for certain electrical components.

The Build Phase

With all the pieces of the puzzle carefully laid out, we could now begin to transform our Maverick from “mild to wild” with this unique trail build that we proudly nicknamed “The Predator”.

We started the build from the ground up and no changes were done to the suspension or shocks. However we did install a 3” bracket lift from S3 POWER SPORTS. The bracket lift is a direct bolt-on lift which installs to the factory mount points on the Maverick. The lift kit achieves a minimum of 3″ of additionnal ground clearance providing that extra height which is sometimes needed on extremely harsh trails.

Next we moved to protecting some of the underbody components. We installed front/rear A-Arm guards from TURNKEY UTV and also installed floorboard rock sliders and skid plates from RICOCHET OFFROAD ARMOR. This extra protection was a welcomed addition especially for some of the rocky trails we were planning to tackle with this unit.

The only performance modification we made to the unit was to alter the vehicles airflow and air intake. To achieve this we installed two-performance products from TURNKEY UTV. First we replaced the factory plastic covers by Turnkey’s “Under Hood Panels”. These new under hood panels help decrease engine temperatures by increasing air flow into the engine compartment and they also look great! Next we replaced the stock factory air intake system with Turnkey’s “Race Air Intake System”. This new air intake system has been engineered and tested to provide maximum airflow to the motor and its innovative design draws air from within the Maverick cab assuring only clean dry air is entering the intake.

The front/rear bumpers and winch were next on the list. For the front bumper we installed a rugged bumper by WARN INDUSTRIES. One of the nice features of this bumper is the integrated winch mounting plate. The winch mounting plate enabled us to easily top mount the WARN ProVantage 4500-S winch. The 4500-S ProVantage winch has many great features and a massive 4,500 lb. capacity with more than enough power to pull your UTV or a heavy load with ease. For the rear we installed a bumper from PRO ARMOR. The rear bumper not only gave the back of the unit the aggressive styling we were going for but also protected the rear-end and other components on the vehicle.

A winch is an add-on that no trail rider should be without. However, sometimes you want to give a fellow rider a quick tow out of a bid. For this we installed KFI Tiger Tail tow system. Its retractable design allows for a quick, easy and clean use for towing or as an anchor-line during poor underfoot winch operations! This unit mounts in the rear of the unit with the Tiger Tail 2” receiver.

As we are all smart trail riders, we carry spare tires, right? We were looking for something that obviously could mount a spare tire but could also hold other essential gear. We found our solution with the PRO ARMOR QuickShot Universal Spare Tire and Accessory Mount. QuickShot’s revolutionary mounting plate allows you to mount hundreds of essential products in various ways. The included jack mounts right to your QuickShot base, making changing a tire or repairs hassle free.

In my opinion, nothing beats cursing your favorite trail while listening to your favorite tunes! This ride needed tunes and for this we needed SSV WORKS. We installed the WP-UO4S (overhead 4 speaker soundbar); the WP-UO4S provides Hi-Def stereo sound and mounts overhead to your stock cage. The system features a charging dock for iPod and iPhone, with built-in 50-watt x4 ultra-efficient low power consumption digital amp designed around a UTV’s charging system, waterproof speakers, includes FM tuner for local radio reception with internal FM antenna. We weren’t done yet, we also installed the under dash SUB BOX with 500 watt 10” woofer. The sub box bolts into the under dash area utilizing the dead space behind the glove box; it is 100% fiberglass construction for the best sound quality and bass response. We wanted tunes, I can tell you that now we had some serious tunes!

Safety while riding on the trails should be of upmost importance to every trail rider, so the following accessories were a must for our build. We first installed the TURNKEY UTV harness bar, which allowed us to install PRO ARMOR 2” 4 point harness. For added passenger safety and comfort we also installed the TURNKEY UTV adjustable passenger grab handle. Lastly, we proceeded to install the AXIA ALLOYS quick release fire extinguisher mount and a universal 2.5lb fire extinguisher. With the following safety add-ons installed we were confident to be able to face any adversities on the trails.

Creature comforts were next on the agenda. EXTERME METAL PRODUCTS’S half windshield was installed; it is made from 1/4″ Thick MR-10 Lexan and looks great once installed. For added comforts from the elements, we installed a PRO ARMOR Aluminum Roof. This roof is made from .080” thick aluminum to ensure strength but yet still lightweight and gave the unit the added style we were looking for. In my opinion no UTV should be without doors. Besides the obvious fact that doors allow you to “enter and exit” the vehicle easily, they also provide more room in the cockpit area. We installed BLINGSTAR “suicide type” doors that are made from aircraft grade aluminum alloy material. These doors follow the Maverick contoured lines beautifully and drastically change the look of the unit. To provide superior comfort for the driver and passenger we installed a pair of PRP SEATS GT SE suspension seats. The PRP GT SE seat features larger seat belt slots to allow easy removal and installation of the seat belts and larger neck slot which allows for the seatbelts to be farther apart to keep the harness from rubbing on the occupant’s neck. These seats have the reputation to be some of the most comfortable seats on the market today.

To complete the installation in and around the cockpit area, we installed 2 round Full Billet convex side mirrors from AXIA ALLOYS. We also installed a hydration pack from PRO ARMOR, the hydration bag mounts to the back of any seat, and offers the ability to carry 3 liters of fluid with you while out riding.

Nothing beats the experience of trail riding at night, but it is important to “see and be seen”.  First up from RIGID INDUSTRIES, SR series 30” LED bar with Spot / Flood Combo was installed. The SR-Series light bar is designed to project light at extreme distances while consuming very little power. The light features a combination of both Spot and Flood versions of the Hybrid optics system and its durable extruded aluminum housing and virtually unbreakable polycarbonate lens are sealed against the elements. For that extra element of “be seen” we also installed a set of red QUICK LIGHT 6” fiber optic whips. These whips look awesome once illuminated and added that element of “wild” to our build.

No build would be complete without the perfect set of tires and rims. EFX PERFORMANCE TIRES provide us with a set of MotoClaw 30x10x4 8 ply tires. The MotoClaw comes standard with incredibly strong lugs, spaced precisely right to provide a smooth ride under the most intense terrain. The MotoClaw tires were mounted on a set of M20 KORE (flat black) 14” rims from MOTORSPORT ALLOYS. The M20 KORE comes standard in a new improved flat black automotive grade paint, which easily sheds dirt, mud and debris. The rims also come stock in a +0mm offset, which allows for better fit, performance and stance. The combination of the MotoClaw tires and KORE M20 definitely contributed to the “HARDKORE” look of our build.

With the installation of the add-ons now completed, we quickly loaded our Maverick into our trailer to drop it off at the team of AFFICHAGE.CA so they could commence the wrap installation. The guys over at affichage.ca are true professionals in the art of wrap design and installation. Watching these guys create and install the wrap was like watching an artist paint on a virgin canvas, totally mind-blowing!

During the course of this article we briefly mentioned many after-market parts manufacturers and their respective products. We would like to thank all these partners for contributing to our build, without them this project would have been impossible. We invite you to visit their websites for more information on the products and services mentioned throughout this article.

A very special thanks to CAN-AM for loaning us the Maverick X xc.

PARTNERS BUILD LIST

The post Can-Am Maverick X Xc – The “Predator” Build appeared first on UTV Planet Magazine.