Headline News
TOUGHEST RACE IN THE U.S. (May 26, 2017 8:04 am)
RACE TO THE TOP OF PIKES PEAK — (May 25, 2017 7:42 am)
UTV BEATS RALLY CARS! (May 24, 2017 2:12 pm)

UTV PROJECT: CYLINDER WORKS/HOT CAMS POLARIS RZR 1100

One man’s perfect RZR By the staff of Dirt Wheels

 

This RZR isn’t just about performance. A Pro Armor cage and seats and PRP harnesses take care of safety.
This RZR isn’t just about performance. A Pro Armor cage and seats and PRP harnesses take care of safety.

 

Most sport UTV owners are content with a few additions, and many of those had the dealer install them before delivery. They are content to spend their time driving the wheels off of the machine at any given opportunity. Then there are owners like Brian Carle. Carle is a long-time dirt biker who finally admitted that keeping up with his adult children had become a health hazard, and he needed a cage. Most people can understand that thinking, but the level of modification on his 2014 Polaris XP 1000 is amazing. Carle has obviously spent many hours in the garage. In very few instances did he pay to have the products installed. He is so serious about tinkering—and driving—his RZR that he bought a spare engine on eBay so he could drive while in the midst of tinkering. He is also very lucky to have the support of his wife Ramona, because she enjoys the outdoors as much he does.

 

Factory UTV’s UHMW plastic skid plate and rock sliders protect the belly of the RZR when the terrain gets toothy.
Factory UTV’s UHMW plastic skid plate and rock sliders protect the belly of the RZR when the terrain gets toothy.

 

IN HIS OWN WORDS

“It has been a lot of fun building this RZR, and I have gotten to know many people in the aftermarket industry that design and manufacture parts that take a good vehicle and turn it into something remarkable. If I had to choose a favorite part of this build, it would be the pleasure I got from building this car, meeting new people in the industry and spending time with my friends. The Pro Armor F1 seats are so comfortable that you don’t want to get out, even after a full day of riding.

“The IMS 5-gallon fuel cell makes that full day of riding possible by providing a total fuel capacity of 14.5 gallons. Night riding is just as fun thanks to Vision X lighting and Trail Tech lights. Large rocks are no longer a concern with the 1/2-inch-thick UHMW skid plate from Factory UTV.”

 

The combination of a big-bore kit, cams, clutch mods and EFI tuning result in a machine that rabbits out of turns when you tromp the throttle.
The combination of a big-bore kit, cams, clutch mods and EFI tuning result in a machine that rabbits out of turns when you tromp the throttle.

 

MACGYVER STUFF

“While building this RZR, I made some modifications of my own. First, I installed an Amazon-sourced $35 Rule 4-inch blower fan to keep the CVT belt cool. I attached it to the inlet tube of the belt housing with two $12.99 Silicone Intakes Systems (www.siliconeintakes.com) 4-inch-to-3.5-inch silicone adapters. With the addition of the fan, my EPI severe-duty belt still looks new after 600 miles of punishment. My clutch kit from SLP Racing has also contributed to the condition of the belt.

 

A Trinity Racing Stage 5 exhaust is another part of the performance package.
A Trinity Racing Stage 5 exhaust is another part of the performance package.

 

“I also added a Blue Sea Systems marine-grade fuse panel under the hood with a switch so I can run accessories, such as the SSV Works 5 speaker sound system, without having the key in the ignition. When sitting around camp at night I can also run the Sick Stick Whips for some sweet light shows.

 

ZBroz Racing serviced the suspension, changed the valving and dialed in the spring package specifically for this machine.
ZBroz Racing serviced the suspension, changed the valving and dialed in the spring package specifically for this machine.

 

“Another modification was to install an $15 Amazon 6-inch light bar under the left side of the bed in case you need to change a belt at night. I also purchased a motorcycle alarm system on Amazon. It works very well and only requires a two-wire hook-up to be sure my XP 1000 is right where I left it.”

 

TCP Performance makes the oversize radiator and radiator fan. Carle is very pleased with how cool it keeps this performance engine.
TCP Performance makes the oversize radiator and radiator fan. Carle is very pleased with how cool it keeps this performance engine.

 

OTHER UNUSUAL MODS

“Another must is a $59 eBay parking brake. A parking brake makes it easier to shift out of park when you are stopped on a grade, and it allows you to lock all four wheels when towing it on a trailer. Another must have are the new Stage 2 Hot Cams. The added midrange-to-top-end power really brings the 1000cc motor to life. The cam swap was very easy to do. I was out driving it an hour after I started the job. Just be certain to check your valve lash to maintain clearance.”

 

Cylinder Works’ big-bore kit is quite comprehensive. It includes a new cylinder casting with a plated bore and all associated parts for 1110cc.
Cylinder Works’ big-bore kit is quite comprehensive. It includes a new cylinder casting with a plated bore and all associated parts for 1110cc.

 

MORE MOTOR

“The cams were round one, and I wanted more power, so we added a Cylinder Works big-bore kit with Carrillo rods to handle the extra power. Harry McDermott (founder of Trinity Racing) ported our head and allowed for the extra cc in the head chamber.

“We built our big-bore motor with the best components available. A Cylinder Works 1110cc big-bore kit with Vertex pistons and Cometic gaskets were all included with the kit. We wanted the power of a turbo motor without all the extra problems related to a turbo setup. The motor still has the manners of a stock motor, but has explosive power for climbing a large hill or when out in open country. With the TCP oversized radiator, overheating problems are a thing of the past.”

THE TEST

Just because one man builds his dream project doesn’t mean it will appeal to everyone, so we put this baby to the test. We were fortunate that our parent company, Hi-Torque Publications, had Glen Helen Raceway rented, so we were able to put it through its paces. Glen Helen offers two MX tracks, some off-road and a short-course track. First on the list was the national MX track that has a long straightaway and a right-hand turn named Talladega. The Cylinder Works RZR was very fast on the starts; the extra 110cc upped the bottom-end power. The acceleration felt like the turbo version of the RZR, quickly climbing into the 60-mph range by the time we hit Talladega. Glen Helen’s hills were no match for all the torque that it produced.

We easily climbed the steepest of them all, Mount Saint Helens, with all four 30-inch DWT Moapa tires churning up the fresh dirt. The machine had enough power to get us out of the smaller turns with a foot full of power to clear some of the tabletops easily. The ZBroz Racing-tuned OEM Walker Evans shocks were a delight. They were plush enough to handle all the chop on the track, yet aggressive enough to handle some of the bigger jumps. It was one of the best-tuned shock packages we’ve felt yet. Unfortunately, we did blow a belt before heading up Mount Saint Helens for the fourth time. We were having so much fun that we forgot to look down at the belt temperature gauge. We didn’t make the same mistake again.

 

BIG-BORE_5-b

 

OFF-ROAD

It was time for some off-road. With how great the suspension was on the track, we thought it might not work as well in the rocks, but we were wrong! We were soaring down a rocky wash, and it soaked up every one of them. The car handled the quick, abrupt turns very well, and the braking system stopped us rapidly, even with the large tires. In the larger rock section, we switched it to low and the big-bore engine did its thing. With that extra torque from the Cylinder Works kit, it provided ample crawling power.

Real babies will melt hearts, and Brian Carle’s RZR baby has the same effect on our staff. It is a truly refined machine. But, just to prove that love is fickle, Carle now has a Yamaha YXZ parked next to the RZR. We can’t wait to see that one!

McDermott Racing: www.mcdermottracing.com, 909-373-1462

• Cylinder head porting & cutting of valve seats: $1050

Hot Cams: www.hotcamsinc.com, 515-402-8005

• Stage 2 hot cams: $529.90

Carrillo: www.cp-carrillo.com

• Connecting rods

Cylinder Works: www.cylinder-works.com, 515-251-4070

• 1110cc big-bore kit/Vertex pistons: $1,195.95

Pro Armor: www.proarmor.com, 888-312-7667

• Roll cage: $1,399.95

• Front bumper: $49.98

• Roof: $450.95

• G2 seats: $429.95

• Door bags: $99.95

• Steering wheel & adapter: $69.95

• Skid plate: $39.95

• A-arm armor: $199.95

• Trailing arm armor: $199.95

• Gear bag: $149.95

• Lower doors: $199.95

Starting Line Products: www.startinglineproducts.com, 800-621-2893

• Clutch: $328.90

• Pistol grip shift handle: $39.95

Dynojet: www.dynojet.com, 800-992-3525

• Power Commander V: $419.99

• Auto Tune: $479.99

• Pod 300 display: $249.99

Factory UTV: www.factoryutv.net, 916-383-2730

• 1/2-in. UHMW skid plate: $559

• 1/2-in. UHMW rock sliders: $198

Attack Graphics: www.attackgraphics.com, 801-465-4382

• Custom graphics set: $275

Uni Filter: www.unifilter.com, 714-535-6933

• Air filter: $64.95

Rugged Radios: www.ruggedradios.com, 888-541-7223

• VX2200 car to car radio kit: $557.01

• 686 inter com with helmet kit: $722.70

Vision X: www.visionxusa.com, 888-489-9820

• 35-in. light bar: $699

• 4.5-in. light cannons: $449 kit

ZBroz Racing: www.zbrozracing.com, 435-753-7774

• Reworked shocks, springs and valving: $995

SSV Works: www.ssvworks.com, 818-991-1778

• Glovebox 10-in. subwoofer system: $349.95

• 1 set of kick panel speakers: $209.95

• 1 set of roll bar speakers: $249.95

• Kicker 400 4-amp: TBA

• Mirrors: $149.95

San Diego Powder Coating: sandiegopowdercoating.com, 619-956-0987

• Powdercoated parts: Varies

Tusk Off-Road: www.tuskoffroad.com, 801-465-3140

• Fire extinguisher kit: $69.99

• Hand holds: $17.99 per side

• Winch and mount: $291.98

• Cab bag: $129.99

• Jack and Jack mount: $54.99

IMS Products: www.imsproducts.com, 800-237-9906

• 5-gallon fuel cell with batteryrelocation kit & Yellow top battery: $849.95

Boondocker turbo systems: www.boondockers.com, 208-542-4411

• Cam chain tensioner: $199

Trail Tech: www.trailtech.net, 360-687-4530

• 70mm LED lighting kit: $299.95

EPI: www.epiperformance.com, 218-829-6036

• Severe-duty belt: $134.95

DWT Racing: www.dwtracing.com, 800-722-3746

• Sector beadlock wheels: $399.95 per wheel

• Moapa 30x10x14 8-ply tires: $169.99 per tire

Trinity Racing: www.trinityracing.com, 909-987-4213

• Exhaust system: $949.99

NRG Innovations: www.getnrgstore.com, 626-369-2668

• Steering wheel: $320

Sandcraft: www.sandcraftmotorsports.com, 480-539-4438

• Center carrier bearing: $240

TCP Performance: www.tcpperformance.com, 208-356-6483

• Oversize radiator & cooling fan: $529.95/radiator, $299.95/fan

Energy Suspension: energysuspensionparts.com, 888-406-2330

• Urethane suspension bushings

Rick’s Motorsport Electrics: ricksmotorsportelectrics.com, 800-521-0277

• Hot Shot voltage regulator

ARP Bolts: www.arp-bolts.com, 805-339-2200

• Cylinder head studs: $155.71

Racepak: www.racepak.com, 888-4294709

• Custom dash and gauge package: $1,170

Razorback Technology: www.razorbackusa.com, 888-525-2858

• Belt temperature gauge: $322

PRP: www.prpseats.com, 800-317-6253

• 3-in. safety harness

EZ adjusters: $139

Comments are closed.