From Stock to Savage: The Ultimate Polaris RZR Pro S Trail Build by Fueled UTV
Some builds start with a clear plan.
Others… evolve.
This Polaris RZR Pro S build is the perfect example of what happens when a simple idea meets the right machine, the right customer, and a team that can make dreams become reality. What rolled into our shop was a brand-new, fully stock Pro S 4 seater with a modest goal: a few OEM Polaris mods and some light upgrades. What rolled out? One of the most dialed ultimate trail and mountain RZR Pro S builds we’ve ever touched.
And yes—we touched everything.
A Customer Who Knows Exactly What He Wants (Eventually)
This wasn’t our first rodeo with Greg (our customer). He’s built multiple machines with us over the years, including a Ranger XD 1500 that many of you may remember from a build video we released a little over a year ago. He is familiar with our team, trusts our recommendations, and—most importantly—uses his machines the way they’re meant to be used.
The Pro S came in clean, untouched, and ready for transformation. As the build progressed, the vision expanded. What stated out as a OEM+ build, turned into an OEM++ plus Plus PLUS build!
Built to Dominate the Trail (and Then Keep Going)
The Polaris RZR Pro S is already one of the most capable trail-width machines ever produced. But when you’re chasing the ultimate trail machine, “stock good” simply isn’t good enough.
37” Tires That Change Everything
We stepped things up dramatically with 37” Maxxis Carnivore tires, instantly increasing ground clearance, traction, and obstacle confidence. Whether crawling technical rock sections, navigating high-speed forest trails, or pushing into unpredictable mountain terrain, these tires redefine what the Pro S is capable of. We are huge fans of the Maxxis Carnivore. It is the ULTIMATE snow tire and handles loose trails extremely well, both west and east coast!
CA Tech Suspension – Clearance Where It Matters
To properly support the larger tires and elevate overall ride quality, we upgraded the suspension with CA Tech A-Arms. Again, additional clearance in all the right places. More importantly, these CA Tech arms are made with 3/16" steel and delete the failure point of the stock shock fork. Simply put, they are bulletproof. We run CA arms on many of our own shop builds, so we know what kind of abuse they withstand!
Creature Comforts… Fueled UTV Style
This build isn’t just about raw performance. The cockpit of this machine is designed to allow for longer rides, no matter what the conditions, ensuring that the passengers are comfortable and out of the elements.
Full Cab Enclosure + Inferno Heater
A fully enclosed OEM cab paired with an Inferno heater turns this Pro S into a true four-season machine. Not to mention, a OEM glass windshield and Dirt Warrior rear windshield to round out the full enclosure. Cold mornings, snowy rides, shoulder-season trips—none of it matters anymore. Flip the switch and stay warm.
PRP Heated & Cooled Seats
Yes—heated AND cooled seats. PRP nailed it with these PRP XCR seats, giving the driver and passenger year-round comfort. Cold days? Heat on. Summer rides? Cool air flowing. Once you ride with these, there’s no going back.
Rugged Radios Communication
Clear, reliable communication is a must—especially on long trail rides or trips with your crew. A Rugged Radios radio and intercom setup keeps everyone connected, whether you’re coordinating obstacles or just calling out the next stop. Plus, the intercom and Alpha Bass headsets makes in car communication simple with your passengers!
Electrical Done Right (Because It Matters)
One of the most overlooked parts of any high-end UTV build is electrical. Our technicians do not skimp or take shortcuts on wiring, and with a build that has as many electrical mods as this one, that's mission critical.
Dual Switch Pros Controllers
With accessories stacking up fast, we installed two Switch-Pros controllers to keep everything clean, organized, and easily controlled. One 12-switch down on the dash, and an 8-switch mounted to the roll bar above the cockpit. Both easily accessible, and makes toggling through accessories a breeze. Lights, heater, air compressor—everything is right where it should be, with room to add more if need be.
Starlink Mini – Mobile Hotspot
This might be one of our favorite mods on this machine: A roof-mounted Starlink Mini. This Pro S is now a rolling mobile hotspot. Whether it’s uploading content, staying connected on extended trips, or having peace of mind in remote areas, this feature takes “over the top” to a whole new level. Secured with a Savage UTV mount on the roof, Greg will stay connected no matter where he is in the backwoods! Shout out to Elon!
360 Degree Lighting
This machine might just be detected by satellites! We threw on a set of Marshin Laser Whips that can be seen from galaxies far and away! Up front we have a Rigid Radiance light bar, Sector Seven lighted mirrors (best in class!), and Baja Designs lights front and rear! We did some badassery with the reverse lights tying into the switch pros, to check that out be sure to go watch the full build breakdown on our YouTube channel!
A True Fueled UTV Build Philosophy
At Fueled UTV, we don’t build machines for parking lots or Instagram photos. We build machines to be used and abused, trusted completely, and enjoyed every mile of the ride. This Polaris RZR Pro S represents exactly that mindset.
- Ready to tackle the toughest mountain terrains
- Comfortable without sacrificing performance
- Loaded with technology, but clean and functional
Watch the Full Build Breakdown on YouTube
This blog launch pairs with a full YouTube build review, where we walk through every major upgrade, explain why each component was chosen, and show this Pro S in its final form. If you want to see how a stock machine turns into a fully dialed trail weapon—this is one you won’t want to miss.
👉 Full parts list with links included below
Thinking About Your Own Polaris RZR Pro S Build?
Whether you’re starting with a brand-new machine or upgrading an existing one, our team does this every single day. From mild trail setups, dune cars, to full-blown custom builds like this one—we’ll help you build it right the first time.
BUILD LIST
Lighting & Audio:
Sector Seven Spectrum Lighted Mirrors with Universal Clamp
Baja Designs Squadron Pro Black LED Auxiliary Light Pod Pair - Universal
Dune Gear Touch Activated Dome Light
5150 Whips 187 LED Bluetooth Whips - (Pair)
Polaris RZR Rigid Chase LED Light Bar
Marshin Whips RGB Lunar Laser Whips Kit