Polaris 2004-2012 Sportsman 800 Rebuilt Engine

Ready to bring your 2004-2014 Polaris Sportsman 800 back to peak condition? This Polaris 2004-2012 Sportsman 800 Rebuilt Engine is engineered for restored performance and long-term reliability. Our meticulous rebuilding process and attention to detail means your engine will be as good as new. Experience the confidence of robust power and dependable operation, whether you’re tackling tough terrain or cruising the trails.

Your Refurbished REV6 Engine Includes These Features:

• Standard No-Fault 1-year warranty with an optional 2-year No-Fault Warranty upgrade.
• All components are cleaned, dismantled, inspected and repaired as needed.
• We restore and reuse as many OEM parts as possible. We inspect and refurbish all OEM parts to guarantee high quality internals that keep your machine running reliably.
• Cylinder head inspected, cleaned, sandblasted, decked, rebuilt to manufacturer spec and undergoes a quality inspection.
• Valve guides inspected and replaced as needed.
• Valves and valve seats are recut/refaced to ensure tight seal, verified with vacuum test.
• Camshafts lobes and journals cleaned and polished, replaced as needed.
• Crankshaft is inspected and verified within OEM specs and, if needed, rebuilt with new rods.
• Crankshaft main journal bearings and balance shaft bearings are replaced with new high-babbitt coated bearings.
• Worn cylinders are replaced with refurbished and hone finished nikasil coated cylinders.
• Pistons replaced with new moly coated pistons and rings.
• Fully inspected engine cases, tested for journal wear, cracks, holes, or excessive wear.
• All gaskets and seals replaced.
• Engine assembled and torqued to manufacturer specifications.

Unmatched Quality & Confidence

At REV6, we are committed to excellence in quality control. Every part, engine, and transmission undergoes a rigorous quality assurance process. Experience the confidence that comes from our dedication to superior craftsmanship and reliability. Our engines undergo thorough multiple inspections by master technicians and pass a stringent quality control process. With over 60+ years of combined experience in the power sports industry, we stand behind our work. This includes our Double Inspection Guarantee: your engine will be assembled by one master technician and then meticulously inspected by another to ensure it’s truly better than new.

Comprehensive Warranty Options

We guarantee your engine will be as good as new or better, standing behind our engines with a 1-year warranty. For even greater protection, REV6 also offers a 2-year, no-fault, no-questions-asked warranty for an additional $450. This means that for two full years, we will replace your engine free of charge, no questions asked, if anything happens! We’ve got you covered.

Core Options: Getting Your REV6 Engine

To receive your new REV6 engine, you have a couple of straightforward options. You will need to either provide your old core engine upfront or pay a refundable core charge of $800.00. If your returned core is in good, rebuildable condition, we will issue a full refund for this charge. If you have a good core ready to return, please give our team a call to arrange the exchange. Additionally, we offer alternatives if you prefer to get your new engine first and avoid the upfront core charge. This option, however, only applies to customers with a pre-qualified core available for exchange. Contact us to discuss your best option.

Unleash More Performance: Custom Upgrades

Looking for more performance from your Sportsman 800? Let’s help put more power to the wheels! Give us a call, and we can design a vehicle that offers more power and fun. Whether you want to maintain reliability while gaining extra power or prefer something more aggressive, we’ve got you covered. Contact us, and we’ll set you up with something exceptional!

Shipping & Lead Time

Engines typically ship within 5 to 10 business days of order. For the most accurate lead times, please give us a call.

Ready to power up your Polaris Sportsman 800? Contact our team today and experience the REV6 difference! Explore our Warranty Policy for full details, or check our FAQ for common questions. Need something custom? Our Engine Rebuild Kit Guide offers insights into comprehensive solutions, including custom kits tailored to your specific needs.

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