Description

Polaris RZR Pro XP Engine Rebuild Service

The RZR Pro XP is built to push hard, and when the engine starts to wear, you’ll feel it—loss of power, rough operation, or inconsistent performance. Instead of chasing issues, a full rebuild restores the engine so it runs strong again.

At REV6, we completely tear down your engine, inspect every component, and correct wear where needed. Then we rebuild it with proper tolerances and refreshed internals. As a result, you get smooth operation, strong power, and dependable performance.

What Gets Rebuilt

This process focuses on restoring sealing, correcting clearances, and strengthening the engine’s core components.

• Complete teardown and inspection of all internal components
• Cylinder head cleaned, decked, rebuilt, and shimmed to specification
• Exhaust valve guides upgraded with manganese bronze material
• Intake valve guides inspected and replaced when needed
• Valves and seats recut and vacuum tested for proper sealing
• Camshaft components cleaned, polished, and inspected
• Crankshaft inspected and verified within OEM tolerances
• New high-babbitt main and rod bearings installed
• Cylinders inspected and repaired or replaced as needed
• Moly-coated pistons and rings installed
• Timing chain and oil chain inspected and replaced when needed
• Refurbished oil pump assembly
• Engine cases inspected and machined for wear or damage
• All gaskets and seals replaced
• Final assembly torqued to factory specifications

Note: Final build details may vary depending on the condition of your core.

Built for Power and Consistency

Once we restore proper sealing and clearances, the engine delivers smoother power and more consistent performance. Because of that, your machine stays strong whether you’re riding hard or covering long distances.

Double Inspection Process

One technician builds your engine, and then another checks every detail before it ships. This extra step helps ensure everything meets spec before it goes back into your machine.

Warranty Coverage

Every engine includes a 1-year warranty. In addition, you can upgrade to a 2-year no-fault plan for extra protection.

Review full details on our warranty policy.

Core Options

You can send in your engine core or choose the refundable $1500 core option. Once your core passes inspection, we return the deposit in full.

If you need your rebuilt engine first, ask about exchange options and we’ll help you get set up.

Looking for Parts Instead?

If you’re not replacing the full engine, you can find 2020-2024 RZR Pro XP transmissions, crankshafts, gaskets, seals, and top or bottom end rebuild kits in our
Polaris RZR Pro XP parts catalog.

If you’re unsure what you need, contact our team and we’ll point you in the right direction.

Before First Startup

Proper break-in helps everything seat correctly and last longer. Skipping this step can shorten the life of your rebuild.

Follow the engine break-in procedure or visit the FAQ page for guidance.

Helpful Resources

• Help Center – shipping and core process details
• REV6 Blog – maintenance and engine tips
• YouTube channel – rebuild walk-throughs
• Engine Rebuild Kit Guide – compare options

Turnaround Time

Most engines ship within 5–10 business days after we receive your core.

Take Action

If your RZR Pro XP isn’t hitting like it used to, now is the time to rebuild it right and get your power back.