ATV/UTV Powersports Engine & Transmission Break-In Procedures
Your engine or transmission has been professionally rebuilt and has not been run prior to shipment. The break-in process is critical to long-term reliability, performance, and proper component seating.
Follow the general guidance below, then download the correct break-in procedure for your specific engine or transmission. Taking your time during break-in now prevents premature wear later.

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Before Initial Startup (Do This First)

• Replace intake boot adapters with new components only (no sealants or silicone)
• Verify engine oil and coolant levels
• Bleed the coolant system thoroughly before running the engine

Coolant Bleeding Procedure

• Leave the radiator cap off
• Start the engine and bleed coolant until a steady stream flows from the bleeder screw
• Continue until all air is removed
• Allow the cooling fan to cycle on and off
• Re-check the bleeder for any remaining air
• Install the radiator cap
• Allow the fan to cycle at least one more time
• Shut the engine off

Once complete, drain the oil and replace the oil filter before continuing.

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Engine Break-In Guidelines (All Engines)

These engines are brand-new rebuilds. Internal components—especially piston rings—require controlled heat cycles and load variation to seat properly.

Break-In Oil Requirements

• Use a dedicated engine break-in oil
• Recommended brands include Royal Purple, Amsoil, or equivalent
• Oil must contain high zinc content
• Most break-in oils are straight 30W or 40W

Break-in oil is especially important for engines with Nikasil-coated cylinders.

During the Break-In Period (First 20–25 Hours)

• Some oil consumption is normal
• Check oil level before every startup
• Add oil as needed to prevent starvation
• Avoid steady RPM or sustained throttle
• Vary engine speed and load during operation

If oil consumption becomes excessive or abnormal, stop operating the machine and contact REV6 Customer Service immediately.

Oil Changes During Break-In

• If oil discolors or breaks down, change it
• An oil change may be required anytime between 5–20 hours
• After 20–25 hours, you may switch to full synthetic oil

Approved oils after break-in:

• Polaris Oil
• Royal Purple
• Amsoil
• Lucas

Oil viscosity should match riding conditions and climate: 5W-50, 10W-50, or 10W-40

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Download Engine Break-In Procedures

Always follow the break-in guide that applies to your specific engine type.

4-Stroke Engine Break-In PDFs

Can-Am 4-Stroke Engine Break-In
Download PDF
CF Moto 4-Stroke Engine Break-In
Download PDF
Kawasaki 4-Stroke Engine Break-In
Download PDF
Polaris 4-Stroke Engine Break-In (General)
Download PDF
Polaris 570 Engine Break-In
Download PDF
Yamaha 4-Stroke Engine Break-In
Download PDF
Universal 4-Stroke Engine Break-In
Use this guide if your engine is not listed above.
Download PDF

2-Stroke & Snowmobile Engine Break-In PDFs

Polaris 700 / 800 Engine Break-In
Download PDF
Polaris 800 2-Stroke Snowmobile Engine Break-In
Download PDF
Polaris 900 / 1000 Engine Break-In
Download PDF
Ski-Doo 2-Stroke Snowmobile Engine Break-In
Download PDF
Universal 2-Stroke Snowmobile Engine Break-In
Use this guide if your engine is not listed above.
Download PDF

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Transmission Break-In Procedure

• Use Polaris AGL Full Synthetic Transmission Fluid only (all others must be approved by REV6)
• Check oil level before operation and add if necessary
• Vary speeds during the first 5 hours of run time
• Avoid heavy loads during break-in
• Perform regular checks on fluids, controls, and bolt torque

First Transmission Oil Change

Change transmission oil after 5 hours to remove fine metal particles created during normal break-in wear.

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Need Help?

If you are unsure which break-in procedure applies to your engine or transmission, contact REV6 before operating the machine. Our team is happy to help ensure your rebuild gets the best possible start.