Choosing Between a Rebuild Kit and a Complete Engine

So your ATV/UTV engine failed, and now it’s time to figure out your next move.

Maybe you’ve got mechanical experience. Perhaps you’ve worked as an automotive tech, rebuilt a Chevy 350 with your dad, or restored a few classics in your garage. Either way, the thought of tackling the rebuild yourself feels like a cost-effective way to get your machine back on the trail.

But is it the right call?

At REV6, this is one of the most common questions we get:

“Should I buy a complete engine or just a rebuild kit and do it myself?”

The short answer: It depends. Let’s break down both sides of the decision.

The Case for a Rebuild Kit

Rebuild kits are appealing, especially when you see a $1,500 price tag compared to the $4,000+ cost of a fully remanufactured engine. The savings look great on paper, and for someone with the tools and time, it is an easy decision.

But there’s more to it.

Most kits include the basics: crankshaft, cylinders, pistons, bearings, and gaskets. That’s a good start—but not the whole picture. A quality engine rebuild requires much more than just replacing the lower end. Critical components like the cylinder head, oil system, and sealing surfaces must also be inspected, machined, and rebuilt properly.

Skipping these steps may save you money now, but it can lead to bigger problems later.

What’s Commonly Overlooked in a DIY Rebuild

Here’s what we often see go wrong when engines are rebuilt at home:

• Worn valve guides, especially on the exhaust side, allow oil to enter the combustion chamber, leading to oil loss or even failure.
• Improper valve seat sealing causes poor compression and performance.
• Warped cylinder heads or out-of-spec case halves that may look fine visually but are far outside proper tolerances.
• Dirty oil galleys that weren’t properly flushed, leading to contamination and premature wear.
• Reused timing guides, oil pumps, and stretch bolts, which should always be replaced.

It’s important to remember: a reliable engine rebuild is more than just a piston swap. Proper rebuilding often requires specialty tools—reamers, fly cutters, protrusion gauges, valve seat cutters—that most home garages don’t have.

The True Value of a Rebuild Kit

Rebuilding your engine isn’t just about saving money; it’s about the experience. Whether it’s a project with your buddies or a weekend bonding experience with your son or daughter, it can be deeply rewarding.

But it’s also an investment of time, effort, and patience.

If you go this route, we highly recommend sending your cylinder head to REV6 or a trusted machine shop. It’s one part of the engine that really can’t be done right without the proper equipment. Have your cases inspected. Replace the oil pump, timing guides, and any torque-to-yield bolts. Check all specs, not just visual condition.

You may not save as much money as you thought, but you’ll walk away with knowledge, pride, and a well-earned sense of accomplishment.

The Case for a Complete Engine

Now, if your goal is to minimize downtime, maximize reliability, and eliminate the guesswork, a complete engine is the way to go.

A REV6 remanufactured engine includes:

• A fully rebuilt and tested bottom and top end
• Professionally machined and spec’d cylinder head
• All necessary gaskets and components
• A 1-year warranty for peace of mind
• A ready-to-install setup that saves hours—if not days—of garage time

For many customers, the most valuable asset they have isn’t just money—it’s time. If you’re balancing work, family, and limited shop space, a fully assembled engine gets you back on the trail without the stress of sourcing tools or risking a missed detail.

The Bottom Line

There’s no wrong choice—just the one that fits your goals, experience level, and available time.

• Rebuild kits are a great learning tool and offer hands-on satisfaction—but only if you’re prepared to do the job right.
• Complete engines provide unmatched convenience, reliability, and support, getting you riding again faster, with fewer headaches.

Whichever path you choose, REV6 is here to support you with quality components, expert advice, and industry-leading engines built to perform.