Description

Polaris Xpedition NorthStar HVAC Engine Rebuild for 2024–2026 Models

This is a build core engine service for 2024–2026 Polaris Xpedition ADV, ADV 5, XP, and XP 5 NorthStar HVAC models. You send your engine core to REV6, and our team rebuilds it from the ground up with careful inspection, upgraded components where needed, and strict quality control.

Because this service is built around your engine core, work begins once your engine arrives and passes the initial inspection. From teardown to final assembly, each step focuses on reliable performance, proper tolerances, and long-term durability.

Included Features & Upgrades

• Standard 1-year no-fault warranty with optional 2-year no-fault warranty upgrade
• OEM components restored and reused when they meet specification
• Complete teardown, cleaning, inspection, and repair as required
• Cylinder head inspected, cleaned, decked, rebuilt, shimmed, and quality checked
• Exhaust valve guides upgraded to manganese bronze valve guides for improved high RPM durability
• Intake valve guides inspected and replaced as needed
• Valve seats recut and vacuum tested
• Camshaft lobes and journals cleaned and polished or replaced as needed
• Crankshaft inspected and verified within OEM specifications
• New high-babbitt coated crankshaft and rod bearings
• Refurbished and hone-finished Nikasil coated cylinders where required
• Moly coated pistons and rings
• Timing chain and oil chain inspected and replaced as needed
• Refurbished oil pump assembly
• Engine cases inspected, machined, and checked for wear or damage
• New gaskets and seals throughout
• Final assembly torqued to manufacturer specifications

Core Options & Warranty

This listing requires either a rebuildable customer core or a refundable core charge.

Refundable core charge: $1,500

If your existing core qualifies, contact REV6 to discuss exchange options that may help reduce downtime.

Every engine includes a standard 1-year no-fault warranty. In addition, you may upgrade to the optional 2-year no-fault, no-questions-asked warranty for added protection.

Built with Multi-Step Quality Control

Every REV6 engine goes through multiple inspection points before shipment. First, one technician completes the assembly. Then, another technician performs the final inspection before approval.

As a result, your rebuilt engine leaves REV6 with the checks needed for dependable performance.

Helpful Resources

Need parts instead of a complete rebuild? Browse related Polaris rebuild kits and parts.

Review our Warranty Policy, visit the Help Center, or contact REV6 for fitment questions and core approval.

For larger purchases, explore our financing options. You can also visit the REV6 Blog for technical rebuild information and ownership resources.

Take Action

Send in your 2024–2026 Polaris Xpedition ADV / XP NorthStar HVAC engine core and let REV6 rebuild it the right way. With nationwide shipping, warranty coverage, and core exchange options, getting your machine back in service is simple.

Thank you for choosing REV6 — trusted by riders nationwide for Powersports engines and parts. Veterans and servicemember discounts are available.