Description

Honda Foreman 500 Engine Rebuild Service

The Honda Foreman 500 is known for getting the job done, but over time, engine wear can lead to hard starts, reduced power, and inconsistent performance. Instead of chasing small fixes, a full rebuild brings your engine back to proper working condition.

At REV6, we completely tear down your engine, inspect every component, and correct wear where needed. Then we rebuild it using proper tolerances and refreshed internals. As a result, your Foreman runs smoother, starts easier, and delivers steady, dependable power.

Core Build Requirement

This is a build-core-only engine service. You send in your engine, and we rebuild it from the ground up using your core.

For shipping steps and preparation, visit our Help Center or contact our team for guidance.

What Gets Rebuilt

This rebuild focuses on restoring sealing, correcting clearances, and improving long-term reliability.

• Complete teardown and inspection of all internal components
• Cylinder head cleaned, decked, rebuilt, and set to specification
• Valve guides inspected and replaced when needed
• Valves and seats recut and vacuum tested for proper sealing
• Camshaft components cleaned, polished, and inspected
• Refurbished crankshaft
• Cylinder inspected, bored and honed, or replaced as needed
• New moly-coated piston and rings installed
• Timing chain inspected and replaced when needed
• Refurbished oil pump assembly
• Engine cases inspected for cracks, wear, and integrity
• 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 Dependability

Once clearances are corrected and sealing is restored, the engine runs smoother and delivers consistent power. Because of that, your Foreman stays reliable whether you’re working, hauling, or riding.

Warranty Coverage

Every engine includes a 1-year warranty. In addition, you can upgrade to a 2-year no-fault warranty for full protection. If something happens, you’re covered—simple as that.

Review coverage details on our warranty policy or visit our FAQ page for common questions.

Looking for Parts Instead?

If you don’t need a full rebuild, you can find pistons, cylinders, gaskets, seals, valves, and rebuild kits in our Honda Foreman parts catalog.

If you’re unsure what you need, reach out to our team and we’ll help you choose the right option.

Before First Startup

Proper break-in helps everything seat correctly and improves long-term reliability.

Follow the engine break-in procedure to get the most out of your rebuild.

Turnaround Time

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

Take Action

If your Foreman 500 is losing power or starting to show its age, rebuilding it now keeps your machine reliable and ready for whatever you throw at it.

We proudly support veterans and active servicemembers with available discounts—thank you for your service.