Description

Polaris Sportsman 500 Engine Restoration (2001-2013 Models)

Over time, internal wear can rob a Polaris Sportsman 500 of power and reliability. Instead of chasing one problem at a time, this engine rebuild addresses the full system. As a result, you get restored compression, smooth operation, and dependable performance across years of use.

Every REV6 engine includes a standard 1-year no-fault warranty. In addition, you can upgrade to a 2-year no-fault warranty for extra coverage. Because our technicians follow strict build standards, you can install this engine with confidence and get back to riding sooner.

ENGINE REBUILD FEATURES & PROCESS

• OEM parts are reused whenever possible and refurbished to spec
• All components cleaned, dismantled, and inspected
• Crankshaft rebuilt and verified within OEM limits
• Bearings inspected and cleaned during teardown
• Cylinders checked for wear and damage
• Worn cylinders bored to the next oversize or replaced
• New moly-coated piston and rings installed
• The timing chain is inspected and replaced when wear appears
• Refurbished oil pump assembly installed
• All gaskets and seals replaced
• Final assembly torqued to manufacturer specifications

CYLINDER HEAD & VALVETRAIN SERVICE

• Cylinder head cleaned, sandblasted, decked, and rebuilt
• Valve guides are inspected and replaced when needed
• Valves and seats are recut for a tight seal
• Vacuum testing confirms proper sealing
• Camshaft lobes and journals cleaned and polished

QUALITY CONTROL STANDARDS

• One technician assembles the engine from start to finish
• A second technician inspects the engine before shipment
• Every build meets the manufacturer’s specifications

ENGINE CORE REQUIREMENTS

A usable engine core is required. You can send in your original core or pay a refundable $500 core charge. Once your core qualifies, we refund the full amount.

However, if you need your rebuilt Sportsman 500 engine first, core exchange options may be available. Contact our team so we can review your options.

LEARN MORE & GET SUPPORT

First, review coverage details in our engine warranty policy. Next, explore rebuild tips on the REV6 blog. You can also find quick answers in the FAQ center or contact our team for personal support.

FITMENT

Polaris Sportsman 500
2001–2013

TAKE ACTION
If your Sportsman 500 has lost compression, burns oil, or runs rough, this rebuilt engine offers a reliable fix. Because it ships nationwide, you can get started right away—add it to your cart and ride with confidence again.

Veterans and servicemembers qualify for exclusive REV6 savings—thank you for your service.