Description

Polaris Ranger 800 Engine Rebuild (2008–2010)

If your Polaris Ranger 800 is knocking, smoking, or losing compression, it’s time for a proper engine rebuild. Rather than relying on a temporary fix, REV6 provides a structured engine remanufacturing service designed to restore reliability, sealing integrity, and long-term durability.

This is a core-required rebuild service. You must send in your original engine core or pay a refundable $800 core charge. Once your core is inspected and approved, that charge is refunded in full. Before shipping, review our engine shipping instructions to ensure proper preparation. We provide insured nationwide shipping for a smooth turnaround.

What This Engine Rebuild Includes

• Standard 1-year no-fault warranty
• Optional 2-year no-fault warranty upgrade available
• Complete teardown, cleaning, and detailed internal inspection
• Cylinder head cleaned, decked, rebuilt to spec, and vacuum tested
• Valve guides inspected and replaced as needed
• Valves and seats recut and refaced to ensure proper sealing
• Camshaft lobes and journals cleaned and polished
• Crankshaft inspected within OEM specifications and rebuilt with new rods if required
• New high-babbitt-coated main and balance shaft bearings
• Refurbished and hone-finished nikasil-coated cylinders
• New moly-coated pistons and rings
• Fully inspected engine cases, checked for cracks and journal wear
• All new gaskets and seals installed
• Final assembly torqued to manufacturer specifications

Additionally, we restore viable OEM components whenever possible to maintain factory engineering standards. However, critical wear items are replaced to prevent premature failure. As a result, the finished engine delivers dependable performance under load and in demanding work applications.

Quality Control Standards

After assembly, each unit goes through a structured verification process. Clearances, sealing surfaces, and timing alignment are carefully checked. Consequently, your engine leaves our facility built for consistent operation and long service life.

Warranty & Support

Your rebuild includes a 1-year no-fault warranty. Furthermore, you may upgrade to 2-year coverage for additional protection. To review complete details, visit our Warranty Policy. If you have questions about the process, the Help Center and FAQ page provide clear guidance.

Ready to Get Back to Work?

Ultimately, a properly rebuilt engine saves time and money compared to repeated repairs. Contact our team today to begin your Polaris Ranger 800 engine rebuild service. You can also explore additional technical insight on the REV6 Blog or watch our process in action on our YouTube channel.

Proudly supporting U.S. veterans and servicemembers with special discounts.