Polaris Ranger 800 Engine Rebuild (2011–2017)

Description

2011–2017 Polaris Ranger 800 Engine Rebuild by REV6

When your Polaris Ranger 800 develops internal engine noise, loses compression, or begins consuming oil, worn internal components may require more than a minor repair. REV6 rebuilds your engine with inspected crankshaft components, refurbished cylinders, new pistons and rings, and a rebuilt cylinder head.

Our technicians evaluate the engine as a complete assembly, checking critical components before machining, replacement, and final assembly. This process helps address wear throughout the engine rather than replacing individual parts without evaluating the surrounding components.

What REV6 Rebuilds Inside Your Ranger 800 Engine

Every rebuild begins with a complete teardown, cleaning, and inspection. Our technicians evaluate component condition and restore or replace parts according to the rebuild requirements.

Cylinder Head and Valve Train

• Cylinder head cleaned, decked, and rebuilt to specification
• Cylinder head vacuum tested to verify valve sealing
• Valve guides inspected and replaced as required
• Valves and seats recut and refaced for proper sealing
• Camshaft lobes and journals cleaned and polished

Crankshaft, Bearings and Cylinders

• Crankshaft inspected against OEM tolerances
• Crankshaft rebuilt with new connecting rods when necessary
• New high-babbitt coated main bearings
• New high-babbitt-coated balance shaft bearings
• Nikasil-coated cylinders refurbished and hone-finished
• New moly-coated pistons and piston rings

Engine Cases and Final Assembly

• Engine cases inspected for cracks and journal wear
• All new gaskets and seals installed
• Final assembly torqued to manufacturer specifications

OEM Component Inspection and Reuse

REV6 evaluates original engine components before determining which parts can be restored and which require replacement. When OEM components remain within specification, our technicians can reuse them during the rebuild.

High-wear components are replaced as required, while the crankshaft, cylinder head, cylinders, and engine cases receive the inspection and rebuilding procedures described above.

Engine Assembly and Quality Control

Before an engine leaves REV6, our technicians verify internal clearances, sealing surfaces, and timing alignment. Final assembly follows manufacturer torque specifications.

These inspections help confirm that the rebuilt engine meets REV6 assembly requirements before shipment.

Polaris Ranger 800 Engine Core Requirements

An engine core is required for this rebuild. You can send your original Ranger 800 engine to REV6 or select the refundable $1,200 core charge option when available.

If you pay the core charge, REV6 inspects your returned engine before determining refund eligibility. A qualifying core may receive the full refund, subject to the applicable core return requirements.

Shipping Your Ranger 800 Engine Core

Before shipping your engine, review the REV6 engine shipping instructions. Follow the preparation and packaging requirements to help protect your engine during transportation.

REV6 provides insured nationwide shipping for this rebuild service. Contact our team if you need clarification about shipping arrangements or core requirements.

REV6 Ranger 800 Engine Warranty

Your rebuilt Polaris Ranger 800 engine includes a standard 1-year no-fault warranty. An optional 2-year no-fault warranty upgrade is also available.

Review the REV6 Warranty Policy for coverage details, exclusions, and warranty requirements.

Rebuilding Your Polaris Ranger 800 Yourself?

If you plan to rebuild your Ranger 800 engine yourself, REV6 also offers parts and rebuild kits for Polaris Ranger models. Compare available components and verify your model before selecting parts for your project.

Browse Polaris Ranger engine rebuild kits and parts to explore your options.

Questions About Your Ranger 800 Engine?

Need help with engine fitment, core requirements, shipping, or warranty coverage? Visit the REV6 Help Center or contact our team before purchasing.

You can also call (801) 489-8697 to discuss your Polaris Ranger 800 engine rebuild.

Send us your Ranger 800 engine core to get your rebuild moving.