Polaris Sportsman 500 Engine (2016–2020)

Description

2016–2020 Polaris Sportsman 500 Engine Rebuild by REV6

Internal wear in your Polaris Sportsman 500 can affect the crankshaft, cylinders, pistons, and valve train. When several components need attention, rebuilding the engine allows REV6 to inspect the assembly and replace the parts identified in our rebuild process.

This rebuild includes a new crankshaft, new cylinders, forged moly-coated pistons, and several additional engine components. REV6 also cleans and prepares the engine cases before final assembly.

What’s Included in the Sportsman 500 Engine Rebuild?

REV6’s Sportsman 500 rebuild includes the following components and procedures:

Crankshaft, Cylinders and Pistons

• New crankshaft
• New cylinders
• Forged moly-coated pistons
• Re-plated cylinders

Water Pump and Internal Engine Components

• New water pump
• New counterbalance
• New lifter assembly
• New valve seal and seat

Engine Cases and Final Inspection

• Engine cases fully cleaned and sandblasted
• Engine assembled by a REV6 master technician
• Second inspection performed by another master technician

New Crankshaft and Cylinder Components

Unlike rebuilds that rely primarily on refurbishing existing components, this Sportsman 500 listing specifically includes a new crankshaft and new cylinders.

REV6 also installs forged moly-coated pistons and completes the listed cylinder replating work. These components are part of the engine rebuild rather than optional additions.

Water Pump, Counterbalance and Lifter Replacement

The rebuild also includes a new water pump, counterbalance, and lifter assembly. REV6 addresses these components during the engine rebuild instead of limiting the work to the crankshaft and cylinders.

New valve seal and seat components are included in the listed rebuild work.

REV6 Master Technician Double Inspection

After your Sportsman 500 engine core arrives, REV6 disassembles and cleans the engine before rebuilding begins.

A master technician completes the rebuild. Then, a second master technician inspects the assembled engine before final approval.

This two-technician inspection process provides an additional quality control check before the engine is returned to the customer.

Polaris Sportsman 500 Engine Core Process

This listing requires your original engine core. Send your Sportsman 500 engine to REV6 so our technicians can inspect it and complete the rebuild.

Before preparing your engine for shipment, review the REV6 engine shipping instructions.

If you have questions about core condition or shipping requirements, contact our team before sending your engine.

Polaris Sportsman 500 Engine Fitment

The supplied fitment for this engine rebuild is:

• 2016–2020 Polaris Sportsman 500

Confirm your exact model year and engine configuration with REV6 before purchasing.

Sportsman 500 Engine Warranty

Your rebuilt Polaris Sportsman 500 engine includes a 1-year REV6 engine warranty.

Review the REV6 Warranty Policy for complete coverage terms and requirements.

Engine Shipping and Break-In

REV6 provides engine shipping instructions to help customers prepare their cores for shipment.

Before operating your rebuilt engine, review the REV6 engine break-in procedure for initial startup and operation guidance.

Questions About Your Sportsman 500 Engine?

Need help confirming fitment, understanding the rebuild process, or preparing your engine core? Visit the REV6 FAQ center or contact our team.

Send us your Polaris Sportsman 500 engine core to get your rebuild moving.