Description

Polaris ACE 900 Engine Rebuild (2017–2019 Models)

When an ACE 900 starts losing its edge, it usually isn’t one single issue—it’s wear across the entire engine. Instead of chasing symptoms, a full rebuild corrects everything at once and brings the machine back to a solid baseline.

That’s exactly what we do at REV6. We break the engine down completely, inspect every component, and rebuild it so everything works together the way it was designed to.

Inside the Rebuild

This service focuses on restoring internal condition—not just replacing parts, but correcting wear and bringing tolerances back in line.

• Complete teardown and inspection of all internal components
• Cylinder head rebuilt, cleaned, and set to proper specification
• Exhaust valve guides upgraded with manganese bronze material
• Valve sealing surfaces corrected and verified
• Cam components cleaned, inspected, and corrected as needed
• Crankshaft checked and verified within spec
• New high-babbitt main and rod bearings installed
• Cylinders evaluated and reconditioned to restore proper finish
• New moly-coated pistons and rings installed
• Timing and oil system components inspected and serviced
• Engine cases inspected and machined where needed
• All gaskets and seals replaced
• Final assembly completed to factory torque specifications

How We Check the Work

Every engine is built by one technician and reviewed by another before it ships. That second inspection step helps catch anything that doesn’t meet spec.

It’s a simple process, but it’s one of the biggest reasons these engines leave the shop consistently.

Warranty Coverage

A 1-year warranty comes standard. If you want additional coverage, a 2-year no-fault option is available. If something fails during that period, we take care of it.

Core Process

You can either send in your engine or use the refundable $1200 core option. Once your core is inspected and approved, the deposit is returned.

If you need the rebuilt engine first, ask about exchange options—we can walk you through it.

Before First Ride

Break-in matters more than most people think. Done right, it helps everything seat properly and extends engine life.

Follow the break-in procedure here, or check the FAQ page if you need clarification.

Need a Straight Answer?

If you’re unsure whether your engine needs a rebuild or something else, we’ll tell you straight. No guesswork.

Reach out through the contact page and we’ll help you figure it out.

Turnaround Time

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

Take Action

If your ACE 900 isn’t running like it used to, don’t keep chasing small fixes. Rebuild it once and get back to a machine that runs the way it should.