Polaris Ranger 500 Engine Remanufacturing Service (1996-2013 Models)

Give your Polaris Ranger 500 the fresh start it deserves. REV6 engines are rebuilt by experienced technicians using precise tolerances, ensuring stronger performance and a longer service life. Every unit is inspected twice before it leaves our shop.

What Your Complete Engine Rebuild Includes

• Standard No-Fault 1-year warranty with an optional 2-year No-Fault Warranty upgrade.
• We restore and reuse as many OEM parts as possible. We inspect and refurbish all OEM parts to guarantee high quality internals that keep your machine running reliably.
• All components are cleaned, dismantled, inspected and repaired as needed.
• Cylinder head inspected, cleaned, sandblasted, decked, rebuilt, rebuilt to manufacturer spec and undergoes a quality inspection.
• Valve guides inspected and replaced as needed.
• Valves and valve seats recut/refaced to ensure tight seal, verified with vacuum test.
• Camshafts lobes and journals cleaned and polished, replaced as needed.
• Crankshaft is rebuilt, inspected and verified within OEM specs.
• All bearings are inspected and cleaned.
• Cylinders are inspected for wear and damage. Worn cylinders are bored to the next oversize and hone finished or replaced.
• Piston replaced with a new moly coated piston and rings.
• Timing chain inspected for stretch and wear, replaced as needed.
• Refurbished oil pump assembly.
• Fully inspected and machined engine cases, tested for journal wear, cracks, holes, or excessive wear.
• All gaskets and seals replaced.
• Engine assembled and torqued to manufacturer specifications.

Engine Core Requirements

Send your original engine core or pay a refundable $500 core charge. If your core qualifies, we’ll refund the full amount. Need your new engine first? Contact us about our core exchange option. Learn more about our Core Exchange Process.

Warranty & Support

Every REV6 engine includes our standard 1-year warranty, with an optional 2-year no-fault warranty available for engines. Questions about install, shipping, or fitment? Visit the Help Center and FAQ, or Contact Us to talk with a tech. For DIY insights and maintenance tips, check our blog and the REV6 YouTube channel. If you’re comparing kit options, see our Engine Rebuild Kit Guide.

Thank you for choosing REV6 — your trusted source for high-performance powersports engines and parts. Proudly supporting U.S. veterans and servicemembers with special discounts.