Description

Polaris Outlaw 500 Engine Rebuild Service – Core Required

This is a build-to-core required listing. You must send us your existing Polaris Outlaw 500 engine for a complete rebuild. We tear the engine down to the bare cases, inspect every component, machine critical surfaces, and rebuild it to manufacturer specifications.

Because we perform the entire remanufacturing process in-house, we control tolerances, CNC machining quality, and final assembly standards from start to finish.

Warranty Coverage

Every rebuilt Polaris Outlaw 500 motor includes a standard 1-year no-fault warranty. In addition, you may upgrade to a 2-year no-fault warranty for added protection.

For complete details, review our engine warranty coverage page.

What Your Complete Engine Rebuild Includes

• Complete teardown, cleaning, and inspection of all components
• Crankshaft rebuilt, inspected, and verified within OEM specifications
• All bearings inspected and cleaned
• Cylinders inspected for wear and damage
• Worn cylinders replaced with refurbished, hone-finished nikasil-coated cylinders
• New piston and piston rings
• Cylinder head cleaned, decked, rebuilt, and shimmed to manufacturer specifications
• Valve guides inspected and replaced as needed
• Valves and seats recut and verified with vacuum testing
• Camshaft lobes and journals cleaned and polished, replaced if required
• Timing chain inspected and replaced as needed
• Refurbished oil pump assembly
• Engine cases fully inspected and machined
• All gaskets and seals replaced
• Final assembly torqued to manufacturer specifications

Why Professional Remanufacturing Matters

First, accurate cylinder finishing ensures proper ring seating. Next, crankshaft inspection protects bearing clearances. In addition, precision valve work restores compression and improves combustion efficiency. Because we follow strict rebuild standards, your Outlaw 500 engine returns ready for dependable performance.

Core Requirement

A rebuildable engine core is required before shipment. Engines are scheduled in the order in which cores are received.

Before shipping your engine, review our core shipping instructions for packaging and freight details.

Need Assistance?

If you have questions about fitment or the rebuild process, visit our help center or contact our team through our support page.

For break-in procedures and engine education, explore the REV6 blog.

Send in your core and rebuild your Polaris Outlaw 500 the right way.