Description

Polaris Sportsman 500 Fuji Engine Remanufacturing

Over time, internal wear can take a toll on a Polaris Sportsman 500 Fuji engine. Instead of fixing one issue at a time, this complete engine rebuild restores the full system. As a result, you get reliable compression, smoother operation, and dependable performance.

Every REV6 engine includes a standard 1-year no-fault warranty. In addition, a 2-year no-fault upgrade is available for added protection. Because our technicians follow strict rebuild standards, each engine leaves our shop ready for hard use.

ENGINE REBUILD FEATURES & PROCESS

• OEM parts are reused whenever possible and refurbished to specification
• All components cleaned, dismantled, inspected, and repaired as needed
• Crankshaft rebuilt, inspected, and verified within OEM limits
• All bearings inspected and cleaned during teardown
• Cylinders inspected for wear and damage
• Worn cylinders bored to the next oversize, honed finished, or replaced
• New moly-coated piston and rings installed
• Timing chain is inspected and replaced when wear appears
• Refurbished oil pump assembly installed
• All gaskets and seals replaced
• Final assembly torqued to manufacturer specifications

CYLINDER HEAD & VALVETRAIN SERVICE

• Cylinder head cleaned, sandblasted, decked, and rebuilt
• Valve guides inspected and replaced when needed
• Valves and seats recut and refaced for proper sealing
• Vacuum testing confirms sealing integrity
• Camshaft lobes and journals cleaned and polished

QUALITY CONTROL STANDARDS

• One technician assembles the engine from start to finish
• A second technician inspects the engine before shipment
• Each build meets the manufacturer’s specifications

ENGINE CORE REQUIREMENTS

A usable engine core is required. You can send in your original core or pay a refundable $500 core charge. Once your core qualifies, we refund the full amount.

However, if you need your rebuilt Sportsman 500 Fuji engine first, core exchange options may be available. Contact our team to review eligibility or learn more about the REV6 Core Exchange Program.

LEARN MORE & GET SUPPORT

First, review coverage details in our engine warranty policy. Next, explore rebuild insight on the REV6 blog. You can also browse common questions in the FAQ center or contact our team for direct support.

FITMENT

Polaris Sportsman 500 Fuji Engine

TAKE ACTION
If your Sportsman 500 Fuji engine has lost power, burns oil, or runs rough, this rebuild delivers a reliable fix built to last. Because it ships nationwide, you can get started right away—add it to your cart and ride with confidence again.

Veterans and servicemembers qualify for exclusive REV6 savings—thank you for your service.