Built in the shop, proven on the trail

Give your Polaris Sportsman 550 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 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.

Core Requirement:

Important: Your rebuilt engine work will only begin after we receive your core.

Our Core Exchange Process is Easy: This is a build core required listing, meaning we need your existing Polaris Sportsman 550 engine here for a complete rebuild. Here’s how simple it is to get your ride back:

1. Place Your Order: Secure your rebuild slot.
2. Prep Your Core: Follow our easy engine core tear-down instructions – just remove exhaust, electrical, or fueling parts.
3. Hassle-Free Pickup: Once your engine core is packaged, we’ll send FedEx right to your door for pickup!
4. Expert Rebuild & Return: After passing our strict quality control, your like-new Rev6 rebuilt engine will be shipped directly back to you.

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.