Polaris Sportsman 850 Engine Rebuild (2008–2022)

Description

Engine Rebuild Service for the 2008–2022 Polaris Sportsman 850

Low compression, oil use, internal noise, or engine damage can leave a Sportsman 850 parked. REV6 disassembles the engine, checks its internal condition, and performs the machining and parts replacement required by the supplied core.

The rebuild uses new moly-coated pistons, high-Babbitt bearings, gaskets, and seals. In addition, reusable OEM components are cleaned, measured, and serviced before assembly.

What Your Engine Rebuild Includes

• Engine disassembly, cleaning, and inspection
• Serviceable OEM components restored and reused where appropriate
• Cylinder head cleaned, blasted, decked, rebuilt, and checked to manufacturer specifications
• Valve guides inspected and replaced as needed
• Valves and valve seats recut and vacuum tested
• Camshaft lobes and journals cleaned and polished, with replacement as needed
• Crankshaft inspected and verified within specification
• New high-Babbitt crankshaft main and connecting-rod bearings
• Cylinders inspected for wear and damage
• Worn cylinders bored and honed to the required oversize or resleeved as needed
• New moly-coated pistons and piston rings
• Timing chain inspected and replaced as needed
• Refurbished oil pump assembly
• Engine cases inspected for journal wear, cracks, holes, and excessive damage
• New gaskets and seals
• Final assembly torqued to manufacturer specifications

The required machining and replacement parts depend on the condition and measurements of the engine core received by REV6.

Core and Shipping Options

This engine rebuild requires an eligible Polaris Sportsman 850 core. You can send your engine first or select the refundable core option when placing the order.

REV6 also offers a shipping-label option for customers who need help sending the core. After purchase, the team provides the shipping instructions and tracking information that apply to the option selected.

The core charge is refunded after REV6 receives, inspects, and accepts the required core under the applicable core terms. Because core eligibility can depend on damage and missing components, contact REV6 if you have questions before ordering.

Fitment

• 2008 Polaris Sportsman 850
• 2009 Polaris Sportsman 850
• 2010 Polaris Sportsman 850
• 2011 Polaris Sportsman 850
• 2012 Polaris Sportsman 850
• 2013 Polaris Sportsman 850
• 2014 Polaris Sportsman 850
• 2015 Polaris Sportsman 850
• 2016 Polaris Sportsman 850
• 2017 Polaris Sportsman 850
• 2018 Polaris Sportsman 850
• 2019 Polaris Sportsman 850
• 2020 Polaris Sportsman 850
• 2021 Polaris Sportsman 850
• 2022 Polaris Sportsman 850

Confirm the model year and engine before ordering. Contact the REV6 team if the ATV has a replacement engine or if its build details are uncertain.

Two-Stage Quality Control

One REV6 technician assembles the engine and verifies the required measurements. Then, another technician performs the final inspection before shipment. This second review provides another check of the assembly and build specifications.

Estimated Rebuild Time

The estimated turnaround is 5–10 days after the required core arrives and passes inspection. However, added machine work, damaged components, parts availability, and current shop volume may affect that estimate.

If you need the engine by a certain date, contact REV6 for the current schedule before placing your order.

Installation and Break-In

Proper installation and break-in help protect the pistons, rings, bearings, and other rebuilt components. Therefore, review the REV6 engine break-in procedure before starting or operating the installed engine.

Warranty, Financing, and Support

This Sportsman 850 engine rebuild includes a 1-year REV6 warranty. An optional 2-year no-fault warranty is also available. Review the policy for its coverage, maintenance, break-in, and claim requirements.

Qualified customers can review REV6 financing options. You can also browse Polaris Sportsman 850 engines, transmissions, parts, and rebuild kits for 2008–2022 models.

Select your core, shipping, and warranty options to get the rebuild moving. For help with fitment or ordering, talk with the REV6 team.