Description

Polaris RZR Turbo XP Engine Rebuild Service (2016–2023 XP & S Models)

The RZR Turbo XP is built for power, but boost also puts more stress on the engine. Over time, wear shows up as reduced performance, inconsistent power, or loss of efficiency. Instead of patching problems, a full rebuild restores the engine so it can handle the load again.

At REV6, we tear down every engine, inspect each component, and correct wear where needed. Then we rebuild it using proper tolerances and refreshed internals. As a result, your engine runs smoother, holds power better, and stays reliable under boost.

What Gets Rebuilt

This process focuses on restoring sealing, strengthening internal components, and improving long-term durability.

• Complete teardown and inspection of all internal components
• Cylinder head cleaned, decked, rebuilt, and shimmed to specification
• Exhaust valve guides upgraded with manganese bronze material
• Intake valve guides inspected and replaced when needed
• Valves and seats recut and vacuum tested for proper sealing
• Camshaft components cleaned, polished, and inspected
• Crankshaft inspected and verified within OEM tolerances
• New high-babbitt main and rod bearings installed
• Cylinders inspected and repaired or replaced as needed
• Moly-coated pistons and rings installed
• Timing chain and oil chain inspected and replaced when needed
• Refurbished oil pump assembly
• Engine cases inspected and machined for wear or damage
• All gaskets and seals replaced
• Final assembly torqued to factory specifications

Note: Final build details may vary depending on the condition of your core.

Built for Boost and Consistency

Once we restore proper sealing and correct clearances, the engine holds boost more consistently and delivers smoother power. Because of that, your machine performs the way it should when you put it under load.

Double Inspection Process

One technician builds your engine, and then another checks every detail before it ships. This extra step helps ensure everything meets spec before it goes back into your machine.

Warranty Coverage

Every engine includes a 1-year warranty. In addition, you can upgrade to a 2-year no-fault plan for extra protection.

Review full details on our warranty policy.

Core Options

You can send in your engine core or choose the refundable $1500 core option. Once your core passes inspection, we return the deposit in full.

If you need your rebuilt engine first, ask about exchange options and we’ll help you get set up.

Looking for Parts or Upgrades?

If you’re upgrading or rebuilding specific components, you can find transmissions, crankshafts, valves, gaskets, seals, ECU tuning options, and top or bottom end kits in our
Polaris RZR Turbo parts catalog.

If you’re unsure what you need, contact our team and we’ll point you in the right direction.

Before First Startup

Proper break-in helps everything seat correctly and hold up under boost. Skipping this step can shorten the life of your rebuild.

Follow the engine break-in procedure or visit the FAQ page for guidance.

Helpful Resources

• Help Center – shipping and core process details
• REV6 Blog – engine tips and performance insights
• YouTube channel – rebuild walk-throughs
• Engine Rebuild Kit Guide – compare options

Turnaround Time

Most engines ship within 5–10 business days after we receive your core.

Take Action

If your Turbo XP isn’t holding power as it should, now is the time to rebuild it right and get your performance back where it belongs.