Description

Ski-Doo 800 HO Engine Rebuild Service (2001–2007)

The Ski-Doo 800 HO is known for strong pull and hard snow performance. However, when internal wear starts to show up, you may notice rough starts, weak throttle response, or power that fades during the ride. A full rebuild brings the engine back the right way.

At REV6, we tear your engine down completely, inspect every key component, and rebuild it with corrected clearances and refreshed internals. As a result, your Ski-Doo 800 HO runs smoother, pulls harder, and gives you the confidence to ride when the snow is right.

Core Requirement

Core required: This is a build core engine service. A rebuildable Ski-Doo 800 HO engine core must be supplied before the rebuild can begin.

Once your order is placed, we’ll send a prepaid shipping label and coordinate pickup. Before shipping, remove your exhaust, fuel-related components, electrical parts, and sensors. After that, we handle the rest—from teardown to final rebuild and return shipping.

For step-by-step instructions, visit our Help Center.

If you want to spread out the cost, check out our flexible payment options to keep your rebuild moving.

What’s Included in the Rebuild

• Standard 1-year warranty with optional 2-year no-fault upgrade
• Full inspection of engine core
• Cleaned, blasted, and inspected engine cases
• Refurbished crankshaft
• Replated cylinders
• Upgraded moly-coated cast pistons
• Seals and gaskets
• Assembly by a master technician
• Quality control inspection

Inspection, Machining, and Setup

Once your engine arrives, we fully disassemble, clean, and inspect it. Then we check crankshaft bearings, rods, crank true, and indexing so the rotating assembly is ready for dependable snow use.

We also inspect the engine cases for cracks, bearing journal wear, and other damage. In addition, cylinders are checked for pitting, scarring, taper, and out-of-round wear.

REV6 performs cylinder replating and machining in-house when needed. For steel-sleeve applications, we also handle cylinder boring with proper piston-to-wall clearance and a clean hone pattern. That way, the piston and cylinder setup is matched for reliable break-in and long-term performance.

We do not charge for disassembly or diagnosis during the rebuild inspection process.

Built for Strong Snow Performance

The 800 HO needs solid cylinder sealing, a healthy crankshaft, and proper piston fitment to run the way it should. Because of that, we focus on the wear points that matter most before the engine goes back together.

In turn, your rebuilt engine delivers cleaner starts, smoother pull, and dependable power when you’re back in the throttle.

Warranty & Support

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

Review coverage in our warranty policy, browse answers in our FAQ, or contact our team before ordering.

For first-start guidance, follow our engine break-in procedure. You can also visit the REV6 Blog or watch rebuild content on our YouTube channel.

Need Help Choosing the Right Option?

If you’re comparing rebuild paths or parts options, our Engine Rebuild Kit Guide can help you understand what fits your repair best.

Fitment

Ski-Doo 800 HO snowmobiles
2001–2007 models

Turnaround Time

Turnaround time depends on core condition, machine work, and parts availability. For the most accurate timing, contact our team before or after placing your order.

Take Action

If your Ski-Doo 800 HO is starting rough, losing pull, or showing signs of internal wear, now’s the time to rebuild it right.

Get back on the mountain with strong, dependable power and confidence in your rebuilt engine.

We proudly support veterans and active servicemembers with available discounts—thank you for your service.