Description

When internal wear starts to affect power and reliability, a complete engine rebuild offers a long-term solution. The Kawasaki Teryx 800 Engine rebuild service restores core systems, corrects wear, and brings critical tolerances back into specification.

Every REV6 engine includes a standard 1-year warranty. In addition, an optional 2-year no-fault warranty upgrade is available for added coverage. Because each engine follows a strict rebuild process, you can install with confidence and get back to riding sooner.

ENGINE REBUILD FEATURES & PROCESS

• OEM components reused whenever possible and fully refurbished
• All components cleaned, dismantled, inspected, and repaired as needed
• Cylinder heads cleaned, sandblasted, decked, and rebuilt to specification
• Valve guides inspected and replaced when required
• Valves and seats recut and refaced for proper sealing
• Vacuum testing confirms sealing integrity
• Camshaft lobes and journals cleaned, polished, or replaced as needed
• Refurbished crankshaft installed
• Refurbished nickel-plated cylinders installed
• New pistons and rings installed
• Timing chains inspected and replaced if wear appears
• Engine cases inspected for cracks, holes, or excessive wear
• All gaskets and seals replaced
• Final assembly torqued to manufacturer specifications

QUALITY CONTROL STANDARDS

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

CORE OPTIONS

This rebuild service requires either receipt of your engine core or a refundable $1,800 core deposit. Once your core arrives, our team inspects it. As long as components show normal wear, we issue a full refund.

However, damaged components may result in a deduction from the core refund. If you want to avoid the core deposit, you can send your engine core first. After inspection, we will contact you before proceeding.

IMPORTANT NOTES

This rebuild list represents a standard service outline. Depending on the condition and specific model variation, your engine may include additional components or require fewer repairs.

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 to discuss your rebuild.

FITMENT

Kawasaki Teryx 800

TAKE ACTION
If your Teryx 800 engine shows wear, noise, or loss of power, this rebuild service provides a dependable fix built for hard use. Because we offer nationwide shipping, you can get started anywhere—add it to your cart and rebuild with confidence.

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