Polaris Sportsman 800 Engine Rebuild Service 2004

Sale $250 off on Engine and 20% off all parts

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POLARIS 04-12 SPORTSMAN 800 ENGINES

Your Polaris Sportsman 800 was built to work hard, but heat, wear, low compression, oil use, or tired performance can eventually catch up. Rebuilding your original engine gives your machine a stronger path forward without gambling on an unknown used engine.

Send in your engine core and REV6 will handle the rebuild with inspection, upgraded internals, precision assembly, and final quality control before return shipment. Nationwide shipping is available, every rebuilt engine includes warranty coverage, and our team is here to help if you have questions before getting started.

Polaris Sportsman 700 engine with Nikasil (Nickel Silicon Carbide) coated cylinders, moly pistons, rebuilt crankshaft and high-babbitt bearings rebuilt by REV6 Powersports

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Polaris Sportsman 800 Engine (2004-2014 Models)

Starting at: $2,975.00

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Questions Riders Ask Before Rebuilding a Sportsman 800 Engine

What signs usually mean a Sportsman 800 engine is ready for rebuilding?

Low power, increased oil consumption, smoke, hard starting, unusual engine noise, or poor compression are all common indicators that it may be time to inspect the engine.

Can REV6 help if I am not sure whether I need a rebuild yet?

Absolutely. Our team can help review symptoms, discuss your goals for the machine, and point you toward a rebuild service or parts option that makes the most sense for your setup.

How does shipping work for an engine rebuild?

After your order is placed, REV6 sends shipping instructions along with a return shipping label so you know exactly how to prepare and send your engine core. Once the rebuild is complete, we ship the rebuilt engine back to you.

Will someone help me through the rebuild process?

Yes. Our customer service and sales teams stay involved throughout the process to answer questions, coordinate logistics, and help make sure you know what to expect from start to finish.

How do I know my engine arrived safely?

Our team tracks incoming rebuild orders through intake and inspection stages so there is visibility as your engine moves through the process.

Can I ask technical questions before sending my engine?

Yes. Our staff works with riders, shops, and mechanics every day and can help answer questions about rebuild expectations, fitment, timelines, and service details.

Call or Text Now 801-489-8697

WE KNOW YOUR SPORTSMAN 800 ENGINE

Every Polaris 04-12 Sportsman 800 engine we build is done by one of our master technicians. With over 35 years of experience, your engine is in great hands.

All Sportsman 800 Engines Include:

Full inspection of engine core
Clean, blasted/inspected engine cases
Remanufactured cylinder head
Nickel plated mono cylinder
Pistons & rings
Valve guides
Intake & exhaust valves
Valve seats
Valve stem seals
HD crankshaft
Crankshaft main bearings

Balance shaft bearings
Balance shaft
Camshaft
Lifters
Pressure relief dowel
Pressure relief spring
Complete gasket set
Water pump mechanical seal kit
Seals
Assembly by a master technician
Quality control inspection

All Sportsman 800 Engines Include the Following Upgrades:

Upgraded moly pistons
Heat treated camshaft
HD twin Crankshaft
Modified pressure relief system
Better piston to cylinder wall specifications
High performance lifters
High temp valve stem seals

We have options in engines to fit your needs:

Parts Warranty Financing

We are so confident in our craftsmanship that each Polaris 04-12 Sportsman 800 engine comes with a 1-year warranty. We offer free shipping inside the 48 continuous states and Canada.

Work with the best when it comes to your Sportsman 800 engine.

we build engines better than new!

Call or Text Now 801-489-8697

POLARIS 04-12 SPORTSMAN 800 ENGINES

Polaris Sportsman 800 Engine (2004-2014 Models)

Questions Riders Ask Before Rebuilding a Sportsman 800 Engine

What signs usually mean a Sportsman 800 engine is ready for rebuilding?

Can REV6 help if I am not sure whether I need a rebuild yet?

How does shipping work for an engine rebuild?

Will someone help me through the rebuild process?

How do I know my engine arrived safely?

Can I ask technical questions before sending my engine?

WE KNOW YOUR SPORTSMAN 800 ENGINE

Work with the best when it comes to your Sportsman 800 engine.

we build engines better than new!

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