New vs. Remanufactured Engines: Which One’s Right for You?

One of the most common questions in the powersports world is:
“Should I buy a brand-new engine or go with a remanufactured one?”

At first glance, “new” sounds like the obvious winner. After all, it’s fresh from the factory, untouched, and never run. But take a closer look—because that shiny “new” engine may be the same design that failed you in the first place. In many cases, a properly remanufactured engine from REV6 can deliver improved performance, enhanced reliability, and a longer lifespan.

Let’s compare the two options so you can make an informed decision.

The Truth About Factory “New” Engines

When you buy a new replacement engine from your OEM dealer—whether it’s Polaris, Can-Am, or another brand—you’re getting the exact same design that came in your machine originally. That means it also comes with the same weaknesses and failure-prone components.

Manufacturers rarely make mid-cycle updates. Instead, they keep producing the same engine year after year until a major redesign launches. At that point, suddenly, there are upgraded valve guides, revised timing tensioners, better oiling systems, and more. Clearly, they knew improvements were needed—but they waited for the redesign.

So, when your factory engine fails and you buy another “new” one, you’re often getting an identical version with the same flaws. No upgrades. No fixes. No better protection against the issues you faced before.

What Is a Remanufactured Engine?

A remanufactured engine is completely rebuilt using a mix of new and serviceable components from a core engine. However, quality varies widely in the industry.

Some companies cut corners with cheap parts and rushed assembly—leading to the “reman” horror stories you may have heard.

That’s not how REV6 operates. Our mission is simple: build engines that are better than new.

How REV6 Remanufactured Engines Are Built Better

Because we remanufacture thousands of engines every year, we see every common failure point on Polaris and Can-Am platforms. We use that data to engineer smarter, longer-lasting solutions.

Here’s how we do it:

• Upgraded Valve Guides – We replace factory guides with high-wear materials to extend service life.

• Improved Timing Tensioners – Our tensioners are more reliable, preventing slack and early wear.

• Precision Tolerances – We correct OEM bearing clearances for better oiling and durability.

• Targeted Component Upgrades – OEM parts are kept where they excel; aftermarket upgrades replace known weak spots.

• Strict Quality Control – Every engine undergoes detailed inspections and measurements. Any part that doesn’t meet spec gets replaced.

Yes, some parts are reused—but only non-wear components that don’t affect performance or reliability. These include:

• Engine cases

• Cylinder heads (after full machining)

• Balance shafts

• Valve covers

Once inspected and machined, these parts are as dependable as brand new—without the added cost.

What About the Warranty?

OEM replacement engines typically include a 30- to 90-day warranty.

Every REV6 engine comes with a full 1-year warranty.

We stand behind our work because we don’t just rebuild engines—we improve them. Our real-world data shows that many of our remanufactured engines outlast OEM replacements.

Should You Worry About a Remanufactured Engine?

Not when it’s built by REV6.

We combine OEM and upgraded components based on proven failure data and engineering expertise. The result? Greater reliability, longer engine life, and thousands in cost savings.

Final Thoughts

“New” doesn’t always mean “better.” Often, it means “the same engine that failed you before.”

At REV6, our remanufactured engines are built smarter, tested tighter, and backed by stronger warranties—so you can spend less time in the shop and more time on the trail.

If you’re replacing your engine, let us show you why a remanufactured option isn’t just about saving money—it’s the better choice.