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LE Nick

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First off, welcome!  I'm trying to compile all of the commonly useful information about Predators and Outlaws in one thread.  I will continue to update the first post with new information and corrections as time passes to keep it clean and easy to navigate.

First things first:  Model history

Predator:

Predators were made from 03-07.  Here's the VIN number breakdown:

VIN # 4XAGA50A*3P00000 = 17 number, letters, and symbols
BREAK DOWN AS FOLLOWS:
1st three digits are: World Mfg. ID
Vehicle Descriptor
4th digit: body style
5th digit: Powertrain
6th & 7th digits: Engine
8th digit: Emissions
9th digit: * = check digit
Vehicle Identifier
10th digit: MODEL YEAR
11th digit: Plant No.
12th - 17th digits: Individual Serial Number

The "build on date" on the VIN sticker can be misleading.  For example, many 07 models were made in late 06.  The same applies for other years.  This sticker should be behind your front bumper on the frame.

03 - gray standard model and black and red Troy Lee Designs (TLD) model.  Color was the only difference.  03's had longer swingarms (about an inch), longer rear shock (about 18.5 inches), and 4x156 rear hubs.  These features were unique to the 03.  03's also had some transmission issues that hit and miss.  Polaris offered an update kit for them.  The frames on the 03's were also weak especially near the rear gas tank mount.  They were bolted on the 03's and tend to crack in that area.  Note:  pictures are only for color reference.  They are NOT exactly the same configuration as production units.
[206h3ba]
[2u8b2om]
04 - gray metallic standard model, black and orange TLD model, red Dale Earnhardt Jr. model, and metallic blue 50th Anniversary model.  04's had the transmission update from the factory, stronger frame (welded gas tank mount), shorter swingarm, 4x110 rear hubs, and a shorter rear shock.  Color was the only difference between the standard model and the TLD.  The Dale Jr. edition had a Pure Polaris bumper and nerfs along with #8 graphics.  The 50th Anniversary model had the Maxxis Razr-r tires and gold colored accents.
[sm8r61]
[50nrth]
[2chq16e]
[295enm9]

05 - red standard model, orange TLD model, and white LE model.  05's had an updated transmission which shifted very smooth along with reverse.  There were also two different transmissions offered: close ratio and wide ratio.  The TLD had the close ratio while the standard and LE had the wide ratio.  The 03-04 transmission was basically a wide ratio tranny.  Both wide and close ratio transmissions had the same first and fifth gear.  The difference was 2nd, 3rd, and 4th.  The close ratio has a tightly spaced 1-4 and the wide is spaced tightly 2-5.  Close ratio is better suited to tight woods and the wide to more open high speed riding.  If the plastics were changed out, the close ratio typically had black side case covers on the engine.  05's also had an inch taller steering stem and a revised seat.  The standard model had Maxxis PR tires, and the TLD and LE had Razr-r tires.  The TLD and LE also sported piggyback front Podium X shocks.  In addition to the piggyback shocks, the LE version had a Pure Polaris bumper, grab bar, and exhaust.
[nnpe28]
[2lk8aoo]
06 - The 06 model year was almost identical to the 05's other than color.  They went with a Piggyback reservoir rear shock instead of a remote reservoir, black frames on all models, and a red standard model, and a white TLD model.  They also offered a black Smiley Edition with the close ratio transmission, Razr2 tires, piggyback front shocks, and a Pure Polaris bumper, grab bar, and exhaust.
[30jmt6a]
[ifnxo2]
[16kxfd4]
07 - The final year of the Predator saw some minor changes.  Colors and options changed.  The standard models were offered in both white and black and had budget front Ryde FX shocks, updated steering to eliminate the PRO steering, Razr PR tires, unique upper a-arms from the rest of the Predators, and several parts that it shared with the Outlaw 500 model (such as the radiator, brake master cylinder, reverse lever).  There was also an LE model that was offered in black that sported Podium X shocks, wide ratio transmission, and Razr-r tires.
[2s7yv0w]
[9bdmbc]

Outlaw:

Outlaws were made from 06-11.

06 - The Outlaw 500 was introduced.  The Outlaw features IRS which was a first on a sport quad.  It shared the same motor/transmission with the TLD Predator (close ratio tranny).  The 06 model also had the coveted Fox piggyback rear shocks that many IRS owners upgrade to along with the Fox front shocks.  The 06 Outlaw 500 was only offered in black and sported Dunlop radial tires.
07 - 2007 saw the introduction of the KTM RFS based 525 IRS.  The 500's were offered in white and black and the 525's were offered mainly in black, but saw a limited build of white plastics.  This was the only year that the 500 and 525 IRS machines were offered for sale at the same time.  The frames between the two models are totally different so there's no swapping motors.  Both 07 models had Ryde FX shocks on all four corners.  The 07 500 also had the wide ratio transmission.  Mid year 07 saw an upgrade to needle bearings on the rear upper outer control arm pivot.  You can tell if your machine is updated by removing the rear tire and checking to see if there is a grease zerk that points outwards on the upper rear knuckle pivot.

08 - From here on out, the Outlaw line was purely KTM powered.  08 saw the introduction of the 450MXR and 525S.  The only things that changed on the IRS was the color and front shocks:  it was now red with a white side panel and had Fox front shocks and Ryde FX rears.  The 450MXR was only offered in red while the 525S was offered in red and white.  The 450MXR featured Podium X front shocks with piggyback reservoirs, and the 525S had standard Fox front shocks.  The IRS retained its Razr-r tires, the 450MXR acquired a set of Razr MX tires, and the 525S sported the old set of tried and true Razr PR tires from the Predators.
09 - This was a big update year for the Outlaw line.  New body plastic and ergonomics were the excitement even though they were only offered in red from here out.  The mechanics of each machine remained mostly unchanged.  Every machine received a suspension upgrade in one way or another.  Both straight axle machines received a cut rear shock (same eye to eye length, but more shaft travel) with new springs.  Because of the increased travel, the brake caliper is rotated to the rear to prevent it from contacting the exhaust.  The front shocks on all machines received a new spring package as well.  The IRS machine went to Fox shocks all the way around along with a new spring setup out back that accompanied the new 10 inch rear wheels which allowed more clearance to the a-arms.  09 also saw the elimination of the "PRO" Outlaw steering and the addition of a traditional steering setup.  All 09 models also had a vacuum operated fuel pump.  All models except the 525S retained the same tires;  it received the Razr-r's that were once on the IRS machine.  The IRS machine also had the battery relocated beneath the radiator and right in front of the engine and had the foot pegs relocated 1" further forward.
10 - 2010 saw literally no changes from the 2009 lineup.
11 - Both straight axle machines were no longer offered for 11.  Only the IRS remained and the only difference was the front hood was changed to red instead of black.


Common issues/problems/things to look for

  • 03 Predators had weak frames near rear gas tank mount.
  • 03 Predators had transmissions which could possibly fail if the update kit was not installed.  By this point in time, if the transmission has not failed, it most likely won't.
  • The boot from the carb to the motor is prone to crack when over tightened on the RFS powered Outlaws.
  • Check to make sure your side panel plastic is not rubbing a hole in the radiator on 06-08 Outlaws.  06 models were especially bad at this.
  • The seat tends to fall off on 06-08 Outlaws.  They updated the seat latch in 08, but the problem remained even though it was not as bad.  The only solution is to extend the tab on the gas tank and pin the rear latch.
  • The sprocket bolts on all IRS machines can loosen if they don't have Loc-tite on them.  There was an update from Polaris that used different bolts and tabs under them that bent up to prevent the bolt from spinning.  Many people had this update fail on them.  The best solution is red Loc-tite with the stock bolts and to keep an eye on them.
  • Be careful with the drain plugs on the KTM motors.  They don't need to be gorilla tight and strip easily.
  • Don't drop the bottom long oil screen into the KTM motor.  Take your time and use something to align the screen with the pocket on the other side of the case.
  • 06-08 Outlaw fenders tend to crack near the rear of the seat and close to the fender "brace".  Fabricate a set of fender braces to eliminate the cracking.  This is especially useful if you ride in the mud a lot.
  • Grease the ball joints and steering ends with a grease needle.  There is very little grease in them from the factory and a little additional grease goes a long way.
  • Front wheel bearings are a weak point on most of the Polaris sport quads.  Either be ready with a set of stock bearings or replace them with a tapered aftermarket set.
  • Keep an eye on the chain slider on all straight axle machines.  They tend to eat through them fairly quickly and will continue eating into the swingarm if you don't catch it in time.
  • If you lose clutch feel on the KTM powered Outlaws and can't see where the fluid is going, your slave cylinder most likely needs to be replaced.
  • If your machine will not start in gear with the clutch lever pulled in, your clutch lever sensor will most likely need to be replaced.  Test this by jumping the two clutch sensor wires together and hit the start button while in gear (have clutch lever pulled in too!).
  • The intake trunk on Predator models has a tough time staying on the carb.  Don't overtighten the clamp as it deforms the trunk and keep a close eye on it.
  • Do NOT stand up the Predators (all years) on their grab bars without first pinching the breather line running from the transmission to the airbox.  If this is left open, all the oil will drain into the airbox.
  • The crank nut on the KTM motors can loosen over time and make the engine sound like a rock crusher.  Simply remove the entire clutch side case cover and see if the nut is loose.  This nut is also LEFT hand threaded!  If it is loose, remove it, clean each surface, apply Loc-tite, and tighten nut.  It is also good practice to let the Loc-tite dry before running the engine.
  • Sway bars on all IRS machines can break at the bend or mounting tabs.  They typically do this under hard use and can damage the CV boots if not caught right away.  Some people have ran a thin cable through the sway bar and attached eyelets to each end and bolted them to the upper sway bar link/sway bar bolt.  Others have replaced the sway bar all together with an adjustable unit from Fuj.
  • Make sure your rear hub nuts are tight and hub bearings are good on IRS machines.  If not, you can break the rear hub where it necks down inside the bearing.  The only way to find if it is broken is if you disassemble the hub or if you leave it long enough for the remaining portion of the hub to strip out.
  • If the rear end of your IRS is clicking (CV joint noise usually while turning) it is because the center machined hub is shot or has debris in it.  You either need to disassemble the entire housing and clean the CV joints or order a complete new assembly (which is very reasonably priced for what you get).
  • If your machine has overheating issues and the rest of the cooling system is working properly, the first thing to do is completely remove the radiator and clean it.  You'll be amazed how much crud is still in a "washed" radiator once you remove it to clean it.  This applies to any quad.  If you know you're going to be riding in mud, cut a same sized furnace filter to place in front of the radiator.
  • Be sure to crack the bleeder screw on the head of KTM motors when refilling them with coolant.  If you don't, this traps an air pocket in the head and causes heating issues.
  • Improper throttle cable adjustment can kill the motor.  Symptoms are usually that you have to hold the throttle slightly or it will die at idle.  Test this by removing the plug attached to the throttle housing.  This is the sensor that monitors if the throttle is stuck open.
  • Keep up on adjusting valves.  The tell-tale sign that your intake valves are tight is if your machine will pop start but not start with the start button.  Once warm, the machine will start with the button.  If you let this go too long, it will damage your valves and head.  KTM's are super easy to adjust valves on while the Fuji 500 is more in depth but equally important.  You can adjust them as frequent as every oil change but make sure to check/adjust them at LEAST once a year.
  • Oil.  Loaded topic, but here is a summary.  Pick an oil that YOU feel comfortable with.  There's typically a balance between price and quality for all oils.  This choice also goes hand in hand with how often you change the oil.  I shoot for every 10 engine hours or less depending on use.  An engine hour meter is a great tool for keeping track of maintenance.  Synthetic or non synthetic doesn't matter as long as it's approved for a wet clutch.
More power you say?

For all of the Polaris sport quads, a full exhaust system is usually a waste of money.  The stock headers flow very well.  HMF and FMF show good gains on these quads with their slip ons and they are reasonably priced.

The 558 kit for the Fuji 500 engines is a great way to gain power for a fair price.

The stock cams in the 500 engine are more than enough for the 558 kit let alone the stock bore.  Leave them alone!  Hot Cams make this motor very weak.

Do NOT use a Big Gun or any other aftermarket CDI on the 500 motor!  All of the cheap aftermarket CDI's don't retard the timing upon startup and can cause the motor to fire in the incorrect direction.  This will fry your one way clutch and send metal throughout your motor.  Vortex or Dyna are safe bets.

Boring the carb on the KTM motors is a great bang for your buck.  Up to a 41.5mm shows no loss on the bottom end (stock is 39mm).

A KTM cam such as an 8/06 or 8/33 will really wake up the RFS based motors.  They are also around $150 so it's a great value.

As for intakes on all these machines, that's up to you.  About any intake will flow better than stock but you have to be careful in a few areas.
  • Removing the lid on all Outlaw models will increase flow.  
  • You cannot remove any lid on the Predator models.  You can however cut a hole in the bottom half of the airbox.  This flows surprisingly well.
  • The Fuji 500 carb is a vacuum type carb.  If the intake does not create enough vacuum, it will not lift the slide properly.
  • Be honest with yourself on the terrain you ride in.  If you're in tons of water, don't put a clamp on filter right off the carb without an airbox.
  • The SRA Outlaw models leave little to no choice of intakes.  Almost all of the aftermarket choices aren't much better than stock.  The only proper "solution" is to get a side mount exhaust, modify the sub-frame, and put an intake where one is supposed to be.  Check out the "strubby mod" to get an idea of one solution.

Jetting

This is a very touchy subject.  I am not responsible for any damages which may occur from jetting suggestions.  These are ballpark estimates assuming everything else is in proper working order.  The BEST way to get jetting information for your application is to buy a wideband air/fuel meter. This is the absolute best money I've spent on tuning.
  • Stock jetting in Predators is a 150 main with a 45 pilot.  Main jets for the Predators are Mikuni small rounds.  
  • Stock jetting in the Outlaw 500 is 145 main with a 45 pilot.  Same carb as the Predator.
  • Stock jetting in the 525 IRS is a 148 main with an OBDVR or OBDVS needle (depending upon year) with a 45 pilot.  The RFS powered machines all have a Keihin FCR carb.
  • Stock jetting in the 525S and 450MXR is a 138 main with an OBDVS needle and a 45 pilot.
If you're adding a slip on exhaust only to any Polaris sport quad, you should be fine with stock jetting.  The Outlaw 500 may be the only one you need to increase the main on.  Polaris didn't recommend any jetting changes for the RFS powered Outlaws using their exhaust (FMF Polaris branded clone).

Adding a full flowing intake to the Predator will require you putting about a 165-170 main in and raising the needle (lowering the clip/towards the pointy end) one or two notches.  The same applies for the Outlaw 500.

Adding a full flowing intake to the KTM powered Outlaws will put you in about the 165 main jet territory as well.  Dropping the clip about two notches will help too.

JD jet kits are a decent value for the customer service you receive, but many have found his needles (most of what you're paying for) to be way too rich for the Outlaw carb.  It's best just to pick up a few mains and start testing.

The needle is the heart of the FCR carb.  Don't mess with changing needles unless you or someone you know absolutely is sure of what they are talking about.  You can mess up everything from idle to full throttle when changing a needle in this carb.

Swapping Parts/Parts cross reference 
  • All Polaris sport quads can swap front wheels.  They all have a 4x156 pattern and about a 4+1 offset.  They share this pattern with Yamaha and KTM sport quads.  Yes, Yamaha or KTM front wheels will fit as well.  The offset may be different, but the bolt pattern is the same.  Pay attention to the type of lug nuts needed and the thread pitch of the studs.  Predators typically had Standard threads and Outlaws moved to Metric threads.
  • All rear wheels will swap EXCEPT 03 Predators.  03's have 4x156 wheels and 04+ machines have 4x110.  Other 4x110 pattern wheels include Honda, Suzuki, Kawasaki, Can-Am, and KTM.
  • The IRS wheels and SRA wheels are the same bolt pattern, but not the same offset.  IRS wheels are a special breed since they are about 6.5+1.5 while the SRA wheels are about 3+5.  You can put an IRS wheel on an SRA and vice versa, but the width of the machine will either be much wider or much narrower.  The stock wheels are as narrow as you can get on an IRS unless custom wheels are made.
  • Rear hubs from all straight axle quads can interchange (Outlaw and Predator).  This means you can convert your 03 to a common 4x110 hub.  Other hubs that will fit are from KTM quads, or Scrambler machines (this will give a 4/4 bolt pattern if desired)  
  • Aftermarket seat covers for all Outlaws 06-08 are the same, 09-11 are the same, and all Predators are the same.
  • Oil filters for the 500 motor are the same as the 400EX.
  • You can NOT swap 03-04 with 05-07 Fuji CDI's.  They are different because of the reverse gear and harness plug.
  • Front shocks on all machines can interchange.  The strokes and eye to eye lengths are slightly different (Outlaw being longer on both) but they will work.  Predator fronts are about 17.5 inches and Outlaw fronts are a hair over 18 inches.
  • Rear shocks on 04-07 Predators can interchange.  06-07 had piggyback reservoirs so if you put the remote reservoir shock on the 06-07 chassis, you have to make a mount for the reservoir.
  • Rear shocks on 08-10 Outlaw SRA's can interchange but watch out for the brake caliper on the 08 models.
  • 03 Predator rear shocks are about 18.5 inches long.  04-07 Predator rear shocks are about 17.5 inches long.  Outlaw SRA rear shocks are about 19.5 inches long.  Putting the 03 Predator rear shock on the SRA Outlaws is a decent way to lower the rear without cutting the shock body.
  • Almost all common motor related parts on an KTM powered Outlaws can interchange with a KTM RFS dirt bike/quad motor.  This includes oil filters, screens, oil filter covers, sprockets, etc.  There are also internal parts that interchange, but I won't get into that.
  • The engine cases on the 07-08 IRS machines are unique to those years' IRS chassis.  Where the pivot bolt would be located on the 07-08 IRS machines is about 3/4" higher than the rest of the RFS engine cases.  The 09-11 IRS machines can swap engines with any SRA machine, or any KTM machine with the same motor.
  • There are no direct engine swaps other than another RFS motor with the exception listed above.
  • All IRS exhausts can interchange.  This comes with one exception.  The header on the 500 Outlaw is larger in diameter than the 525 header.  You will need to decrease the diameter of a slip on from a 500 Outlaw if you are putting it on a 525 Outlaw IRS.  One place this is done often is when putting the dual exhaust made for the Outlaw 500 on the 525.  In almost all other situations, it is easier and cleaner to buy the proper exhaust.
  • You can swap exhausts from 525 IRS to SRA Outlaw quads or vice versa as long as you bring the header with the silencer.  The header on the IRS is shorter than the SRA hence the different lengths of slip on exhausts.  They both have very similar bends.  The reason for the length difference is access to the exhaust clamp.
  • All front a-arms on Outlaw quads are the same.
  • All front ends (arms and tie rods) are the same for 03-06 Predators.
  • Lower a-arms are the same on all Predators.
  • Steering components are the same on all 06-08 Outlaws.
  • Steering components are the same on all 09-11 Outlaws.
  • 09-11 Outlaws share tie rod ends with Sportsman 550's and 850's.
  • All plastics can interchange with their common years:  03-07 Predator, 06-08 Outlaw, and 09-11 Outlaw.
  • Batteries are the same on all Outlaws and Predator 500's.

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2007 LTR450 2012 Sportsman 850HO EPS
LE Nick

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Reply with quote  #2 
If anyone has any new information or corrections, feel free to post them and I'll add them to the first post.

Also I'm not quite sure where I should have put this, so it can be moved to an appropriate section if you see one more fit.

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LEOGM5150

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Reply with quote  #3 
so far i think you nailed it and this is a great spot. thanks for all your hard work nick.
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FROM: POWELL WYOMING USA

MY GREATEST FEAR IS THAT WHEN I DIE MY WIFE WILL SELL MY TOYS FOR WHAT I TOLD HER I HAVE INTO THEM...

2014 POLARIS RZR 4 900 EPS
2012 POLARIS RZR 4 900 XP
2008 POLARIS RZR 800
2008 POLARIS OUTLAW 525S LE
2007 POLARIS OUTLAW 525 IRS
2000 400 RCR TWO STROKE SCRAMBLER
2001 400 TWO STROKE SCRAMBLER
2005 SKI DOO 1000 TWO STROKE SAND SLED
Kmack

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Reply with quote  #4 
A lot of good info in one place. Very nice.
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From: Artesia, New Mexico

BE POSITIVE - Because, if you think you CAN or if you think you CAN'T, you are right!

2009 Outlaw 525 S
2008 KTM 525
2004 KTM 525 EXC Dual Purpose Bike
1998 Yamaha 600 Grizzly - Elk Hauler
dirtymike

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Reply with quote  #5 
wasnt there a problem with the early predators of oil leaking into the carb if stood up for transportation or whatever?
LE Nick

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Reply with quote  #6 
Added to common issues.  Thanks.
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Kmack

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Reply with quote  #7 
Maybe could mention that the crank nut on the right side tends to come loose causing a noisy engine, seems to be a common problem.

Also, not all the 09 IRS machines came with 10" wheels. A friend of mine had one that still had the 9" wheels on it, and they rubbed the arms like always.

But like I mentioned before, this is a lot of really good info. Nick, really appreciate your efforts here.

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From: Artesia, New Mexico

BE POSITIVE - Because, if you think you CAN or if you think you CAN'T, you are right!

2009 Outlaw 525 S
2008 KTM 525
2004 KTM 525 EXC Dual Purpose Bike
1998 Yamaha 600 Grizzly - Elk Hauler
Fuj

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Reply with quote  #8 
Known issues with the IRS sway bars....Breaks at the
bends and snapping the rod end mounting tabs off
from aggressive use.

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LE Nick

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Reply with quote  #9 
Added issues.  Thanks.

Did your buddy buy that 09 used?  Every 09+ I've seen has 10" rear wheels stock.

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Reply with quote  #10 
Another thing is keep your rear IRS bearings fresh and tight or your rear hubs will snap off.
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FROM: POWELL WYOMING USA

MY GREATEST FEAR IS THAT WHEN I DIE MY WIFE WILL SELL MY TOYS FOR WHAT I TOLD HER I HAVE INTO THEM...

2014 POLARIS RZR 4 900 EPS
2012 POLARIS RZR 4 900 XP
2008 POLARIS RZR 800
2008 POLARIS OUTLAW 525S LE
2007 POLARIS OUTLAW 525 IRS
2000 400 RCR TWO STROKE SCRAMBLER
2001 400 TWO STROKE SCRAMBLER
2005 SKI DOO 1000 TWO STROKE SAND SLED
Kmack

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Reply with quote  #11 
Quote:
Originally Posted by LE Nick
Added issues.  Thanks.

Did your buddy buy that 09 used?  Every 09+ I've seen has 10" rear wheels stock.

It was boought used but completely stock, tires and all, with very little use. No indication of anything ever done to it. Had talked to someone else about this too because my understandidng was that they came with 10" wheels, can't remember who it was but they said that theirs came with 9" also. Seems kind of confusing to me, so I'm not 100% sure of the situation.

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From: Artesia, New Mexico

BE POSITIVE - Because, if you think you CAN or if you think you CAN'T, you are right!

2009 Outlaw 525 S
2008 KTM 525
2004 KTM 525 EXC Dual Purpose Bike
1998 Yamaha 600 Grizzly - Elk Hauler
LE Nick

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Reply with quote  #12 
Got it.  Thanks Leo.

That's interesting Karl. 

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irsLover

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Reply with quote  #13 
Sorry for a dumb question guys, but what does "RFS" stand for?
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I'm riding a 2008 KFX450R right now but hope to sell it soon and get a 2009-2011 525irs
LEOGM5150

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Reply with quote  #14 
I do believe it is racing four stroke.
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FROM: POWELL WYOMING USA

MY GREATEST FEAR IS THAT WHEN I DIE MY WIFE WILL SELL MY TOYS FOR WHAT I TOLD HER I HAVE INTO THEM...

2014 POLARIS RZR 4 900 EPS
2012 POLARIS RZR 4 900 XP
2008 POLARIS RZR 800
2008 POLARIS OUTLAW 525S LE
2007 POLARIS OUTLAW 525 IRS
2000 400 RCR TWO STROKE SCRAMBLER
2001 400 TWO STROKE SCRAMBLER
2005 SKI DOO 1000 TWO STROKE SAND SLED
TxOutlawRider

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Reply with quote  #15 
RFS is certainly allot easier to remember than what "KTM" stands for.... 
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Reply with quote  #16 
Quote:
Originally Posted by TxOutlawRider
RFS is certainly allot easier to remember than what "KTM" stands for.... 


I know that one!!!  KTM = keep the motor

And I see your confusion. I'll change most of the "RFS" acronyms to "KTM".

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Reply with quote  #17 
My only imput so far is you state that if the irs is ticking you say it's junk and replace it. I have twice had this issue from a ripped cv boot and debris got into the housing causing the noise both times I have takin the cv's apart cleaned and regressed everything and been fine. No replaced parts besides the ripped boots.


One other thing I just saw correct me if I'm wrong but didn't 07's come with ride fx shocks all the way around not just in the rear? I know my 525 did I have no clue about the 500's though

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TxOutlawRider

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Reply with quote  #18 
Quote:
Originally Posted by LE Nick
Quote:
Originally Posted by TxOutlawRider
RFS is certainly allot easier to remember than what "KTM" stands for.... 


I know that one!!!  KTM = keep the motor

And I see your confusion. I'll change most of the "RFS" acronyms to "KTM".


Ok, well just to avoid any confusion in the future, why don't we all use the proper name from here on?...   "Kraftfahrzeuge Trunkenpolz Mattighofen" ???  LOL!!!!

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Reply with quote  #19 
Quote:
Originally Posted by outlaw525
My only imput so far is you state that if the irs is ticking you say it's junk and replace it. I have twice had this issue from a ripped cv boot and debris got into the housing causing the noise both times I have takin the cv's apart cleaned and regressed everything and been fine. No replaced parts besides the ripped boots. One other thing I just saw correct me if I'm wrong but didn't 07's come with ride fx shocks all the way around not just in the rear? I know my 525 did I have no clue about the 500's though


Changes made Kyle.

And you're right.  I was somehow thinking 08 when I put that in the 07 area.

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Reply with quote  #20 
http://en.wikipedia.org/wiki/KTM

Kraftfahrzeug Trunkenpolz Mattighofen was the original name

Kraftfahrzeug means motor vehicle

Trunkenpolz was the founders name

Mattighofen is a city in austria 

pretty interesting
 

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MY GREATEST FEAR IS THAT WHEN I DIE MY WIFE WILL SELL MY TOYS FOR WHAT I TOLD HER I HAVE INTO THEM...

2014 POLARIS RZR 4 900 EPS
2012 POLARIS RZR 4 900 XP
2008 POLARIS RZR 800
2008 POLARIS OUTLAW 525S LE
2007 POLARIS OUTLAW 525 IRS
2000 400 RCR TWO STROKE SCRAMBLER
2001 400 TWO STROKE SCRAMBLER
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Reply with quote  #21 
This is amazing and we'll done nick. You are going to put us out of business with this post.
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Reply with quote  #22 
First off thanks for taking the time to do this. I think everyone who signs up should be directed to this before they as any questions. Haha.
Maybe touch on cooling issues. Mud caked in radiator. Hot temp light coming on.

Importance of adjusting valves on pred and outlaw and how often.

Throttle issue on outlaw(having to stay on the gas or it cuts out) adjusting the connectors.

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Reply with quote  #23 
I say when you sign up you automatically get sent here and told to read this. Then you have to answer a short 3-5 simple question quiz about the models to receive posting privileges lol
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Reply with quote  #24 
Updates added.

Thanks for the comments.  I've been thinking of doing this for a while and a bored Sunday brought it out of me.  haha

I'm liking that quiz idea!

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Reply with quote  #25 
reason for not having the outlaw photos ? lack of photos or just ran out if time?
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Reply with quote  #26 
how can you have a bored sunday with all those toys????
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Reply with quote  #27 
Add maybe that ONLY 03 pred shocks can go on the SRAS and be a nice upgrade? I think both myself and Blake Sturm after getting the shock redone found that this was a very sucessful upgrade, but I'm fairly certain it's only the 03 pred shocks, only ones long enough.
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2015 season. 2010 mx/xc collab build in the works. 
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Reply with quote  #28 
As for the missing pictures, all of the Predator ones were on one of the "old" sites so I copied and pasted them in here.  Easy peasy.  Getting the missing Predator pictures and all the Outlaw pictures is on my "to do" list.

It's too cold out for me.  I'm done with winter for this year and I don't have many exciting projects going around that justify freezing my butt off.

I'll make a note of it.

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Reply with quote  #29 
I will try to see if I can direct newbies to this thread. You guys may have to be in charge of enforcing the quiz and grading it.
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MY GREATEST FEAR IS THAT WHEN I DIE MY WIFE WILL SELL MY TOYS FOR WHAT I TOLD HER I HAVE INTO THEM...

2014 POLARIS RZR 4 900 EPS
2012 POLARIS RZR 4 900 XP
2008 POLARIS RZR 800
2008 POLARIS OUTLAW 525S LE
2007 POLARIS OUTLAW 525 IRS
2000 400 RCR TWO STROKE SCRAMBLER
2001 400 TWO STROKE SCRAMBLER
2005 SKI DOO 1000 TWO STROKE SAND SLED
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Reply with quote  #30 
Well Nick ya' don't need to, but when you start working on
the Outlaw pics, here's one that was actually the concept
grandfather a year before the actual production Outlaw
came to light. Even though I'm not much for an IRS, the
Polaris Revolver with it's naked looks, impressed me. Note
the placement of the sway bar !! I always wondered how
many  of these things were made.

Attached Images
Click image for larger version - Name: PolarisRevolver.jpg, Views: 318, Size: 104.95 KB 

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Reply with quote  #31 
FAIL! just getting prepared lol
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Reply with quote  #32 
There were actually two different Revolver concepts.  The first was Predator based model that was released in 2005.  The second was the IRS model named "Revolver Reloaded" which was released in late 2007.  It didn't foreshadow the IRS quad, but it did foreshadow the 09 styling.  The headlight, seat, and lines on many of the styling panels are the same as the 2009+ models.
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Reply with quote  #33 
Ya I was just going to say that looks just like an 09+ with a 500 stuffed in it!
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Reply with quote  #34 
another area of concern is the peg frame area on at least the 2007 525 irs if not all outlaws. i never had an issue with my first outlaw but after a lot of mud water and racing by the first owner then a lot of dirt mud and pressure washing by me i sold it to claudio and he had each of the pegs tear off under his extreme girth to find the peg to frame area full of rust and totally rusted out on the inside. i felt bad for him he fixed it and moved on. i just got this outlaw and i never thought about it again until i went out wheelyed it all over yesterday. when i got back i had steered clear of all the mud i seen and did most of my riding on dry pavement. well the whole rear of the irs from the pegs back was covered in gooey thick rust colored mud. i found the 2 holes that were oozing the crap and tipped the outlaw on it's grab bar and it just kept oozing and oozing. i finally pumped a whole can of wd 40 in the frame, until all that oozed out was clean wd 40. then i drilled new holes at the lowest point in all 4 frame rails just behind the pegs. the current drain or vent holes are like 5 or 6 inches up on the frame and could trap in a lot of water. i am not saying this needs to be done it is just how i decided to solve this possible issue from rusting my foot pegs off as claudios did from the inside out. i know a few other members on our site have had this same issue.

in these pictures the top holes on all 4 frame rails were the existing the lower ones on all 4 are the new 3/16 inch holes i drilled much lower than the originals.







the holes could be drilled at a lower point if you also wanted to drill the skid plate. i just figured that would add to the crap and grime getting trapped in between the engine, frame and skid plate.

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FROM: POWELL WYOMING USA

MY GREATEST FEAR IS THAT WHEN I DIE MY WIFE WILL SELL MY TOYS FOR WHAT I TOLD HER I HAVE INTO THEM...

2014 POLARIS RZR 4 900 EPS
2012 POLARIS RZR 4 900 XP
2008 POLARIS RZR 800
2008 POLARIS OUTLAW 525S LE
2007 POLARIS OUTLAW 525 IRS
2000 400 RCR TWO STROKE SCRAMBLER
2001 400 TWO STROKE SCRAMBLER
2005 SKI DOO 1000 TWO STROKE SAND SLED
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Reply with quote  #35 
Pobly a good idea Leo, really, what's the point of putting those holes up so high? Seems it would just let more stuff in. Could fill that area with spray foam, just dont let anything in to begin with.
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Reply with quote  #36 
i too had that issue on my 06 with the same resolution but i drilled mine under the skid. i almost forgot about that
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Reply with quote  #37 
Will have to check this. Last thing I want to do in a race is land hard and bust all that off
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Reply with quote  #38 
Nice write up.  I was doing research and another update that was done on the 2009 525 IRS is a smaller Fuel tank and it is lighter.
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Reply with quote  #39 
I know this is probably a dumb question, but why not just put a dab of sealant over the holes that let the water in? 
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Reply with quote  #40 
Checking the parts browsers for options, I came
across the 07 Outlaw steering knuckles as listed
for that bike only. When you go to the 08 models,
it says the 08 knuckles are the same thru 2011.
What make the 07 knuckle special, if anything at
all ??

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Reply with quote  #41 
The 07's had weaker spindles.  That's it.
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Reply with quote  #42 
Thanks Nick. I was going to PM you about it directly, but
I figured It would be better for everyone to see.


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Reply with quote  #43 
Craftsmanship;;  the engine is a jap. great posts guys!!
longlived

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Reply with quote  #44 
I was wondering if anyone knew what the size of the bolts or what kind of bolts hold the rear plastic on to the frame for a 06 predator 500 and the bolts for the airboz bracket that hold the airbox to the frame and where i can get them. thank you
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Reply with quote  #45 
A lot of good info and I was reading that the predator,ktm, and scrambler all can interchange rear hubs but I was wondering if you can interchange with any other like yahamaha or Honda or something
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Reply with quote  #46 
I was wondering about swapping the stock cv carb on the predator for a fcr carb from the outlaws I read some reviews on this but they all used a fcr from a Honda what are your thoughts on this I really would like to know
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Reply with quote  #47 
Quote:
Originally Posted by Ultrakillpv
A lot of good info and I was reading that the predator,ktm, and scrambler all can interchange rear hubs but I was wondering if you can interchange with any other like yahamaha or Honda or something


No. That would take an axle and carrier swap.

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FROM: POWELL WYOMING USA

MY GREATEST FEAR IS THAT WHEN I DIE MY WIFE WILL SELL MY TOYS FOR WHAT I TOLD HER I HAVE INTO THEM...

2014 POLARIS RZR 4 900 EPS
2012 POLARIS RZR 4 900 XP
2008 POLARIS RZR 800
2008 POLARIS OUTLAW 525S LE
2007 POLARIS OUTLAW 525 IRS
2000 400 RCR TWO STROKE SCRAMBLER
2001 400 TWO STROKE SCRAMBLER
2005 SKI DOO 1000 TWO STROKE SAND SLED
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Reply with quote  #48 
Quote:
Originally Posted by Ultrakillpv
I was wondering about swapping the stock cv carb on the predator for a fcr carb from the outlaws I read some reviews on this but they all used a fcr from a Honda what are your thoughts on this I really would like to know


Yes that can be done. It takes a bit of work but it can be done.

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FROM: POWELL WYOMING USA

MY GREATEST FEAR IS THAT WHEN I DIE MY WIFE WILL SELL MY TOYS FOR WHAT I TOLD HER I HAVE INTO THEM...

2014 POLARIS RZR 4 900 EPS
2012 POLARIS RZR 4 900 XP
2008 POLARIS RZR 800
2008 POLARIS OUTLAW 525S LE
2007 POLARIS OUTLAW 525 IRS
2000 400 RCR TWO STROKE SCRAMBLER
2001 400 TWO STROKE SCRAMBLER
2005 SKI DOO 1000 TWO STROKE SAND SLED
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Reply with quote  #49 
Quote:
Originally Posted by longlived
I was wondering if anyone knew what the size of the bolts or what kind of bolts hold the rear plastic on to the frame for a 06 predator 500 and the bolts for the airboz bracket that hold the airbox to the frame and where i can get them. thank you


I would check the RMATV parts schematic for those screws.

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FROM: POWELL WYOMING USA

MY GREATEST FEAR IS THAT WHEN I DIE MY WIFE WILL SELL MY TOYS FOR WHAT I TOLD HER I HAVE INTO THEM...

2014 POLARIS RZR 4 900 EPS
2012 POLARIS RZR 4 900 XP
2008 POLARIS RZR 800
2008 POLARIS OUTLAW 525S LE
2007 POLARIS OUTLAW 525 IRS
2000 400 RCR TWO STROKE SCRAMBLER
2001 400 TWO STROKE SCRAMBLER
2005 SKI DOO 1000 TWO STROKE SAND SLED
qddshift

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Reply with quote  #50 
has anyone ever converted an irs over to a straight axle.
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