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Maxzapata

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Reply with quote  #1 
So I couldnt find a forum on this so I thought I might ask if yall know of anyone who makes a big bore kit for an 08 outlaw s with the cylinder and all. I know thumper racing does but i havent read much good reviews on it.
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2008 Polaris Outlaw 525s Limited Edition
2003 Polaris Predator Troy Lee Edition
2003 Yamaha Raptor 660
2000 Honda Foreman 450 ES
distraction628

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Reply with quote  #2 
Well most of us that have built sleeve style kits have had mediocre success. I had done over 40 kits and had about a 85% rate. Best is to get the factory kit at about a $1000 or get there cylinder (SXS00540001) and head gasket and get your own choice of piston, You will also need copper sealing washers for the cylinder/head bolts.  
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07 525, 06 500, 10 525s 09 RZRs, 04 Ram 2500 Cummins 6spd, 08 Fuzion toy-hauler
Bings outlaw

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Reply with quote  #3 
Distraction can u fill us in on what fails with the big bore kits. I'm also in the market for a 540 kit and have been looking at the thumper racing one. Seems to have good reviews over at ktmtalk.
distraction628

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Reply with quote  #4 
it's really simple. The sleeve is a wet sleeve, so that means iron ( gray or ironite, ductile ) all cool and expand at different rate then the cast aluminum. So they can get pinched out of round after some heat cycles. ( yes a cylinder can put that much pressure on a sleeve) You can do cryogenics to help prevent this to a point. The cost is about $100 for a cylinder to be done. So by the time I added a second coolant port and cryo, I couldn't compete on price anymore with the big name guy.  Even if my kits where better over all. ( just my opinion ) I used to install someone else kits...had more then my share of failures.
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07 525, 06 500, 10 525s 09 RZRs, 04 Ram 2500 Cummins 6spd, 08 Fuzion toy-hauler
kiwi-craig

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Reply with quote  #5 
Yeah I've had 5 fail....... Best was 20 hours, one went out of round in 1/2 hr..... All went out of round and several expensive failures later.......
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KTM SX 505 2009 lots of stuff pushing 60 plus HP and revs to the moon, Full Walsh / PEP suspension, lots of trick stuff.....

KTM XC 554 2009, lots of trick stuff, 68hp / 44 ft lbs of brute force, ultra lite crank & lite flywhee, full JB / PEP suspension all wrapped in white plastic

Polaris 525 IRS 2011, the new toy ! LSR A arms, shortened Front MXR shocks & custom springs, PP bumper, nerfs and rear grab bar, Revalved and resprung rear end, FUJ lowering blocks, FUJ adj sway bar. Taper bars / hand guards / Trail tech GPS unit.
Engine: Yoshi slip on, kiwi custom intake, hi flo water pump, Modded carb (41mm rejetted & adj accel pump).
next round of mods: 8-33 cam / fastway steering damper / BB kit /lite flywheel all on the shelf waiting for install........

LTR 495 2007, 200 hrs and still going like a rocket, BB kit transformed this engine + yoshi motard cams, it hauls.
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