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AlliedCeaser

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Reply with quote  #101 
I am unsure that brand the new clutch is, but ill measure thickness. And thank you very much for telling me about the service manual, very simple now!
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
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          K&N Full Air Filter
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AlliedCeaser

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Reply with quote  #102 
Need some urgent help here... I am reassembling the engine today, but I have run across a problem that when i go to put the two main cases together and tighten the screws, the crank no longer spins... Has anyone heard of this happening??? Our first assumption was that the bearing are not fully seated, so are they supposed to be flush in the case?
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
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ko66

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Reply with quote  #103 
Quote:
Originally Posted by AlliedCeaser
Need some urgent help here... I am reassembling the engine today, but I have run across a problem that when i go to put the two main cases together and tighten the screws, the crank no longer spins... Has anyone heard of this happening??? Our first assumption was that the bearing are not fully seated, so are they supposed to be flush in the case?


They need to be pressed to stop, also make sure your crank is measuring correctly. If its to wide out of spec this will also happen.
AlliedCeaser

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Reply with quote  #104 
Crank was measured to spec as per service manual, hopefully these bearings just hadn't been installed all the way... 
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
ko66

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Reply with quote  #105 
Quote:
Originally Posted by AlliedCeaser
Crank was measured to spec as per service manual, hopefully these bearings just hadn't been installed all the way... 


if they are not that will do it, Also if the seal on the crank is pressed in to far that will do it too.
AlliedCeaser

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Reply with quote  #106 
Crank seal as in the one on the clutch side? Will check as well.
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
AlliedCeaser

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Reply with quote  #107 
Does anyone have the part number of the clip that holds the lower cam chain gear on behind the flywheel?
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
gen3usa

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Reply with quote  #108 
 RING-SNAP DIN0471 25X1.2MM
7710597

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2007 Polaris Outlaw 525 w/IRS 12.5:1, 806 cam, FMF exhaust, Faast FlexBars
2001 Polaris Scrambler 400 (gone and missed), 2001 Polaris Scrambler 500 (gone and missed), 1996 Polaris 400 sport (serious tank),1981 Harley Shovel head chromed and decked out!

gen3usa

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Reply with quote  #109 
http://www.partzilla.com/parts/detail/polaris/PP-7710597.html
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2007 Polaris Outlaw 525 w/IRS 12.5:1, 806 cam, FMF exhaust, Faast FlexBars
2001 Polaris Scrambler 400 (gone and missed), 2001 Polaris Scrambler 500 (gone and missed), 1996 Polaris 400 sport (serious tank),1981 Harley Shovel head chromed and decked out!

gen3usa

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Reply with quote  #110 
The races need to be pressed on all the way, make sure you put the appropriate shims behind each too!
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2007 Polaris Outlaw 525 w/IRS 12.5:1, 806 cam, FMF exhaust, Faast FlexBars
2001 Polaris Scrambler 400 (gone and missed), 2001 Polaris Scrambler 500 (gone and missed), 1996 Polaris 400 sport (serious tank),1981 Harley Shovel head chromed and decked out!

AlliedCeaser

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Reply with quote  #111 
Thank you for the part number, and we found why the crank wouldn't spin.
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
AlliedCeaser

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Reply with quote  #112 
How much should the crank be able to move side to side in the cases? Im not talking about the rod, but the whole crank assembly?
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
ScramblerXLE

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Reply with quote  #113 
There is a spec for side to side clearance in the service manual. You adjust it by adding or removing shims under the inner races on the crank. I'm out of town and don't remember the spec off hand, but it's in the engine assembly section.
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2015 KTM 525XC
2009 KTM 525XC
2009 KTM 450XC
2009 KTM 250XC
2005 Predator 558 (project)
2003 Cannondale 440 (project)
2006 KLX 250S
2002 Scrambler X 500
Sold, crashed, or otherwise gone: 2008 YFZ450, 2005 Predator 500 LE, 2007 Outlaw 525, 2003 Cannondale 440
AlliedCeaser

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Reply with quote  #114 
Jumped the gun on this question, after installing primary gear and nut, all the play was taken up. It is now virtually perfect in every aspect. At this rate, ill have a running engine next weekend.
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
AlliedCeaser

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Reply with quote  #115 
Can someone link me to a good cam chain riveter? Preferably eBay.
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
gen3usa

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Reply with quote  #116 
Did you even type one in on ebay? Dude!

http://www.ebay.com/itm/New-Motorcycle-Cam-Drive-Chain-Breaker-Riveter-Rivet-Riveting-Cutter-shop-tool-/321135882124?hash=item4ac530af8c&item=321135882124&vxp=mtr

I have this one and love it... in fact just used it again for the second time....flawless

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Founding Father of Gen3usA

2007 Polaris Outlaw 525 w/IRS 12.5:1, 806 cam, FMF exhaust, Faast FlexBars
2001 Polaris Scrambler 400 (gone and missed), 2001 Polaris Scrambler 500 (gone and missed), 1996 Polaris 400 sport (serious tank),1981 Harley Shovel head chromed and decked out!

Rkangel

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Reply with quote  #117 
The factory KTM chain breaker/riveter is the best and the most fool proof, but a bit more expensive at $135-$145.  The universal breaker/riveters (Motion Pro, Tusk, etc...) may work, but I have never personally tried one on the cam chain.
Factory Chain Breaker/Riveter
http://www.motosport.com/dirtbike/oem-parts/ktm/2006/525sx/special-tools/rivetting-tool-timing-chain/59029020000
Universal Chain Breaker/Riveter
http://www.ebay.com/itm/New-Chain-Cutter-Breaker-Riveting-Rivet-Tool-set-ATV-Bike-Motorcycle-Cam-Drive-/311068830758?hash=item486d25ac26&item=311068830758&vxp=mtr



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AlliedCeaser

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Reply with quote  #118 
Iv found some, just wanted to be 100% when spending $20 on a tool im going to use once. Thanks for the links, just bought.
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
ko66

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Reply with quote  #119 
I have used the universal tool, If you do things right theres nothing to worry about. I have taken my engine to redline with no issues as of yet if that helps. But the factory tool is good, Just expensive.

gen3usa

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Reply with quote  #120 
The tool can be used for the cam chain, drive chain and most chains we deal with! Great tool to have in the box when you do your own work.
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2007 Polaris Outlaw 525 w/IRS 12.5:1, 806 cam, FMF exhaust, Faast FlexBars
2001 Polaris Scrambler 400 (gone and missed), 2001 Polaris Scrambler 500 (gone and missed), 1996 Polaris 400 sport (serious tank),1981 Harley Shovel head chromed and decked out!

AlliedCeaser

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Reply with quote  #121 
[IMG_3864_zpss38mvw35] 
[IMG_3866_zpsxi48ajqi] 
[IMG_3869_zps4eto3mqk] What I got done last weekend... Got to study for finals this weekend so no work.. Running possibly in 2 weeks!

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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
TxOutlawRider

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Reply with quote  #122 
Looks good, but personally, Ive never had real good luck using that style of head gasket.  I usually use the composite type. 
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AlliedCeaser

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Reply with quote  #123 
Well at this point im a master on this engine, and along with this handy chain riveter tool I got in the mail Thursday, I have no fear of opening this engine back up and doing the work 100% myself.
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
AlliedCeaser

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Reply with quote  #124 
Hey guys, some more questions as my father and I are have a little trouble. We are at the point where we have locked the crank, dropped the cam in, and riveted the chain together. As we put the valve cover on, the intake valves were completely tight, and my dad is worried that the cam was installed on the wrong crank stoke? When the crank is locked at TDC, and the valve covers are installed, are all the lifters able to be moved freely? Because ours do not.. We have followed the instructions almost religiously so we need a little help here. Thanks! [biggrin]
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
ko66

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Reply with quote  #125 
Sounds to me either you are not tdc or the cam did not line up and last you adjustment screw are to tight on the valves.
TxOutlawRider

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Reply with quote  #126 
If you think you may have put it together wrong, then don't hit the starter button.  I'd pull the cover off the flywheel side of the engine, put a wrench on the crank nut, and slowly turn it by hand.  (It probably would be a good idea  to remove the spark plug too)  You will feel it tighten up as the valve springs compress but if it starts to bind, then stop.  If it binds then pull the rocker cover off, find tdc, and make sure your timing dots are correct. 

However, it sounds to me like your valves may be adjusted too tight... but better safe than sorry. 

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AlliedCeaser

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Reply with quote  #127 
On the cam, there is a "Drain bore" that is supposed to be facing up, so that is how i placed the cam in, but it seems to be flipped 180. Seems someone has had the cam apart and assembled wrong... Once again i'm dealing with other peoples mistakes with this engine. Opinions on running the cam with the drain bore facing down?
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
TxOutlawRider

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Reply with quote  #128 
Quote:
Originally Posted by AlliedCeaser
On the cam, there is a "Drain bore" that is supposed to be facing up, so that is how i placed the cam in, but it seems to be flipped 180. Seems someone has had the cam apart and assembled wrong... Once again i'm dealing with other peoples mistakes with this engine. Opinions on running the cam with the drain bore facing down?


There are two dots on your timing gear that should be level with the edge of the cylinder head when the engine is at TDC. 

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AlliedCeaser

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Reply with quote  #129 
Yup, engine locked at tdc with locking screw, and cam gear set in with two timing marks even with the head. On the cam, the decompression mech is supposed to be facing up, along with the drain. So when i installed the cam with drain up, now the decompression mechanism is facing down sense the cam was assembled wrong. So many problems... [sign0063]
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
TxOutlawRider

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Reply with quote  #130 
Im really not sure what the "cam drain" is that you're referring to, but I think you can only put that cam gear on the camshaft one way or the hole for the decompressor won't line up. 
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AlliedCeaser

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Reply with quote  #131 
https://drive.google.com/file/d/0B9CpA5UNf65CZkc3ZWxKbHE3VWc/edit

Page 238 is where im at with this engine as we speak.

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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
TxOutlawRider

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Reply with quote  #132 
Ok, that's what I figured... that drain bore (6-11) doesn't rotate (its part of the water pump seal) , it should face up once the cam is in place and shouldn't move after you've tightened the rocker cover down.  It allows any water to escape in the event of a water pump failure.  So the decompressor may be down now, but when you rotate the engine again, it will be on top.  The cam doesn't turn at the same speed as the crankshaft. 
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AlliedCeaser

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Reply with quote  #133 
Quote:
Originally Posted by TxOutlawRider
Ok, that's what I figured... that drain bore (6-11) doesn't rotate (its part of the water pump seal) , it should face up once the cam is in place and shouldn't move after you've tightened the rocker cover down.  It allows any water to escape in the event of a water pump failure.  So the decompressor may be down now, but when you rotate the engine again, it will be on top.  The cam doesn't turn at the same speed as the crankshaft. 


But does the cam need to have the decompressor facing up to clearance my valves? And what size feeler should I have? Also is it as simple as having the engine at tdc to adjust all clearances?

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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
AlliedCeaser

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Reply with quote  #134 
And sorry if I'm asking some blatantly stupid questions as I'm not experienced with these engines
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
gen3usa

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Reply with quote  #135 
its best to keep TDC while doing adjustments, make sure you lock the crank to TDC, then use a simple automotive feeler gauge.
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2007 Polaris Outlaw 525 w/IRS 12.5:1, 806 cam, FMF exhaust, Faast FlexBars
2001 Polaris Scrambler 400 (gone and missed), 2001 Polaris Scrambler 500 (gone and missed), 1996 Polaris 400 sport (serious tank),1981 Harley Shovel head chromed and decked out!

TxOutlawRider

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Reply with quote  #136 
You just need to be sure the lobes on the cam are both facing down when the engine is at TDC before you adjust the valves.  If they are pointing up (making the valves open), remove your lock bolt and then slowly rotate the engine until you reach TDC and the lobes are both facing down.  Then lock it (I don't but you might want to), then adjust your valves with the feeler gauge (its easier if you use the bent style, but I usually just bend mine to fit). 
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AlliedCeaser

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Reply with quote  #137 
So before I did my valves, I rotated the engine till the next TDC, and that seemed too free all of the rockers and allowed me to continue. Now if it wasn't for a missing seal shaft that goes on the reverse, it WOULD have been running.. Well im still putting the engine in the frame, atleast that will make me happy [biggrin]
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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
AlliedCeaser

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Reply with quote  #138 
Whats up with this guys???!??! Tightened down to spec, seated in the ranks key.. don't know why there is so much thread left?
[IMG_3968_zpsto5hzwwn] 

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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
ScramblerXLE

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Reply with quote  #139 
Pretty sure that's not a KTM/Polaris ATV flywheel

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-Walt GNCC # 728 (GNCC - Vet A)
2015 KTM 525XC
2009 KTM 525XC
2009 KTM 450XC
2009 KTM 250XC
2005 Predator 558 (project)
2003 Cannondale 440 (project)
2006 KLX 250S
2002 Scrambler X 500
Sold, crashed, or otherwise gone: 2008 YFZ450, 2005 Predator 500 LE, 2007 Outlaw 525, 2003 Cannondale 440
AlliedCeaser

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Reply with quote  #140 
Yup, your right. Add this to the list of engine parts we received back that did not belong to us.

Well, atleast I got to see the engine in its completed state..
[IMG_3976_zpspievwybm] 

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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
AlliedCeaser

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Reply with quote  #141 

Hey guys! Today the outlaw was fired up for the first time, and is now ready for some heat cycles!! I would like to thank everyone that helped with all of the questions I asked. Here is a short video before I adjust the valves tomorrow!!! 


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2008 Outlaw 450 MXR Solid Axle
Mods - Big gun Full Exhaust
          Jetted
          K&N Full Air Filter
[3895E9D9-C0BA-4A0F-9DC1-930DCCB7F619_zpsih6gc06e] 
Kmack

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Reply with quote  #142 
Hey, that sounds like a KTM engine. HA!! Nice work!!
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2009 Outlaw 525 S
2008 KTM 525
2004 KTM 525 EXC Dual Purpose Bike
1998 Yamaha 600 Grizzly - Elk Hauler
colombiamaestro

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Reply with quote  #143 
hi  i am new to this forum but i have read many ktm 525 irs problems ,  its haoppens to me the sma eproble of the man of the video thas is running thru the dunes and sudenly his atv stops and never igntion again,  buyt when i went to the  mechanic it tell s me that i blew the motor i mean not the piston nbut the crabnks shaft nad  that is has some  signs of metal inside , so then my question is  what parts shouls i change i mean should i chamge the psiton , tythe valves  the  and what elese because i dont understand  all this many parts that this motor has and also i live overseas in colombia and it extremely more difficult for me to buy things, so idont know if someone can help me givving me a guide of the  parts that i should buy from new. and i thnik that i blow my motor i dont know why, yhe only thing is that its was popping a lot   i mean it weas exhausting and it only has like 60 hours of use, so iil aprecciatte  some help with this thanks soon i will post some photos.

thanks what should be the basic motor overhaulling and which parts should y buy from new. thanks
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