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Fossil85

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Reply with quote  #51 
10983282_848558995235035_6799799318903955109_n.jpg  After a couple of heat cycles, the shrapnel is coming out.  With the head gasket leak and the mystery "knock", I'm going to give it a complete rebuild.  Time to yank it out of the frame again.

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2008 Outlaw 525IRS xc race quad
1996 Kawasaki KX125 play bike
2008 Outlaw 525IRS project
LEOGM5150

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Reply with quote  #52 
bummer that looks like rod bearing.
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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
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2008 POLARIS RZR 800
2008 POLARIS OUTLAW 525S LE
2007 POLARIS OUTLAW 525 IRS
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gen3usa

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Reply with quote  #53 
yes it is, just did my motor and thats what my plug looked like, i was lucky though that the rod didnt lock it up!
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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!

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Reply with quote  #54 
Geeze Roger...
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Fossil85

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Reply with quote  #55 
I was hoping the damage was limited to the head, but it wasn't.  The radiator fan wasn't working(broken wire), so I assume the previous owner overheated it  which would explain the warped head.  All in all though, I would blame most of this engines problems on being rebuilt by a local Polaris dealer.  I think me and a friend are going to rebuild this one ourselves. 
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2008 Outlaw 525IRS xc race quad
1996 Kawasaki KX125 play bike
2008 Outlaw 525IRS project
Kmack

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Reply with quote  #56 
Quote:
Originally Posted by Fossil85
I was hoping the damage was limited to the head, but it wasn't.  The radiator fan wasn't working(broken wire), so I assume the previous owner overheated it  which would explain the warped head.  All in all though, I would blame most of this engines problems on being rebuilt by a local Polaris dealer.  I think me and a friend are going to rebuild this one ourselves. 


No one cares about your machine the way you do. Doing it your self is half the fun of owning one of these things and you will get better quality work like that.

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From: Artesia, New Mexico

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2009 Outlaw 525 S
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Reply with quote  #57 
Just out of curiousity, are those shavings magnetic (are they iron or aluminum)?
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2007 Outlaw IRS

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Fossil85

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Reply with quote  #58 
I didn't check.  I figured they were aluminum shavings from the head.  I cleaned the screen and put it back in and ran it a little more, so I'll check and see if the latest shavings are magnetic or not. probably tomorrow night.
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2008 Outlaw 525IRS xc race quad
1996 Kawasaki KX125 play bike
2008 Outlaw 525IRS project
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Reply with quote  #59 
The only reason I ask, is if its aluminum, it may be shavings from where the cam chain ate up the head/case area, but you also have a knocking noise on the right side, which may be a the famous KTM death rattle, and if that nut has gotten real bad I hear it can create some shavings on its own (or maybe it damaged the clutch basket when it abruptly stopped).  Either way, if the shavings aren't magnetic, it may not be all that bad.  Are there any big chunks stuck to the magnetic oil drain?
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2007 Outlaw IRS

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Fossil85

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Reply with quote  #60 
No big chunks on the oil drain.  Actually, the only thing out of the ordinary is the short screen; which is basically clogged with aluminum looking shavings....
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Reply with quote  #61 
You may want to check your clutch basket and that big nut that's known to come loose.  I could be wrong, but I'm betting if its all aluminum, then its not a bearing. 
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Fossil85

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Reply with quote  #62 
Well nothing was  magnetic at all. 
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2008 Outlaw 525IRS xc race quad
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2008 Outlaw 525IRS project
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Reply with quote  #63 
Quote:
Originally Posted by Fossil85
Well nothing was  magnetic at all. 


Then I doubt it was a bearing.  That isn't to say that you not need bearings, but I suspect its trash from the timing chain grinding or maybe that nut came loose on the other side and has been grinding the case.  Its worth a check.  The 525 ATV motor has allot of screens and filters in place to keep that debris from getting into the lubrication system. 

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2007 Outlaw IRS

"Outlaws are the Chuck Norris of the quad world."
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