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Blown 331

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Reply with quote  #1 
I bought my outlaw at the end of last riding season so I don't have much time on it. I did notice some oil splattered around my front sprocket area from the few times I have ridden it. I wasn't sure if it was the seal behind the sprocket leaking engine oil or if it was clutch oil. Well my hydraulic clutch no longer works so I guess I have my answer. Sounds like I just need to replace slave cylinder. Is this correct? Theres really no where else it would be leaking clutch oil down there is there?
I know the master cylinder cap says mineral oil but where exactly should I get that? And also where's a good place to get the slave cylinder? Partzilla is $142 which is about eight bucks under list. Could my clutch line be leaking?

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2008 Polaris Outlaw 525s
2005 Polaris Scrambler 500 4X4
1994 Polaris Indy XLT
1986, 1986, 1985, 1985, 1985 Polaris Scrambler 3-wheeler
1987, 1987, 1986 Polaris Trail Boss (4-wheelers are good for parts)
Deadman

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Reply with quote  #2 
Usually when the slave itself is bad the oil runs into the engine and gets burned.  I think you have an exterior leak of some sort.  Clean it up good and check it closer.
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Blown 331

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Reply with quote  #3 
Thanks for the info. I'd hate to buy a slave if its not needed, but my clutch oil went somewhere and I've got an oily mess near the front sprocket.
Where can I get mineral oil? Dealer only or can I ask for it at Autozone or anything?

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2008 Polaris Outlaw 525s
2005 Polaris Scrambler 500 4X4
1994 Polaris Indy XLT
1986, 1986, 1985, 1985, 1985 Polaris Scrambler 3-wheeler
1987, 1987, 1986 Polaris Trail Boss (4-wheelers are good for parts)
ScramblerXLE

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Reply with quote  #4 
It's a pain to bleed, but the FRE KTM team was running Synthetic ATF (like Mobil 1) in their hydraulic clutches.  I've been running it since 2009 with no issues.  It doesn't boil as readily and seems to do a better job lubricating the sealing O-ring as well since I haven't trashed a slave cylinder on it yet.  (trashed 3 of them on magura blood across all my KTMs)  While it sounds like you have clutch issues to sort out as well, it also sounds like the oil is more likely just a countershaft seal.
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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
Blown 331

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Reply with quote  #5 
Thanks! It seems like ATF would make a leak easier to differentiate between and engine oil leak as well. I'll try that. There is some heavy dampness on my master at the boot but no drips. It doesn't look like the master lid has ever been off.
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2008 Polaris Outlaw 525s
2005 Polaris Scrambler 500 4X4
1994 Polaris Indy XLT
1986, 1986, 1985, 1985, 1985 Polaris Scrambler 3-wheeler
1987, 1987, 1986 Polaris Trail Boss (4-wheelers are good for parts)
Deadman

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Reply with quote  #6 
Theres O rings in the master to rebuild, so don't be afraid to do that too someday.  
The clutch is super easy to bleed in my mind and I'm no super skilled mechanic guy.  

Just find a druggy friend and borrow a syringe from him and put a piece of silicone vacuum line on it that fits the nipple on the bleeder on the slave.  Crack the bleeder open as you force the fluid into the nipple.  Esentially u fill it from the bottom, then theres never air in it.  Works great, takes 2 minutes.   Takes longer to fight the syringe from your drugster buddys hands than this job takes.  

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Rkangel

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Reply with quote  #7 
When swapping the mineral oil out for ATF, did you have to flush out the system?
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outlaw525

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Reply with quote  #8 
just to the best you can it dosent have to be perfect, of course the more its cleaned up the better. Walt(scramblerXLE) is the one that got me to change after I trashed 2 on the mineral oil that was a few years back no issues since.        all I did was separate the hose from the slave drain the hose it till it stopped dripping the Oil then took the slave apart blew it out with an air gun, filled it with ATF and reassembled it , then filled the master with atf and let it drain down the line till it started dripping out the end then I reconnected the slave to the hose. this pretty much took care of having to bleed the system it was pretty much done for me I just had to get the last little bit out.
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Blown 331

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Reply with quote  #9 
What I'm planning on is wipe out the master the best I can, its looks pretty bad in there.  The fill with Moblie 1 ATF and draw it through the slave with mityvac until I see the color change.  Then I'll know the mineral oil is gone and I'm hoping for no air that way.  Then I'll re-evaluate the leak.   
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2008 Polaris Outlaw 525s
2005 Polaris Scrambler 500 4X4
1994 Polaris Indy XLT
1986, 1986, 1985, 1985, 1985 Polaris Scrambler 3-wheeler
1987, 1987, 1986 Polaris Trail Boss (4-wheelers are good for parts)
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Reply with quote  #10 
I would recommend pulling the slave cylinder.  There's 1 snap-ring to remove, then the piston and all the fluid will come out.  Once it's apart, you can inspect the bore for wear.  If you see bare aluminum, you need a slave.  I know some guys have had master cylinder issues, but I haven't seen that near as often as I've seen trashed slave cylinders.  It would be worth a look.
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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
Blown 331

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Reply with quote  #11 
Can I buy the slave cylinder seals anywhere?  I can't find them. 
You know what would really be nice?  A cable conversion! 

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2008 Polaris Outlaw 525s
2005 Polaris Scrambler 500 4X4
1994 Polaris Indy XLT
1986, 1986, 1985, 1985, 1985 Polaris Scrambler 3-wheeler
1987, 1987, 1986 Polaris Trail Boss (4-wheelers are good for parts)
Deadman

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Reply with quote  #12 
You can buy a slave rebuild kit for like $100-150!  lol   You get the piston and seals all as one.  

If you rebuild the master, make sure you get the right diameter, its stamped on the bottom of the master I think.  if my memory serves me right its like 9.5 I think, but don't quote me on that!  


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Blown 331

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Reply with quote  #13 
I'm with Scrambler XLE as far as this being a pain, holy shit what I wouldn't give for a cable conversion!
Now how can I be sure all the air is out? When shifting into gear from neutral it does clunk a bit and the bike moves forward ever so slightly. I can't remember if it was like this before or not. I know normally a dragging clutch makes it hard to find neutral, which Outlaws are kind of known for anyway. Well it's real easy to find neutral so I'm thinking it might be ok but I'm not sure.

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2008 Polaris Outlaw 525s
2005 Polaris Scrambler 500 4X4
1994 Polaris Indy XLT
1986, 1986, 1985, 1985, 1985 Polaris Scrambler 3-wheeler
1987, 1987, 1986 Polaris Trail Boss (4-wheelers are good for parts)
Deadman

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Reply with quote  #14 
They all jump forward a little when putting them in gear.  Mine all did.
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2012 Renegade 1000 X XC!
Blown 331

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Reply with quote  #15 
The air is definitely out of the system.  I had to loosen the little adjustment on the clutch lever because the lever would have to be almost all the way about before it would move. 
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2008 Polaris Outlaw 525s
2005 Polaris Scrambler 500 4X4
1994 Polaris Indy XLT
1986, 1986, 1985, 1985, 1985 Polaris Scrambler 3-wheeler
1987, 1987, 1986 Polaris Trail Boss (4-wheelers are good for parts)
sherby

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Reply with quote  #16 
i have an outlaw 525 with the ktm motor. i need to know which ktm bike will have the same clutch system. i beleive i just need the master cylinder. can anyone help? new to this site and not to sure how to ask questions. thanks guys
TxOutlawRider

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Reply with quote  #17 
If I remember right, the master cylinder you're looking for will say "9.5" on it (which I think is what most of the KTMs used).  Also, you might want to replace the Magura fluid with ATF (I've been using Castrol Chrysler ATF+4 type synthetic as it is a little thinner, but I doubt it makes any difference).  I went through a couple of master cylinders and a slave cylinder using the Magura Blood, but after I switched to ATF fluid I haven't had any problems (and its allot cheaper and easier to find when youre out trail riding). 
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sherby

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Reply with quote  #18 
so if i ordered a 9.5 mm magura master cylinder off partzilla that would be the same?
sherby

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Reply with quote  #19 
reason i am asking is my bike has been at the shop for 2 months already, and polaris says it will be another month before it comes in
Rkangel

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Reply with quote  #20 
Interesting.  Polaris tells us that the clutch master cylinder assembly is in stock.  It's the same part number from 2007 to 2011.  Is your shop a Polaris dealer?
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2009 Polaris Outlaw IRS
sherby

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Reply with quote  #21 
where are you looking? yes it is a polaris dealership. just want to start riding already the weather is great. anything that will work is fine. suggestions welcome
Rkangel

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Reply with quote  #22 
I work for a Polaris dealer.  Our parts department says Polaris shows them to be in stock.   Depending on the warehouse it is coming from, most dealers in the lower 48 should be able to get it within a week.  The part number for the assembly is 2010292.


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2009 Polaris Outlaw IRS
sherby

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Reply with quote  #23 
That is everything? How much? I just pull the clutch and there's nothing there. Going to get everything right up to the end of the cable/hose. How could I attempt to bleed it? I live in canada lol the top 10. I found a guy with a parts bike, he's going to send me the whole set up
TxOutlawRider

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Reply with quote  #24 
The last time I bled mine, I used a syringe my wife had left over from injecting poultry with spices and a piece of vacuum hose.  I took the top off the master cylinder and put a rag around it to keep from making a mess.  Then loosened the bleeder on the slave cylinder a little (make sure its clean),  slipped the vacuum hose over the bleeder and pushed the ATF until it came out the master cylinder.  Tighten the bleeder, unhook the hose, and filled the master cylinder and put the lid on.
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2007 Outlaw IRS

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Reply with quote  #25 
The assembly lists for $370 U.S.
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2009 Polaris Outlaw IRS
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