2008 Outlaw 525 IRS Build

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2008 Outlaw 525 IRS Build

PostAuthor: TMoney » Thu Feb 19, 2015 3:00 pm

I will fill this in after work!

Brap brap [dance]

Edit:

So I already had a 2006 Polaris Outlaw 500 IRS that I was running, and it was just a LITTLE fun. A few months ago, my good buddy Sam convinces me I need a new project alongside my basket case 1982 YZ125J. $700 later, I've now got most of a 2008 Polaris Outlaw 525 IRS sitting in my garage, the engine a box of parts. This model has a KTM powerplant, so it should be considerably faster than the already fast 2006 500. I sold the 125 for $650 after I got it going, so I guess it paid for the next project!

Anyways, I've bought a manual, a complete gasket set, and I've ordered a new rear axle kit for the 525. Soon the crank and cylinder will be of to Mongoose for a rebuild and replate, respectively. Can't wait to get this thing going, shouldn't take too long once parts come through. Other things to come:

- Crank bearings and seals
- Clutch (probably, although the existing plates seem pretty good)
- Heavily tempted to go for a cam, high comp piston and exhaust, but I'm not sure I want to empty my pockets that much

I'll get pictures up soon.
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Re: 2008 Outlaw 525 IRS Build

PostAuthor: BowlEEac » Mon Feb 23, 2015 2:52 pm

You know what my vote is on the high comp piston and cam... MORE POWER!!!

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Re: 2008 Outlaw 525 IRS Build

PostAuthor: TMoney » Mon Feb 23, 2015 3:24 pm

So the Outlaw 500 goes something like this: https://www.youtube.com/watch?v=u8V07pN ... e=youtu.be

Not bad, but nobody ever said faster was worse.

So here's the 525, as it sits. Really just a complete box of parts.

Image

I have recently decided that with a little effort and Plasti Dip I can turn it into something like one of these:

Image

Which is badass, hold your comments. That oughta make the shite plastics look a little nicer. Plus it's a Halo quad! Christ that's awesome.
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Re: 2008 Outlaw 525 IRS Build

PostAuthor: TMoney » Tue Feb 24, 2015 7:42 am

Image

Since the other parts aren't yet in, and I need a paycheck before dropping $500 at Mongoose Machine, I decided to experiment with Plasti Dip on the plastics. I treated a small section on the backside of one of the plastic panels.

Image

This was 3 thin coats applied over 90 minutes, 30 minutes between coats as per the instructions. It resulted in a approx. 0.5mm coating that was surprisingly hard to peel after about 8 hours of curing. I am very impressed. The only issue is that the masking tape doesn't create a terribly clean line. That needs more experimentation if I'm gonna try some different colors together.

Image

Prep work was minimal. I first washed the parts, then went over them with 000 steel wool with WD-40 as a lubricant, which I've used to polish chrome before. Turned out pretty well, and the Plasti Dip smoothed out some of the deepish scratches.


It's gonna be a sick army quad, bro.
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Re: 2008 Outlaw 525 IRS Build

PostAuthor: sexonwheels » Tue Feb 24, 2015 3:51 pm

Down for the Halo quad. [partydance]
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Re: 2008 Outlaw 525 IRS Build

PostAuthor: TMoney » Wed Feb 25, 2015 6:38 pm

Image

Heres a complete panel with plasti dip. Not totally sure it's tough enough for the application but it seems pretty good at this point.

I'm picking up my service manual and gasket set tomorrow so I can start checking out the rebuild process.
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Re: 2008 Outlaw 525 IRS Build

PostAuthor: DIR » Thu Feb 26, 2015 6:14 pm

that looks awesome!
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Re: 2008 Outlaw 525 IRS Build

PostAuthor: TMoney » Mon Mar 02, 2015 4:50 pm

Looks like this project is gonna be slowed down for a couple weeks. I got the FSM from Polaris, but my dad's quad seized while I was riding it the other day so I guess it needs a new to end first! Oh well.
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