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my new 2007 ktm powered irs 525 outlaw

9K views 72 replies 9 participants last post by  LEOGM5150 
#1 ·
i first just want to say that i had the pleasure of driving 24 straight hours through to souix falls to meet SSJEFF half way between powell wyoming and indianapolis indiana. we traded my busted 2008 rzr for his 2007 525. aftewr 2.5 hours sleep from 6 am to 9:30 am, i brought it home put my pipe on it, my thumb throttle, a bar par and tightened jetted and tuned it. i then charged the batttery and rode the snot of this thing for the last 2 hours and although i am thrashed i couldn't be happier with the trade thanks jeff. great guy to deal with.

i now know what all you irs guys are all raving about. i had never rode a piped filtered and jetted 525 before. this thing rips. everyone who says you can't slide an irs outlaw is lost. this thing power slides for miles in any gear way better than my old predator did. talk about light years ahead of any other sport quad i have owned or ridden. this coming week i will get my lm1 wide band on and get it tuned even better. i think there is more power to be had at my elevation as i have not got rid of a popping on decel otherwise throttle response and midrange is insane with this thing. jeff says it has a hot cam in it. i have no interest in changing that. this power is perfect for my wide open desert.

here are my pictures after i got it real dirty.
 

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#52 ·
Did Jeff install a oil cooler on that bike ?? If not you might want to look into one for the high speed dune running you do.
 
#54 ·
LOL I just might!!! LOL


















You are joking right??? You have been gone for awhile so I was just making sure you were joking.
 
#56 ·
Bob, hoe many adaptors are left? Can't be too many....
 
#57 ·
Wasn't there something about it being better to getOEM countersprockets vs aftermarket ones cuz the OEM where the proper width(thickness) and lined up better?

And Leo NOCHAINLUBE/WAXon the CV boots!!!!!!!!!!!!!!! Nein! Nada! Zip! Spray ahead of the rear sprocket. I even put a rag over my boot while lubing. Do the D-man trick of amour-all-ing the boot. He's never had a boot issue in all his IRS years.Lube destroys the boot.
 
#59 ·
The chain lube really seems to destroy them from what guys here report. I hardly use any chain lube, because it just makes a mess anyway.
 
#61 ·
I spoke with Leo last night. WOW is he liking it. He and I have a lot in common as he is already thinking BB. I suggested the 570. Maybe Walt can say something about the 570 he has in his KTM.

You guys mentioned how great this site is meeting people and I have to agree. Being involved with the site has been great. It is great to get the PM you guys have sent to see that I have been a help and saved someone the heart akes and moneyI have went through. Funny thing is that I met pred03tld on here and I was using his trailer.

Leo and I were probably gone when we met since we had both been on the road waking up early and driving for 12 hours. We had a long way home so the swap only lasted about 45 minutes in the parking lot of a BFE strip mall/gas station just off of highway 29 in South Dakota between Sioux City and Sioux Falls. I think it was the Beresfield exit.
 
#62 ·
finally changed my oil for the first time it was a piece of cake. boy was there a lot of metal chunks on the screen and a big glob on the magnetic drain plug. i am thinking it is time for bottom end bearings. i was not so worried about the loud bottom end as i have heard them sound like that before but that was more metal than i have every pulled out of a running engine. it was enough chunks and shaving to cover a penny.

it sure runs good though and looks great. i might just ride it until it pops and build a new one or a big bore. here is some more pictures after i washed it today.
 

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#66 ·
it is pretty normal for a glob of shavings and some pieces on the screen for some reason. It could need them though. With it getting quieter through the RPMs it does not make sense though.
 
#68 ·
Take my word on this, it is far cheaper to repair it now, while its still running, than it is to repair it once it lets loose!!!
 
#70 ·
I did!!!! LOL


I had a brain fart and put the piston in backwards. I had marked the piston as to which side was the exhaust and the intake but put the paint pen mark on the intake side of the piston. ( The custom piston does not come with any makes on it as to which side is which!! )

When I went to put it all together I forgot that I had marked the intake side and just put the piston in with the marked side pointing to the exhaust, just like every other piston I have ever put in. Well, I goofed and the end result is a trashed motor for my parts wall of shame!


Learned a very expensive lesson that day!!


Now that I am finally back to work, its my hope that I will have a new & improved 570 up and running by the upcoming holiday weekend. I'm going to be boxing everything up this weekend and shipping it all over the Travis to have him assemble a new one up for me.
 
#72 ·
leo, Thats alot of metal. I know my 525 is pretty fresh yet, but I don't see anything on my screens, or my drain plug, other than a few almost "hair-like" pieces of fuzzy metal, and I assume thats from the clutch, and is likely just fibers.

If you have metal like that, something is happening. no clue what, but something. Might just be in the tranny, but its a sign of bad things to come.

My 07 had like 90ish hrs on it when i sold it, and it didn't show any signs of metal ever in the oil.

Hope it all just goes away, but its likely the opposite.
 
#73 ·
i went and rode the snot out of my irs again for about 2 hours of hard riding. i came home and changed the oil again. it was dark again this time already but only a little filings like i am used to seeing were on the drain plug. very minor. i pulled the clutch cover and checked the crank nut and it was tight as ever. clutches looked good no chunks or pitting. i put in new filters again cleaned both screens and almost no filings on them either. i did not like how black and gritty the rotella oil was after 2 hours. so i switched to honda sj 10 40 this stuff quieted the engine quite a bit, shifted real smooth and looked clean after another hour of riding. i think i like this stuff a lot better. i have been running it in my sportster and have really liked the improved shifting i have and it comes out clean. 1,700 ml of oil again puts me at no lower than 1/4 glass and no more than 5/8 glass. peace out suckas!
 
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