My 2008 Outlaw 525 IRS - Polaris Riders
 
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Old 11-20-2014, 11:56 AM Thread Starter
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Join Date: Oct 2014
Location: Limestone TN
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My 2008 Outlaw 525 IRS

I bought this off craigslist and it came from the sand dunes in Missouri.

pic from the sales ad



hauling it home from Asheville NC



when I got it home, I noticed an oil leak from the bottom oil screen threaded plug. I replaced that along with CV axles, boots, chain and bearings in the rear end. I also upgraded the front wheel bearings to the tapered kit from Boss Bearings. After reading about a few issues and recalls with these bikes, I pinned the seat latch and installed tether cable to rear sway bar. I also ordered the hardened steel primary nut from DJH and installed full skid plates from PRM-atv. The fuel petcock was leaking and nearly impossible to remove so I added a new larger IMS tank and new petcock.







Now all I need is heel guards or nerf bars to complete the underbody protection. Eventually, I want a (somewhat quiet) forestry approved full system exhaust and new tires. I would also like to widen the atv about 1in all the way around but am not a fan of spacers.

Do they make a Rekluse clutch setup for these ATV's?

In the near future, I'm planning on purchasing new DG front bumper and wider PRM grab bar along with a 450r thumb throttle.
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Old 12-31-2014, 08:51 PM Thread Starter
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One of my front tires kept leaking down rather quickly (overnight) and I couldn't find what it was. I sprayed the tire with soapy water multiple times looking for a leak and couldn't find one so I pulled it and unmounted the tire from wheel. It had all kinds of gunk and buildup inside apparently from previous owner using slime or fix a flat or something. After soaking in parts washer for a while and then sandblasting a little, I was amazed at how corroded and eat up the factory aluminum wheel was.







I have never saw an aluminum wheel in that bad of shape. I wanted to weld it up at first but I think it's beyond repair so I just bought this used DWT blue label wheel off eBay



and then decided to buy a new tire also to not have mismatches on front anymore

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Old 01-05-2015, 01:02 PM Thread Starter
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Since in running the oversized IMS tank, I had to ditch the tank cover and modify the side pieces a bit. Fitment is not as good as I would like but it'll do I guess.



Any suggestions?

Also, I got the new front tire and wheel mounted and installed today


08 Outlaw 525 IRS, 87 Lt250r Quadracer, 01 Lt80, 96 Lt80, 98 Pw80
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Old 02-16-2015, 05:49 PM Thread Starter
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Got a few more goodies for this quad today.

DG V-lite front bumper



And a new grab bar





I tried finding designs that matched the shape of this quad the best I could. Now I kinda wish I would've gotten the DG V-pro bumper instead of the V-lite but oh well

08 Outlaw 525 IRS, 87 Lt250r Quadracer, 01 Lt80, 96 Lt80, 98 Pw80
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Old 02-23-2015, 06:54 PM Thread Starter
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The flag mount tab on my new rear grab bar was rubbing the tailight and was bugging me so I had to get rid of it and grind it smooth.



Looks cleaner and fits better now I think

08 Outlaw 525 IRS, 87 Lt250r Quadracer, 01 Lt80, 96 Lt80, 98 Pw80
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Old 03-06-2015, 09:14 PM Thread Starter
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I bought a set of CFM Performance aluminum radiator shrouds for this bike off eBay






08 Outlaw 525 IRS, 87 Lt250r Quadracer, 01 Lt80, 96 Lt80, 98 Pw80
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Old 05-21-2015, 11:21 PM
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cool ride, man!
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Old 03-27-2018, 02:56 PM Thread Starter
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Since photobucket is junk now and wants you to pay.
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08 Outlaw 525 IRS, 87 Lt250r Quadracer, 01 Lt80, 96 Lt80, 98 Pw80
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Old 03-27-2018, 03:02 PM Thread Starter
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Here’s more
Attached Images
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08 Outlaw 525 IRS, 87 Lt250r Quadracer, 01 Lt80, 96 Lt80, 98 Pw80
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Old 11-17-2019, 02:32 PM Thread Starter
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Join Date: Oct 2014
Location: Limestone TN
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I just ordered a Big Gun Evo R full system exhaust for this atv. Can’t wait to see what it sounds like and hopefully get a little power gain.

08 Outlaw 525 IRS, 87 Lt250r Quadracer, 01 Lt80, 96 Lt80, 98 Pw80
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