just got my outlaw serviced went for a ride yesterday and it ran perfect for 2hrs then i lost all power like a spark plug fouled (which i changed) wasnt the prob any ideas It wont start turns over quicker if you give it a little gas as i say it died  

need a little more information.

are you getting spark at the spark plug?

are you getting fuel to the cylinder?

How much compression are you getting?

also do a search on polaris recalls for your atv. there are a ton of them, and polaris may cover the repairs.  

yep getting spark fuel but seems to be no back pressure from exhaust when turning it over  

could have sheared the pin on the flywheel, thus getting the timing could be off.

what year is it?  the reason i ask is that the 2007 outlaw has a ktm (australian) engine on it instead of the polaris engine.

the ktm engine does so much better than the polaris engines.  

however check your rings, put a compression guage on it, if it's even 5 psi lower than it should be it wont start.
if the compression is low yank the cylinder and check to see if it is scratched.

even if not you'll need to at least hone the cylinder so the new rings can seat in, if it is scratched you'll have to bore it out if the scratches aren't too deep.  

i say its a warrenty job then its only done 5 hours and yes its 07  

and im not happy scraped money up for service so i could ride xmas time and bike shop aint open till 2/1/08 spewing  

I see POlaris constantly in my shop, the holidays brought even more of them to work on. (people getting repairs as christmas presents. I personally repaired two on christmas eve so customers could have their atv running for christmas.)

I have to honestly say that it seems the more repairs you do to polaris the more repairs they need.
Polaris has already issued recalls for the 08 machines.

the ktm engine is a better engine than the polaris engine, but it is full of polaris components. which means you are going to have some issues.

if you had it serviced what did they do?  did they re-adjust the valves?  if so it may be a bad valve. burned, broken or bent. (which could cause no back pressure from exhaust, and as well cause a loss in compression.)
The ktm 525 engine has a four valve overhead cam. with roller rocker design, so it is very possible in the readjustment they got the adjustment off and bent a valve, or it broke after the adjustment while riding.

the ktm designed engine is still a new design for polaris and the valves set differently so it is very possible they didn't get it exactly right in the readjustment.  

thnx for ya help wolf i want this bike for enduros so i dont know now might buy the new ktm atv  

i'll be honest with ya, you might want to look at another company for an atv.
Polaris has had so many problems that they have paid out millions in settlements with people who lost arms and legs while riding their atv's due to factory defects.
and the 2008's are already having recalls issued.
not to mention i work on polaris more than any other atv.
 I get to see the defects that POlaris admits to as well as the ones they won't admit to.

I understand if you are sold on polaris, buy what you want.  but be careful!!


they can get you hurt seriously or in the least they will cost you a ton of money in repairs.  

well, the KTM motors are made in Austria, not AUSTRAILIA, and they contain NO polaris components, they are made in the same factories that put engines into KTM quads and dirt bikes. The 510cc "525" motor has proven itself for many years for its reliability and power. The only thing polaris has to do with the motors, is they buy them from KTM. Ask anyone who actually deals with quads, Polaris is famous for being very reliable. Ive owned a predator 500, and now an Outlaw 525s, and i wouldnt consider buying anything else. So you might want to do some research before you start brand bashing  

yeah i get austria and australia reversed sometimes.
it's fairly common alot of people do this. so iam not perfect. but anything i had said about polaris is fact and is there for all to look up themselves.

not to mention 7 of the most active posts on here are for polaris machines,and some of them for outlaw 525 problems) so the evidence bears out the truth even here.



anyrate the ktm engine is not completely ktm, the stator inside is all polaris, meaning as well the engine had to be designed differently than other ktm engines to accomodate the polaris stator.
these stators have failed for years due to polaris failing to seal the covers, as well as failing due to defective stators.
if the stator goes bad and they see dirt or moisture inside that cover(which on any other atv is sealed) they void the warranty for you and you end up paying for repairs because of polaris' poor design.

but it's obvious with polaris puting a ktm engine in it and the constant problems with polaris engines, that they can't figure out how to build an engine that will last or stay running.

As well to note, the ktm engine has the polaris hydraulic clutch which the engine had to be designed differently to accomodate.
so it's not your standard ktm engine nor is it all ktm.

as well all of the wiring and electrical components are all polaris, that means you get the same defective ecm that polaris has had recalls on for years.

and the outlaw has had it's own recalls as well.


since 1999 polaris has had to issue 13 recalls
Yamaha has only had 4
Honda has only had 7

and polaris had to issue recalls on the 2008 models in 2007.

the Co-Founder of Polaris went on the record as saying
"if we made 400 machines, we got 500 back"
(it's public record so you can look it up on the internet)

so they know they have serious issues with quality.
yet year after year they do nothing to better the quality of their machines.

and the customers suffer for it.
polaris has paid out over 3 million in settlements due to serious injuries caused by their defects.

things like the steering stem was defective, so it came apart while riding and you suddenly had no steering, this first happened in 2005 on the Ranger model, then they thought it would be a good idea in 2006 to put this same steering stem in the Hawkeye model.... you'd think they would care about their customers and use better quality materials, but not polaris, and not while there is a fast easy dollar to be made.

Brake caliper bolts falling out while riding, leaving you suddenly with no brakes.

Transmission bolts backing out and causing the transmission to lock up while riding. People were seriously hurt with multiple broken bones and internal injuries reported.

Defective throttle cables and housings that caused the throttle to stick wide open suddenly.

oil lines that leaked and caused 2nd and 3rd degree burns to the rider.

ecm's that overheated and caused fires that burned the rider or the house down. these first showed up in the 2004 models yet polaris thought hmmm... lets put the same defective ecm's in our 2005 models.

fuel tank valves that were defective and caused fires that burned the rider or their house down.
these showed up first in 2004, then the same defect showed in the 2005 models, then again the same defect showed up in the 2007 models, then again in the 2008 models. (again they know there is a problem but do nothing)

it seems that Somehow polaris thinks these defective materials will get better with age, so they just hang on to them and reinstall the left over stock of them in newer models, to save a few dollars, all while charging you more each year for their atv's.

Still, year after year Polaris does nothing to correct these defects but passes them on to the next year models.

but don't take my word for it, check them out on the consumer product safety commission website.

in Ohio, Polaris had atv's that were such poor quality that they fell easily into the legal category of being "lemons" (it's listed on the internet so you can look it up)


still polaris would rather give you an indendant suspension and steel braided brake lines rather than design them better to get the defects out of them.
honestly what good are an indendant suspension or steel braided brake lines if the atv doesn't run or it causes serious injury.

they could buy better electrical components for their machines, but they choose not to.

they could spend a little more time on quality control to make sure the steering stems don't come loose, or that brake calipers stay on,and so on. or even that they don't repeat constantly the same defects year after year,
 but they don't.
they'd rather make a fast buck than care about their customers safety.

I am so glad you have owned yours without issue, simply you are one of the lucky ones,(geeze just look at the posts for problems with the outlaw on here)  and Iam sure there are thousands of polaris customers who envy you.
some of which are my customers.
I have lowered my labor rates for polaris to help my customers. afterall they shouldn't have to pay for Polaris' lack of quality.

all american?  not so, they have at least 1 atv that was made in taiwan. the only thing you can call american made on it are the decals.
as well Polaris is Co-owned by fuji heavy industries.

so you'd nprobably be surprized at how much of that "american made" polaris is actually made in taiwan.

I'd love to see Polaris step up to the plate and address their quality issues.
but to date they haven't.
and the dealers are notorious for refusing to honor the warranty.

I'd love to say buy "american made" but with polaris i can't.  

I have a 500 that did the same thing.  Thought it was a bad plug.  New plug did not help.  Seems like it has jumped timing.  I get gas shooting out of the carb.  will not even come close to starting with starting fluid.  Have spark, have compression.  
I did find oil inside my stator cover, normal?
And to reply to all the polaris bashing, I own 2.  outlaw 500 and trailboss 330 and both are junk.  If a screw/bolt isnt missing it because the factory stripped it putting it in. all other non-stripped have fallen off (polaris style loctite i guess).  I have had 4 welds break and 1 fox spring break.  my trailboss has never idled correctly even with 3 trips to the dealer (chapparel does not know what they are doing.  bunch of kids that know nothing). Polaris or Unison?  same company?  both are junk
I tell everybody i know what kind of crap polaris makes.  People stop to look at my 500 and say 'thats cool'  then i proceed to tell them the problems i have.  No pride or bragging rights of owning this junk.
And YES, polaris does not care about its customers which is why i will never buy another. I have called, emailed and have to keep calling to get a response.  They are too busy fielding other customer problems. Just bought a honda two wheeler.  

you know i'd really prefer to not be able to say anything bad about Polaris, but they make it so necessary.

and with the high prices they charge for their defective machines, you'd think they would do some quality control.  god knows they can afford it!!  

Wolf, that is some funny S2#$ you are posting are you selling any of that stuff you been smokn?  

I do own an Outlaw 525 IRS 2007 for 2 months and i burned the starter.  Why?  Beacause i put too much oil in the motor.  My dealer told me i am not the first... So be careful not to put more than halft the oil lever glass on side of motor.
Wanted to share info.