polaris outlaw 450 big bore kit

sskip75 · #1 (**permalink**) 02-13-2011, 08:41 PM

I'm looking for info on changing my 08 450 to a 525. I have done a little research and the only things I can find are changing cylinder, piston, and slight adjustments in carb. I have a manual and was able to find some info there, and have talked to local dealer with out much luck. Has anyone heard of this being done? Or, does anyone know how to accomplish this? Any help would be greatly appreciated.

OUTLAWMUDDER · #2 (**permalink**) 02-26-2011, 06:38 PM

Sounds right. The ktm 450 and 525 are practically the same motor just with a different bore and cylinder. All you should have to do is buy a 525 cylinder and piston, or have your cylinder bored, and buy a 525 piston. The 450 has a 89mm bore, and the 525 has a 95mm bore. Then of course you will have to jet accordingly, for your increase in displacement. Good luck with everything.

CB BLR · #3 (**permalink**) 02-26-2011, 07:51 PM

Why not just turn your 450 into a 540 or 570 and be done?

It only takes a different sleeve which is available from KTM or Thumper racing to get to these displacements.

Chris

sskip75 · #4 (**permalink**) 02-27-2011, 05:04 AM

I recently spoke with Daryl Rath of Rath racing, and he brought up the 540 kit. I did not know there was a big bore kit for this bike. I'm going to pick one up but need to get some more info about the reliability. I can do the change but do not want to rebuild after every ride. We only get to ride about 4 times a year and put about 150 miles per ride on. So I guess my next step is to research the reliability issue.