2007 Polaris Outlaw 525 engine rattle

The air cleaner came apart and this knock was caused by foam stuck on top of the piston. No dirt was found in the motor, so I got lucky.

Category:

Autos & Vehicles

Tags:

• rfs
• ktm
• atv
• quad
• sand
• dirt
• motor
• rebuild
• backfire
• intake
• air-cleaner

[wranglerguy106]

Sorry this is kind of off track.... but where did you get the oil filter covers??

[DeanB44]

@wranglerguy106 All the nick nacks were on the quad when I bought it.

[DeanB44]

Drained the oil today and found sand on the short screen. Pull the seat and found the air filter has came apart. No way to avoid a rebuild now.

[kjsmolik]

Yes thats what the ticking noise is. Does the noise go away or get quieter when you pull in the clutch?

[DeanB44]

@kjsmolik I just watched the video again and it apprears that the ticking sound is not effected much by the clutch, but the deeper rattle sound is reduced when the clutch lever is pulled in.

[kjsmolik]

The 525 is noisy to begin with but they are notorious for the crank nut coming loose. Take the clutch cover off and see if the crank nut backed off. If its loose then it will make all kinds of noise and it will get worse the more loose it gets. The first year or 2 525's were bad for this. The new ones have been fixed. Sounds like your valves need adjusted also.

[DeanB44]

@kjsmolik Thanks for your reply. I have checked the primary nut and It was fine. Yes, I do need to check my valves. Is that what the ticking sound is?

[500502]

Sounds like my outlaw right before it ........Well dont know but it got louder than than when i let off the gas it sounded like a train coming apart.. it is in the shop now so i can let you know what they find...

[kjsmolik]

@DeanB44

That sucks. They say the KTM needs rebuilt every 100hrs or so anyways. Once you do the rebuild put in a 12.5:1 piston in. Dont go stock compression. You can still run pump on 12.5 compression and you will gain some more torque. Junk the stock air filter. Get a K&N with outerwears or a Uni dual stage filter.

[tundradirtbiker]

They never get very quiet. I rebuilt the top end and replaced the CCT with a manual unit due to 'play'. Still sounds like a KTM. Quite exhaust equals noisier engine as well.