Ask The Editors: Polaris Outlaw 525 KTM Parts

Ask The Editors: Polaris Outlaw 525 KTM Parts

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Polaris Outlaw 525 valve cover gasket
The brief partnership between Polaris and KTM works in this rider’s favor.

Dear ATVC: I have an 08 Polaris Outlaw 525 with a slight oil leak coming from the valve cover. I can’t find the gasket anywhere to fix it and Partzilla doesn’t have anything listed and I can’t find the OEM part. Currently sealed with RTV but I assume that’s not how it came factory. Also, anyone know if the KTM 525xc has the same engine? I can find a valve cover gasket for the 07 525xc but nothing when searching Polaris Outlaw 525.

You’re right, it did not come with a messy gasket sealant job from the factory. You’re in luck, however – the Polaris Outlaw 450 and 525 were indeed completely compatible with any OEM parts from the KTM XC ATV models.

While the first choice would always be opting for the correct OEM park when it comes to gaskets, should you ever find yourself in a predicament, we’ve had decent luck in the past purchasing a sheet of gasket material from the local automotive parts store for under $10, laying the gasket between the cover and the block, then using an x-acto knife to carefully cut the outer dimension of the imprint left behind by the mating of the two surfaces.

For best results, addition of a sealant in the the situation is recommended as well.

The good news, however is that while Polaris isn’t restocking the Outlaw parts supply, their brief partnership with KTM in that era assures a healthy OEM (and aftermarket) marketplace for years to come. The Austrian company keeps healthy parts backlog support.
Polaris Outlaw 525 valve cover schematic
Once you secure the OEM KTM part #, you should be able to quickly locate even more affordable aftermarket offerings from companies like Moose, Quadboss, Tusk, Pro-X, Vertex (Winderosa), Athena, Cometic etc.

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