Hey guys,

Couple things:
1) I posted a bio and 2 pics of my new outlaw so you guys could put a face and story to the name.
2) There are a few things all outlaw owners should know about setting up their 525's for optimal performance.

The KTM 525 motor is jetted lean to make emissions standards. In the cold temperatures much of the country is experiencing, this makes for extremely lean combustion. The 148 main that comes in the machine stock is not going to damage the engine, but the spark plug is actually white, meaning that the "Fastest Accelerating Stock ATV" has potential to be far faster. The hot ticked is JD Jetting's Jet kit for this engine. Talk to the tech support folks there and they can tell you what to run. For me, the hot ticket seems to be the blue needle on the third clip (this needle is richer than stock) and the 170 main jet. I tried a 162, not wanting to go all the way to the 170, but after I ran around for a while, the electrode on the plug was STILL white, the 170 gives a nice spark plug color, and the transition region from half - full throttle is very smooth with no flat spots. Monday, EHS Racing should be finishing up their Prefilter Airbox lid for this thing, which I will be purchasing and then the Outlaw will be put on an exhaust gas analizer to get the really optimal settings which will be posted here. So far, the 170 main and the Blue needle work well for seat-of-the-pants feel, and spark plug color, but i'm sture it can be optimized further.

Again, these changes are not necessary, but they do really wake the 525 Outlaw up even more than it is stock. Further optimized settings will be posted as i said and evasiveone or myself can help you with setup further if you need. There is also an "O-Ring mod" which makes for some EXTREME throttle response, but i have refrained from doing so as yet, as i didn't want to play with the carb that much, and to be honest the racing that i will be doing will be 1.5 hr harescrambles, and i think that the smoother the power delivery, the better i'll hold up. Evasiveone can offer more information regarding what results you will see if you do this mod, as i'm fairly certain he's done it.

Anyway, hope this information helps any 525 Outlaw owners [img]i/expressions/face-icon-small-happy.gif[/img]!

P.S. This thing is unreal! i will be posting a ride review as soon as the snow melts and i can actually use the power, and feel the suspension over some jumps and stuff, however first impressions are fantastic!

 

whats the horsepower output with the JD jet kit, and are you running without your air box lid. I know you guys told me to buy a JD jet kit but I had Dynojet do my carb. they did not charge me so i figured if it didn't work i would change it. without the air box lid it shows a peak of 41.73 max power and after jetting 43.03 max power (with stock exhaust). In a few weeks they will be putting on an FMF pipe that is being made right now. Then i will see what happens. thanks for the info on the prefilter airbox lid, i really need one.

 

I imagine the HP numbers are comparable. Fact is there is only one real "right" way to jet a carb for a given set of conditions, anything else is either too rich or too lean. I'm sure that Dynojet used an exhaust gas analyzer to determine the correct settings for your 'Law. That pretty much means that they'll likely come to the same conclusion that JD did in the end. Not sure if they changed your needle, but since the KTM engine has been around for forever, i could definately see them already having a proven needle for it. Either way, i'll have more info once I get the ESR lid and put it on the analyzer. Until then, i am in fact running w/ the airbox lid on. What jets did dynojet wind up using for your carb? and did they change the needle? also, when is FMF gonna be done w/ their pipe? they are the ones KTM uses for factory race teams, so i imigaine their pipe puts out respectable numbers for this machine. Also do you know what model? (Q or no?) i need to stay legal for the trails, so anymore than 94 decibles and i'm pretty much out... thanks!

 

Vegas thanks for posting. Really glad to see they did not charge you since you allowed them to use your bike as a mule.

43.03 hp with stock filter and exhaust!! Those are really impressive numbers for stock.

Did they give you a copy of the dyno? I would love to see the power curve after jetting. I know after jetting mine it was a huge difference on how the power was delivered.

I highly suggest the o-ring mod to anyone with the 525. It makes a substantial difference in throttle response. With the James Dean kit part #JDK002 you will receive the jets and needles and also 2 o-rings and instructions for the 0-ring mod. The smaller o-ring adds 40% to pump speed and the thicker o-ring adds 80% to pump speed. The KTM bike guys say that the bigger o-ring makes the throttle snappy, but since the quad has 100 pounds on the bikes I went with the big o-ring and love the way the bike reacts with the throttle.

 

I put the graph Dynojet gave me in my pic. They are going to do more after they get the FMF exhaust pipe for me. As far as what they change, they put a C131 jet (Dynojet number) after they took out the A148 stock jet and they changed the needle. I am still trying to get more info from Dynojet, but the guy that did the work is out of town. As far as the exhaust pipe I won't know till they get it. Thanks for your input, there really is no one I know out here that knows this quad.

I took it out for a little spin today and did notice I could run more between 4th and 5th gear where before it was 3rd and 4th when on the rocky trails out here. I will do the o-ring when the exhaust is put on.

 

Hey sry to change the subject, but what are the top speeds of the new 525's?..

 

stupid ? all quad are geared from the factory to due around 75MPH

 

43hp on a stock quad sounds real good, i think the ds650 has higher numbers than that but its 100lbs heavier too.

Doesnt the predator make 38-39 hp in stock form, so i think a pred with a pipe and filter should be able to hang with a stock outlaw. thats pretty good. (other than that it supposedly requires more maintainance than the outlaw 525)

 

i think i'm gonna go back to the 162 main... the 170 made the outlaw back-fire once yesturday! temperatures reached almost 50 here in MI, which is a far cry from the 4-10 degrees F I was runnin' at when i put in the 170. I think the 162 should be a nice all-weather jet, as it was only a little light-colorrd at about 4 degrees lol. I'll keep you informed...

also, the EHS lid is not yet ready, but again, i'll let you guys know when i get the call. I'm gonna do the 162 swap tomorow and if the temperatures stay as they are i'll hopefully have a little seat time on it to let you guys know what happens. I guess the 170 worked great before b/c it was hella-cold and I was only runnin' like half throttle breakin' it in... oh well, i'll let you guys know more as i continue to tune this thing for optimum performance now that i'm starting to use more of the throttle, i think 170 will be a little much as condition slowly move towards spring time [img]i/expressions/face-icon-small-tongue.gif[/img]

P.S. Cal i think you're right the DS makes like 46 right? as you stated that motor if very strong, but the x-tra 100 lbs is what hurts. (well i think the extra wieght has something to do with why they ride so nice, but it seems to hurt it in the straight-line is what i mean.) Either way, i like that the 525 'Law makes near the DS's level of HP, as i've always respected that big can-am engine a bunch [img]i/expressions/face-icon-small-wink.gif[/img]

 

Hello fellow 525'ers!
I used JD's suggested settings, red needle clip 5th from bottom (the bottom is the red dot, right?), 162 jet (stock everthing else), and small o-ring, and it is working good so far! Might try the thicker o-ring, but even with the thinner one the throttle response is snappy. Is there an easy was to install a different jet?