recently purchased new 08 outlaw 525irs and have same problem with backfiring and hesitation when starting out. would like to try a jet kit. live in pa. where altitude ranges from 1500-2500 ft. would like to know which kit to try as there are different ones and different stages. any help would be appreciated. thanks.

 

I've heard this to be a problem with outlaws. I think I read some wear that the head pipe don't line up right with the exhaust pipe. your getting a leak which makes it back fire.
There is a fix. Do a search and you should be able figure it out.

 

THE HEAD PIPE IS TO LONG, remove exhaust pipe and trim about 1/8 inch from exhaust pipe where it connects to the exhaust manifold, the pipe hits the spring tabs before it has a chance to seal.

 

thanks. checked it out and definetly leaks around exhaust pipe on one side. took it apart and going to take it to work tomorrow where i have better tools to trim pipe. thanks for info. i'll let you know if it worked.

 

trimming pipes didn't work. still leaks. seemed tight until i tightened the manifold bolts. think i might weld pipes to manifold. anyone ever done that?