Just picked up an outlaw last night and the guy pointed out that the rear brake caliper was quite loose (1/4" of play) he said he had it at the dealer and the dealer said it is just the way they are designed. Any threads on hear about the rear brakes on the straight axle outlaws?

 

Check the rear caliper mounting bracket at the front where it slips over a bushing and see if if has up and down movement there. The bushing is replaceable (#5136470) which may or may not remove all of the slack. The rear brake caliper bracket is similar to the the one used on the old Polaris Sportsman 6x6 and it also has a replaceable bushing,but would(when worn down )make a clacking noise when the brake was applied as the bracket clacked forward and back a little on the bushing and support! OPT

 

It also has a big gun exhaust on it and I noticed it backfires badly on let off from high rpm. The guy said it was "jetted" but didn't know what jets or sizes. From what I've read I think I need a 165 main but that is about all. What size pilot and anything else that might help?

 

Back firing on some aftermarket exhausts are a common thing even if jetted spot on! A lot of the cause is unburned gas mixture igniting in the hot pipe,plus have had some "flame out" when shutting off,learned quickly not to be in the back when this happens as I've walked past one and had the hair on my arms burnt!
As far as jetting,do a "plug chop" first at high rpms, kill it and wait until it cools a while and check the condition of the plug. Electrode and base should be a medium tan,if whitish,then running a little lean! If hesitates or stumbles on take off,then it a good sign could need jetting change. This depends on altitude,temperature,stock air filter or aftermarket,etc as to jetting change. Main jets go from 130-170, pilot jets from 42-50. See what the plug looks like first,then its a process of finding what size works best on the jets if needed! This is something that takes a little patience and trial! OPT

 

What air filter are most of you guys running?

 

The backfiring could be caused by a leak where the header pipe meets the head. Mine had that problem from day one. I ended up going with a full FMF exhaust and put a bead of high temp silicone around the adapter on the head before sliding the header pipe on. After about 5-6 weekends of riding i have to take it apart and reseal it because it will start backfiring again.

 

How about the oil? I read that a lot of guys are running the Rottella T synthetic but when I was a Walmart the only synthetic was Rottella T6. Is that the same thing or not?

 

Same thing! Rotella T6 5w 40 synthetic(blue bottle).The white bottle is 15w 40. BAD thing is our Wallyworld got wise and it now costs as much as Mobil 1 or the other synthetics. Have used it in my Honda and my son uses it in his SV1000 Suzuki. OPT

 

Just got the "2nd" oil filter for it last night and I had already bought Amsoil 0w-40 for this oil change (then I'm switching to Rotella). But anyways, I noticed (what I thought to be) excessive metal in the screens and on the magnetic oil plug. It makes me a little nervous but I checked both oil filters pretty good and didn't see ANY metal. So my question is if it is on the screens and plug but not the filters, is it most likely coming from the clutch and tranny and not the engine or is it something to really worry about?

 

backfiring isnt normal on any quad. period. its a problem. 99% of the time it's a leak in the exsaust system or a lean pilot setting. start the quad cold and have a friend hold his hand over the end of the pipe. look and listen for leaks. fixem if found.

Pilot setting
when going from wide open to off throttle the engine is unwinding and just using the pilot/idle curcit. as a test use a small screw driver and open the air fuel screw a good turn counter clockwise. this will add fuel and eliminate the backfire ....