Predator 500

  

The dyno chart above shows the stock Predator 500 horsepower in blue. Our CT Sonic Pipe with jet kit is shown in red.

 

CT Racing has been working overtime on the Polaris 525 Outlaw quads. We have been doing the motor work for the factory backed desert team, Hancock Racing, as well as Quad Magazine's Nick Nelson. Nick is racing both the 525 independent and solid axle models and we have done a significant amount of testing on both. CT’s owner Allen Knowles, is also going to be racing a Polaris backed entry at two GNCC rounds and one WORCS Series round for R&D. We now offer pipes for both the 525 and 450.

Our 450 pipe program is now complete. We are producing just over 48 rear wheel horsepower out of the 450. The pipe will be shipped with a jet kit including main jets, pilot jet, and a titanium needle. The pipe is shipped with 14 discs as that is what we found produces the most horsepower on the 450. We are running a modified air box lid (significantly opened up) and stock filter to produce this horsepower.

We have a very good engine  program for both the KTM 450 and 525 motors. We have done many of the KTM 520 and 525 two wheel motors and have been working for years with Ed Teixeira and his Honda chassis KTM powered 525 desert racer.

We also have a lot of information for setting up the chassis. So if you have questions or need help, feel free to call us. We have been working very hard with TCS/Race Tech developing shocks and have also been testing the Fox Floats. Along with the Rath Racing sway bar, we have the Outlaw independent  handling extremely well.

 

Outlaw 525

The dyno chart above shows the stock Outlaw 525 horsepower in blue. Our CT pipe with jet kit is shown in red.

 

Below is a list of 10 things to make your Outlaw better. This was written in 2007 by CT's Allen Knowles after racing the Polaris Cup with the '07 model Outlaw. Some of the things could have been addressed by Polaris on the '08 and '09 models, but much of it still applies.

CT Racing's Top 10 Things To Do To Make Your Outlaw Better

  1. The KTM 525 responds very well to a pipe. The CT Sonic Pipe has been the choice of most of the top riders racing the Outlaw including Jeff Hancock for his off road racing effort, Daryl Rath to win the Stateline Supermoto Championship, Nick Nelson for his Polaris Cup effort, among others. The CT Sonic Pipe utilizes the spark arrestor disc system so you can tune it for both performance and sound.
  1. Heat can be an issue in slow tight woods riding and racing. We've found that a motor can actually run cooler if you pull the thermostat off of it and run the hose just straight to the top of the head, eliminating the Y section of the radiator hose altogether. You will need to plug off where the hose leads to the cylinder.
  1. The foot pegs seem to be a bit too far back with the seat arrangement. When you slide forward on the seat, it actually is hard to stand up and ride aggressively. We had an upholstery shop add 1” of 00 foam to the front half of the seat, then blend it in toward the back. We then covered it with a CT graphics kit with seat cover.
  1. Change the front wheel hub bearings. The stock bearings are on the marginal side for serious off road racing. If they fail, it leaves you with a junk brake rotor and ruins the spindle and hub. Pick up some quality Japanese bearings at a bearing house. Spend a couple of bucks now to eliminate a big bill later.
  2. Install a set of Fasst Flexx bars along with their anti vibration bar inserts. This combo can really save you some energy and they'll take some of the pounding away from your hands and arms.
  1. A steering stabilizer is pretty much mandatory for off road riding on the Outlaw. It does not have a lot of caster. This makes it quicker turning which is is good, but it also wants to rip the bars out of your hands when you're pounding through the rocks and tree roots. The Precision is arguably the best damper you can buy. It's adjustable for range of motion along with stiffness. The expensive dampers like the Precision are stiff when the bars are straight, but they brake free when you have the bars turned. So you don’t waste energy cranking the bars when the quad is sideways.
  1. A PWR radiator can add some margin of protection for heat issues, especially if you run a lot of tight trails where the radiator is not getting lots of air. We also recommend putting screen or residential heater element foam in front of the radiator in muddy conditions. If you let a radiator get packed with mud, it stops working and you will eventually cook your motor.
  1. Stiffer anti-sway bars let you be more aggressive with your cornering so it doesn’t roll over in the corners. We tested two, one from Rath Racing and one from Cross Country veteran John Gallagher Sr. Both worked well.
  1. Aftermarket suspension will help any quad. We turned to TCS/Race Tech Suspension to make our Outlaw better. Their shocks will let you plane the top of the whoops instead of wallowing through them. They'll also provide a plusher ride and more wheel travel.
  2. An IMS tank might be a good move on this quad. IMS is making a high capacity tank that allows you to run a million miles before you need to refuel. It’s nice to have the capacity so you don’t have to worry about fuel on the long rides.

 

Part #

Description

 Price  
Exhaust
PP-P450 Polaris Outlaw 450 Pipe Kit

Polaris Outlaw 450 exhaust kit includes a stainless header, muffler with 14 discs, and jet kit with titanium needle.

 $534.95 
PP-P500 Polaris Predator 500 Pipe Kit 

Polaris Predator 500 exhaust kit includes a stainless header, muffler with 12 discs, and jet kit.

 $507.95  
PP-P525-I Polaris Outlaw 525 Pipe Kit - IRS

Polaris Outlaw 525 independent exhaust kit includes a stainless header, muffler with 12 discs, and jet kit.

 $534.95
PP-P525-S Polaris Outlaw 525 Pipe Kit - Solid Axle

Polaris Outlaw 525 solid axle exhaust kit includes a stainless header, muffler with 12 discs, and jet kit.

 $534.95

PP-P525-SM Polaris Outlaw 525 Pipe Kit - Side Mount

Polaris Outlaw 525 side mount exhaust kit includes a stainless header, muffler with 12 discs, and jet kit.

 $534.95

 
PP-DISC-12K CT Spark Arrestor 12 Disc End Cap Kit with Bolts $93.95
PP-DISC-14K CT Spark Arrestor 14 Disc End Cap Kit with Bolts $101.95
PP-TURN-D   Turn Down End Cap

Turn down tip includes 6 stainless steel bolts.

This turn down tip CT sonic pipe, and any pipe that uses the 4" Supertrapp disc System.

 $54.95 

Intake
AF-PD-222 Polaris Predator 500 Pro Design Pro Flow Foam Air Filter Kit $170.95
AF-PD-211 Polaris Predator 500 Pro Design Pro Flow K&N Air Filter Kit $189.95
AF-PD-258 Polaris Outlaw 525 Independent Pro Design Pro Flow Foam Air Filter Kit $170.95  
AF-PD-259 Polaris Outlaw 525 Independent Pro Design Pro Flow K&N Air Filter Kit $189.95  
Engine Components
PI-JE-209286 Polaris Predator 500 JE Hi Performance Piston Kit - 99.2mm 11:1 Comp Ratio $159.15
PI-JE-221843 Polaris Predator 500 JE Hi Performance Piston Kit - 99.2mm 12.5:1 Comp Ratio $172.20
PI-JE-274173-PS Polaris Outlaw 525 JE Hi Performance Pro Series Piston Kit - 95mm 12.5:1 Comp Ratio $186.75
PI-JE-274174-PS Polaris Outlaw 525 JE Hi Performance Pro Series Piston Kit - 95mm 13:1 Comp Ratio $186.75
PI-JE-274175-PS Polaris Outlaw 525 JE Hi Performance Pro Series Piston Kit - 95mm 13.5:1 Comp Ratio $186.75
PI-W8692DA '03-'09 Predator 500/'06-'09 Outlaw 500 Wossner Hi Performance Piston Kit - 99mm 12.5:1 Comp Ratio $166.45
PI-W8693DA '07-'09 Outlaw 525 Wossner Hi Performance Piston Kit - 95mm Stock Comp Ratio $166.45
PI-W8693D200 '07-'09 Outlaw 525 Wossner Hi Performance Piston Kit - 97mm Big Bore Stock Comp Ratio $166.45
PI-W8694DA '07-'09 Outlaw 525 Wossner Hi Performance Piston Kit - 95mm 12.5:1 Comp Ratio $166.45
PI-W8694D200 '07-'09 Outlaw 525 Wossner Hi Performance Piston Kit - 97mm Big Bore 12.5:1 Comp Ratio $166.45
GA-C7971-EST Polaris Predator 500 Cometic EST Complete Top-end Gasket Set (includes valve stem seals) - 99mm

EST = Extreme Seal Technology

 $78.38
GA-C7944-EST Polaris Outlaw 525 Cometic EST Complete Top-end Gasket Set (includes valve stem seals) - 95mm

EST = Extreme Seal Technology

 $67.95

Clutch
CL-H254 Polaris 450MXR/525IRS/525S Hinson Billetproof Inner Hub $294.00  
CL-BLT254 Polaris 450MXR/525IRS/525S Hinson BTL Series Slipper Clutch Inner Hub/Pressure Plate Kit   $1,092.00  
CL-C254 Polaris 450MXR/525IRS/525S Hinson Billetproof Clutch Cover $152.00  
Shop Services
LB-PORT-4V Polaris 450/500/525 Head Porting

CT Racing has done significant amounts of flow bench and dyno testing to offer you the best port layout for your application. We highly recommend getting a valve job at the same time the head is being ported. Our CNC valve job ties in with the port work to offer extremely effective flow numbers.

 $350.00  
LB-022 Polaris 450/500/525 3 Angle Valve Job

Quality valve job. Seats not included.

 $144.00  
LB-023 Polaris 450/500/525 5 Angle Radius Race Valve Job

The 5 angle radius Race valve job significantly raises the flow characteristics at low valve lift and definitely shows a horsepower increase throughout the useable power curve. Seats not included. 

$192.00  
LB-023BV Polaris 450/500/525 5 Angle Radius Race Valve Job for +1mm Intake & Exhaust Valves

The 5 angle radius Race valve job significantly raises the flow characteristics at low valve lift and definitely shows a horsepower increase throughout the useable power curve. The 5 angle valve job really shines on big valves as the seat diameter is opened up all the way into the aluminum casting, blending to the port work. Adding +1mm valves to a modified engine package helps the mid to top-end horsepower. Most aftermarket hi compression pistons are clearanced for +1mm valves. Seats not included.

 $240.00  
LB-010 Split 4 Stroke Cases, Inspect Crank & Trans, & Reassemble $475.00  
LB-KTOP Disassemble & Reassemble Polaris 4 Stroke Top-end (from bottom-end only) $300.00  
LB-019 Disassemble Head, Clean Ports, Lap Valves, & Reassemble $65.00  
LB-026 Rebuild 4 Stroke Crankshaft (labor only) $75.00  
Ignition
IG-P50-DFS9-1P '03-'04 Polaris Predator 500 Dynatek Programmable Ignition

Direct plug in performance: 4 programmable timing curves, programmable rev limiter, external curve selector switch, plug-in module replacement, and more.

 $332.50
IG-P50-DFS9-2P '05 Polaris Predator 500 Dynatek Programmable Ignition

Direct plug in performance: 4 programmable timing curves, programmable rev limiter, external curve selector switch, plug-in module replacement, and more.

 $332.50
Controls
CH-FLX-QR1431-** Fasst 1-1/8" Flexx Bars

These are the best off road bars money can buy. Bars come with three different elastomers to get the proper cushioning for your type of riding along with a cross bar pad in your color choice of blue, grey, or red. A 1-1/8" bar mount kit is required.

 $329.95
CH-TG-CRHI

Tag T-2 CR High Bend 1-1/8" Fat Bars with Bar Pad

Bars are available in black or silver and bar pads are available in black, blue, or red. A 1-1/8" bar mount kit is required.

 $89.95

CH-TG-UNMNT

Tag Universal 1-1/8" Bar Mount Kit

This is a clamp set than converts your stock 7/8" bar clamp to the 1-1/8" Fat Bar set up. Can be used with any brand 1-1/8" bars.

 $49.95
IG-KS Pro Design Tether Kill Switch - Black, Blue, or Red $36.95

Order By Description Power Madd Hand Guard Kit

Kit includes hand guards and mount kit. Hand guards are available in blue/black, black/black, silver/black, white/black, yellow/black, and blue/silver.

 $52.95
Brakes
BR-SL-PRED500-F Streamline Steel-braided Front Brake Line Kit (specify color & length)

Available in black, blue, clear, green, red, or smoke. Some colors and lengths may need to be special ordered.

$92.95
BR-SL-PRED500-R Streamline Steel-braided Rear Brake Line (specify color & length)

Available in black, blue, clear, green, red, or smoke. Some colors and lengths may need to be special ordered.

 $42.95
BR-SL-BLC-1 Billet Brake Line Clamp - 1 pair (specify color)

Can be used with any 3/4" or 1" diameter A-arm. Available in black, blue, red, or silver.   

$29.95
Axles
AX-DB-20-1163P '03-'07 Predator 500/'08-'09 Outlaw 525S Dura Blue Eliminator 2+2 Extended Axle 

The Eliminator axle used for all forms of racing and high performance applications. Many of the models come with the patented Posi•Lock system which removes threaded sections from the flexing area of the shaft (a source of crack generation).

 $468.90

Graphics
GR-P525-BLU CT Graphics Kit with Seat Cover, Outlaw 525 - Blue $139.95  
GR-P525-RED CT Graphics Kit with Seat Cover, Outlaw 525 - Red $139.95
GR-P525-SIL CT Graphics Kit with Seat Cover, Outlaw 525 - Silver $139.95  

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