'05 Raptor 660R Won't Start (lots of detail)
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Thread: '05 Raptor 660R Won't Start (lots of detail)

  1. #1
    Stock, ready to MOD Bcronk77's Avatar
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    '05 Raptor 660R Won't Start (lots of detail)

    Hello all,

    I am new to the forum and would like to say thank you in advance for any help you can give me.

    I purchased a 2005 Raptor 660R that had no compression at the plug, with compression checker, but was def blowing air out the exhaust. I got it home and found that the center valve was stuck open due to being bent.

    I replaced all 5 valves and made sure to lap them during the replacement process. The cylinder looked ok to me so I only replaced the Piston and Rings along with the valves and all necessary top end gaskets. I checked the top ring gap at 2 inches into the cylinder before installing the cylinder and piston. Top ring gap was well within spec' at around .40 mm.

    After installing, cylinder, new piston and head with new valves, I installed the timing gear and cam shaft and set the timing. When bolting the timing gear to the cam shaft, I was sure to keep the fly wheel lined up with the "l" mark on the engine case, the cam shaft lobes down with outer two holes facing up, then lined the cam gear outer punch marks with the top edge of the head and the third punch mark up. I was also sure to put the punch mark of the decompressor in the up position and the two decompressor pins in the cutouts of the actuators.

    Once everything was assembled, I did a compression test. While doing the compression test, the battery went dead. I hooked jumper cables up to my TRX450S and retried compression test. I could only get to 90psi then the starter relay would just crackle. I bypassed the starter relay by placing the jumper cable positive on the output side of the starter relay (the side where the cable goes to the starter). I decompressed the cylinder by pressing the release button on my compression checker and retried the test. I could only get to 90psi and the engine would just seem to lock up. I removed the compression checker and retried turning the engine over to make sure it wasn't actually locked up. It turned over without stopping leading me to believe the starter was too weak to turn the engine over above 90psi.

    Next I figured the starter was just weak so I thought I'd reinstall the plug and try pulling the bike with my TRX450S. When my friend and I tried this, the back wheels would just lock up and skid across the pavement, even in second gear.

    I am at a loss guys. If I can't get the bike to turn over continuously, I can't think of any way to troubleshoot the "won't start" issue. I did check for spark and it has spark. When I remove the plug, it smells like gas so I'm pretty sure I'm getting gas. The problem is it will only turn over a couple times before locking up (or whatever is happening). NOTE: the positive jumper cable is pretty hot after attempting to jump the bike.

    Pleas help!!!!

  2. #2
    Stock, ready to MOD Bcronk77's Avatar
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    I got no responses from anyone on this forum however, I will go ahead and post the fixes in case someone else needs help in the future.

    Update:

    I reinstalled the plug after getting 110psi on the compression checker, using truck battery to crank. I sprayed starter fluid into the intake manifold, in order to eliminate compression, air and spark as the issue for not cranking, and the bike started right up. I will be cleaning carbs and replacing starter relay as well as battery.

    Bottom line:

    Bike skipped time and bent valve. Replaced piston and rings as well as all valves and valve seals, made sure to lap valves during install.
    After reassembly, could not turn over with battery even if charged.
    When performing compression check using truck battery, only got 110psi.
    Bike starts at 110psi using starter fluid with no issue.
    Clean carbs, replace starter relay and battery.

  3. #3
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    If a 660 does not run, first thing is to clean the carb. And if you can a K&N throw it away and get a foam filter.

    Coop we miss you brother..

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