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Discussion Starter #1
Hello all! I'm getting back into riding quads and tinkering with them. Thought that I would use this thread as mostly a motivator and log of efforts for myself. Hopefully you all will enjoy and feel free to let me know what you think of the build. Thanks.

Ok, so I picked up a pretty sweet deal on this 2001 Raptor 660 from my good friend and thought that I'd do a frame off rebuild on it.




Got her home and started cleaning up what the pressure washer left behind. It's a solid "ten footer" quad. It needs a LOT of small things to be 100% again. The only major thing wrong with this quad, that I know of, is some play in the steering.




Pulled the seat off and noticed it is already outfitted with a K&N air filter and a nice electrical box holding the battery in all snug, lol.



Also, the floats in the left carb seem to be a bit high as it has a slow drip of gas onto the motor, and it also dies occasionally after coming to a stop.





Got the plastics off and most of the big items still seem to be in good shape mechanically.




Pulled the somewhat dented Pro-Circuit T4, which is loud as $hit!, and noticed that some of the packing is blown out and probably has never been repacked.




Pulled the manifolds and bead blasted them. Stainless always cleans up well!






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Fender brackets bent and filthy.




All cleaned up, corners rounded, straightened. These should look a lot better.




I have noticed that the rear fenders don't have the best support from these tiny brackets. Has anyone else done anything different to help support these big fenders? Has anyone made extended brackets or extra brackets?
 

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Discussion Starter #2
Nasty...






Engine is now out and i rolled her outside to clean the frame some more.




This is the color that I will be putting on the frame very soon.



More miscellaneous bits cleaned and blasted.


 

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Discussion Starter #3
Swingarm is off and I found some bushing problems!



Stripping...



Tie rod ends are bent to hell.


Moar blasting!


At some point, someone has wheelied the shit out of this quad and bent up the subframe a bit as well as ripped off the grab bar.




Cleaned, deburred, and primed.




Cleaned up and smoothed the area near the footpegs.


Finally, today I've been concentrating on some carb cleaning.


 

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Love an old 660 build. Toss that K&N in the garbage and get a foam filter on there. No offroad anything should have a K&N on it.
 

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What did you soak the carbs in? Were those float bowls that clean straight out of the solution?
 

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Discussion Starter #7
First I soaked everything in Berryman chemdip, 2nd zep degreaser in the parts washer which you see in the pic, then finally washed everything with dawn & hot water.

No, I actually bead blasted the bowls to get them that bright, they just wouldn't clean up to my liking any other way.
 

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It looks good so far. I have restored a few 660's and had a 700. My next project is going to be restoring a 700 and you are making me want to get the project going!
 

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Discussion Starter #9
That's great man, I'm glad to hear it. I typically like to stick to the older 2-stroke dinosaurs, but this is now a semi-old bike now, and I felt that it needed to be saved.
 

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Discussion Starter #11
Nothing to speak of really. Starting to rebuild the carbs a little and cleaning misc. parts.

I've got so many different things going on at once, it's been hard to solely focus on the raptor. I'm semi-restoring an old 1986 Jamis BMX bike for a paying customer, so that is the most important at the moment.
 

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I have never heard of Jamis. I have an old Race Inc. and 87 GT Dyno hanging on the wall that needs restored. lol
 

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Discussion Starter #13 (Edited)
I finished smoothing and finishing a few parts of the frame and got the primer sealed.




Basecoat:





Red Metalcast:








It really needs one final wet coat to be "complete." IMO

Pro-Circuit T4 Mods: The silencer originally had a huge dent in it, so I hacked it off behind the dent and just made a shorty silencer, a: because I thought it would look cool and different, b: because I doubt that anyone else has one, and c: because who cares! And, yes.....I do realize that it will be loud as shit!! No surprise there.







I have collected some parts recently to begin rebuilding the quad, so that should be under way very soon! Stay tuned!
 

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Discussion Starter #16

Looks like this ole' girl was running rich. That's ok, we'll get those carbs tuned right real soon .



Sent from my iPhone using Tapatalk
 

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Discussion Starter #17

The a-arm bushings were a tad tired and under greased, so I picked up some bushing stock and made some new ones, as they are quite expensive to buy.

They turned out pretty good...


Sent from my iPhone using Tapatalk
 

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Discussion Starter #18
The engine was one helluva greasy mess at first, but I finally got her all cleaned up and painted with engine enamel.





 

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Discussion Starter #19
A-arms were looking a mess, but I finally got them all cleaned up along with a lot of other parts.




Also found out that the carrier bearings were trashed along with the front wheel bearings....




New bearings in the front hubs.
 
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