Hey,
I have an '02 Raptor andit had this problem out of the blue. It ran great, in fact I rode it for a 4 hr ride and no problems. The next week I hopped on it to ride it back to my woods and it quit as soon as it was warm. It WAS jetted at 160/165 with a K&N and a SuperTrapp pipe. I also had a reverse bypass from Ripper Racing. I have since jetted it back to stock, put the stocker pipe back on and taken the reverse bypass off to no avail. I get the same reaction. I also adjusted the valves to the factory specified clearance. I can start it at full choke and it will run for approximatly 1 minute and will quit and won't start until it cools down. When it is running you cannot give any throttle or you get backfiring and sputtering, sounds like when a parking break or reerse switch is sticking, but its not that either checked all of those. I must admit I am stumped and frustrated. I think that it is definitly a fuel problem but not sure what to check next. I just want to ride again!

 

more than likely its jetted wrong...it does sound like a reverse switch is sticking though, but even if it was it shouldnt be stalling out...

 

Thats the thing... I ran it jetted like that for 6 months with no problems. Then one day it just quit. Plus it is still doing it and I have everythign back to stock specs, including the jetting. Man I am running out of ideas!

 

I dont know much about Raptors.... but.....my Tigershark is equiped with a overheating sensor that cuts off the engine if it overheats. Im pretty sure Raptors are water cooled, so have you checked to make sure your water is circulating and keeping your engine cool. Maybe its hydrolocked and needs to be burped... just some ideas... I am by far no Raptor expert.

 

Try to narrow down the reason for the no start.
Itll be either no fuel, or no spark.
The no spark will be easy to figure out. Bring a spare spark plug with you, and when it dies, unhook the spark plug in the machine...hook up the spare plug, hold it against the head, and turn it over. Got spark?

 

Ok you're gonna say BS to what I am about to tell you but I had a warrior that would do the "exact" same thing. It almost drove me crazy. It had a loose/dirty connection at the battery, I cleaned and tighented the battery terminals and never had a problem after that. Like I said you may think that is BS but that was the only thing I done to it and it cured the problem, I would have never thunk it.

Maybe this is your problem, maybe not but it's worth a try.

Clean and tighten your ground cable where it goes to the frame/engine as well.

Caanan

 

Sounds like ignition or fuel delivery problems.

Did you check the fuel lines for kinks? Have you had the fuel cap off the tank to check for vapor lock?

Ignition cut out could be loose plug wires, damaged coil.

I had a Banshee that had the exact problems your having. I put a new coil and wire on it, changed the fuel hoses, synched the carbs. It would always stall once it was warmed up, flying down a road in 6th gear, overheated. Once stalled, there was no spark till the motor was completely cooled down. Im told that my stator was probably to blame, but ill never know.

 

Mine was the parking brake sensor. Even though the parking brake was off it was still cutting the ignition off. Check to make sure your bypass was done correctly. Maybe put it back to original on that part?

 

If it were a Bomb, I would tell you that your Rectifier was out. On the early year model bombs the rectifier would fail, letting the Stator over-charge the system, The CDI would recognize this and cut the fire to the plugs(anything over an IDLE) to protect the system. To test this you can actually turn the Head lights on, and see if that cures your problem. The lights draw enough jiuce from the battery and will let the engine rev.. If it does work, then you will need to change your rectifier ASAP . it will ruin your battery if not changed.





Bigger.

 

I would start at the beginning with a fresh plug.