I agree... we should check the valves and make sure they're still moving.

Everything is grounded correctly and we triple checked all connectors are good. We can swap parts with another 02 Raptor if need be.... we did that when troubleshooting the stator. CDI and rectifier are connected, all other connections are solid. And we're getting plenty of spark, so I think it's gotta be something with the intake.

Could a problem be caused from excissive cranking? This bike got cranked A LOT while trying to troubleshoot. Did we crank it out??? hehe

 

LOL. Yeah that is a problem with Raptors, but from what you said its not what your having trouble with. If the starter sounds like it is free wheeling, and the piston isn't moving, you have "cranked it out". That is the dreaded one way symptoms.

 

So I'm joking about 'cranking it out'. I know that the piston must be moving now that I think about it. 'Cause when I use different throttle positions when cranking, the speed the engine is cranking changes slightly. Like it's breathing better when I have it fully open vs. fully closed with the choke on. So the piston has to be moving.

Maybe something happened with the timing chain and the valves?

We were able to turn the crank slightly counter clockwise by turning the flywheel. Only turned maybe 1/16th of a turn. Would that do anything to hurt the engine?

I'm really stumped here guys.

 

The only thing that turning the engine over can harm, as long as everything is in good shaped first (IE good timing chain, no bent valves, ect), is if the fly wheel loosend up a little. This could cause the fly wheel key to shear off...which would be bad.

Can you check the timing? Do you have a timing light?

 

I agree, it almost sounds like something broke apart inside. If its not your valves then its lower in the engine. I would check your stator and I hope you dont find a bunch of metal in there shorting out your stator!![img]i/expressions/face-icon-small-shocked.gif[/img]

I would try pulling the cover off before you do anything else.

 

if you think your piston is no good take the plug out.......crank it up and put a match to the plug hole to see if you can see the pistion moving lol.....I AM JUST KIDDING DONT DO THAT I WONT BE RESPSONSIBLE FOR WHAT HAPPENS....honestly if you think its your piston or vavle....take a compression test. !!!!!!! if thats fine then....get some either and try it.....dont overlook the small stuff....check your airfilter check the exhaust return lines for blockage.....dont overlook anything......take off the air box and spray directly into carb....i dont know what i am talking about lol

 

I agree... we should pull the *&^%% stator cover and see wha't going on in there.

We've changed out the plug twice, so I know it is not the plug. and the plug fires fine when I try it outside of the cylinder.

I don't think the stator is getting shorted out as we have a wonderful spark. That's why I think something is going on in the intake, or perhaps the timing/timing chain.

I'll check it out and let you guys know... thanks for your help!

 

Maybe you should've stuck with the 250r? [img]i/expressions/face-icon-small-wink.gif[/img] j/k...sounds to me like your timing is off. My raptor didnt start a couple of days ago (no spark) and it turned out to be my CDI box, a connector was loose. If you have spark and gas, its timing.

 

JMO, but I wouldn't pull the cover yet. I mean whatever is wrong in there can be checked outside the cover more easily and quickly. If you have spark at the right time then there shouldn't be a reason to pull the cover.
I guess as a last resort I would pull it, but not untill then.

Again, thats just my opinion.

 

He did say he had some noise and then it was going away, sounds like it chewed up something. I would drain the oil and see if there is any metal in it. OR YOU FORGOT TO PUT OIL BACK IN IT WHEN YOU REPLACED THE STATOR????? Just a thought.