Yamaha Discussions about Yamaha ATVs.

*Rappy!* Raptor 660 Build Thread

  #1  
Old 09-14-2015, 02:17 PM
bmxatv10's Avatar
Pro Rider
Thread Starter
Join Date: Jan 2001
Location: TN
Posts: 370
Likes: 0
Received 0 Likes on 0 Posts
Smile *Rappy!* Raptor 660 Build Thread

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.

Name:  099_zpsbmmxer2s.jpg
Views: 92961
Size:  178.0 KB
Name:  102_zpshutzfmay.jpg
Views: 92920
Size:  187.2 KB

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.

Name:  182_zpssyqk10rv.jpg
Views: 92918
Size:  147.5 KB
Name:  183_zpsacysb22u.jpg
Views: 92723
Size:  148.0 KB

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.

Name:  180_zps8dmyc9jm.jpg
Views: 93161
Size:  180.3 KB
Name:  179_zps4rvkz1dp.jpg
Views: 92706
Size:  143.6 KB

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.

Name:  165_zpsc1m9mfwh.jpg
Views: 92410
Size:  120.6 KB
Name:  178_zpstyvr6e1y.jpg
Views: 92385
Size:  105.1 KB

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

Name:  201_zpsnjqdilsz.jpg
Views: 92762
Size:  154.8 KB
Name:  215_zpsbg6g9iai.jpg
Views: 92927
Size:  145.7 KB

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.

Name:  222_zpswwiutkoo.jpg
Views: 92635
Size:  130.0 KB
Name:  221_zpsx4oslbh0.jpg
Views: 92681
Size:  142.2 KB
Name:  218_zpsilhkh3fd.jpg
Views: 92862
Size:  166.3 KB

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

Name:  229_zpsjet83ps3.jpg
Views: 92834
Size:  160.9 KB
Name:  254_zpslqxradcu.jpg
Views: 92625
Size:  130.9 KB
Name:  262_zpsujxfnkbw.jpg
Views: 92856
Size:  214.2 KB
 
  #2  
Old 09-15-2015, 01:44 PM
bmxatv10's Avatar
Pro Rider
Thread Starter
Join Date: Jan 2001
Location: TN
Posts: 370
Likes: 0
Received 0 Likes on 0 Posts
Default

Fender brackets bent and filthy.

Name:  263_zpspxriqqrn.jpg
Views: 92959
Size:  224.1 KB
Name:  264_zpsfexcgh2v.jpg
Views: 92741
Size:  198.0 KB

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

Name:  265_zpsspfgm306.jpg
Views: 92831
Size:  194.0 KB
Name:  266_zps35o55r9a.jpg
Views: 92245
Size:  102.2 KB

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?
 
  #3  
Old 09-16-2015, 11:47 AM
bmxatv10's Avatar
Pro Rider
Thread Starter
Join Date: Jan 2001
Location: TN
Posts: 370
Likes: 0
Received 0 Likes on 0 Posts
Default

Nasty...

Name:  289_zpsuxaaiau6.jpg
Views: 92652
Size:  173.4 KB
Name:  290_zpswo7t1zki.jpg
Views: 92590
Size:  156.5 KB
Name:  294_zpsqmgl28ef.jpg
Views: 92628
Size:  166.7 KB
Name:  304_zps7i1h2cbk.jpg
Views: 92597
Size:  169.1 KB

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

Name:  318_zps0zpeu2rw.jpg
Views: 92548
Size:  148.1 KB
Name:  321_zpsobdicjel.jpg
Views: 98199
Size:  216.6 KB

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

Name:  323_zpsocncsrew.jpg
Views: 92260
Size:  117.8 KB

More miscellaneous bits cleaned and blasted.

Name:  5B8EFBD7-D83D-4D52-99E9-BED76ACD5873_zpspxoylqfe.jpg
Views: 92971
Size:  355.4 KB
Name:  3223C8EF-1EAA-4E12-97DE-68D0CBFC3048_zpsdug5pzsv.jpg
Views: 92983
Size:  333.0 KB
 
  #4  
Old 09-17-2015, 07:57 AM
Extreme Pro Rider
Knows Old ATV Questions!
Join Date: Sep 2003
Posts: 5,127
Likes: 0
Received 0 Likes on 0 Posts
Default

Excellent! I may lambaste the original Rappy from time to time, but properly set up they are actually a great quad. Glad to see someone bringing this old war horse back to her former glory (or most likely even better than original.)
 
  #5  
Old 09-18-2015, 11:14 AM
bmxatv10's Avatar
Pro Rider
Thread Starter
Join Date: Jan 2001
Location: TN
Posts: 370
Likes: 0
Received 0 Likes on 0 Posts
Default

Absolutely, thanks. Yes, I am not the utmost raptor fan either, but they definitely deserve to be better taken care of than this. Please stay tuned for further updates!
 
  #6  
Old 10-20-2015, 03:29 PM
Range Rover
Join Date: Apr 2008
Location: Houston, Texas
Posts: 113
Likes: 0
Received 0 Likes on 0 Posts
Default

For support on the rear fenders, I actually fabricated something out of 1/2 steel conduit. the lil tabs that bolt to the brackets broke on both sides. No flapping since I made the new brace.

The bead blasted parts look awesome! What type of glass bead are you using?

Since this is an 2001, does it have the tranny mod? Might be a good time to correct that issue while you have it apart.
 
  #7  
Old 10-20-2015, 09:38 PM
bmxatv10's Avatar
Pro Rider
Thread Starter
Join Date: Jan 2001
Location: TN
Posts: 370
Likes: 0
Received 0 Likes on 0 Posts
Default

Thanks for the conduit idea. I might have to do something similar.

I'm just using glass bead media, that's all I know, lol.

I'm not sure if this quad has the "tranny mod" done to it or not. But it runs and shifts excellent and has for a long time so I have no worries. I will not be tearing into it.
 
  #8  
Old 10-21-2015, 10:32 AM
Range Rover
Join Date: Apr 2008
Location: Houston, Texas
Posts: 113
Likes: 0
Received 0 Likes on 0 Posts
Default

The early 01 660s had a tranny issue with 2nd gear. They corrected the issue in the later 01 models. Hopefully you have one of the later models.

I use glass bead as well, but I am thinking what you are using may be a finer grit. Your bead blasted parts look a lot better than mine. lol
 
  #9  
Old 11-11-2015, 01:50 PM
bmxatv10's Avatar
Pro Rider
Thread Starter
Join Date: Jan 2001
Location: TN
Posts: 370
Likes: 0
Received 0 Likes on 0 Posts
Default

Swingarm is off and I found some bushing problems!
Name:  F677E0AC-BD4B-4945-8FBD-FCDCED004C52_zps8mybwrh0.jpg
Views: 92452
Size:  149.8 KB
Name:  IMG_3259_zpsj74da0fo.jpg
Views: 92602
Size:  204.3 KB

Stripping...
Name:  F677E0AC-BD4B-4945-8FBD-FCDCED004C52_zps8mybwrh0.jpg
Views: 92452
Size:  149.8 KB
Name:  IMG_3259_zpsj74da0fo.jpg
Views: 92602
Size:  204.3 KB

Tie rod ends are bent to hell.


Moar blasting!
Name:  IMG_3303_zpsjnohjdkz.jpg
Views: 92678
Size:  193.0 KB

At some point, someone has wheelied the **** out of this quad and bent up the subframe a bit as well as ripped off the grab bar.
Name:  IMG_3444_zpsuelzafox.jpg
Views: 92459
Size:  161.4 KB
Name:  IMG_3445_zpsfdhvhv8h.jpg
Views: 92483
Size:  179.0 KB
Name:  IMG_3446_zpshfd0fcxg.jpg
Views: 92488
Size:  149.2 KB

Cleaned, deburred, and primed.
Name:  IMG_3451_zpskhemb3jd.jpg
Views: 92415
Size:  147.9 KB
Name:  IMG_3452_zpsckq465mo.jpg
Views: 92735
Size:  218.1 KB
Name:  IMG_3460_zpseuawh8ax.jpg
Views: 92658
Size:  232.8 KB

Cleaned up and smoothed the area near the footpegs.
Name:  IMG_3747_zpss11rbotm.jpg
Views: 92241
Size:  121.3 KB

Finally, today I've been concentrating on some carb cleaning.
Name:  IMG_3722_zpslc3pb6pl.jpg
Views: 92449
Size:  153.3 KB
Name:  IMG_3819_zpsmfzjwg1e.jpg
Views: 92277
Size:  147.0 KB
Name:  IMG_3820_zpsmyrog0os.jpg
Views: 92495
Size:  164.6 KB
 
Attached Images
File Type: jpg
IMG_3259_zpsj74da0fo.jpg (204.3 KB, 143 views)
  #10  
Old 01-04-2016, 12:48 PM
bmxatv10's Avatar
Pro Rider
Thread Starter
Join Date: Jan 2001
Location: TN
Posts: 370
Likes: 0
Received 0 Likes on 0 Posts
Default

I finished smoothing and finishing a few parts of the frame and got the primer sealed.
Name:  IMG_3998_zpspdof3koq.jpg
Views: 92543
Size:  224.1 KB
Name:  IMG_3999_zpsytqdlxey.jpg
Views: 92104
Size:  110.3 KB
Name:  IMG_4002_zps2iwivhxs.jpg
Views: 92374
Size:  169.9 KB

Basecoat:
Name:  IMG_4094_zpstohinvhs.jpg
Views: 92469
Size:  199.0 KB
Name:  IMG_4095_zpsreqqgt3b.jpg
Views: 92297
Size:  145.2 KB
Name:  IMG_4096_zpsy4tvpfsb.jpg
Views: 92046
Size:  87.5 KB
Name:  IMG_4097_zpswj6m9haf.jpg
Views: 92306
Size:  170.7 KB

Red Metalcast:
Name:  IMG_4110_zps7nzuc5fz.jpg
Views: 92353
Size:  161.1 KB
Name:  IMG_4111_zpscqo2flgz.jpg
Views: 92375
Size:  189.8 KB
Name:  IMG_4113_zpsloszi4nn.jpg
Views: 92368
Size:  170.6 KB
Name:  IMG_4114_zpsdeab7cej.jpg
Views: 92225
Size:  178.5 KB
Name:  IMG_4115_zpstavmnw9r.jpg
Views: 92043
Size:  112.3 KB
Name:  IMG_4118_zpszzqwkpck.jpg
Views: 92426
Size:  208.8 KB
Name:  IMG_4249_zps3f2uk9sn.jpg
Views: 91954
Size:  109.9 KB
Name:  IMG_4250_zpsj8jc5mk9.jpg
Views: 92065
Size:  100.3 KB
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 ****!! No surprise there.
Name:  IMG_4192_zpsaeea4zsz.jpg
Views: 91970
Size:  90.9 KB

Name:  IMG_4208_zps914kmlyx.jpg
Views: 92293
Size:  177.1 KB
Name:  IMG_4209_zpsxvjhbgg8.jpg
Views: 92377
Size:  193.0 KB
Name:  IMG_4254_zpssx7reupd.jpg
Views: 92160
Size:  140.2 KB
Name:  IMG_4255_zpsswz8v7cj.jpg
Views: 92246
Size:  164.1 KB

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

Thread Tools
Search this Thread
Quick Reply: *Rappy!* Raptor 660 Build Thread


Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service

© 2019 MH Sub I, LLC dba Internet Brands

We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.
 
  • Ask a Question
    Get answers from community experts
Question Title:
Description:
Your question will be posted in: