Just bought an 04 Raptor 660 -- and, you guessed it, CARNAGE as usual!!

[Nick_R_23]

Well I sold my banshee project last month because there was just more wrong then I wanted to deal with. With that out of the way, I managed to finish up all my other projects (minus a few small easy things), so I decided to pick up a new one to keep me busy. So I dragged home this 2004 Raptor 660 for 300$, with a seized engine. Story on it is that this guy's buddy had 2 of them, he was riding it one day and it suddenly locked up on him, so they took the engine and a few other parts off this one and made a 'good' one and a 'parts' one, and I bought the parts one. Its missing the seat, tank, radiator, exhaust, and wheels mainly. As soon as I got it home I tore the engine apart.

Turns out the lower rod bearing seized. Hard. And I mean HARD. I can guarantee that motor went from 6000 rpm to 0 instantly, the bike stopped on a dime and the guy that was riding it went flying. Heres what I found as I dug further into the engine.

Crank rod is bent
http://i84.photobucket.com/albums/k28/Nick_R_23/GEDC0423.jpg

Flywheel key got ALMOST sheared, its barely holding together.
http://i84.photobucket.com/albums/k28/Nick_R_23/GEDC0424.jpg

Not sure if this is supposed to be this way or not, but the gear appears to have rotated as the screws are no longer centered in those holes.
http://i84.photobucket.com/albums/k28/Nick_R_23/GEDC0425.jpg

Upon removing the clutch and other various gears, I found the bearing race split open on the counterbalancer.
http://i84.photobucket.com/albums/k28/Nick_R_23/GEDC0427.jpg

And a couple other cracks around the balancer bearings as well.
http://i84.photobucket.com/albums/k28/Nick_R_23/GEDC0428.jpg

http://i84.photobucket.com/albums/k28/Nick_R_23/GEDC0429.jpg

http://i84.photobucket.com/albums/k28/Nick_R_23/GEDC0430.jpg

And, the balancer itself. Keep in mind that shaft is damn near 1 inch thick, and its broke cleanly in half.
http://i84.photobucket.com/albums/k28/Nick_R_23/GEDC0426.jpg

And the machine itself.
http://i84.photobucket.com/albums/k28/Nick_R_23/GEDC0431.jpg

http://i84.photobucket.com/albums/k28/Nick_R_23/GEDC0432.jpg

Itll take a few parts (I need both center cases, rod kit, counterbalancer, and a clutch basket) but its going to be a lot easier then doing that banshee. I have a thread in the classifieds of all the parts I need so if you have anything please let me know!!

It also came with a nice set of ProTaper Hi Bend (?) handlebars, and a beefy full underbody skidplate.

Well, whatdya think?

-Nick :TrikesOwn

[super90]

I would say that motor is toast! Kind of sad how people can completely trash a 5 year old quad! 300 isnt bad though, probably could part it out for more.

[SYKO]

street bike motor time!!!! yamaha R6 or R1 !!!!!!

[smokinwrench]

Wow that is trashed. I would say complete motor to fix is cheapest, part out whats good from that one. $300 is a steal.

[Xowner]

geez wtf caused that?

[rdlsz24]

That's worse than the carnage in a KFX 400 I bought. The rod broke while the kid was riding it. The piston of course went zinging into the valves, etc and took out the cylinder as well. The stub of a rod went to town on the bottom end as well. I replaced it with a complete engine from eBay and parted out what was salvageable from the toasted motor.

Rob

[Nick_R_23]

I would say that motor is toast! Kind of sad how people can completely trash a 5 year old quad! 300 isnt bad though, probably could part it out for more.

No kidding, If I bought a new quad Id probably make it last the rest of my life!!


street bike motor time!!!! yamaha R6 or R1 !!!!!!

This could be a possibility :naughty: ....how close does it drop in?


Wow that is trashed. I would say complete motor to fix is cheapest, part out whats good from that one. $300 is a steal.

I would go this way, but shipping a complete bottom end up here would probably cost more then what Ive paid for it! :lol: A pair of cases, balancer, and rod kit would be a cheaper option in my situation.


geez wtf caused that?

I think it played out like this...apparantly the rod pin on these was misaligned from the factory, and it has something to do with how much oil the lower bearing gets, and since it wasnt aligned it gets starved for oil. The lower rod bearing seized up, which was the main problem. The counterbalancer is gear driven right off the crank, and the sudden lock up of the crank caused the keyway on the balancer gear to shear and spin the gear around 180*. This threw the balancer out of time with the crank, and when the crank came around again, the rod struck the balancer, breaking the balancer in half, and also bending the rod. (There are impact marks on the rod consistent with the balancer damage). The impact on the balancer, and probably the fact that it now sat crooked in the case, caused the surrounding bearing support areas on the cases to crack. Also, since the flywheel was driven straight off the crank, the sudden stop caused the flywheel which was still trying to rotate to almost shear the key like that. Overall it was just a big chain reaction, one thing led to another.


That's worse than the carnage in a KFX 400 I bought. The rod broke while the kid was riding it. The piston of course went zinging into the valves, etc and took out the cylinder as well. The stub of a rod went to town on the bottom end as well. I replaced it with a complete engine from eBay and parted out what was salvageable from the toasted motor.

Sounds like that wouldve been quite a mess! I would do this also if it didnt cost so much to ship stuff up here.

-Nick :TrikesOwn

[SYKO]

I will get pics of a 600 raptor with a R1 motor in it for you there is one at my buddies shop

[badasskfx]

the one way clutch on the flywheel is spent. the bolts arent on center because they are about to sheer...

[SYKO]

I will post pics later of the raptor with the R1 motor wedged into it.

[BigGreenMachine]

I don't think the R1 is a "drop in" kinda deal.

[SYKO]

http://i42.photobucket.com/albums/e306/southgacustoms/atv%20parts/8.jpg

http://i42.photobucket.com/albums/e306/southgacustoms/atv%20parts/7.jpg

http://i42.photobucket.com/albums/e306/southgacustoms/atv%20parts/6.jpg

http://i42.photobucket.com/albums/e306/southgacustoms/atv%20parts/5.jpg

[cr480r]

If I found a scattered 660 raptor for $300 it would definately get repaired with a fresh YZ250 powerplant...

[Dirtcrasher]

Just read this post....

WOW - That motor grenaded!! I can't believe all the cracks and shearing going on :lol: Are those Raptors known to be junk if over revved? (must have a limiter) and the oil isn't maintained.....

And that R1 motor seems to fit perfect in the Raptor chassis :D I like it but it would be one hell of a ride!

[Atc GuY]

Any updates?

[300rman]

If I found a scattered 660 raptor for $300 it would definately get repaired with a fresh YZ250 powerplant...

same. always liked the look of the raptors, although a KX500 motor would be a better power matchup lol, and would definitely be original.

[300rman]

just noticed the rust on some of those bearings. has that been sitting for a long time?

[Charles Ford]

I have a seat that needs recoverd for $20.00 plus shipping.
Chas

[Nick_R_23]

Sorry about no updates, I dont have this machine anymore. I got in contact with a local guy who was into Raptors and had his stolen (fell off the trailer, they noticed and turned around to go get it, but someone had already loaded it up and made off with it that quick!! :eek:) He ended up getting it back, but it had been rallied and needed a lot of parts. I asked him what it needed, and he listed off almost everything that was still good on mine, so I told him what I had and he bought it all for what I payed for it. I kept the Protapers for my 250R though! :lol: Im glad that it at least went to good use, he needed it more then I did. I have plenty of other projects that are keeping me busy however!!

-Nick :TrikesOwn

[MyMistress86R]

Were you friggin stupid? Why would you even get involved with something like that?