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Discussion Starter · #1 ·
Well as a few of you may know, I sold my 700 last September. Got into street bikes over the summer, and just didn't get out on the quad anymore. After nearly ten years and four quads, it just sat there. I spent all my time on the new interest: Ninja 650... Had a lot of fun on it over the summer, but now that it's put away for the winter, it's just got to where I can't stand not having a quad!

So a couple weeks ago I picked up a winter project: a well used and worn 2005 Raptor 660R. It had been used for MX, and was well set up with a full Yoshimura exhaust, aftermarket aluminum air box, K&N filter, EBC heavy duty clutch and springs, Fly Racing handlebars, ODI grips, Moose hand guards, aftermarket Nerf bars, G-Force axle, and YFZ front shocks (there may be more, this is just what I have discovered so far tearing it down…) All of which must have been fairly recently added, as none of them were nearly as worn as the rest of the quad. It is a strong runner, starts right up with no smoke; good smooth idle, tight sounding engine with very snappy throttle response.





Radiator slightly bent , but not leaking




I know it's not a Honda, and doesn't look like much, and believe me it needs a lot of work and parts. But the rebuild is underway, and I hope to be back out there riding by late March or early April.

Aaron
 

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so whats your plans? are you gona paint the frame and stuff or just clean everything up? looks like it gona be a fun project
 

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700woodsrider,
Looks like a great project. If you do repaint it why not black and red. We all know that that color combo is faster than just black. :lol::lol: Keep us updated on your progress.
Sid
 

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Sweet bike, keep us updated on it. I have a Raptor build going on right too.
 

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Discussion Starter · #5 ·
Well I had to replace the frame, it was bent up front between the lower arms. Scored a very nice frame off another 2005 that hardly has any wear. Also got both lower arms off that same bike, again like new parts. Will be cleaning up and re-painting the upper arms and subframe. Got all new suspension bearings in, and a new aftermarket rear carrier, the original one was cracked.





Old Vs New Carrier




Got a thread going over on Raptor forum about it: http://www.raptorforum.com/forums/showthread.php?t=87904
 

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Discussion Starter · #7 ·
Had to go in deep - got to checking out the engine and discovered a galled upper rod and piston wrist pin. Had to split the cases and replace the crank, rod, and piston, and will have it bored .020 over. Lot of work...









Fun...
 

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Discussion Starter · #9 ·
It takes up every bit of my free time, and it has been a very busy last several weeks...

I enjoy the work, but the cost does always add up more than you expect.
 

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It's coming along Aaron. You'll hafta let me go for a ride on it when its done! :hey: I remember my buddy's 660 w/a 686 BB kit on it. That thing was fast! Couldn't keep the front end on the ground! Keep the updates coming. I enjoy reading about it!
 

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Looks like a nice project. Still cant believe you sold the xx though. Looks like its just me and Dave left for the Kentucky rides.
 

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Discussion Starter · #12 ·
Looks like a nice project. Still cant believe you sold the xx though. Looks like its just me and Dave left for the Kentucky rides.
I hope to have it together and running by late March or early April. I know it's not a 700XX, but there will still be Kentucky rides :tup:
 

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Discussion Starter · #13 · (Edited)
Getting the motor back together now, had to replace the crank, rod and piston, and have the cylinder bored .20 over.



Doing this by myself, crash course in Engine Rebuild 101:lmao:
 

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I hope to have it together and running by late March or early April. I know it's not a 700XX, but there will still be Kentucky rides :tup:

Nice rebuild project. My brother bought the same bike for his son that rode with us. He just did some major work on it. Glad to hear the rides are still on. Looking forward to getting out soon.
 

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Discussion Starter · #17 ·
Major Progress!

Got the motor all back together this week, and today I got it back in the new frame (original frame was bent), hung the swing arm and rear suspension, installed the oil tank and lines, and got the stem in.



 

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Nice job, but how the hell do you get away with that in the house? My wife would never go for that, lol.
 

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Discussion Starter · #20 ·
Nice job, but how the hell do you get away with that in the house? My wife would never go for that, lol.
One word - Single...

Well I now have everything back in the frame. Since my last update I have installed the subframe, and the rest of the harness and hoses, carbs, exhaust, and everything else required to make it run. Now to get it outside, put the tank back on, and see if she starts!

 
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