Yamaha 660 Raptor Rebuild

By Midwest Traction on August 29, 2017 in Stories

After my success with the Blaster project, I decided to attempt a rebuild on a quad that was strong from the start to see how I could improve it. I shopped around and found a nice deal on a 2001 Yamaha 660 Raptor. This model has some known issues, so I quickly put it to the test.

Before replacing several major components, I broke something just about every time I took it out. And it broke me a couple of times, too. When I sold this machine in 2006, though, she was a strong one.

The first day at home, I took it for a spin and found out that it sat too high and narrow for the flat track. I broke three ribs finding out how easy it high-sided.

Installed a lowering kit and fabricated a relocation mount as I wanted to keep my head lights.

In order to keep the rubber side down during while turning, I installed wheel spacers for a wider stance.

First look at the quad with brand new Pure Sports Bandit Flat track tires on ITP T-9 Pro wheels. AC front Bumper, Rear Grab Bar, and Stickers added.

Discovered two known problems at this point: 1) Second gear is gone and 2) the clutch is on its way out. The 2001-02 660cc Raptors are notorious for blowing second gear. Having to use a gear that's too high for reverse is hard on the clutch.

Took the engine out and someone borrowed my front bumper.

Cases split.

New Wiseco Hot Rod Crank Kit installed.

Old transmission with the new 2003 gears installed.

I did some head work, adding new titanium valves and retainers with upgraded springs to a new Hot Cam.

I had a good friend, Larry Zumbrun from LZ Racing, do a porting job. He’s the best top-end guy around. Larry put together a New Wiseco racing piston in a newly bored sleeve. I made a few other modifications to the engine and transmission and added a new clutch basket and HD clutch disc before putting it back in the chassis.

Look closely and you can see the cool, new exhaust working its way around.

After adding a new Scorpion exhaust, she’s ready to roll! Awesome-running machine.

Here she is showing off her under carriage with an AC rear skid plate and nerf bars, a GYTR frame, and A-Arm Armor.

Also added some trail-riding, general purpose tires – 22-11.00-10 Maxxis All Trak in the rear and 22-7.00-10 Maxxis Front Pros up front. They are all mounted on ITP C-Series Cast polished wheels. Oh, and more stickers. Doesn’t she look mean?

Power Madd Hand guards help to keep the grips clean. And more stickers.

Moose shock covers, GYTR frame protectors, DG coolant and brake reservoir protectors.

A better look at the clean Scorpion Exhaust with an FMF sticker (just because it looked cool, and surprisingly never melted off).

Trail Tech dash board and Renthal bars with a tethered kill-switch and twist throttle. The little red thumb lever in front of the throttle was a quick reverse switch.

Ready to get serious. Looks good, doesn’t she? Take a long look because it’s the last time you’ll see her this clean.

Lock and load – going riding. Hatfield & McCoy, here we come.

Home-sweet-home, West Virginia. Hatfield & McCoy Trails Heaven is the best place I’ve ever had the pleasure to ride.

Making her earn her keep.

This hill is a lot steeper than it looks – out of our group, only two of us went to the top.

We made it and here is a picture from the top, looking down at this beautiful country.

I didn’t quite make it up this coal hill, but the tires started spewing coal down the hill. When I got off, the front end was tilting back, so my buddy Ken held her down while I took a picture before climbing back on. These pictures never look as steep as being there.

Another neat thing about Hatfield & McCoy is they let you ride all over town. Here we are gassing up the quads and getting some grub.

Easiest and cheapest way to clean your quad before loading up to go home.

This photo is from a winter ride at a buddy’s hunting lodge in southern Ohio. Blew out my rear end on this trip! On the quad, that is.

Cold, muddy ride at Haspen Acres in Indiana. Burned up another clutch and broke my rear fender mounts from the weight of the mud. It took me days to get all this mud off.