My New Build

[dragonz]

I have almost finished re-building my Raptor.
Been a long slow process, mostly due to being away from home too much for work, but It is almost finished.
I still have some painting & things to do to make it look pretty again, & then some dyno time to ensure I'm getting the most out of it.

I have taken various pics & note during the course of the build, & I will (eventually) put it into the thread in chronological order to give you some idea of what goes into a serious build.

However, ‎3 things I have learn't today:
1/ 719cc Raptor will pull wheelies in 1st, 2nd, 3rd, 4th, & 5th, followed very shortly thereafter by hitting the 9200rpm rev-limiter
2/ I may need to swap the quick-twist for the standard twist throttle, currently acts as a light-switch! Part Throttle, what is that?
3/ Always double check the lock-tabs on the output shaft nut (holds the front sprocket on the shaft).
I now need a new nut & lock-washer....................

Apparently the 39mm FCR's are supposed to lack bottom end, I couldn't tell, was too busy trying to get the front wheels back on the ground & change gears :-)


You know when you get that little noise in the back of your head saying re-check everything?
Listen to tht voice.
I lost the nut of the output shaft, & spilt a little oil on the drivedway. Could have been much worse! If that had come off while I was in 4th gear, front wheels pointing skyward, at full noise, the damage to the bike & myself could have been considerable. Double-check the re-check :-)
 

[Mad Dog]

I have the vortex and the push-pull for the fcrs.  the vortex was a bit quick, but it was preferred over the dual cable push pull both in terms of control and the field of rotation.

Check out this list, it has all the details on the twists.  I bought the yfz vortex kit for my fcrs and it worked fine, but get an extra 2" longer cable if you end up buying a cable as well.

http://www.motionpro.com/motorcycle/articles/view/301/throttles_and_throttle_kits/

[dragonz]

Thanks for the info MD
I have a vortex, & on the FCR's it is only about 1/5 - 1/4 twist.
Pretty abrupt to be sure.
Might get a CR Comp & try that

Regards
D

[Mad Dog]

Someone had recommended the CR Pro for me, I ignored them and got the vortex.  The Comp is a very popular setup for honda atvs, should work well on the raptor as well.

[dragonz]

On further investigation I found that mine is a Turbo.
This is good, as there is a choice of 2 different twist tubes, with different rates.
Mine had the highest rate, so have ordered one of the lower rate tubes.
Slots straight into the housing, no other mucking about required

[dragonz]

ok, time to show off a little.
Take one beat up 660 raptor in need of seroius TLC.
step 1/ Rebuild Engine.
In the time honoured theory of "do it once, do it well.....
Put a new crank in, stroke it while you're at it. (needed new bearings anyway, & the stock rod is not noted for longevity.
New Piston, lets put a bigger one in, & up the compression (just because we can)
New cam to work with the bigger capacity.
HV port the head.......
FCR39's

Step 2/ Tidy up the chassis & handling
Now, looks a bit scruffy.
Paint the Head as the motor goes back together, & Paint the frame while it was all apart.
New +3+1 a-arms (already had the 450 calipers)
Already had the G-Force Axle & Hubs, & Lengthened Swingarm
New Skid Plate
New Chain-guide & Rollers

Plastics look a  bit rough.
Graphics kits on E-Bay all suck.
I'll Paint my own!

So, how do you like it?

[dragonz]

More pics of the graphics.
Didn't quite come out how I hoped, but I'm pretty happy with it.
See how good it looks after a few races & trips to the dunes............

[dragonz]

& this is how NOT to do your graphics............
But I had fun

First fully mask the plastics out
Then cut out the bits you want to paint

Then paint them

I used the PPG plastic painting system
Cleaner, Plastic Adhesion Promoter, & Plasticiser additive in both the Base Coat (colour) & the 2-pack Clear.

The Clear didn't spray that nice, probably needed more thinners.........
Too late now

[Krandall]

Looks killer, phil!!!!!!!!!!!!

[Peelz]

 

dig the color.

[Mad Dog]

I like the build, and the aesthetics are great too.

[Cammy]

Very nice! I thought the paint job turned out well!

[Bert]

   looks great

[dragonz]

Was pleased with the overall paint job.
Figure it needs a little something to lift the look slightly, same as the original '03 660LE.
Just a little silver on the "Yamaha" & 660 logos

Figure I will get some 719R logos cut for it, & some smaller "YAMAHA" logos just to finish it off.

If you try this on a bike, add almost double the thinners you normally would to the clear-coat.
Once the plasticiser is added, with normal thinning it looks right, but it doesn't "flow" as nicely on the surface.

Having trouble getting hold of the dyno guy, so about to thrash it up & down the road a little & see how I go with the overall tuning.
I got it spot on last time.
Took it to the dyno, ran it up & they said "what are you doing here?..........."
 

[HK 45 Nut]

Why put 719 on it and advertise, its fun to make people wonder what just happened.