I have a major problem. This is going to be long. First, let me say that I'm a competent mechanic. I have built many quads, cars, rotary engines, street bikes, etc. I have worked in the custom automotive and racing industry for 12+ years. I can turn a wrench with confidence.
Second. The toy in discussion is a 2004 Raptor. I got it at the end of Summer for a decent price, knowing it needed work and knowing we were going to tear it down and build it the way we wanted for my son to race this coming summer in a local drag series. It ran well, but not perfect. It had issues. Wrong nuts, bolts etc. Minor things. A missing clutch return spring, things like that, that just bug me. I like things done right.
What I did: I tore it down to the frame with motor in it. Mostly to replace a-arms, bushings, fix minor issues, replace clutch lever with aftermarket one, brake block off, intake, slip on exhaust, etc. I put it back together, and I cannot for the life of me get it started. I'll try to go through more thoroughly what I did. I put a Vito's jet kit in the carbs. I have gone through them several times and did the clear tube method on them. The fuel levels seems to be perfect. I put a k&n filter with holes in the lid. I did an aftermarket clutch lever, getting rid of the rear parking brake. I did many things to the frame and wiring. Mostly cleaning and refining things. When I replaced the coil with another one, simply because the original had a bad boot, and didn't seal on the plug the way I wanted it to. It did work though. I put a Leo Vince slip on exhaust on. I put everything back together, and nothing. An occassional pop out of the exhaust. I thought it was no or weak SPARK. I tested the spark by grounding the NEW spark plug, and all is well. I even disconnected the regulator to test the stator. Still no starting. I switched back to the original coil. Same. I tore apart the wiring harness from the "computer" CDI, forward to the front of the bike to check for any frayed wires. Nothing. Re-taped everything back together, nicely. I tried again. Nothing. I re-checked clear tube drains. Perfect. It seems like the motor isn't getting any fuel. I am trying to start it with no intake on it now. Just looking into the carbs. What should I be seeing. The right carb seems to seep a small amount of fuel up through the needle valve "hole" and the left, nothing. I tried spraying starter fuel through carbs.....nothing. I have turned fuel screws from 1.5 turns out all the way up to 3 turns out. No help. What am I missing? I do have a question. This bike wasn't well put together when I tore it apart. I know each intake tube, has a hose that runs to the top of each carb. There is a plastic "T" fitting between the carbs that swivels up and down. Where does that go to? I had no hose to it. Oh, I also dremeled out the intake boots to "port match" them to the head. Jetting shouldn't really matter so much to start, but as stated above. It is a Vito's jet kit with 155 and 160 mains, 25 pilots and their needles on the 3rd clip. I have the fuel screws at 1.5 turns out. I should atleast get it started with this. I do get the occassional backfire and flame out of the exhaust, but not even trying to start. I just don't seem to "feel" fuel in spark plug hole with my finger, nor is the spark plug very "wet".
I know this is alot, but I hope the more information I give, the easier it will be to diagnose. This thing ran 1 month ago when I tore it down. I did alot to it all at once, but nothing so major that it shouldn't have started right up. I have a fresh battery, with a charger on it as needed. I will gladly deposit $50into the person's paypal acount that diagnoses this problem and helps me get it running. I promise. Please feel free to call me to discuss and please ask any and all questions or suggestions. I can try anything and get back to you a.s.a.p.
Thank you,
Throttlejunkie
four zero four - 787 - three eight five seven
Second. The toy in discussion is a 2004 Raptor. I got it at the end of Summer for a decent price, knowing it needed work and knowing we were going to tear it down and build it the way we wanted for my son to race this coming summer in a local drag series. It ran well, but not perfect. It had issues. Wrong nuts, bolts etc. Minor things. A missing clutch return spring, things like that, that just bug me. I like things done right.
What I did: I tore it down to the frame with motor in it. Mostly to replace a-arms, bushings, fix minor issues, replace clutch lever with aftermarket one, brake block off, intake, slip on exhaust, etc. I put it back together, and I cannot for the life of me get it started. I'll try to go through more thoroughly what I did. I put a Vito's jet kit in the carbs. I have gone through them several times and did the clear tube method on them. The fuel levels seems to be perfect. I put a k&n filter with holes in the lid. I did an aftermarket clutch lever, getting rid of the rear parking brake. I did many things to the frame and wiring. Mostly cleaning and refining things. When I replaced the coil with another one, simply because the original had a bad boot, and didn't seal on the plug the way I wanted it to. It did work though. I put a Leo Vince slip on exhaust on. I put everything back together, and nothing. An occassional pop out of the exhaust. I thought it was no or weak SPARK. I tested the spark by grounding the NEW spark plug, and all is well. I even disconnected the regulator to test the stator. Still no starting. I switched back to the original coil. Same. I tore apart the wiring harness from the "computer" CDI, forward to the front of the bike to check for any frayed wires. Nothing. Re-taped everything back together, nicely. I tried again. Nothing. I re-checked clear tube drains. Perfect. It seems like the motor isn't getting any fuel. I am trying to start it with no intake on it now. Just looking into the carbs. What should I be seeing. The right carb seems to seep a small amount of fuel up through the needle valve "hole" and the left, nothing. I tried spraying starter fuel through carbs.....nothing. I have turned fuel screws from 1.5 turns out all the way up to 3 turns out. No help. What am I missing? I do have a question. This bike wasn't well put together when I tore it apart. I know each intake tube, has a hose that runs to the top of each carb. There is a plastic "T" fitting between the carbs that swivels up and down. Where does that go to? I had no hose to it. Oh, I also dremeled out the intake boots to "port match" them to the head. Jetting shouldn't really matter so much to start, but as stated above. It is a Vito's jet kit with 155 and 160 mains, 25 pilots and their needles on the 3rd clip. I have the fuel screws at 1.5 turns out. I should atleast get it started with this. I do get the occassional backfire and flame out of the exhaust, but not even trying to start. I just don't seem to "feel" fuel in spark plug hole with my finger, nor is the spark plug very "wet".
I know this is alot, but I hope the more information I give, the easier it will be to diagnose. This thing ran 1 month ago when I tore it down. I did alot to it all at once, but nothing so major that it shouldn't have started right up. I have a fresh battery, with a charger on it as needed. I will gladly deposit $50into the person's paypal acount that diagnoses this problem and helps me get it running. I promise. Please feel free to call me to discuss and please ask any and all questions or suggestions. I can try anything and get back to you a.s.a.p.
Thank you,
Throttlejunkie
four zero four - 787 - three eight five seven