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Discussion Starter #1
ok i got a 2003 raptor 660 and it will not turn over the starter switch started to smoke when i pushed the start button know no spring action in the button so i thought there was an electrical short somwhere so i went and got another wire harness with new rectifier cdi and starter switch it did not smoke but freaken button has no spring to it again and it seemed to get hot now could it be the starter this is what i thought so i put some power to the starter and it turned over and fired right up so know it was getting spark for this is the first time i had heard the bike run so i know the stater, cdi, rectifer and coil all work so the onley thing i can think is the starter is bad man this got me upset iv been out there for a while trying to figure this out someone please help
 

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Master of the Electron
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Let's get our vernacular straight here - what are you calling the 'starter switch' - the momentary contact switch mounted inside the left handlebar switch cluster, whose contacts are closed when you press the start button (this is what it should be), or the starter relay (also called starter solenoid) under the seat, near the CDI? Or to phrase this differently - where (physical location) on the bike does it get hot when you try to start the engine?

I suspect your use of 'starter switch' is incorrect, making our remote troubleshooting difficult. The starter switch is up on the bars. The starter solenoid (starter relay) is under the seat.
 

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Discussion Starter #3
Ok sorry about that understandable I ment the starter switch on the handle bars it has the choke all together the first time I pushed it smoke came out of the button had no spring action to it what I mean by that is when I pushed the start button it was solid basically it burnt out the sping on the inside of it so it don't pop out now I figured there was a short in the switch got a new one changed it same thing happened so I got a hole nother harness with a new starter switch,cdi box,rectifier,coil,and the starter sylanoid one that is under the seat and wouldn't ya know it did it again so I tried tried to pop start it from the starter syliond touched the two and it started right up no choke straight bone cold I'ma be working on it I'n about two hrs I really do apretiate your help from my understanding you are the man with this raptor electric everyone says you are on this site so I give u fool respect on that and if you can't understand me I will try my best to explain better thanks
 

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Discussion Starter #4
Ok thanks to all those that answered my pms I started by checking the wires with a ohms tester started from the battery and what ya know the darn thing was reading crazy so I replaced the Old wire that goes from the starter to the starter sylanoid then I replaced the positive wire that goes from the battery and the starter sylanoid but know I got a new proble I'm try to do my research and can't find it I'll post it thanks to all
 

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So I’m having the similar issue. My starter switch is smelling burnt and goes flat like the spring is gone in the button. My batter terminal was shot and have recently bought a new battery with a tight connection. Hopefully that helps my issue. I bought a new starter switch on the way so Any input would be great
 

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Master of the Electron
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When you pressed the button was the starter cranking over as it should?
 

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Master of the Electron
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The old terminal was loose and I believe burned up the starter switch on the handle bar
That is possible if the ground to the CDI was interrupted or, perhaps, if the battery's ground cable was not making good contact at either end... good find and glad you successful in repairing it!
 
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