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Discussion Starter #1
Hey fellas, I just picked up a neglected '05 yesterday. Guy said it "needs a transmission, it's hard to start"... not real sure what the correlation is between trans gears and starting. Previous owner said it was having shifting issues... he had the crankcase swapped out with a used bottom end that has a new crank and bearings, then said it became "hard to start".

SOOOO... I bring home the raptor and the spare crankcase and get to looking this thing over. So much sh!t missing or half assed, it drives me nuts. But, I love a project and bringing something back from the dead... well, I got what I asked for.

I have started reassembling the bike at least getting it to a point where I can try to start it. First thing I noticed, the battery was toast. So I swapped my antigravity battery over from my motorcycle, motor turns over. Lots of turning over, no vroom vroom... Pull plug, wet plug, so we got fuel... no spark.

I read Morph's thread and then went through all the "doh" items... bike's in neutral, switch is "on", I have fuel pouring out of the gummed up carb drain, I pulled the rectifier plug and still no spark. I am going to test the coil, but honestly, I figured with all the other stuff the bike needs, it wouldn't hurt to replace a bunch of these parts anyway.

So currently I have ordered:

CDI (are the 30 dollar amazon ones bad?...a little late to ask I guess)
Coil
Rear master cylinder
Rear grab bar
Front fender bracket
Raptor hardware kit
Random exhaust hardware
Seat cover
New headlight bulbs (1 is out and I HAVE to have them match)

Bottom line, I am wondering if the "hard to start" was due to poor maintenance and a series of bad parts... I can only hope it's that and not crankcase internals... But I am prepared to have to split the case if need be.

Future purchases will include:

Sprockets and chain (thinking about a 12T)
Air filter (what should I run? K&N?)
Jet kit
nerf bars
graphics kit

I want to see how it performs before I do much more. Then it will be a matter of cleaner her up just to get her dirty on the trail. Sorry for the novel... figured I would give as much detail as I can in case someone sees something I may be missing.


I will try to get some pics up soon. :beer:

Travis
 

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Discussion Starter #2 (Edited)
Here are some pics from the add and from her ride home. My 5 year old daughter parked her's beside mine in the driveway... thought that was cool.
 

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Discussion Starter #3
Add a carb rebuild kit, clutch perch and a new rear brake light switch to the parts list.

I pulled the tank and petcock, cleaned those out, replaced the fuel line with some I had laying around. I am going to try to get as much done as I can while I wait for the CDI and coil.

The clutch lever has as much up down travel as it does in and out! hahaha... so it was time for a new lever/perch too.
 

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I think the CDI we purchased was from EBay, $30 and that was a couple years ago, zero issues since. That's a good list to start with, let's see how it works when you get them.

Love the pic with daughters bike.
 

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Oh ya, I gotta know, what is this "Buffalo theory" you believe in??
 

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Discussion Starter #6
A great philosopher once stated...

Well, ya see Norm, it's like this... A herd of buffalo can only move as fast as the slowest buffalo. And when the herd is hunted, it is the slowest and weakest ones at the back that are killed first. This natural selection is good for the herd as a whole, because the general speed and health of the whole group keeps improving by the regular killing of the weakest members.

In much the same way, the human brain can only operate as fast as the slowest brain cells. Excessive intake of alcohol, as we all know, kills brain cells, but naturally it attacks the slowest and weakest brain cells first. In this way, regular consumption of beer eliminates the weaker brain cells, making the brain a faster and more efficient machine.

That's why you always feel smarter after a few beers.

-Cliff Claven
 

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Pure genius, I am a believer, lol.
 

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Discussion Starter #8
So the wife and I hopped on netflix... did a fake new years countdown and got the kiddos to bed. Verizon is in a pissing match with ABC, so my wife is furious she can't see Seacrest's new years special... so off to the garage I go.

This bike keeps getting better and better. Previous owner BYPASSED the kill switch by sticking a cheap @$$ fork wire terminal in the harness side connector and electrical taping it in. So I pulled that fire hazard out of there, cleaned up the contacts on the connectors and reconnected the engine kill switch. ha. I keep finding little stupid stuff like the rubber grommets for the headlights are on the post, but not mounted to the headlight, so the headlight is just rattling around. Just laziness.

I should have a buttload of parts coming in over the next 5 days. Love some ebay, amazon and some other websites I found selling OEM parts.
 

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Discussion Starter #9
Happy New Year's guys! Be prepared for another long and frustrated post.

Cup of coffee, threw the garage doors open (it was 70 degrees here today), put an 8# pork butt on the smoker around 7am and got to work on the raptor.

Figured I would work on other stuff while I wait for the coil and CDI units to arrive. I took off the exhaust, wire wheeled it and painted it with high temp exhaust paint. I found that the spark arrestor has already been removed (get to that in a sec)

I took the cowl off and sanded it down, the previous owner "sanded" it with something like a flipping butcher's knife it looks like and then half assed spray painted it. So I sanded the deep gouges out, primer, sand, paint. Looks much better.

I also pulled the carb off... and why should I expect it to be any better than the rest of the bike!? I will say that the carb wasn't god awfully dirty, but it had some junk in it. The hilarious part was seeing the white house silicone used to seal up the boot to the cylinder. I have some plastic razor blades... I love those things! I took one of those and cleaned up the mating surfaces. I stuck my cellphone endoscope down into the jug and noticed some of the silicone fell down in there, so vacuum and then compressed air... blew the crap out. I also noticed how clean the intake and valve is! So that's promising.

I took apart the rest of the carb apart, I want to document the jetting I have currently. 25 & 145 (and get to this is a sec). I reassembled and put it back on the old girl. I also found that the vent line for the mikuni was disconnected, I chased the hose back to find it was pinch shut between the rear plastics and the frame. So I fixed that.

So in 3 days I have done some electrical work, cleaned up the exhaust, flushed out the tank, cleaned the gas cap and carb. So now I am ready for that CDI to see if I get spark!

I did notice when I was putting the forward/reverse lever back, that the heim joint was hitting a motor mount. So I wonder if this caused the "transmission" issues that the PO spoke about. I loosened the bolt, added a washer on 1 side and now it clears fine and rows through all the gears. Fingers crossed. I'd hate to do all this work just to find out I need to pull the motor.

FINALLY... I have a couple questions... Like I said, the spark arrestor is gone.

1- What is this air box mod I have heard about?
2- What filter should I go with? K&N or Uni? Which model number? And do I need an adapter?
3- What size main jet should I be looking at? I will be mostly running at sea level, but plan to go to the mountains some with it this year.

BBQ and black eyed peas was d-lish... drinking a beer and posting my updates here. Sorry for the long winded post. I like to document everything as I go along so I can refer back in case something happens. Honestly, it seems like it's just me talking to Morph. hahaha.
 

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Yep, you're talking to Morph since he's the expert on the 350. But we all read your posts looking for a way to spend your money, just keep it up. You have over 80 views.

WELCOME TO THE FORUM.
 

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Discussion Starter #11
Yep, you're talking to Morph since he's the expert on the 350. But we all read your posts looking for a way to spend your money, just keep it up. You have over 80 views.

WELCOME TO THE FORUM.
Yeah, that is one thing I have noticed...the 350 sub forum doesn't get a ton of traction compared to the 660 or 700 forums...

Also, my ego takes a bit of a hit everytime I read a 350 thread that says... "My wife's 350" or "My kid's 350" hahaha...
 

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Discussion Starter #12
Here are a couple of pics from my work yesterday.
 

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Making good progress. That was a train wreck, lol. I have attached a clicky to a thread in that sub forum that should answer your questions.

https://www.raptorforum.com/forums/73-raptor-350-discussion/27667-raptor-350-basic-mod-list.html

They are really an underrated trail machine, don't let it affect your ego, lol. I think by air box mod you are referring to no lid on it. Just adjust jets accordingly. It's a good looking color scheme, ours is just all blue. Unmodified and completely stock.
 

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Discussion Starter #14
I am not sure if I want to remove the lid 100%. I might try to figure out a way to get a high flow filter on there and see how she does.

I think between these little items and maybe a 12 tooth front sprocket, I should be okay. The trails around here aren't high speed trails, more small boulders, logs and some mud.

Where does everyone order their jets from?
 

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I have gotten from RMATV or another great site with jets and lots of info is Jets R Us. You can always leave the lid on, get those little circle attachments that fit in there, allowing more air flow. Ours is stock lid, no problems at all on the trails, we also have stock sprockets.

http://www.jetsrus.com/
 

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Discussion Starter #16
Was back in the office today after being on a 10 day vacay... tough getting back into the swing of things.

Fortunately no more crazy surprises found this afternoon! I got the header bolted back up, adjusted the clutch lever properly, oil change, robbed some hardware from the spare bottom end and did just a general nut and bolt tightening in prep for the coil and cdi coming tomorrow.

Real quick, the carb vent hose... I noticed there is a Y and a short section of tube with a 90º in it then the long section that runs to the back of the frame. The short section is a drain? So that the carb doesn't pull water in? I can't find where it would hook up otherwise.

I read through the jetting basics thread. I went on Jets R Us and ordered up some jets. Annoying to pay as much for shipping as you do a jet. But I ended up ordering a couple of different sizes for riding at different elevations and conditions.

I'm like a kid at christmas waiting for boxes to arrive. Hopefully I will have some good news tomorrow!
 

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Discussion Starter #17
Well hells bells boys... Replaced CDI... no spark, replaced coil, no spark. Im looking at the little green relay... What's that for?

I am going to take a look at the stator here in a sec.

...mildly bummed... Its turning over and I smell fuel... so I know i'm close.
 

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Discussion Starter #18
Instead, I made some progress on other things to make me feel better... I got my grab bar installed, rear brake light switch installed, new rear master cylinder installed and bled.

Now time to look at the spark issue. There is a small green relay, part number ACA12115-4, I am not sure if that is functional... I am also not sure if that would inhibit the coil getting spark. I there a way I can jump the wires to find out?

I also want to check the stator... I need to read up on how to do so. Silver lining, I have a spare coil and CDI (if that wasnt the cause). Always good to have spare parts for rides.

Any tips on what else to check or how... I'd appreciate it!
 

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Discussion Starter #20 (Edited)
Travis, I had this thread a couple years back, not sure if you came across it but perhaps something in here might help. I have ours under covers right now so I am going off memory. If I recall there was a few ways to test different items, something under the hood in front of the handlebars. Maybe skim through my thread...

https://www.raptorforum.com/forums/73-raptor-350-discussion/356193-raptor-350-dead-water.html?highlight=Dead+water
Oh yeah, I read through that thread earlier this week... Thats why I was hoping it was a CDI. Unfortunately it doesn't look like the case in my situation.

So to summarize where I'm at...

- I tried an AGM battery: No spark
- I tried my lithium ion battery: No spark
- Swapped in New CDI: No spark
- Swapped in new coil: No spark
- That damn aca12115-4 relay crapped out... neutral light won't come on unless I jump the sky blue to the white/black: Still no spark (ordered another one of those)
- Took apart the kill switch and cleaned the contacts, nothing appears to be grounding out.
- Checked the regulator with the multimeter: Checked out fine
- Checked Stator wiring: I believe I was supposed to get White/Blue to White/Green 450-550 Ohms and Red to Green 0.5 Ohms. I got Open Line on all combinations accept Red to White/Blue: 0.2 Ohms. So that leads me to think the stator crapped out. So what the hell, ordered one of those.

At this point, everything in the electrical system aside from the regulator and the starter solenoid will be new. Like I said, trying to find the positives. It will be good to have trail spares for CDI and coil.

Time for a beer... need to kill off some slow brain cells.
 
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