2001 Yamaha Raptor 660 No Spark

[Its_Chaynes]

so recently i picked up a 2001 yamaha raptor 660. it doesnt spark. i have tested the ignition coil, it checks out, the spark plug is good (tested in another bike), replaced the cdi, as well as the starter relay, now it keeps blowing the fuses on the starter relay. before we replaced the cdi unit and starter relay, the bike would have the accessories come on, such as the neutral light and tail light, and also WOULD spark when the killswitch was flipped on and off very fast. Since then, weve just blown fuses with no spark. any help would be appreciated. Thanks!

[S.O.A.N.Z]

pull your kill switch apart - might be shorting out

[Its_Chaynes]

So a quick update on this issue: (better desc. of whats happening)

 

Recently i picked up a pretty rough, raptor 660. I purchased it knowing there were electrical problems, thinking i could easily fix them. Boy was i wrong  . So i went through the routine of checking for no spark. I tested the plug by placing it in my dirtbike, had spark. Checked the coil resistance, not reading great so i ordered one of those to be safe. I also ordered a new stator as ours read dead short on some of the terminals. these two problems i know will be resolved with the new parts. The thing im most concerned about is this black wire. its a black wire coming from the CDI that looks like its running to the spark plug coil. however, this wire was cut. upon giving the starter solenoid power, all of the lights work, as well as the ignition button, but when we try to connect the black wire back together, it gets very hot, sparks, and in our first extreme test, smoked  . Any Help at all would be greatly appreciated. 

(and yes, i did try unplugging the rectifier/regulator to no avail.  )

Also forgot to mention, i have a new CDI and both yield the same result. im just mainly focused on finding out why that black wire is causing shorting somewhere.

[Its_Chaynes]

3 hours ago, S.O.A.N.Z said:

pull your kill switch apart - might be shorting out

Also did this to begin with. cleaned up the contacts and its working as intended. sorry for not mentioning this earlier

[Its_Chaynes]

Please help correct me to any wiring i may have wrong. its a 2001 raptor. the switch is a mimic for the key, and the last two pictures is the black wire im talking about. 

[S.O.A.N.Z]

did you disconnect the kill switch ?

those wires are still attached

[Its_Chaynes]

thats just to mimic the keyswitch. ours was broken so i wired up a switch in place of it. its not faulty, as it works fine. however, the black wire coming out of the CDI, i grounded it to the frame, instead of the other part of the cut black wire, and there isnt any shorting. so i know something between the cdi black wire and the other black wire its supposed to be connected to is touching a hot wire. ^^^the last picture is the picture of the wires im talking about btw. im just really at a loss as to why i cant connect them without shorting.

[Its_Chaynes]

We replaced the stator, coil, cdi, and still nothing. we stripped the wiring harness completely off, and are going to try and locate the source of the problem. we dont want to resort to buying a new wiring harness, as they are really expensive and uncommon used, especially on a 2001 660.

 

Please Help, nobody has so far

[theBIGnaud]

2 hours ago, Its_Chaynes said:

We replaced the stator, coil, cdi, and still nothing. we stripped the wiring harness completely off, and are going to try and locate the source of the problem. we dont want to resort to buying a new wiring harness, as they are really expensive and uncommon used, especially on a 2001 660.

 

Please Help, nobody has so far

Have you looked for wire harness schematics? That would give you the baseline you need. When does that black wire have power? Key on? Engine crank? Anything other than spark not working? That wire harness looks super toasted.. With all that splicing and melting, any number of shorts could be happening when its powered up. Resistance testing isn't really the BEST short finder. I would be surmised if the CDI or ECM was toast as well. You could try to find a wrecked raptor and swap it out. You will probably need ALL of the electrical from a loner bike to sub in for the current one. 

[Its_Chaynes]

15 hours ago, theBIGnaud said:

Have you looked for wire harness schematics? That would give you the baseline you need. When does that black wire have power? Key on? Engine crank? Anything other than spark not working? That wire harness looks super toasted.. With all that splicing and melting, any number of shorts could be happening when its powered up. Resistance testing isn't really the BEST short finder. I would be surmised if the CDI or ECM was toast as well. You could try to find a wrecked raptor and swap it out. You will probably need ALL of the electrical from a loner bike to sub in for the current one. 

 

I just went and picked up a new 2001 wiring harness today. (by new i mean off of a parts bike) and need some help figuring out what goes where. all of the connectors are there, but some things look like they go to ground. not 100% sure on some thimgs. any help would be appreciated. Thanks!

[theBIGnaud]

5 hours ago, Its_Chaynes said:

 

I just went and picked up a new 2001 wiring harness today. (by new i mean off of a parts bike) and need some help figuring out what goes where. all of the connectors are there, but some things look like they go to ground. not 100% sure on some thimgs. any help would be appreciated. Thanks!

here is a l ink to a supposed diagram, i hope this helps. Lay out the wire harness and id all of the terminals.. http://www.oscargp.net/2001-yamaha-raptor-660-wiring-diagram.html

[Its_Chaynes]

On 7/14/2018 at 6:48 PM, theBIGnaud said:

here is a l ink to a supposed diagram, i hope this helps. Lay out the wire harness and id all of the terminals.. http://www.oscargp.net/2001-yamaha-raptor-660-wiring-diagram.html

I know this post has been dead in the water. Just recently got back into working on my stuff. Life changes over the course of a couple years, I’ve got a 3 1/2 year old and one on the way, I got married, so much has happened! 
 

As far as the raptor goes, I still have it. Just recently got around to working on the thing again! Anyways, it ended up being the CDI. I ordered a 2001 but the one the company sent me wasn’t actually for a 01 so it shorted when I tried to use it. Swapped it eventually with a buddies 01 cdi and I was in business. 
 

Fast forward to today, I was rebuilding the carbs when I ran into an issue. One of the air fuel screw needles broke off in the carb and I can’t get it out! Any tips would be appreciated.