Q414.001 2001-2005 Yamaha 660R Raptor

Stage 2

For mildly tuned machines using a modified air box, with a stock or aftermarket filter. May also be used with a good aftermarket exhaust system.

Parts List

2 Main Jet Main Jet Main Jet Main Jet Main Jet Main Jet Main Jet Main Jet Fuel Needles Slide Springs Needle Springs Adjusting Washers E-Clips DJ136 DJ138 DJ140 DJ142 DJ144 DJ146 DJ148 DJ150 DNO660 DSP026 DSP77 DW0001 DE0001

STAGE 2 INSTRUCTIONS

1. Remove the intake snorkle from the air box lid. With a sharp knife remove the two flaps shown in Fig.C. The intake snorkle should look like Fig.D after the flaps are removed. NOTE: This step must be performed in-order for the jet kit to function properly. 2. Remove the vacuum slides from the carbs. Remove the stock needles & spacers, noting the order of assembly(Fig.A). 3. Install the Dynojet needles on groove #4 from the top, using all stock spacers. Install the Dynojet slide springs (DSP026) in place of the stock slide springs. NOTE: The DSP77 springs do not have to be used, they are supplied in case the stock springs are misplaced. After installing the slides in the carbs be sure to check slide movement manually before air box installation. 4. Remove the stock main jets. Replace with the Dynojet main jets provided. If you are running the stock exhaust use the DJ142 in the left carb and the DJ144 in the right carb below 3000 feet, DJ140 in the left carb and DJ142 in the right carb from 3000 to 6000 feet and DJ138 in the left carb and DJ140 in the right carb above 6000Feet. If you are running an aftermarket slip-on exhaust with a high flow baffle, use the DJ144 in the left carb and the DJ146 in the right carb below 3000 feet, DJ142 in the left carb and DJ144 in the right carb from 3000 to 6000 feet and DJ140 in the left carb and DJ142 in the right carb above 6000 feet. If you are running a full aftermarket exhaust with a high flow baffle, use the DJ146 in the left carb and the DJ148 in the right carb below 3000 feet, DJ144 in the left carb and DJ146 in the right carb from 3000 to 6000 feet and DJ142 in the left carb and DJ144 in the right carb above 6000 feet. Be sure that the jet you are changing is the main jet. 5. Locate the fuel mixture screws (Fig. B). Carefully turn mixture screws clockwise until seated, then back out 3 turns.

Q414.001

Fig.C Remove these flaps from the snorkle. The jet kit will not work properly with these in place. Fig.D
Your snorkle should look like this after modification. Fig.B

Dynojet Parts

The cup around the main jet must be reinstalled.

Main Jet Location

Stock parts

Mixture Screw Location

DRI YAMAHA RAPTOR 660/740 NATIONAL KIT ASSEMBLY TIPS
2001-2005 Models SPECIAL NOTE: DRI does not recommend working on the engine of your Yamaha Raptor 660 without the assistance of the Genuine OEM Yamaha Service Manual.
ASSEMBLY: It is strongly recommended to follow all instructions in OEM Yamaha Service Manual, specifically for torque values and cam timing set. Also consult the DRI Tech Sheet for 4-Stroke Top End Assembly. SPECIAL NOTE: It is also advisable to read DRI TECH Sheet 4-Stroke Upgrade Components BREAK-IN: Read and follow instructions for DRI TECH Sheet 4-Stroke Engine Break In. *NOTE: Engine will run better after it has 3-5 hours on it. VALVE SETTINGS: Valves should be checked initially every 3-4 hours for first 12-hour period after initial set-up and every 20 hours after that. Consult your camshaft specification card for correct clearances. Stock clearances no longer apply after camshaft has been upgraded to a DRI camshaft. DRI CAM SETTINGS (Clearances must be set and checked with engine cold) Cam Profile Number 280 XX14 Intake.005 -.007.005 -.007 Exhaust.007 -.009.007 -.009
PISTON RINGS: Piston ring installation is a very delicate procedure and should be performed by a trained professional. All rings MUST have gap checked. *DRI recommends consulting their 4-STROKE PISTON RING ASSEMBLY TIPS install sheet before attempting to install your rings. COMPRESSION RELEASE: DRI recommend using the factory compression release system that is attached to the camshaft. Install and adjust exactly as per the instructions in the OEM Yamaha Service Manual SPARK PLUG: Use NGK IFR9H11 Gap: 039 -.043.
AIR INTAKE: DRI recommends using a Pro Flow Air Cleaner kit, with K&N Filter. For best performance it is recommended to use stock air box with lid removed. EXHAUST: For maximum performance use Fat Boy 4 Complete Stainless Exhaust System. Turndown and or spark arrester are optional FUEL: Use VP C-12 Fuel. Motor Octane 108

Current as of 7/13/2009

OIL: Maxima Premium 4 10W40 *Consult Honda OEM Service Manual for oil capacity specifications. **NOTE: The Honda TRX 450 has a unique oiling system. The motor and transmission are fed by separate oil. They must be checked and changed in separate ways. Consult manual for additional details. CARBURETION: It is recommended when installing these engine kits to upgrade the carburetion. DRI recommends an Edelbrock Carburetor Kit. (Carburetors are available from DRI in thumb or twist. Call for additional details) *Using the stock carburetor is not a recommended. TOP END SERVICE For maximum performance top end should be serviced at least every 20 hours. For standard usage top end should be serviced at least every 50 hours. A top end service includes checking, valves, valve sealing, piston clearance, cam chain and tensioner, lower rod bearing etc. Piston clearance should be kept between.0015 -.0025 not recommended to exceed.004 Ring end gap should be kept.015 -.020 not to exceed.020 Consult DRI or a qualified technician for additional assistance. CRANKSHAFT: For Standard usage stock rod should be sufficient. Under serious performance conditions an upgraded connecting rod may be required. Contact DRI for additional details. GEARING: OEM Gearing 14/38, Dune Riding 14/38, Hill Racing 13/48, MX Racing 15/38-40 IGNITION: It is recommended to use a Vortex X10 CDI unit with this engine kit CLUTCH: The clutch must be kept in excellent condition for maximum performance to be delivered. Call DR Tech department with any questions regarding clutch performance or upgrades. RADIATOR: STARTER CLUTCH: NOTES 1. Valve clearance and Deck height must be checked. Valve to Piston clearance should be minimum.040, Piston to Head clearance should be.060. 2. Must use special modified DRI steel head gasket DRI is not responsible for any engine component (gears, rod, etc.) fatigue or failure due to increased horsepower and torque.