2001-2005 Yamaha Raptor 660R

Exhaust Installation

q       Remove the stock exhaust system

q       Install the Sparks head pipe.

q       The head pipe should be centered between the engine cases and frame.

q       Tighten the exhaust stud nuts up to 11 ft/lbs

q       Slide the rear section onto the head pipe

q       Replace the stock bolts into the rear section and tighten

q       If there are any clearance issues, simply loosen the exhaust stud nuts slightly and rotate the head pipe until everything clears properly.

Jetting recommendations

q       We recommend the use of the Dynojet jet kit.

q       They include thorough instructions with their kits.

q       We do recommend the addition of 27.5 Mikuni pilots in both carburetors.

Air filter installation & maintenance

q       Remove all of the stock air filter and its components.

q       Thoroughly clean the air box and air boot. Dirt is your motors number 1 enemy.

q       Follow the installation instructions from Pro Design.

q       Oil your clean air filter with a good pour on type oil, we recommend DT-1, Moose or UNI air filter oil.

q       Pour a liberal amount of oil all over foam and massage the oil into filter and squeeze out any extra oil.

q       Install the filter tighten the clamp and you are ready to go.

q       It is important to clean and oil the filter whenever it gets dirty.

q       To clean it, we recommend using filter cleaner like Moose. Other options would be kerosene or mineral spirits and then a good degreaser like Simple Green, 409, even a good dishwashing soap.

q       The goal is to get all of the old oil and dirt out of the filter. Rinse well and dry before re-applying the oil.

q       DO NOT use gasoline to clean your filter. It can significantly shorten the life of the foam and loosen the glue.