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Venom

2003 Raptor 80 shifting problem

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Hi All,
I did a total restoration on a 2003 Yamaha Raptor 80. Rebuilt the engine and tranny.. Started it up today and it runs great. Took it for a ride and the transmission worked perfectly. Adjusted the carb a little more and went for another ride. It ran awesome, pulled into the workshop shifted into neutral ( Neutral light came on) and shut off the bike. went to roll it and noticed she would not roll. Turned on the key and neutral light was on... After some troubleshooting I found that she is in first gear with the neutral light on and will not shift into neutral... It seems to up shift fine into 2nd and 3rd and then back down to 1st. I am hoping somebody can shed some light on what is happening... Thanks for any help...

80.jpg

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It honestly sounds like you have a broken spring in the transmission someplace.  Especially if the neutral light is coming on on.  I would start at the neutral safety switch and see whats going on in there and if it looks ok then unfortunately your going to have to split the transmission again.   

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Thanks for the response... I had a feeling splitting the case was going to be needed... All I had left was to put on the plastics.... I will update here with what I find..  Thanks again...

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Ok , got the motor out.. Took off the clutch cover. The shift shaft is working properly and all springs are intact and working properly. The shift cam assembly seems to only be turning between 1st and 2nd gear. No neutral or 3rd gear.  Next I will disassemble the engine and split the case.... It would have been so nice if it was a spring..... More updates coming...

IMG_20200124_102350.jpg

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God forbid it should be something simple. Looks good and clean and a clean work bench/work area, that's important.  Let us know what you find. Did you order new gaskets or were the old ones salvageable? 

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Once I split the case and was manually trying to go through the gears by hand I could feel it binding up... I took out all the transmission parts and inspected each one according to the service manual. Everything was fine and in spec. I reinstalled everything and the gears changed like butter, as they should. Something has to have caused the issue... I need to really look at everything....

IE1.jpg

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Luck was on my side....  While inspecting everything while the engine was in Neutral I grabbed the case and main axle shaft to move the engine for a better look and low and behold it was no longer in Neutral even though the transmission had not changed gears...  After gently moving all the transmission parts in every direction looking for slop I found a slight movement of the Main Axle Shaft. It was sliding about 1/8" left and right. This was enough to engage 1st gear and Neutral..  Upon further inspection I found that the plate that holds the Main Axle Bearing in place had come loose and the bearing had moved out 1/8" creating the shifting problem.  I tightened the plate back up and no more shifting problem.  The two screws that hold in the bearing plate had been torqued down according to the Service Manual. This time I added Loctite before torquing them down. Just in case this ever happens to anyone else I have added a photo showing the location of the Bearing Plate. It sits behind the clutch... That is correct... Behind the clutch... If I had initially seen that I would not have had to split the case... 🙄

BP1.png

Edited by Venom

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47 minutes ago, Frank Angerano said:

God forbid it should be something simple. Looks good and clean and a clean work bench/work area, that's important.  Let us know what you find. Did you order new gaskets or were the old ones salvageable? 

I may have been able to salvage the gaskets, but I decided to play it safe and get new ones..  I have a post on here about the complete restoration of this Raptor 80. I have been slacking on adding updates, but have all the photos and will update it soon..  https://www.quadcrazy.com/atvforum/topic/14419-2003-yamaha-raptor-80-restoration/

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