Do you own an ATV? Join our Forum!
As a member, you can post in our forums, upload your photos and videos, use and contribute to our downloads, create your own member page, add your ATV events, and even start your own ATV club to host your own club forum and gallery. Registration is fast and you can even login with social network accounts to sync your profiles and content.
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...
I started this project a while ago.. I have decided to make one thread I can continuously update..
So , here we go. I got this Raptor 80 in really bad condition.. Rear end frozen, Engine toast, tires dry rotted, tons of rust..etc.. They admitted they beat on it very hard.
Since they do not make these with a drive shaft anymore I decided to restore it from top to bottom..
These are photos of when I got it home.
Next up, the tear down..
First, I needed to tear it down and determine if the rear end was still good... As we all know... That is where it would be cost prohibitive to restore if it is trashed..
Got it completely stripped down and I lucked out... The rear Drum brake was caked solid inside with dried mud. That was causing the rear end to lock up. Took off the rear brakes and the rear end spun perfectly smooth.
Once I got it all stripped apart I needed to take the finish off all the parts. I am going to be powder coating the frame and many parts.. Once the finish is off each part it will need to be sandblasted to white metal .. The guy I use for powder coating gives me a hefty discount if I bring the parts to him ready to go.
You could just sand blast, but that would take a long time to get the finish off. First I used Aircraft Paint Remover.. That stuff is pretty toxic Goggles and Resperator are required. That quickly gets you down to the metal... Then you can sand blast to white metal pretty quickly...
I had another thread I had started about a problem with the tear down... It has some great info .... here is the link... It is about removing the frame bushings. ....
So just as a general FYI, it might be good to check replacement parts before installing. If possible, check clearances with a micrometer before going through the trouble of assembly. I say this as I bought a new driveshaft yoke for a Kodiak because the ujoint dropped a cap and got the yoke in a bind...blowing the yoke and middle drive gear to shreds. So I replaced the middle drive gear and bought a new yoke and ujoint kit from Caltric. Caltric is usually pretty solid replacement parts. The new yoke however was a good 4mm too narrow for inside lock ujoint caps. Disappointing since it came as a kit from Caltric.
Ended up taking an angle grinder to the new yoke and thinning material off to get it to the needed 41.25mm opening size. Sucks having to disassemble everything again and start over but my fault for trusting replacement parts. Nearly 40 years of turning wrenches and I made a rookie mistake.
Similar Tagged Content
By Resurgence Small Engine Inc.
Used ATV parts available from Resurgence Small Engine Inc.
All parts have been identified by manufacturer's part number, photographed, and listed on our website.
Our used OEM parts are available for up to 60% off dealership prices. This way you can maintain your machine with well-made OEM parts at a more affordable price!
Compatibility can be confusing, but we’ve simplified it for you. Browse our current parts inventory by type, make, year, & model or search by OEM part number.
We make the logistics easy with our Free Shipping Promotion on US orders over $100!
Visit our website to view our current inventory:
Parts are located at Resurgence Small Engine Inc. in Wasilla, AK. Free local pick-up is available and our website is configured for domestic US shipping. For international orders, please contact us.
More parts & models to be listed continuously! As of August 2018, parts are available for the following ATV models:
Parts are listed for many models, currently including:
Kawasaki 2003 KFX400 Polaris 2010 Ranger 500 4x4 HO EFI Suzuki Quadrunner 250 LT4WD 250 LTF250 500 LTF500F King Quad 250 LTF4WDX 300 LTF4WDX 450 Quadmaster 500 LTA500F 4x4 Eiger 400 2x4 400 4x4 Ozark 250 LT250 Vinson 500 LTA50F Yamaha Banshee 350 Big Bear 350 Raptor 350 Warrior 350 Wolverine 350 More parts & models will be added continuously!
Resurgence Small Engine Inc.
Hello guys! New to the forum, and fairly new to ATVs. I've driven them, but never owned one. Now I do own one. Just picked it up today. It's a 1999 Yamaha Big Bear 350. It's been through some stuff. The guy I got it from told me the previous owner removed the front diff because he didn't want to replace the half shaft. So it's 2wd, even though it's supposed to be 4x4. Lovely. I can deal with that for now.
More importantly, I need to get it running. The carb needs to be rebuilt. The guy I got it from said he sprayed it all out and it still didn't work. I'm concerned he might have damaged it or not put all the parts back. I was looking at a replacement carb, and the OEM parts is $600. I'd rather not spend $600 if there are any other options. I have seen carbs on Amazon and eBay that are in the $40 - $100 range that say they fit. Anyone have experience with these? I'm going to get a rebuild kit for the current carb just to make sure that won't fix it.
Thats the first thing with it. Secondly, it was completely rewired. I need to find a original wiring diagram so I can put it back how it was, with a key and all. Currently it's wired with just a rocker switch. Any sources for a service manual that would include wiring diagrams?
Thirdly, is the Big Bear 350 a good atv? I picked it up for $700. It does start and run when you spray starting fluid into the air intake, so I am not concerned about the engine being bad. I plan to use it for the farm, running around and carrying things with it like minerals and feed and such. Not really for mudding and things like that. How good is the 99 350?
I am certain I will have more questions as I examine it more, but that's all for now. Thanks in advance for the assistance!
By Guest Fox300exchic
If we had a dollar for every time the question “Which is really faster, the 700 or the 450?” shows up in our inbox, mailbox, or voicemail, we’d be putting this magazine together from a bungalow on a barely inhabited tropical isle named Quadhama.
Recently Browsing 0 members
No registered users viewing this page.