There is a comment thread below where something explained how the gear dogs for the 2001 Raptors can get sheared off and need to be replaced with a 2002-05 2nd gear pinion and a 2nd gear wheel. Any search online will have the threads where people had issues with the 2001's with their second gear and needing to replace them because of the gear dogs
I have a 660 raptor that does not go into 2nd gear but 1st and all other gears work fine. I took it apart thanks to your videos and 2nd gear seem fine nothing bent or broken any information will be greatly appreciated. Thank you
Look at the comments on this video, a guy explains what happens with the 2nd gear with the gear dogs shearing off and not engaging, seems to be very common for 2001 raptors
Just wanted to start off by giving you some props. The Raptor how to videos are awesome, very informational thank you for walking us through this rebuild journey.. I think I am having one problem for some reason my balancer and crankshaft are touching. Where the balancer is supposed to go through the crankshaft slot. It rubs it is there supposed to be a washer
@@JOATD There should not be a washer, it's a straight drop in to the roller bearing. If you need a reference, the manual PDF is in the description, on page 5-69 starts the disassembly of the crank and the balancer if you want to follow along with it
Great video! That’s very informative - but I have to ask - why didn’t you replace your second gear and 4th gear wheel as the 2001 have issues. You went that far into it, especially removing the pressed reverse gear. My second gear of my 2001 still works but I have to shift very slowly and deliberately before applying power.
I wasn't aware of that issue, the only issue I have with my transmission is that my neutral would not be fully in place 1/10 times. Sometimes when I tried to put it in neutral, it would go "clickclickclickclickclickclickclick" until I had to jam the shifter down to get it out of whatever it was in then redo it
@@Hunters_Mechanics I would seriously consider replacing the second gear and 4th gear wheel as a set before putting your cases back together. Even for future resale value - telling people that 2nd gear issue is fixed will allow you to ask for more. Google Yamaha Raptor 660 2nd gear issue and fix. You can buy used transmissions from later models or just replace those specific gears.
@@gordonwbell Ill look into it, thanks for bringing it to my attention! Eventually, I will be replacing the crank when I get out of college and I most likely replace those two then for reliability purposes
Hunter Brother !!! I gots a good question!! When you pulled the 2nd gear wheel off the drive axle the flat side was facing down , But when you reassembled the 2nd gear wheel the flat side was facing up ,,,,???? Which is it ?? Im confused lol
I just realized that when reassembling the drive axle I called the 4th wheel gear as the "2nd wheel gear" and I said it twice 🙃 the 4th wheel gear is the double sided gear with gear dogs on both sides and the smaller dogs face towards you when assembling, then the 2nd wheel gear follows with the holes facing towards the small gear dogs, sorry for that confusion! 😅
Have you split the case to look at the transmission gears? You may be missing some gear dogs off the gear itself, shift fork is worn out completely, or something broke with the shift drum. If the rest of the gears work, then the clutch and clutch basket wouldn't be the issue, it would be the gear and related hardware itself
Got cases split, only thing I noticed is the collar was not inside spring on shift shaft and the main axle bearing in case is crunchy? Forks looked good and moved freely, and 5th gear looked good?
Great Job, Hunter! One question, plz: do you know what are the references of yours tools that u used for unmont the transmission? They did the job easier.
The tool set that I used to press off the reverse gear is the Harbor Freight Bearing Puller set: www.harborfreight.com/bearing-separator-and-puller-set-62593.html The snap ring pliers I think I got at Autozone years ago, similar part: www.autozone.com/test-scan-and-specialty-tools/snap-ring-pliers/p/oemtools-snap-ring-pliers-set-4-piece/532465_0_0 The press I have in the shop to press the reverse gear back on is this hydraulic press although one this big is not needed for this job: www.harborfreight.com/20-ton-shop-press-32879.html The other set of snap ring pliers I have no idea what brand there are or where they were bought from. They are my grandpas from years and years ago lol hope this helps!
@@Hunters_Mechanics you have helped me a lot, but I will use your knowledge again if you permit. Still with Raptor 660r (2007, but in Brazil). I have a engine, but I am not sure if it is 2001 or 2002+ (US). I must buy a wrist kit (wrist, bearing and pin) They are very similar, but not equal. Wrist and bearing are compatible with all years, but pin isnt. There are specific codes. 2001 (3YF-11681-00-00) Weight 1.1875 lb = 538g 2002+ (5KM-11681-00-00) Weight 1.125 lb = 510g The only difference that I have noticed is the Weight, but this is not a good parameter. Do you know how can I be sure if the pin is a 2001 or 2002+? Why they are not compatible one another? Thanks!!!
@@heltongoncalves5996 I can't say I've noticed there was a difference in the pin for the 2001 compared to the 2002+, when I bought my kit, It came with a new piston with a wrist pin that fit. What I've found online is that 3YF-11633-00-00 has been superseded by the newer wrist pin with the number 3YF-11633-01-00. I don't know where your second part number came from but here's the website I use to buy my oem parts and it'll show what vehicles fit that same wrist pin: www.motosport.com/oem-parts/part-number/3YF-11633-01-00?mmy=yamaha%3Braptor%20660%3B2001
@@Hunters_Mechanics I think I should have written **Crank Pin, not only Pin. Sorry. In fact, the Pin is the same for all years, but we have a difference in Crank Pin for 2001, that I still havent found. Do you know where can I see the parts dimensions? There is a little difference in Crank Pin for year 2001, ans I must discovery what is the year from the Crank Pin that I have in my table. Thank u again!
@@heltongoncalves5996 ahh yes I do see where there is a different part number for it. All I've found is this: www.partzilla.com/product/yamaha/5KM-11681-00-00 , it shows the length of the pin but for the 2001 part number it doesn't. I don't know if there is a length difference or any visual difference from yours but its worth a look at. If I had my case apart I'd measure it for you 😂
Nothing was wrong with it, just had the engine torn down and thought I'd go ahead and clean the shafts and the gears and make a video while I'm there to inform others how to do it!
Hey a I rebuild mine I replaced 2nd gear is a 2001 all gears shift fine but It just won’t go into reverse at all is ther something I missed when I reinstalled the reverse lever any suggestions thanks
Is your reverse lever pulled far enough through the case that you can put the snap ring on it? That's something I realized I forgot on mine was to pull it far enough through, there's a groove on the reverse lever for that snap ring to ensure its lined up for the shift drum. I had to use a longer bolt that fit the thread of the reverse lever and a socket over top of the lever to pull it through all the way then install the snap ring, worked after that
Yes the washer and snap ring are where they shut be. I removed the cable and I try to move the lever whit my hand but it just feels like it hits in something but never shifts in to reverse
No it just hits in something and it doesent move much. I saw in your video you shift drom the metal tip on top was towards the transmission gears and when I did mine it was faicing towards the bottom of the case maybe that’s why my reverse lever is not on the right grove
@@JoseRamos-yv2xg Or its a chance that its not in a grove at all. I honestly don't know what else it could be but Id try to put it in neutral, then ensure that its pulled all the way through. I wish I was at the garage so I could show you how far it needs to move
i got 1 more question 😂 is the Main Axle specs u showed for you're year only? Im working on a 04 660cc and the Main Axle is at 114.71mm . thats awhole mm off 🧐 srry but i dont have a manual 4 reference
@@tydoubleu5734 are you talking about the measurement from gear to gear? If so if yours is off, that just means that the reverse gear is either pressed too far on or too far off
You can get them from sellers like www.rockymountainatvmc.com www.motosport.com/ or www.partzilla.com/ , or last resort, pay the premium price from a Yamaha dealer
Great job brother. This is the best RUclips video I n raptor by far.
I got a 2006 grizzly 660 I watched your video on the timing everything kind of similar in the raptor
Great job at explaining everything bro I enjoyed watching this!
I have 2001 raptor 660 the 2nd gear doesn’t engaged can you give some tips how can I fix it
There is a comment thread below where something explained how the gear dogs for the 2001 Raptors can get sheared off and need to be replaced with a 2002-05 2nd gear pinion and a 2nd gear wheel. Any search online will have the threads where people had issues with the 2001's with their second gear and needing to replace them because of the gear dogs
I have a 660 raptor that does not go into 2nd gear but 1st and all other gears work fine. I took it apart thanks to your videos and 2nd gear seem fine nothing bent or broken any information will be greatly appreciated. Thank you
Look at the comments on this video, a guy explains what happens with the 2nd gear with the gear dogs shearing off and not engaging, seems to be very common for 2001 raptors
Just wanted to start off by giving you some props. The Raptor how to videos are awesome, very informational thank you for walking us through this rebuild journey.. I think I am having one problem for some reason my balancer and crankshaft are touching. Where the balancer is supposed to go through the crankshaft slot. It rubs it is there supposed to be a washer
Before the balancer goes in the case is there supposed to be a washer that lifts it up just a little
@@JOATD There should not be a washer, it's a straight drop in to the roller bearing. If you need a reference, the manual PDF is in the description, on page 5-69 starts the disassembly of the crank and the balancer if you want to follow along with it
@@Hunters_Mechanics yeah I pulled up the diagram and I see that there is no washer is it a reason that they're touching
@@Hunters_Mechanics do you have an email where I can show you a picture
@@JOATD bacon626262@gmail.com
End also the L shif fork is little wear out has some marks
Great video! That’s very informative - but I have to ask - why didn’t you replace your second gear and 4th gear wheel as the 2001 have issues. You went that far into it, especially removing the pressed reverse gear. My second gear of my 2001 still works but I have to shift very slowly and deliberately before applying power.
I wasn't aware of that issue, the only issue I have with my transmission is that my neutral would not be fully in place 1/10 times. Sometimes when I tried to put it in neutral, it would go "clickclickclickclickclickclickclick" until I had to jam the shifter down to get it out of whatever it was in then redo it
@@Hunters_Mechanics I would seriously consider replacing the second gear and 4th gear wheel as a set before putting your cases back together. Even for future resale value - telling people that 2nd gear issue is fixed will allow you to ask for more. Google Yamaha Raptor 660 2nd gear issue and fix. You can buy used transmissions from later models or just replace those specific gears.
@@gordonwbell Ill look into it, thanks for bringing it to my attention! Eventually, I will be replacing the crank when I get out of college and I most likely replace those two then for reliability purposes
@@Hunters_Mechanics you’re welcome! Keep up the good work. I always enjoy your content.
@@gordonwbell second gear fix is the same reason i had to tear mine appart i used 03 transmission gears as replacement
Hunter Brother !!! I gots a good question!!
When you pulled the 2nd gear wheel off the drive axle the flat side was facing down , But when you reassembled the 2nd gear wheel the flat side was facing up ,,,,???? Which is it ?? Im confused lol
I just realized that when reassembling the drive axle I called the 4th wheel gear as the "2nd wheel gear" and I said it twice 🙃 the 4th wheel gear is the double sided gear with gear dogs on both sides and the smaller dogs face towards you when assembling, then the 2nd wheel gear follows with the holes facing towards the small gear dogs, sorry for that confusion! 😅
Haha engine go brrrrrrrrrr
Got a 02 660 raptor, no 5th gear, like going into neutral, all other gears work fine? New clutches and clutch basket but still no 5th? Thanks
Have you split the case to look at the transmission gears? You may be missing some gear dogs off the gear itself, shift fork is worn out completely, or something broke with the shift drum. If the rest of the gears work, then the clutch and clutch basket wouldn't be the issue, it would be the gear and related hardware itself
I have not split case yet, got to get started soon. Thanks @@Hunters_Mechanics
Got cases split, only thing I noticed is the collar was not inside spring on shift shaft and the main axle bearing in case is crunchy? Forks looked good and moved freely, and 5th gear looked good?
Great Job, Hunter! One question, plz: do you know what are the references of yours tools that u used for unmont the transmission? They did the job easier.
The tool set that I used to press off the reverse gear is the Harbor Freight Bearing Puller set: www.harborfreight.com/bearing-separator-and-puller-set-62593.html
The snap ring pliers I think I got at Autozone years ago, similar part: www.autozone.com/test-scan-and-specialty-tools/snap-ring-pliers/p/oemtools-snap-ring-pliers-set-4-piece/532465_0_0
The press I have in the shop to press the reverse gear back on is this hydraulic press although one this big is not needed for this job: www.harborfreight.com/20-ton-shop-press-32879.html
The other set of snap ring pliers I have no idea what brand there are or where they were bought from. They are my grandpas from years and years ago lol hope this helps!
@@Hunters_Mechanics you have helped me a lot, but I will use your knowledge again if you permit. Still with Raptor 660r (2007, but in Brazil).
I have a engine, but I am not sure if it is 2001 or 2002+ (US). I must buy a wrist kit (wrist, bearing and pin)
They are very similar, but not equal. Wrist and bearing are compatible with all years, but pin isnt. There are specific codes.
2001 (3YF-11681-00-00)
Weight 1.1875 lb = 538g
2002+ (5KM-11681-00-00)
Weight 1.125 lb = 510g
The only difference that I have noticed is the Weight, but this is not a good parameter. Do you know how can I be sure if the pin is a 2001 or 2002+? Why they are not compatible one another? Thanks!!!
@@heltongoncalves5996 I can't say I've noticed there was a difference in the pin for the 2001 compared to the 2002+, when I bought my kit, It came with a new piston with a wrist pin that fit. What I've found online is that 3YF-11633-00-00 has been superseded by the newer wrist pin with the number 3YF-11633-01-00. I don't know where your second part number came from but here's the website I use to buy my oem parts and it'll show what vehicles fit that same wrist pin: www.motosport.com/oem-parts/part-number/3YF-11633-01-00?mmy=yamaha%3Braptor%20660%3B2001
@@Hunters_Mechanics I think I should have written **Crank Pin, not only Pin. Sorry. In fact, the Pin is the same for all years, but we have a difference in Crank Pin for 2001, that I still havent found.
Do you know where can I see the parts dimensions? There is a little difference in Crank Pin for year 2001, ans I must discovery what is the year from the Crank Pin that I have in my table. Thank u again!
@@heltongoncalves5996 ahh yes I do see where there is a different part number for it. All I've found is this: www.partzilla.com/product/yamaha/5KM-11681-00-00 , it shows the length of the pin but for the 2001 part number it doesn't. I don't know if there is a length difference or any visual difference from yours but its worth a look at. If I had my case apart I'd measure it for you 😂
Hunter mechanic I have cuestión what was the problem in this transmission
Nothing was wrong with it, just had the engine torn down and thought I'd go ahead and clean the shafts and the gears and make a video while I'm there to inform others how to do it!
Hey a I rebuild mine I replaced 2nd gear is a 2001 all gears shift fine but It just won’t go into reverse at all is ther something I missed when I reinstalled the reverse lever any suggestions thanks
Is your reverse lever pulled far enough through the case that you can put the snap ring on it? That's something I realized I forgot on mine was to pull it far enough through, there's a groove on the reverse lever for that snap ring to ensure its lined up for the shift drum. I had to use a longer bolt that fit the thread of the reverse lever and a socket over top of the lever to pull it through all the way then install the snap ring, worked after that
Yes the washer and snap ring are where they shut be. I removed the cable and I try to move the lever whit my hand but it just feels like it hits in something but never shifts in to reverse
@@JoseRamos-yv2xg it should only move like 30 degrees, its a pretty small movement, are you sure the reverse lever is pulling it all the way?
No it just hits in something and it doesent move much. I saw in your video you shift drom the metal tip on top was towards the transmission gears and when I did mine it was faicing towards the bottom of the case maybe that’s why my reverse lever is not on the right grove
@@JoseRamos-yv2xg Or its a chance that its not in a grove at all. I honestly don't know what else it could be but Id try to put it in neutral, then ensure that its pulled all the way through. I wish I was at the garage so I could show you how far it needs to move
i got 1 more question 😂 is the Main Axle specs u showed for you're year only? Im working on a 04 660cc and the Main Axle is at 114.71mm . thats awhole mm off 🧐 srry but i dont have a manual 4 reference
Oh and this is b4 disassembly of the Main Axle
@@tydoubleu5734 are you talking about the measurement from gear to gear? If so if yours is off, that just means that the reverse gear is either pressed too far on or too far off
@@tydoubleu5734 also the pdf of the entire manual is in the description for your convenience 😉
@@Hunters_Mechanics awesome perfect thanks brother !!! PDF 👌
Where can you get the gears for the transmission?
You can get them from sellers like www.rockymountainatvmc.com www.motosport.com/ or www.partzilla.com/ , or last resort, pay the premium price from a Yamaha dealer