The 2001/2002 Raptor 660R has a problem with breaking 2nd gear and you have to replace a number of gears and parts to modify the problem. I have broken 2nd gear twice now and have made a plan to correct the problem. The newer model has a 4 dog gear that is much stronger, but the mating gear is a different ratio 30 teeth where the old gear is 29 teeth. For this mod I have made a 29 tooth gear to mate with the 4 dogs of the improved Yamaha gear.
These gears are available from me for the mod. "firstname.lastname@example.org"
Now my 2nd gear is lasting as it is 66% stronger.
This is not a "scam" as you say, I have done the mod and it is the cheapest way out, only 2 gears to buy. I know the 2002 2nd gear has 4 dogs this is the one I used. It is stronger than the 3 dogs, 66% stronger "measure and calculate it before you chirp". Then I made a new matching gear with 29 teeth to fit in the 2001 box. By the way I bought my Raptor in beginning 2002 and it has this problem. Therefore it is a 2002 model built in 2001.
So it's a more complicated and likely more costly solution to a problem that had already been resolved by the manufacturer?
The 02 swap is pretty commonplace, in fact there is a site all about the transmission issues. It's called www.raptortranny.com
I am aware of this site and have done extensive research, my method you keep all the parts except for the 4 dog gear that you buy from Yamaha and I make the mating gear with 29 teeth. As simple as that and cheap.
Which 29 tooth gear? For instance on a 2003 transmission, the 21T 4th gear pinion is the gear that the 4 dogs on 2nd engage with. On the drive shaft the 2nd gear pinion must mesh with a 30 (THIRTY) tooth gear, not 29. You CAN NOT use a 2002+ 2nd pinion with a 2001 2nd gear wheel. The 4 dogs on the 2nd pinion will not engage with the 6 slots on an 01 4th pinion and the 2nd pinion of a 2002+ transmission has a different gearing ratio than the 2nd gear wheel found on the drive shaft. Using your gearing you will seize the transmission.
So as you said, "measure and calculate it before you chirp".