660 transmission trouble. - Yamaha Raptor Forum
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post #1 of 26 (permalink) Old 07-08-2019, 06:04 PM Thread Starter
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660 transmission trouble.

So, this 660 is having some issue with the trans, me thinks. It'll go in 1st and it will want to move (I haven't take it out of the garage) but, I can't seem to get it into Reverse and when I put it in N I hear a loud clacking sound coming from the engine somewhere. And while that noise is happening, the countershaft sprocket kinda twitches like it wants to start turning. Is this gonna be an engine split? I've only done one engine split. I rebuilt a Honda 500 Foreman engine last year. That was kinda fun. I guess I can do this one too.
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post #2 of 26 (permalink) Old 07-09-2019, 01:07 AM
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You're going to have to take it out of the garage and try to RIDE before passing judgement.

'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
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post #3 of 26 (permalink) Old 07-09-2019, 05:14 PM Thread Starter
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I can do that. I'll take if for a little spin this evening
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post #4 of 26 (permalink) Old 07-09-2019, 07:00 PM Thread Starter
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So, I pushed it out of the garage and fired it up. It was in N. It ran for about 3 seconds, with the clacking sound, and died. Now it seems like it's stuck in gear and I can't get N or any gear. Gotta be something in the trans, huh? I had to jack it up with a floor jack and push it back into the garage. Doh!
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post #5 of 26 (permalink) Old 07-09-2019, 08:26 PM
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Ought to be able to push it by pulling on the clutch lever... no?

'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
'04 Suzuki LTZ400
'16 RZR XP4 1000 Turbo
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post #6 of 26 (permalink) Old 07-10-2019, 05:35 PM Thread Starter
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Nope.
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post #7 of 26 (permalink) Old 07-11-2019, 12:39 AM
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Well, that suggests either a seized output shaft or seized axle shaft... I'd pull the chain to determine which.
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'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
'04 Suzuki LTZ400
'16 RZR XP4 1000 Turbo
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post #8 of 26 (permalink) Old 07-14-2019, 03:46 AM
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This may sound silly but have you made sure that the Forward/Reverse lever is all the way in the forward position. On my 350 if I don't have it all the way it will make the clacking sound and not move anywhere. When I put it in Forward I have to release the clutch and let it engage before I can move the Forward/Reverse lever all the way to the Forward position. Hope this helps.
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post #9 of 26 (permalink) Old 07-15-2019, 02:07 AM
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Good call Gilly - make sure the spring is properly returning the reverse lever, left rear lower side of the case.

'01 660 Raptor, Burgard +2+1 arms, YFZ Shocks, LSR anti-vibe, CTR pipe, jetted, K&N
'01 Polaris Scrambler 400, K&N
'02 Honda 400ex, Big Gun pipe, jetted, K&N, Lonestar +2 A-arms, Lonestar anti-vibe
'04 Suzuki LTZ400
'16 RZR XP4 1000 Turbo
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post #10 of 26 (permalink) Old 10-09-2019, 07:06 PM Thread Starter
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Quote:
Originally Posted by QuadManiac View Post
Good call Gilly - make sure the spring is properly returning the reverse lever, left rear lower side of the case.
Well, I finally tackled the 660 trans problem. Definitely something inside the trans. I got the motor out an up on the bench and I'm having some real trouble getting the primary drive nut and the balance gear nuts loose. From the service manual it says to stick a pc of aluminum into the gears to hold while you loosen the nuts. From the illustration where they show the aluminum pc being put, it would mean that the nuts are L.H threads. Anyone[IMG class=inlineimg]https://www.raptorforum.com/forums/images/smilies/huh.gif[/IMG] I don't see anything in the manual to suggest that other than the illustration. Helllllllppppp. [IMG class=inlineimg]/forums/images/RaptorForum_vbtoucan/smilies/tango_face_smile_big.png[/IMG]


These pcs of metal debris came out of the R side about where the shift shaft goes in. Something is definitely broken in there!



660 transmission trouble.-20191009_161503_1570663334714.jpg

Last edited by HeWasRidinDirty; 10-09-2019 at 07:22 PM.
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