2003 Yamaha Raptor 80 Restoration - Yamaha Raptor Forum
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post #1 of 7 (permalink) Old 10-09-2019, 06:23 PM Thread Starter
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2003 Yamaha Raptor 80 Restoration

Hi, All

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..
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Last edited by Venomous; 10-09-2019 at 07:24 PM.
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post #2 of 7 (permalink) Old 10-09-2019, 06:32 PM Thread Starter
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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 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...
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post #3 of 7 (permalink) Old 10-09-2019, 06:35 PM Thread Starter
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I had two other threads I had started about the tear down... They have some great info .... here are the links... One is about removing the frame bushings and the other is how to obtain the Yamaha tool for taking apart the rear end....

https://www.raptorforum.com/forums/7...nion-gear.html

https://www.raptorforum.com/forums/7...-bushings.html
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post #4 of 7 (permalink) Old 10-09-2019, 06:39 PM Thread Starter
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Ok, getting out the Spanner nuts in the rear end was a job, but the frame bushings were the worst... See the details in the links above.

Now the parts were ready for sandblasting and then to be dropped off at the Powder Coaters.

I am going with a Translucent Candy Apple Red Metallic.. First they lay down a chrome powder coating and then powder coat over that with the candy apple red.
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Last edited by Venomous; 10-11-2019 at 12:14 PM.
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post #5 of 7 (permalink) Old 10-09-2019, 06:40 PM Thread Starter
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Ok, parts are back...... These are all the parts I had done... The photo does not do the color justice. Outside in the sunlight it sparkles and looks like a candy apple.
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post #6 of 7 (permalink) Old 10-09-2019, 06:48 PM Thread Starter
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First thing to do is to put in the new Frame Bushings.. I have a 20 ton press, but it would be pretty awkward to use for the bushings.. So, I made a bushing insert tool. It is 7/16" Threaded Rod, 3 - 7/16" Nuts 4 - 7/16" Regular Washers and 4 - extra thick 7/16" Fender Washers. The thicker and stronger the washers the better. I greased up the bushings and they went in with some wrenching. The last 1/8" was tough to get in, but the tool worked...
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Last edited by Venomous; 10-09-2019 at 07:26 PM.
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post #7 of 7 (permalink) Old 10-09-2019, 06:53 PM Thread Starter
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I got the front arm installed and I think I want to buy new shocks..

Can anyone recommend some shocks they have used and like?
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