Well, it seems to have happened again - first my 01 tranny went last year and now it seems my 02 is locked-up somehow. It's stuck in reverse. Here's what happened: I was riding along and everything was great, went to shift to 2nd and it wouldnt engage. I stopped, and the shifter moved up and down a bit but wouldnt engage in to second or neutral. Out of curiosity, I put it in reverse, it engaged, and now it's stuck in reverse. No bad noises or grinding or any symptoms or warnings what so ever. I'll be pulling it apart this week.

Anybody else had this same type of failure? When my 01 failed it was a nasty loud "tranny coming apart" noise. This time it just wont shift. Very strange......

Grrrrrrrrr [img]i/expressions/face-icon-small-disgusted.gif[/img] I'm not enjoying fixing the tranny once a year.....?

 

Could be the shifthead. I had that problem when my shifthead shattered.

 

Check the reverse cable to make sure it is not hung up. Just a slight chance there. The other thing that would cause that is a shift fork.

 

I'm thinking it pretty much has to be related to a shift fork or the shift drum (after looking at the service manual). Mainly because the gears seem OK (at least reverse seems normal) and 1st was fine except for not being able to shift.

I'm real curious to see what the heck happened in there.

 

Sounds like a bent "L" shift fork (shift fork 1) which does 2nd and reverse.

The reverse cable is only a lockout, it cant engage reverse by itself

 

It would be nice if only the shift drum was damaged or out of align. Sounds like a shift fork though. What shift forks did you replace when you were in there before? My first tranny failure needed all shift forks replaced and the engine only had around 200 hrs on it. Thats not beating on the shift forks either.

 

Sounds reasonable about the shift fork - it could likely have been stuck in 2nd rather than first. How do they get bent if the gears are not messed up ? I replaced the forks with new ones when I did the 02 conversion and woulnt think there is any significant stress on them if the gears are working normally ? I'm guessing the area where the shift fork contacts the spinning gear is all galled or tore up too ??

I hope to get it torn apart this week......it's kinda hard to get motivated. Is this Raptor tranny thing hopeless ?

Thanks for the info and I'll keep ya posted.

 

You should have never had tranny trouble again IMO. I would closely inspect the shift drum while moving the shifter after taking the side cover off. This is the first I have heard of an 02 conversion having tranny trouble....keep us posted and good luck.

 

Gary,

I agree - I'm thinking maybe the shift drum or the bar that the shift forks slide on might have had undetected damage when the 01 came apart. I didnt replace those items since they "looked" OK. It lasted a year of very hard riding but maybe something wasnt perfect. I'm quite sure the gears are OK so the main failure point seems to have been fixed.

We'll see...... I just hate to have to tear it all apart AGAIN so soon.

 

is this a common prob with the raptors? what year did the have a 6 speed