Last winter I sent my raptor's head and cylinder to trinity for their 686 kit. I put the top end back together and it ran great! I loved the power. After putting about 15 hours on the engine, second gear broke. I took the engine to the local shop and waited a couple months for the 2002 tranny parts to come in. Finally get it back and during the test ride it gets stuck in first gear. I took it back to the shop, they pulled the clutch side case off and a piece of the primary gear was in the shift rachet mechanism. They had to replace the clutch basket and all the gears on that side. They were nice enough to pay for it, though. I get it back again after a couple of weeks and after less than 5 hours riding it is broke again! I was coming down a hill in 5th gear and heard an awful noise and the engine started to lock up. I pulled the clutch in and coasted to a stop. The engine would turn over but made a dragging sound. I took the clutch side case off and a tooth was broken off the little gear that meshes with the primary gear. I don't think its the tranny, but I think its something major and undoubtedly expensive! I couldn't deal with it anymore. It's going to sit till this winter. I bought an '89 zilla to ride in the meantime. With only a pipe the zilla accelerates at least as fast as my 686 did. I never thought I would own a suzuki, but I really like this quad. Hopefully the raptor won't cost a fortune to fix, but it probably will!

 

UHH you don't think a 89 Zilla won't be a matinence nightmare?!?!?!

They are monsters & there are a lot of tricks to fix the strange things they do.

Oh yea it sounds like the one way starter gear. Sorry you've had such bad luck with your Rappy!

 

Nahh, they are not bad. Keep air filter clean, and gear oil changed and you will be fine.

You bought an 89' Zilla, so you dont have to worry about the head gasket. (87' had the 6 stud head) The only thing is that every Zilla will need the main bearing boss's machined and inserts pressed in. The 500 crank is to heavy for the material Suz. used for the main bearing boss's.
(aluminum?)

-Matt

 

It's definately not the one-way starter clutch. Thanks anyway.

 

I worked at a Suzuki dealership back in the days when the QuadRacers first came out.

I remember very well, all the problems that the 500 QuadRacer had, and still has. Sadly, this machine is a POS, plainly put. I hated seeing them come in to the shop. They did ok for the average rider, but those that were raced stayed in the shop more than at home with the owner.

I would take it easy on the 500 till the Raptor was fixed and then put it on the first sucker that came along.

Captain

 

I would find another mechanic for the Raptor....it sounds like the mechanic overlooked some lunched parts during round 1. My experience with the LT500 is reliability is on par with the 2001 Raptor.....take that as you will. The LT engine is a CAKE WALK to work on though.....bonus points (2-stroke)!

 

<< I would find another mechanic for the Raptor....it sounds like the mechanic overlooked some lunched parts during round 1. My experience with the LT500 is reliability is on par with the 2001 Raptor.....take that as you will. The LT engine is a CAKE WALK to work on though.....bonus points (2-stroke)! >>




I couldn't have said it any better myself!

By the way, what was the outcome on your Rap Gary?

Swy

 

Doh! I knew I was forgetting something.....posting my findings! Check this link.....Pick Here I had part # 18 backwards....effectively locking the shift drum! So after $1,400 and 2 months downtime (priceless), the Rap is back in 1 piece.....with all of the gears functioning properly + good shifting tentencies. I have a lot of riding too catch up on....starting this evening. I appreciate most of your advise (did'nt like the connecting info....I installed a 10.75 JE on the stocker..lol) and look forward too speaking with you again sometime. Later.

 

garyc660R=== 2 months downtime (priceless),

You need a back up quad. Something that doesn't break. I would suggest an older Honda TRX300 2 wheel drive. I have personally witnessed these machines do incredible and daring stunts.

That way you won't totally forget all your riding skills(priceless).

You can even fix up baskets to take your pets along for the 4 wheeling fun.

Chet

 

yup, that mechanic definitely fudged the job (twice) find another mechanic. I wouldnt be surprised if it is your tranny that locked up and chucked a piece at that primary gear.. and its not the only damage I bet.