Lord have mercy. Help if you can. our 2005 raptor 50 decided it won't start anymore. We have only had it for 2 days, you can imagine the boys disappointment. I changed out the spark plug, still not starting. It turns over, has gas in it. After that, I am completely ignorant. Ya'll being the wise people, and the shop not being open, I hope you can offer some suggestions. The more technical, the more I become confused. I will accept any help. Thank you.

 

hey hey slow down with the taking any more of that rig apart . its real simple 1 make sure you are in N and not D. 2 make sure the hand brake on the left side with the locker is in and locked little metal tab pushed down ok . last but not least make sure the tether clip is in postion if all eles fails make sure the wires to the tether are secure . that should do it if all yu are getting is turning over with no starting i went throuigh the tether thing once pretty funny in the end took two minutes then my kid pointed it out to me good luck

 

CJ5350

If your really interested in changing the 50cc to a 3-speed there is a tranny for sale on ebay. it however is going to be alot of work you may not want to do since you now have an 80cc.

I purchased an early 90's 80cc for my sons raptor 50, that we are now doing some work on before we replace the 50cc. instead of messing with the wiring harness on the frame, an since I had the crankcase covers off anyway, I chose replace the generator assembly on the 80cc with the raptor 50/80 one. this allows the engine to connect directly to the present wiring harness. You can remove the one from your 50cc or purchase one for about $100.

you can also look online for a company called sumitomo which happens to make the connectors and wiring harness for yamaha. you may be able to purchase a couple of the generator connectors from them and change out the ones on the 80cc. however I don't know what the time, cost or special tools needs would be to do this.

 

atvingnc, thanks for the info...So the 50 Generator should fit straight in my 80 case???

 

CJ5350

if you get onto one of these sites

http://www.rivamotorsports.com/
http://www.yamahasportsplaza.com/
http://www.worldofcycles.com/

you can get a list of all the parts, part numbers and prices. you will see that the crankcase for say
a '94 badger (motor I have) is identical to the Raptor 50 or 80. This means that the generator assembly from these years will all fit one another. You will also see that the pulsar coil and generator coils are the same for these years but the generator assembly number is different. The number of wires and their functions are the same in each model but the connectors between the motor and frame wiring harness are different ,so the part number has to change to keep track of this. bottom line is that the 50cc generator assembly should fit nicely into the 80cc case. this will keep you from having to alter anything on the frame. In the next couple of weeks I will be doing this myself, so if you attempt it before that let me know how it goes. If you plan on doing it you will need to get some type of tool to hold the flywheel (I had a buddy make me a homemade tool that fits into the two holes on the flywheel) and a flywheel puller for $10-$15 dollars. also I usually pick up any gaskets for any covers or surfaces that I will be removing or seperating since I have found that the gaskets normally don't survive the procedures very well.

 

Putter700, any idea where I can a wiring diagram....saw a picture of the cdi that should be on the engine I'm getting and it's completly different from the little 50 one....is it just the connector that are different???

CJ5350

sorry, been busy, last week of kids in school annd one promoting from 6th grade!
took the week off to do all the events.

i have not run across a wiring diagram for them yet, how did the carb work and throttle go?

you said you got an 80cc and box, did you get the 80 cdi??

 

Thanks again guys, The engine is still sitting on Ohio...I'm waiting for a mate to bring it out to Sydney Australia in the next two weeks... Just trying to get as much info before he leaves as second hand parts are very far and few apart out here...but I will take pictures as I go and will post the results..

 

OK...engine is just about to hit our shores....so fingers crossed It will be going in in the next two weeks...if there is any interest I'll post photos of the swap

 

keep us posted on your progress

still havent decited which to do. sell the 50 and get an 80 or do what you are doing. its going to be one or the other. riding season is comming on fast.

 

Putter700R, CJ5350,

I am presently in the middle of reassembling a '94 badger 80 replacement engine I bought for our Raptor 50. It came w/o the flywheel and generator and a banged up shift shaft. I decided to put some time into it and replace some parts and at the same time give my 7 yr old a chance to
see what is going on in the motor that he will be running the hell out of. I am learning that doing this is not exactly cheap (especially if
you don't have some of the tools needed) but we are having a good time at it (more me than him I'm sure). We will be replacing the shift shaft, clutch springs, clutch plates, various oil seals, new generator with connectors for raptor 50 wiring, 0.5 mm over bore on cylinder, new rings, and new piston (we'll probably do something on the valves also since we'll have the head off).

CJ5350
if you can post some pictures on how you make the cut-out for the plastic to get the shifter to be accessable i'd appreciate it. I have been considering removing the full footrests and putting in foot pedals like the 80, but my son is not very receptive to this.