So far they have only made 5 speed Raptor's

 

Sounds like a shift linkeage problem. Better check that carefully before you assume gears, forks, or drum is bad. Not very likely the shift fork shaft itself would bend, at least without some serious binding at the pedal.

 

Not a bad thought but I've eliminated the linkage - been using the IMS direct shifter.

 

No!! I mean the INTERNAL linkeage. The part that connects the shift shaft to the shift drum, that turns it one way or the other depending on upshift or downshift. I'm not too familiar with Raptors, but I have a LOT of experience with Motorcycle transmissions. I just checked a schematic on the web of the Rap tran. It looks almost EXACTLY like the set-up Honda used on mid 80's trx and atc 250's. I'll bet either your shift shaft broke (specifically the shift plate part), or possibly the torsion spring the goes around it. Another possibility is that the fastener that holds the detent (they call it a "segment" in the breakdown) has come loose.

 

Dzzy,

OK - I sure hope that's the problem rather than the tranny ! Sounds reasonable.

You have given me new hope !

I've already pulled the head/cly and removed the engine but havent pulled the clutch side cover off. I'm thinkin removal might not have been necessary if it's the shifter stuff.........I should have left it installed and pulled the side cover to confirm the linkage looked OK.....

We'll see tonite if I wasted a bunch of time.....and gaskets.

Eric