I searched using several types of word searches but no prevail...

I have a 04 Raptor 660. While slinging some loose mud (on and off for 3-5 minutes), my bike wouldn't move but continued to run. I did notice a peculiar smell (I don't know what a burnt clutch smells like but I guessed it as that). Shut it off, let it cooled and still wouldn't move. The next day I started it up, put it into the only gears I could seem to get it to go into, 1st and reverse, and it moved forward for about 10 feet and then did the same thing.

Beleiving what I thought it to be, a fried clutch, I removed the clutch cover (using the raptortranny.com as a guide). The oil smelled terrible, enough to make you sick but I never got down to smell it when I changed it before. Inside the cover was small fragments of "I don't know", mainly on the inside cover that houses the actual clutch itself.

I took the 5 bolts off and pulled the plates out (clutch). They did not appear to be anything wrong with them (like seized together or broken) but I don't really know what to look for. The piece that the clutch sits over (cog wheel) was somewhat black like dirty. Maybe that's nothing but everyting else seemed to be cleaner looking.

I did notice the outside of the clutch housing seem to have some scarring on it, like scratches, but it didn't look like it was touching anything.

I read some posts that maybe the clutch wasn't adjusted properly at the dealer/factory.

What I am asking is,

-is it the clutch or the transmission that is bad?
-what can I do to prevent it from happening again?

Additional info: I purchased it new in '04, I change the oil in it maybe twice a year, I only ride it maybe 40 hours a year (travel far to ride so it's a deterent), I do ride it weekly in my neighborhood to keep the inside "lubed".

Any help is greatly appreciated. Ask if I left anything out...Thanks

 

Are the plates warped? (take them out and set them on a flat surface and push down see if the other end rises)
Do they have signs of thermal damage? (discoloration)
Not to bash you but did you put the right kind of oil in it?
Any chance water got in your crankcase?

There are friction plates which have little 1cmX1cm pads on them. Then there are the steel plates which are steel and have a polished look to them. Are any of the pads missing? they should be fairly thick too about the thickness of a popsicle stick.

Something else just hit me. Any chance that the main clutch nut that holds the basket on came loose?

 

What oil are you using?

Best Regards[img]i/expressions/face-icon-small-smile.gif[/img]

 

[img]i/expressions/face-icon-small-happy.gif[/img]

 

One can only guess the results to expect from half knowledge?

Best Regards[img]i/expressions/face-icon-small-smile.gif[/img]

 

Thanks for the help. I took the plates and seperated them without losing any kind of order. The plates that had actual ridges on them were quite thin. Not even close to a popsicle if that was close to what it should be, but the second plate from the bottom was completely smooth (shiney) and broken into about 8 pieces. No warping that I could tell in any of them.

So it would seem the clutch gave out, but was it due to a improper clutch setting or ridding style based upon what is listed?

I used yama lube oil in it, 20W-40.

Even if it's a dead thread thanks again.

 

8 peices u say?? that isn't good.. i'd say that is your problem right there

 

It could be any of the things you listed.

You want to make sure that when you pul the clutch all the way in it is completely disengaged. Some people subconciously dont pull the clutch all the way when they shift, which will take its toll over time. Then again you might of just had a bad clutch.

Yamalube is cool but I would switch to a better brand name, just make sure its motorcycle safe. Amsoil, Mobile 1, klotz, motul. Anything like that will work better than yamalube.

Now is a good time for a clutch upgrade.