Does anyone have a problem when trying to shift from 1st gear to neutral? Two things will happen when I try this, one the shift lever feels normal and you will see the light indicator flash real quick and you'll be in second, or the shift lever will be real stiff like you are in gear and hard to pull it out. In either case sometimes you hit neutral, sometimes you don't and when you don't you may need to try it several times to get it to go to neutral.

Does the clutch need to be adjusted and how do you know when it is set right? I also tried bumping the machine forward a little in first then shift to neutral and sometimes this works and sometimes it doesn't.[img]i/expressions/face-icon-small-disgusted.gif[/img][img]i/expressions/face-icon-small-confused.gif[/img]

 

I haven't eperienced that problem at all, but I would make sure your clutch is adjusted properly. From where the lever connects (or opens from the perch) to the perch, you should have free play of 1/4-3/8". You will have to test this to make sure the clutch is fully engaged when pulling in, if not just adjust it enough that it is.

Hope to have helped.

 

How do you test for the free play? Do you start to pull the clutch in until you can feel it disengage, then this would be your free play? The locking nut at the perch has loosened due to vibration and I think the adjusting screw may have loosened also.

 

Another easy way to help find neutral is to rev the engine a little as your shifting into neutral.

 

Free play is the slack in your clutch lever before engagement. Again you want roughly 1/4-3/8 play or slack before engagement. To test, start the engine, go through warm up and in the stooped position, shift into first with the clutch pulled in. Rev the engine a bit and see if the quad sit's still or moves forward. If it moves forward, then you need to take some play or slack out of the clutch (too much play, need to tighten). You can adjust the clutch in 2 positions, one is on the right side of the cases and the second on the perch itself.

 

One thing I've noticed with the two Raptors I've worked on is you have to take a close look at the shift linkage. When my buddy adjusted his shift lever to fit his big foot with riding boot under the lever and above the nerfs, he got it up too far so the linkage was at such an angle that you could'nt shift it if you tryed. There is a happy mediam. It felt like it was internal but not. Also, we keep those linkage knuckles lubed up and it makes shiftes smoother. Might not be your problem, but it is something we check before our rides.