Raptor 660 Bottom End Tear Down: Clutch, Splitting the Case, and Transmission

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First video of the series where I go into detail about tearing down the Raptor 660 bottom end. Starting with the clutch, the primary and secondary gears, and the oil pump. Then removing the speed sensor cog, all the shifting mechanism, then splitting the case. Lastly, I remove the transmission and the countershaft.
I will have the rebuild video soon after I get the parts in for my bottom end, in the meantime as always, any questions/comments/concerns ask them below and I'll try to get back to everyone!
RAPTOR 660 SERVICE MANUAL PDF:
drive.google.com/file/d/0BxP0...
Chapters:
00:00 Intro
00:44 Clutch Cover Removal
01:30 Clutches Removal
04:12 Clutch Basket Removal
05:43 Primary and Balancer Gear Removal
07:56 Oil Pump Removal
09:06 Speed Sensor Cog Removal
09:36 Shift Shaft Removal
11:28 Shift Mechanism Removal
12:30 Spitting the Case
14:17 Transmission Removal
16:17 Balancer Removal
16:24 Outro

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15 июл 2024

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Комментарии : 72

@Phil4013 2 года назад

This video is awesome. Excellent explanation and heads up on stuff. Clear and smooth. I just tore mine down completely bare. I was digging for second but decided to restore it all together.

@emiliointili7314 3 года назад

I split the case two weeks ago, I wish have your video then haha Very nice work dude

@gallardo420s 3 года назад

Good video. You explain everything pretty dang good.

@magik7800 3 года назад

Verry good video. Verry detail kip them coming bro.

@bryantlong5535 2 года назад

Tore my 05 apart and replaced the crank And all the seals and bearings watching these videos great job thank you very much for sharing if ur ever in Michigan u should come out and ride with us, ty again

@zevolty 3 года назад

You need more recognition

@cranedaddy678 3 года назад

Excellent video.

@R1Brooklyn 6 месяцев назад

Cool video.

@codylaws9369 3 года назад

Dude you got amazing videos.

@Hunters_Mechanics 3 года назад

Thank you!

@gordonwbell 3 года назад

Great video Hunter! I think I’m going to have to tear mine apart again. 2nd gear is having trouble engaging. I can engage if I go really smooth and hold the clutch in for a half second. It will definitely not engage from a stop at all. I took a gamble last spring when I overhauled most of the engine that 2nd gear was ok.

@Hunters_Mechanics 3 года назад

Does it just resist when try to engage second or does it grind it hard when trying? My neutral gear used to grind HARD if I didn't get it just right and I still have no clue what's caused it just looking at the gears, shift drum, and forks

@sabadabigarage1595 Месяц назад

1 7/8 socket seems rather big for that nut. Shouldn’t it be 1 7/16 instead. Great video btw. Well explained

@Hunters_Mechanics Месяц назад

Definitely should be 1-7/16", I was probably well beyond tired tearing in to this years ago lol

@TeamWaxOffroad 3 года назад

So is it a similar process for other four wheelers? Awesome video man you explain things perfectly

@Hunters_Mechanics 3 года назад

Similar to manual sport ATV bottom ends, anything with an automatic or clutchless shifting will be much different

@TeamWaxOffroad 3 года назад

@@Hunters_Mechanics alrighty thanks a bunch!

@Made2Fly6400 Год назад

Love the video! What do I do if the 5th gears isn’t working?

@tjsassparilla9125 6 месяцев назад

Did you ever do a video about putting all of it back together becuse that would be awesome and I'm kinda screwed becuse when my case split it all didn't come off on 1 side as a matter of fact everything but the crank came off on the side it wasn't supposed to so all the diagrams from yamaha and all the videos I've found everything is upside down and backwards so I'm having a helluva time figuring out what's what and what goes where

@ethanmcgillicuddy425 2 года назад

Sweet video thanks for sharing. I own a 2001 660 just pulled the motor because the oil pump seized up with clutch basket pieces. Gonna be looking for an oil pump and gear,clutch basket, friction kit, and engine gaskets anyone in particular you recommend getting reasonable prices from? Single dad just looking to trail ride with my boys no high performance needed low budget Thanks so much 👌👍

@Hunters_Mechanics 2 года назад

The oil pump w/gear is only OEM as far as I know, honestly OEM clutch basket would be the cheapest and safest option to go with as the Wiseco (which I prefer) is much more expensive. All of the gaskets I buy are from Cosmetic if I can get them in their kits, if not I just use OEM. I would try rockymountainatvmc.com since I have bought from them multiple times and they have extremely competitive prices with the other sites. If they are out, the next bet is partzilla but I have had some issues with shipping times with them, hope this helps!

@wozzatez6221 Год назад

Great video mate my crank balancer seems to slightly touching my crankshaft when I fit the other side casing together will it pull the balancer over slightly away from the crankshaft in Centre between the crankshaft...

@Hunters_Mechanics Год назад

When you add the primary and secondary gears back on to time the crank and balancer, the counter balance shouldn't touch the crank

@jamesrawls4666 3 года назад

Great video, is it necessary to remove the jug to split the case.I just got a 660 and the guy had gotten it on trade and knew nothing about it. The second gear is out ( no pull, just grinding). I am fairly mechanically inclined, and am considering replacing it myself. Also I would like to know how to identify any none factory -internal Parts. Thank you

@Hunters_Mechanics 3 года назад

You will have to remove the jug since the case split is directly in the middle of the bore, it can be difficult to identify non oem parts but some have a part number, usually starting with 5LP- that will help identify Yamaha oem. I always have a rule of thumb that if its a questionable part, replace it anyways

@timrogers9440 2 года назад

I'm having troubles getting the brass pieces off the cable.

@justinbeauchamp6236 Год назад

Can you take the crank out without pulling all those gears out

@JayJay-tz3dg 5 месяцев назад

Hunter your the man! Who makes that Manuel??

@Hunters_Mechanics 5 месяцев назад

I'm not sure, I believe I got it from ModdedRaptors website ages ago

@alexanderdesiata2713 Год назад

where can I find a complete rebuild kit

@rogsands5644 10 месяцев назад

Started tearing into mine today, my crank has no up and down play, but .60mm of side to side play, your thoughts on the side to side?

@Hunters_Mechanics 10 месяцев назад

There should not be any up and down play, but side to side clearance is 0.32-0.64mm so you are within tolerance, I have the manual for it in the description if you need it!

@ktr78130 3 года назад

Do you have to tear down the motor or get it out of the chassis to change the clutch? From what I saw in your vid it seems you can do it pretty easily from the chassis

@Hunters_Mechanics 3 года назад

You can change it while it's in the chassis, that's the first thing I had to do when I got the 4 wheeler

@ktr78130 3 года назад

@@Hunters_Mechanics bro your videos good and keeps getting good!

@jonathanrossi4336 3 года назад

Did you get all your parts I all most got all mine and am about split case love to have rebuild video from ya this tear down video helped me alot Thanks

@Hunters_Mechanics 3 года назад

I have yet to order mine, been focusing on school at the moment. Only 3 weeks left then I'll be dedicating a lot of time to getting everything back together and the videos out for it

@jonathanrossi4336 3 года назад

@@Hunters_Mechanics understand that totally....good luck with finals or whatever I'll be looking forward to rebuild video hopefully have mine back together by then but good no got that coming some time if get stuck haha....not many good videos out there on that 660 engine....and this is all a first for me haha

@Hunters_Mechanics 3 года назад

@@jonathanrossi4336 I get that, sometimes I feel like I should wait till I have the entire rebuild done before uploading the teardown so I don't have people waiting on me to get time or parts in for the rebuild lol

@JOATD 2 года назад

Okay so I have a question I bought a 2003 Raptor 660 used the motor will start but it was leaking oil from the clutch cover. When I remove the cover the primary drive gear and the clutch housing gear we're missing teeth I found majority of the broken teeth at the bottom of the motor. Is there any way that broken gear teeth could have made it to other parts of the motor. If so what is the best way for me to remove

@Hunters_Mechanics 2 года назад

Yes, depending on how small the pieces are that broke off, some of it could have gotten trapped in the oil pickup or made its way to the oil hole that connects to the crankshaft. If I were you, I'd split the case and ensure you don't have any more pieces or shavings in any oil hole, oil pump, pickup, inside the bottom of the case near the transmission, or inside the oil tank

@JOATD 2 года назад

@@Hunters_Mechanics ok thank you very much

@JOATD 2 года назад

@@Hunters_Mechanicsto split the cases open I'm going to have to remove the motor?

@Hunters_Mechanics 2 года назад

@@JOATD Yes, have to disassemble the top end to split the case and has to be out of the chassis. Its all up to you whether you want to go down that route, I'm just saying that's what I'd do. I'd rather not have a small shaving ruin the entire engine down the road lol

@JOATD 2 года назад

@@Hunters_Mechanics you're right I just wanted to make sure that's what I had to do thank you so much

@willcountypowersports6338 2 года назад

I’m having a difficult time putting the shift mechanism back together any tips on how to do that or a video?

@Hunters_Mechanics 2 года назад

I have my video for the entire rebuild scheduled for Wednesday (which I do go how to put together the shift mechanism) if you can wait till then, I can tell you it's insanely frustrating to put back together lol What specifically are you having trouble with?

@willcountypowersports6338 2 года назад

@@Hunters_Mechanics well getting the plate on with the two bolts after it was installed was like impossible then my brother took it out and the spring and pin flew across the shop

@Hunters_Mechanics 2 года назад

@@willcountypowersports6338 Haha yeah, I did that while recording that section, took me a few tries to get it all in one take. If you want I can share the non-final section of that video that just has me assembling it and putting it on the engine if you want, just need your email

@ktr78130 3 года назад

There’s no gasket between the left and righ sight of the crank ??

@Hunters_Mechanics 3 года назад

You mean like the two cases? I have already had my case apart before I did the video so most of the gasket material is already off but there was a fine layer of permatex on it

@angelobrown8551 3 года назад

Can you take the left casing off without taking the clutch cover off

@Hunters_Mechanics 3 года назад

You'd have to take all of the snap rings and gears off the right side (which is under the clutch cover) to get the left case off

@tydoubleu5734 2 года назад

Quick question brother. Dose the reverse fork HAVE to come out 2 get the gears out ???

@Hunters_Mechanics 2 года назад

Are you talking about the reverse lever for the shift drum? If so, no you don't have to, you can lift it off the shift drum and take everything out without taking the lever out

@tydoubleu5734 2 года назад

@@Hunters_Mechanics Yupp exactly that part !! Thanks so much for the quick response ur awesome man!!! i have my brothers 660 cases split and the gears just came in today so im about 2 pull the transmission thanks 2 ur info Thanks again

@Brian-mc4pd 3 года назад

This is not what this video is about, but there are only a few of you doing anything with Yamaha Raptors. Do you know what the dimensions are for the main frame tubing of Raptor 660 or 700 - the outside (diameter) appears to measure 1.125 (1 1/8), but I need somebody to verify. I can not measure the thickness (gauge) of that tube. Does anybody know what the specs are on the main frame tube - both diameter and gauge? Another way to put it is if you were going to replace some part of the main frame tube, what size DOM would you get? Can be Raptor 660 or 700. Thanks

@Hunters_Mechanics 3 года назад

If you commented this past weekend I could have measured mine, I wont be back in till next weekend (not this coming), if no one commented ill try to remember and measure

@the_ltz_guymaster7912 Год назад

Anyway i can access my clutch without draining my oil

@Hunters_Mechanics Год назад

I suppose you could tilt the 4 wheeler on the left hand side so the oil will fall to that side but I've never tried it

@austinsober8761 3 года назад

Man how much would you charge to split my case and put new transmission in my 5th gear comes in and out

@Hunters_Mechanics 3 года назад

I would like to start getting into it if I wasn't in school for the summer as well, I got stuck with in-person classes and it ruined my plans to do more videos or start fixing others :/

@austinsober8761 3 года назад

I see man well gotta to make a video of how to reinstall the transmission

@Hunters_Mechanics 3 года назад

@@austinsober8761 plan on finishing the recording of it this weekend, I was just going to finish the bottom end but as of now, I am still waiting on parts for about 2 months now

@austinsober8761 3 года назад

Dang I hope it not like that when I get into it lol I wanna get in and out I just have to change my transmission you recommend me doing anything while I have it opened?

@Hunters_Mechanics 3 года назад

@@austinsober8761 id just make sure you do a thorough cleaning of all the old oil and oil passages, ive found some metal in several places it shouldn't have been in 😬 even when I took the gears off the tranny shafts, I found metal in the oil passages for it