Plastic and Exhaust Removal

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The First step to every big job is to secure a well lit, well ventilated work area. Work on any motor should be performed indoors whenever possible. Repairing a raptor transmission may require that the motor be apart for several weeks because of backordered parts so its imperative that you have a secure location as well and a way of organizing your parts. Another good thing to do is wash the quad thoroughly to make the job alot cleaner, unfortunately it has been below freezing here for a while so pictures of my quad will show it.

Plastic Removal

1. Remove the seat, you wont need it for a while.
2. Remove the plastic over the tank using a Phillips screwdriver (1/4 turn to release the grommet)
3. Remove Front radiator cover using an allen wrench
4. Remove the headlights (2 bolts each) using 10mm socket and set aside
5. Remove the 3 10mm bolts for the front plastic (2 behind tank, 1 in front of radiator
6. Remove the Bolts for the fender support (down on the fenders - using 10mm wrench and Phillips screwdriver
7. From the front of the raptor, remove the front plastic, you will have to bend it slightly to clear the bars
8. Turn off the fuel and remove the fuel line from the gas tank
9. Loosen and remove the 3 10mm bolts securing the tank to the frame make sure to take the metal bushings from the tank rubbers or you will lose them
10. Remove the tank and set aside, be careful since the fuel petcock is mounted on the bottom not to drop the tank

Exhaust Removal

1. Loosen the exhaust clamp holding the muffler to the head pipe
2. Remove the 2 12mm bolts holding the muffler to the subframe
3. Remove the muffler
4. Remove the rear heat shield from the pipe using allen wrench
5. Loosen the clamp at the front of headpipe
6. Remove 4 10mm nuts from exhaust studs on engine head
7. Pull the header from the engine and remove
8. Replace exhaust stud nuts to prevent damage to threads on studs