Raptor 90se assembly manual
Step 1-1-2 [click here for index]

Step 1. Do not put loctite on the threads of the pinion gear that go into the bell as the manual indicates. The engine always tightens this gear so the only purpose it would serve is to make things more difficult on you if you need to remove the clutch bell. When you screw the pinion gear into the bell make sure the bottom edge of the teeth touch the top of the clutch bell.
Note: when I was threading the pinion gear on the bell it created a few strands of metal that ended up at the clutch bell bearing. Make sure you check for any strands of metal and remove them

Step 2. Install the bearing all the way down against the teeth of the pinion gear. Place blue loctite on the threads of the nut then tighten it on top of the bearing.

Step 3. Place the top bearing in one of the bearing blocks and the pinion gear/bearing in the bottom position.

EXTRA: This is an extra procedure you can do if you want. By drilling a hole through the bearing block and pinion gear this will allow for easy removal of the clutch bell. After removing the starter shaft you place a rod through the holes and this will lock the pinion gear in place allowing you to unscrew the clutch bell. The bell can become very tight sometimes. If you choose to do this use a 2mm or 1/8". Whatever size you drill it test fit it with the rod you want to use to lock this in place. One of my allen wrenches fit the hole I drilled perfectly. I started with the pinion gear installed in one of the bearing block halves. As you can see in the picture on the right I drilled near the top of the pinion gear and through the bearing block. Next I put the other half of the bearing block on and put the drill bit through the holes I already made. This aligned the drill bit so that the hole in the second half of the bearing block would be aligned with the others.

Step 4: Put the four spacers in. Install the e-clip on the start shaft. Next insert the start shaft and install the start coupler. Make sure you do not have slop in the start shaft. By this I mean if you can pull/push on the start coupler and feel it move back and forth then loosen the set screws and try again. Push up on the start shaft while pushing down on the start coupler. And make sure you align the set screws in the coupler with the flat spots on the start shaft. A good way to know you are on the flat spots is to lightly tight the set screw until you feel it touch the shaft. Then back it out a 1/4 turn and rotate the coupler back and forth. You should feel it rotate a degree or so then bump each direction. Center it up and tighten both set screws. Put blue loctite on the set screws.

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