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Clutch Basket (Interchangability)

Joined Feb 2002
219 Posts | 72+
Melbourne, Victoria, Australia
I have a 00 FE501-E that broken a tooth off the kick starter idler gear and it's taken out the clutch basket gear in the process. I can't seem to get a clear understanding of what is/isn't interchangeable so I'm looking for some guidance. The idler gear seems pretty simple and interchanges up to the 07 model. For the clutch basket I have a brand new old stock 03 650 basket and for all the measurements I've taken it appears to be the same but I'm not 100% confident. Any held/guidance would be appreciated.
 
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interchangeability not Interchangability (freek'n i-Pad)
 
From what i can work out;

Kick Start Idler Gear
2000 - 230 015-01
2001 - 230 015-01
2002 - 230 015-01
2003 - 230 015-01
2004 - 800.33.053.000 - Supersession from 230 015-01
2005 - 80033053000
2006 - 80033053000
2007 - 80033053000
2008 - 80033053000

Clutch Basket
2000 - 230 002-01
2001 - 230 002-01
2002 - 230 002-01 - Supersedes to H23000201
2003 - 230 147-01 - Supersedes to 800.32.000.078
2004 - 800.32.000.078
2005 - 800.32.000.078
2006 - 800.32.000.078
2007 - 800.32.000.078
2008 - 800.32.000.078

It appears that the kick start idler gear can be used from 00 all the way up to 08. The clutch basket is common from 00 to 02 models then changes at the 03 model.

QUESTION - How can i identify a Pre03 & Post03 clutch basket? Is it an obvious diference or a minor change in tolerance or material? I have a handful of clutch baskets that could all be 02's or earlier and don't have an 03 to compare against, that i know of.
 
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The transmission was modified with a different tooth profile between 2001 and 2002. The easiest way to determine how the engine was built is to look at the counter balancers' drive shaft. The early shaft has a straight surface and the later one has a diameter change between the position for the timing sprocket and the drive gear (tapered).

The following gears are not interchangeable between 2001 and 2002/2003: Counter balancer, balance drive shaft, drive gears on balancer drive shaft and crank shaft and also the outer clutch basket.

This is a direct quote from the 03 workshop manual. The difference in tooth profile may be subtle. Many have replaced their 01-02 counter balancer with the factory updated part (double row bearings), did not check the tooth profile and ordered the mid 02 and up part or just ordered the 03 part thinking it was the updated part they needed. The result was a loud gear whine. Husaberg makes a special updated double row bearing counter balancer specifically for the 01 and early 02 models. You could probably find a good used clutch basket from a 01, hopefully from a 400. The 01's had a defective torque limiter which would damage the clutch basket if a backfire occurred during starting. Mostly the 650's were affected. A warranty replacement torque limiter was given to all 01 model purchasers.
 
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Thanks Husabutt,
So am I to understand that if a mechanic had an 01 and an 03 clutch basket on the bench and mixed them up there is no way of working out which is which?
I have plenty of spares and I know there from various bergs from 01 to 04 but none are catalogued. I'm reluctant to buy more parts given that I've probably got what I need, I just don't know what is what. :eek:

Thanks, Rod
 
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Thanks Husabutt,
So am I to understand that if a mechanic had an 01 and an 03 clutch basket on the bench and mixed them up there is no way of working out which is which?

Unfortunately that does seem to be the case.
 

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