Clutch outer basket question on a 2002

When I got my 2002 FC550 it wouldn't shift into neutral with then engine running... I know, I know... it's normal, sorta!

So, I ordered new friction discs, new steels, and a new clutch hub and outer basket almost a year ago now, the old drum and basket were grooved pretty good. When I went to install these parts almost a year ago, I found that my outer basket had the brass bushing and NOT the roller bearings as I expected to find in a 2002 engine. I didn't have the roller bearings on hand, so I installed all the new parts except the outer basket (because the brass bushing is a smaller O.D. than the new basket). I rode the bike all last summer and it worked great, but still can't get neutral at a standstill.

So, I ordered up some roller bearings and today I tried to install the new outer clutch basket. It was a tight fit going in, and after it was in place it seems very tight and the engine will not rotate freely like it does with the original outer basket.

I'm a bit confused on what I am working with, and what the differences are. I know the gear pitch changed somewhere, and there were a number of incremental changes in the clutch designs from 2002 upward. But if anyone can provide some ideas on what I have and what I need to upgrade this basket that would be great!

A few facts:

- This engine has the brass bushing under the outer basket and has the circlip to hold the clutch on, not a nut.
- It does NOT have the "pin style" clutch drum.
- One of the two roller bearings, when installed onto my input shaft, ride partially on the shaft spline.
- The new outer basket that I have is supposedly part number 230-147-01

So... is it impossible to use this outer basket on my engine? I'm thinking that is the case.. (anybody need a new outer basket?).

Duane

nsman, thanks! That's pretty much the conclusion I was coming to after looking at the parts list again after I had posted.

So... I have a late-2002 outer clutch basket for sale, brand new, never used. Anybody need one? I'll post it up in the classifieds.

ElSnorro, I was thinking the same thing... maybe I should just change my crank and balancer gears, but I'm only looking for a good working clutch, it would just be easier to get the right basket. Also.. if you have an early -02 like me with the old gear pitch, and you are running the newer style basket, supposedly your needle bearings are running partially on the output shaft spline rather than a smooth surface! I would expect this to be a failure point also... but maybe not.

DuaneB