Is it the pulley seal? Did you put a new quad o-ring in when you changed the pulley???
As log as you have it apart you might as well replace the wedding band seal too, it can save you from going back in later.
John

 

No John I didn't do the quad seal but I will.
Spanners , yes unfortuneatly I am getting pretty fast at pulling it
apart,trying to picture in my pea brain mind if I have to pull the main shaft bearing race to replace quad seal and main seal. At least just last week I got the pulley tool made up.
- pull clutch assembly
- pull inner
-pull wheel axle so belt will loosen off pulley
- reassemble after replacing every seal visible
Piece of cake, man I am about fit to be tied.

 

You don't need to pull the mainshaft race....lucky you, I usually cut the ******* off with a dremel.

 

If I'm remembering correctly from doing my last tranny rebuild the quad
Seal is in the end of of the main gear (2 sets of needle bearings inside) , big oring on main gear and tapered end of spacer goes against oring and big main shaft seal in the case correct? Funny manual doesn't show Big oring.

 

Got to thinking about this, don't I need to pull the race to be able to change quad seal which I beleive is inside the main shaft gear?
I had a another brain fart, do these Ultima cases have an overflow vent by chance? When I was putting belray transmission oil in( cold) I put more than the normal 16 oz that I normally put in, it was showing just below upper scribe with dipstick on top lip ( not screwed in) , I probably put closer to 20 oz no more.i have heard of overflow in gear cases before.

 

The wedding band seal comes out with a heavy duty pick or a small flat bladed screwdriver. pull the inner race out when you take the seal out and make sure the o-ring/quad seal is in there, the inner race is clean and put back in facing the right way, Lube all the rubbing surfaces of the seals and the shafts they contact too!!!
John

 

If you just doing the main seal the race stays on, the quad seal will go over the race if you lube it but I was assuming you had done the wedding band seal.....if the leak is only out of the main seal the others might not need doing......always, always do every seal in sight when the bike is that far apart.

Don't forget gear lever seal and starter seal too. There is a new double sided starter seal available that lasts forever.

 

Plus 1 on the new starter seals, they're the nuts. I haven't heard anything bad about the Ultima cases yet.
John

 

Thanks guys for the info , I bit the bullet and ordered the race removing tool, after using it once I said I gotta get one for myself. Nice having the right tools.
I checked the dip stick and it was still just below the bottom line hot. I'm hoping its just seals that need replacing and the main shaft big bearing cast area doesnt have an issue.
I'm also bringing my old tranny case to the welder to get repaired.

 

When you put the race back on remember to leave space behind it so it can be pulled next time. I believe it's .100", but you should check your shop manual to ensure that it's the right dimension.
John