If the main drive bearing race looks good, rough it up some on with 600 grit wet and dry. I use an electric drill with socket adapter to spin the shaft.

If you replace the shifter seal, I'd pull the top tranny cover and move the shifter out of the way before pulling the seal.. The sucker is tiny and easy to either scratch the shaft or the seal hole when trying to dig it out..

Both the shifter shaft and inner primary seals will be brown viton.

 

I haven't checked the swingarm bushings yet but the belt and pulleys look basically new. No cracks or missing teeth. I'm going to leave the belt alone at this point I think. I think it has another 50K in it. Knock on wood...

 

I think I'll replace the friction plates in the clutch since I have it apart. Any recommendations? I was thinking the Barnett carbon fiber set from JP Cycles looks OK. Thoughts?

 

I'd use the kevlar ones.. I've had good luck with them.. The CF ones not so much tho I may have toasted them in another bike. I got 60000 out of the kevlars in a 07 flhtc with a 103, worked heads, throttle body, cam etc using the stock early spring and stock plate count kevlars. Had to go to 380 lb se spring when I built it to a 107. That worked for another 45000 but the plates were pretty much shot by then..

A good indicator that you clutch has been slipping is dark primary oil at oil change.

 

Replace the big oil seal on the transmission (item 16)
Shift shaft seal (item 29)



Look for leakage between the mainshaft and the main drive gear, if in doubt replace seal (item 14), this seal has driven people crazy trying to find a leak because they didn`t know the seal existed.

 

I decided to go with the Barnett extra plate clutch kit from J&P Cycle.

 

you won’t regret it. That set up grabs re@lly good.

 

He will regret it.. That setup grabs really good..

 

I wouldn't have paid extra for black. When I bought the kit at the dealer they gave me a choice and it seems they were about the same. It has been a couple of years.

 

Bad news all... I need advice.

I completed all the repairs with the primary. New seals throughout, new main shaft race, shifter bushings, gaskets, Barnett clutch kit, etc. Everything seemed right as rain, until today... noticed a leak again. See pics. Seems to be coming from the same location as original. All that work is out the window. I'm disappointed and disgusted. I did the absolute best work I could do because that bike is the one I'm married to. (My other one I'm just dating.) I didn't cut corners and was very methodical with each thing.

If all that stuff is new, and let's just assume for the sake of argument that I didn't mess something up, what else could be leaking?

I really don't want to pull the whole thing back apart again. I mean, I enjoy it but now I'm frustrated and just want it fixed... I need to simmer a bit and decide if I want to pull it all apart or take it to the dealer - which I haven't done with this bike in years. I try to take care of things myself and up until now, I've done a damn good job of it.

What would you guys do? It's not a money thing. I can afford it. It's more a point of pride, I guess. I'm just really bummed.