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Old 08-09-2014, 07:02 PM   #1
UT R1150R OP
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New main seal leaking after 100 miles. Save me from myself!

After a long, arduous clutch change and other scheduled maintenance, I finally got my 2004 R1150R (50,000 miles) back on the road.

I changed the transmission input and output seals, replaced the slave cylinder, lubed the input splines, installed a Siebenrock clutch and changed the main seals.

The bike ran perfectly, the clutch was solid and everything seemed great - until I pulled over to double check things. There was oil pretty much all the way around where the transmission mates with the engine. There was enough that it actually created droplets on the bottom of the engine by the time I got home. It was definitely oil and not DOT 4.

I installed both main seals following some instructions I found on here and using some tools I had at home. Sadly, I did something wrong. If the dealer had still been open, I would've ridden straight there and bit the bullet. Now that I've settled down a bit, I'm considering tearing it all apart again tomorrow and then re-installing the seals but using the BMW tool.

Can anyone here let me know how much the BMW seal installer tool costs? If anyone has one and wouldn't mind me borrowing it I'd appreciate it immensely. Beer, pizza, etc. would all be in order

Thanks for listening. This was more of a counseling session for me at this point.

I'll keep this thread updates as I go so I can help others avoid similar circumstances.

UT R1150R screwed with this post 08-09-2014 at 11:18 PM
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Old 08-09-2014, 10:53 PM   #2
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Well, 2 hours and twenty minutes after deciding to do this on my own, I've gotten my bike torn down to the main seal. I was correct - it's definitely leaking.

I guess the good news is that I'm pretty fast at taking it apart now.

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Old 08-09-2014, 11:17 PM   #3
Antti
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I did same job last winter, except I do have cable clutch.

Did you use tape on shaft when inserting the seals? If not it might be sharp edges on saft which have damaged seal. I use just some electric tape and lube it and the seal with rubber grease before assembly. Make sure that seal sets straight.
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Old 08-09-2014, 11:34 PM   #4
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I just removed the seals. The inner one was not completely seated at the bottom. I checked it several times before installing the outer seal but for some reason it was out by about 1 mm when and there was a little puddle of oil in between both seals.

To install them, I used a thin but sturdy piece of flexible plastic to protect the seals against the edges of the shaft.

I'll do some more homework tomorrow to figure out where to get the BMW tool and how much it'll cost.

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Old 08-10-2014, 01:37 AM   #5
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I believe I've found the part numbers for the seal installation tools

From largiader.com...

11 5 660 - R1100/1150 rear main seal installer (661/662)
11 5 700 - R1150/K inner rear main installer (701/702/703)

It's not yet clear to me if these are two tools or five.
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Old 08-10-2014, 01:44 AM   #6
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11 5 600 is an assembly, which is made up of 11 5 661 and 11 5 662. Price is $92.77

Haven't found 11 5 700 yet
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Old 08-10-2014, 03:28 AM   #7
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It's easy to screw up a seal install. I put in thousands in industry over my career and would machine my own install tool if needed, but generally they were not required.

How thick was the plastic you used? Too thick can stretch the seal and a sharp edge can cut it.

You must drive the seal in dead square with a properly sized tool just under the seal's OD. Use a thin a shim as possible to prevent seal stretch, cover it in grease, wrap it over the male shaft to prevent the lip from being damaged. I used a Bud beer can to cut a shim to wrap with as they are very thin. Burnish all cut edges so they are rounded with no sharpness to possibly cut the seal lip.

It's a bitch to do a job over again. The BMW tool will improve your odds of success for sure
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Old 08-10-2014, 11:10 AM   #8
UT R1150R OP
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Thanks for the input guys. I'm going to order the BMW tool (collect the whole set!) and hopefully be back on the road by next weekend.

If anyone in the SLC area is attempting a clutch job I'd be happy to help - but wait to see if I get it right the 2nd time. I also have a bunch of other BMW tools that I can bring along that will hopefully make the job easier for you.
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