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KGT Spline Lube

Semper_Fi

Honey Badger
The articles, posts and comments in this tech section are posted by individual members and reflect their personal thoughts and experiences with repairing, maintaining, and generally working on motorcycles. This information may require specific knowledge and skills, may or may not be correct or current to model.

The authors of information found here and the BMW MOA take no responsibility for ensuring the accuracy of any information (including procedures, techniques, parts numbers, torque values, tool usage, etc.), or further for any damage of any kind or injuries incurred or caused by anyone following the instructions or information found here.

It is the duty of the individual to either assume the liability himself for responsibly using the information found here, or to take the bike or accessory to a Dealer or other qualified professional service.


Lastly, please ensure you dispose of your used chemicals, oils and fuels in an environmentally responsible manner. Most Auto Parts stores and service stations will accept used oil and lubricants, tires and batteries, please check for your local availability.

This article, text and photos are Copyright of the individual authors and the BMW MOA, any copying or redistributing is permitted only by prior written authorization.
 
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Introduction and Structure of DIY

This pictorial is a step thru for lubricating the splines on the final drive.

With the new style KGT (MY2009) the final drive has a drain plug at the 6 o'clock position, so it is not required to drop the rear drive to drain it.

However, it is neccesary to drop the final drive to lubricate the splines - this covers it.

As many of the preparation steps and re-assembly are similar to that noted on the Rear Drive Fluid Change please refer to that post for the following information

Posts numbers 1 thru 18 are for preparation work

Post numbers 31 thru 40 for assembly work.

This procedure starts at the point of removing the rear caliper.
 
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Spline Lube Process

The overall process for lubricating the rear drive splines is as follows:

Items 1 thru 4 covered here: (Link For Preparatory Work)

1 - put bike on centerstand
2 - remove muffler
3 - remove rear wheel
4 - remove caliper

Items 5 thru 14 are discussed in this pictorial

5 - remove speed sensor
6 - remove speed sensor wire harness from rear drive and driveshaft tunnel
7 - disengage brake strut
8 - drop rear end
9 - disengage driveshaft
10 - lube spline on final drive
11 - lube shaft end of driveshaft
12 - lift rear end
13 - engage brake strut
14 - reconnect speeed sensor and wire harness

Items 15 thru 18 are covered here: Link For Reassembly

15 - complete speed sensor harness routing
16 - install caliper
17 - install rear wheel
18 - install muffler
 
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Tools and Supplies

- Flat blade screwdriver

- 16mm wrench

- T45 Torx bit

- Torque wrench

- Lubricant - Honda Moly 60 Lube (or equivalent)


NOTE - the bike should be in neutral so you can freely move the disc around.
 
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Getting the rear end ready

Picking up the procedure with the caliper removal Link For Preparatory Work

We now have to remove the entire Speed Sensor and wire harness from the rear drive and Driveshaft tube to be able to drop the drive.

This comprises 5 specific locations to address.

The first is the speed sensor itself.
 

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The second is the clip location at roughly the 7 o'clock position
 

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The third is the second clip location at the 5 o'clock position
 

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The fourth location is a screwed in cable guide. Use a T-25 torx to remove
 

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The fifth and final position from where to disengage the Speed Sensor wire harness is on the underside of the driveshaft tunnel
 

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Once the sensor harness is disengaged you can remove the speed sensor and harness assembly.

Use a flatbladed screwdriver to get behind the sensor as shown and GENTLY pry out to extract from the final drive.

NOTE - there will be some slight resistance as there is an o-ring seal

NOTE 2 - check the o-ring for cracks, cuts, wear and if noted replace it, also it is good practice to replace the o-ring if it has been inserted/extracted 3 times or more.
 

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Move the brake disc as neccesary to allow sufficient space to remove the sensor completely from the rear drive housing.
 

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Adjust the disc accordingly to carefully remove the entire sensor and harness assembly and set aside.
 

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Disengange Driveshaft Strut

Now that the speed sensor is out of the way, we can now get ready to drop the final drive.

To do this you need to disconnect the Driveshaft strut.

You will need a T45 Torx and a 16mm wrench.

NOTE 1 - once you take the bolt out of the strut the drive will drop - BE PREPARED and support the drive as you remove the bolt so you can control the drop.

NOTE 2 - Be aware that fluid WILL leak out of the drive (spped sensor hole) if you drop it and have not drained it. It's not a tremendous amount but there is spillage. BMW has a special blocking tool you insert in the speed sensor hole to avoid this (P/N 33 1 591). Please be aware of this or have the fluid drained before dropping the drive completely.

SHOP TIP - according to the service manual BMW recommends replacement of the nut once you have removed it. The BMW Part Number for the Nut is 07119902754

Shown below is the bolt head detail
 

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This is the 16mm Nut details - this is the one which needs replacement after a 1 time use.

SHOP TIP - according to the service manual BMW recommends replacement of the nut once you have removed it. The BMW Part Number for the Nut is 07119902754
 

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The removal process:

You can do it one of two ways:

1 - hold nut and loosen with torx

2 - hold with torx and loosen with wrench - whatever works
 

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With strut bolt removed - drop the final drive.


NOTE - I am supporting the final drive with my right hand.
 

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The drive is hung up....what now!!!

I have run into this issue in that when I drop the drive the driveshaft female coupler does not disengage from the male spline end of the final drive.

To address this you will need to PUSH BACK the driveshaft coupler with a screwdriver.

NOTE - Support the back end of the drive because as soon as you decouple the driveshaft the drive drops.
 

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Tada

Rear drive dropped, you can now proceed with the lubrication process.

NOTE - I already removed the rubber accordion boot.

IMPORTANT NOTE - what you are looking at is how the splines were at 1200 miles, totally dry from the factory
 

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Please be aware of large plastic washer that is located on the spline end
 

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