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KGT Spline Lube

The next steps are the actual application of the grease.

First clean off the area and then apply the grease

This is the grease I use, available at Honda parts stores
 

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Apply the the moly paste onto the spline.

The best way to do it is by hand.

Please note this stuff is very messy and quickly gets everywhere - best thing to do is put on gloves, appliy liberally and wipe off any excess.

NOTE: after the spline was lubed I installed the flat washer, this ensures that you get the whole spline - then just drop the washer right on top.
 

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Repeat for the driveshaft side

Clean out coupler
 

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At this point with the spline and coupler lubed you can put it back together.

1 - you need to assemble the accordion boot

2 - you locate the accordion boot onto the driveshaft tube

3 - you line up the spline to the coupler and insert the spline into the coupler

4 - connect driveshaft strut onto to rear drive housing and throw the driveshaft bolt in to support and free up your hands.

The highlighted area shows the notch feature which fits into the driveshaft tunnel receiving feature

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Shown below is the "rear" portion of the accordion boot - meaning the portion of the accordion boot that is placed on the driveshaft tunnel
 

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Matching receiving cut out for locating feature of accordion in driveshaft tube
 

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There are two internal support rings for the accordion boot.

The larger one is for the "rear" portion of the boot and it also has a location feature shown below.
 

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Insert the "rear" support ring into the accordion and matching the required alignment features

Locaton feature on the according boot highlighted below
 

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Rear retainer inserted into boot

The four plastic clips shown will locate and hold the boot onto the driveshaft tunnel
 

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Install the small "front" accordion retainer onto boot
 

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Install the completed accordion assembly onto the driveshaft tunnel.

You may need to support the coupler so you can cleanly clip the accordion onto the driveshaft tunnel.
 

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At this point we are ready to reconnect the rear drive to the driveshaft coupler.

Bring up the rear drive and try to line up the drive splines to the shaft coupler, as shown below.

Note the angle of approach.

Once there, push up

If it is not going in completely, move the disc slightly back and forth, until the alignment comes in and push up completely to mate the two parts.
 

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POP - you're in.

Throw the driveshaft strut bolt in place to free up your hands.

Clean area up of any lube, change your gloves if you wore them and let's get ready to re-assemble.
 

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Five main steps in the reassembly

1 - replace driveshaft strut nut and torque to spec

2 - reinstall the speed sensor wire harness and speed sensor

3 - install the caliper

4 - install the rear wheel

5 - install the muffler
 
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Install a new strut retaining nut onto the strut retaining bolt and torque to 42 Nm (30.97 ft/lbs)
 

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Insert the speed sensor into its hole.

Double check the o-ring for any damage

Slighly lubricate the o-ring to ease insertion

Put the speed sensor straight onto the rear housing and press evenly and smoothly and GENTLY.
 

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Tighten the bolt using a T-25 - spec is 4Nm (2.95 ft/lbs) - I do it hand tight
 

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With the speed sensor correctly located run the speed sensor wire harness onto its mounting and attach points.

With the sensor in place, the proper routing and slack will fall into place. You will be able to tell that the routing is being done correctly as you install.

Working from the speed sensor to the front of the bike, insert the speed sensor harness into the reataining clip at the 7 o'clock position.

Ensure it is fully inserted as shown before proceeding.
 

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Repeat again for the retaining clip at the 5 o'clock position
 

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