Trail Tech 6141-29 User Manual

HONDA CRF FLYWHEELS 6140-XX, 6141-XX

Tech Support: 360-687-4530

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010-ELV-30

INSTALLATION INSTRUCTIONS

HONDA CRF FLYWHEELS

STEP 1: BEFORE YOU BEGIN

WARNING:
ALL TRAILTECH FLYWHEELS WILL CHANGE THE PERFORMANCE OF YOUR VEHICLE. It is highly recommended that you spend the time
necessary to familiarize yourself with the performance changes, and become comfortable with the way the bike produces power with the new
part.

You will need a Honda CRF flywheel puller for this installation.
An impact ratchet is also highly recommended.

STEP 2: INSTALL FLYWHEEL

1. Drain 20% of the oil from the bike first.

2. Shut the gas supply off on the bike, then lay it over on its side. A
small amount of gas will leak from the overflow tubes when the bike
is first laid down.

3. Remove shifter.

4. Remove 8 bolts holding the side cover on (no need to remove one
of the oil filter bolts).

5. Remove oil fill cap.

6. Disconnect clutch cable and lay cable out of the way.

7. Remove side case and lay it next to the main case to avoid
removing any wires. TAKE CARE - do not allow the two alignment
pins to come loose from the side case. They CAN stay in the side
case or in the main case, but you don’t want them to fall out and get
lost; or, even worse, dropped in the oil for later consumption by the
motor!!

8. Use a 17mm deep socket and impact ratchet to remove the
flywheel retaining nut. If an air ratchet is not available, hold the rear
wheel while removing the 17mm flywheel nut. Note: If a Deep socket

is not used damage to the crankshaft oiler may occur.

9. Use flywheel puller to remove the flywheel. Remember to install protective nut on to crankshaft to avoid damage to end of
flywheel. Note: there is a small hole on the shaft that allows for oil flow to the crankshaft - using the correct flywheel puller will

protect this hole.

10. Install new flywheel and torque flywheel bolt to 47 foot pounds. Do not use thread locking compound. Use the shear pin on
the crank to line up the keyway on the flywheel with the crankshaft.

11. For ease of assembly, connect clutch cable before installing bolts.

12. Replace the side case. Use a new gasket if necessary. Torque side case bolts to 7 foot pounds. Do not overtighten these
bolts! Replace the shifter. Make sure the bolt threads
in smoothly - cross threading is easy.

SIDECASE MODIFICATION:
CRF450 Flywheels: 6140-33, 6140L-33, 6140-35, 6140L-35

The heaviest CRF flywheels (33-35 oz.) require modifications
to the side case for installation. Please refer to image for
guidance.

The two solder balls should have the tops filed flat. Stop filing
if you start to see the wires in the solder. On the ‘04 CRF, the
rib is made of a softer material than it is on the ‘02/’03 models.
This drawing shows a ‘02 CRF side case modification in its
completed state.

TRAILTECH INC. WARRANTS TRAIL TECH FLYWHEEL PRODUCTS TO BE FREE FROM DEFECTS IN MATERIAL AND WORKMANSHIP UNDER NORMAL USE AND IF PROPERLY
INSTALLED FOR A PERIOD OF SIX MONTHS FROM DATE OF PURCHASE. IF FOUND TO BE DEFECTIVE AS MENTIONED ABOVE, IT WILL BE REPLACED OR REPAIRED. THIS SHALL
CONSTITUTE THE SOLE REMEDY OF THE PURCHASER AND THE SOLE LIABILITY OF TRAILTECH INC. TO THE EXTENT PERMITTED BY LAW, THE FOREGOING IS EXCLUSIVE AND

IN LIEU OF ALL OTHER WARRANTIES OR REPRESENTATIONS WHETHER EXPRESSED OR IMPLIED, INCLUDED ANY LIMITED WARRANTY OF MERCHANTABILITY OR FITNESS. IN

NO EVENT SHALL TRAILTECH INC. BE LIABLE FOR SPECIAL OR CONSEQUENTIAL DAMAGES.

LIMITED WARRANTY