HONDA CRF450X Flywheels Installation Instructions
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.
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 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 manufactureer specification. Do not use thread locking compound. Use the woodruff key 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. You will need a Honda CRF flywheel puller (TT part# 6600-P02) for this installation. An impact ratchet is also highly recommended.
Note: Trail Tech CRF450X flywheel is provided with one M6×25MM BHCS to replace the timing chain guide bolt (A), and a M6×12 BHCS to replace the guide retainer bolt (B). These bolts allow for the flange on the exterior of the flywheel to clear the fasteners. Trail Tech is not liable for any damage due to the improper installation or lack of installation of these bolts. Contact Trail Tech Tech-Support for further questions.
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