Trail Tech FLYWHEEL KIT: KTM 6300-22 User Manual
Installation instructions, Ktm 4 stroke flywheels step 1: before you begin, Step 2: install flywheel
010-ELV-33
KTM 250-525 EXE 4STK FLYWHEELS 6300-XX
Tech Support: 360-687-4530
LIMITED WARRANTY
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.
INSTALLATION INSTRUCTIONS
KTM 4 STROKE 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.
STEP 2: INSTALL FLYWHEEL
1. 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.
2. Remove the shifter bolt and shifter.
3. Remove the (4) m6 bolts holding the side cover on.
4. Remove any zip ties securing the stator wires to give the cover some room to move to the side.
5. Remove side case and lay it next to the main case. 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!!
6. Use a 17mm 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.
7. Use flywheel puller to remove the 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.
8. Install new flywheel and torque
flywheel nut to OEM torque spec. of
44ft lbs. Do not use thread locking
compound.
9. Replace the side case. Use a
new gasket if necessary. Torque side
case bolts to 7 foot pounds. Do not
overtighten these bolts!
10. Replace the shifter. Make sure
the bolt threads in smoothly - cross
threading is easy.
You will need a KTM 4 Stroke flywheel puller for this installation.
An impact ratchet is also highly recommended.
Note: If converting an SX bike to the EXC
stator and this Trail Tech flywheel, remem-
ber to remove the two spacers that hold
the trigger sensor close to the SX flywheel.
They are not necessary with the larger
flywheel, but are not anchored in place,
so must be removed to prevent possible
engine damage.