modifications described in the following text are for educational purposes only.
In no way do I recommend that you apply these modifications to your own
motorcycle. If you do choose to go ahead and modify your motorcycle based on the
information in this document you will accept all responsibility for your own
actions. The author(s) of this document, and host(s) providing it for you,
accept no responsibility whatsoever. If you are unqualified to make any of the
changes described herein but are bent on doing the modification, seek out a
knowledgeable friend or professional mechanic for assistance.
instructions for the Totally TTRs fitting kit for Acerbis 22litre Tank to a
TTR250 plastic tank Open Enduro
photos that follow include some of a metal tank OE but these apply to both metal
and plastic tank models. Where the plastic tank model differs relevant photos
have been included.
you will need to remove your seat and old fuel tank.
the 2 frame bolts that connect the engine mounts but leave the rest of the
engine mounting brackets in place as shown in this photo.
need to bend back the horn so that it is flat to the cylinder head.
The following instructions are specific to the plastic tank models.
You will need to drill a 9mm hole below the hole that is already in the frame
is lots of extra strength and gussets around this area and the hole at the
bottom will be fine.
Next you will need to use
the locking nut and washer (as supplied) and one of the old bolts from the
engine mount, as in the photo below.
drilling the hole, you will need to remove the rear shock reservoir to
gain enough room to get at the bottom of the bolt and fit the washer and locking
You will need to do the nut
and bolt up loosely for now, so you can fit the tank.
alternative fitting solution is to use an
8mm aluminium Rivnut which doesn't involve drilling through the frame. Also,
a captive nut could be welded to the frame. However, it is accepted that most
owners will not have access to a
Rivnut tool or welding equipment in which case, drilling the hole is a
perfectly acceptable solution.
will need to fit the petrol taps to the Acerbis tank.
Then fit the larger brackets to the tank making sure you use a bit of Loctite on the threads.
Then fit the brackets but just do the bolts up finger tight for now.
the self-adhesive rubber strip to the frame.
can locate the tank onto the bike.
tank is in position, fit the 2 long frame bolts with washers. These will need to
be fitted from the right-hand side.
old locking nuts from the engine mount bolts but do not
fully tighten them up at this stage.
You will then need to fit the tank and need to tighten this bracket in the
You will then be able to
tighten up all the nuts, bolts and seat allocating plate.
now tighten up all these nuts and all the other nuts and bolts
that have been fitted.
the seat. Make sure you push down on the middle of the seat as you slide it to
fit into the locating brackets on the base of the frame and the new one on the
tank. This will become apparent when fitting.
need to push the seat forward quite hard and hold it there while you get the 2
bolts fitted under the seat.
fuel lines and then you
Compiled by Steve
Attfield, Devon, UK
- all you ever wanted to know
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