TTR250 bottom end engine strip and rebuild

DISCLAIMER: The 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.

 

Fitting instructions for the Totally TTRs fitting kit for Acerbis 22litre Tank to a TTR250 plastic tank Open Enduro

NB The 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.

Firstly you will need to remove your seat and old fuel tank.

Remove 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.

 

You will 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 here

There 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.

After 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 nut.

You will need to do the nut and bolt up loosely for now, so you can fit the tank.

An 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.

Next you 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.

Now fit the self-adhesive rubber strip to the frame.

Then you can locate the tank onto the bike.

Once the tank is in position, fit the 2 long frame bolts with washers. These will need to be fitted from the right-hand side.

Use the 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 correct position.

You will then be able to tighten up all the nuts, bolts and seat allocating plate. 

 

You can now tighten up all these nuts and all the other nuts and bolts that have been fitted.

Next fit 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.

You may need to push the seat forward quite hard and hold it there while you get the 2 bolts fitted under the seat.

Fit the fuel lines and then you are done.

Enjoy!

Steve

Steve Attfield

Compiled by Steve Attfield, Devon, UK

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