Fixer's TTR250 Top Suspension Bush Kit

Step-by-Step Guide with Photos for fitting the Top Suspension Bush Kit.
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.




Put the bike on a stand so the rear wheel is off the ground. Remove the seat to see the top shock mounting.



Remove both side panels (we put the screws back into the holes for safekeeping)





Remove top airbox bolts NOTE...Please be aware that the 'captive' nuts on all three airbox fixings aren't always quite so captive and have a habit of dropping out onto the floor. A dab of grease or instant gasket will keep them in place.





Remove Left-Hand subframe rail





Undo the Jubilee clip (Phillips screw) holding the intake tube to the carb



Remove lower air box bolt on Right-Hand side



Roll the air box out and down through the Left-Hand side of the frame. Disconnect the breather pipe from the breather on the airbox



Undo clips holding shock reservoir to frame mounting and remove clips - bottom one first then lift the reservoir and slide the top clip off the bottom.



Disconnect battery negative connection



Taking care not to ground the screwdriver (the negative connection tends to hang against the battery terminal) undo the positive connection and remove the battery



Screws put back into terminals so we don't lose the nuts!



All 3 bolts holding the battery case are removed next







Remove the positive lead from the battery box



and the bolts are fitted back into the frame for safekeeping



The shocker lower mounting bolt is next to be undone...there's no nut on the other side as the shock lower yoke is threaded!



A strap has been fitted between the subframe and the swinging arm to take the weight



Notice the bolt for the top shocker mounting has been fitted from the battery box side. When we replace the top mounting we fit the bolt from the Left-Hand side of the bike so if we need to remove the rear shock again we don't need to disturb the battery box!



TRICKY BIT - thread the shocker reservoir through the frame to remove the shock assy



Reservoir out and the shocker is lifted up off the lower linkage....



...up through the top of the subframe to allow the lower yoke out of the swing arm.



Shock assembly is out!



Using a punch, tap one of the collars out of the bearing





Brian used the vice, a 28mm and 10mm socket to push the remaining collar out



et voila Monsieur...the collars are free!



Make sure the gap in the circlip is away from the 'meaty' part of the shocker eye...



drill down just past the circlip and 'break' the drill out of the side of the eye ..





Using a small pin punch or similar, hook out the circlip...careful, they tend to fly when released!





Repeat the drilling and hooking for the other side

Using a 28mm and a 17mm socket push the old bearing out of the eye. This can be tapped out with a hammer if you don't have access to a vice.



All parts removed from the eye. If the eye has a build up of 'crud' on it please scrape around it with an old blunt knife. It doesn't need to be pristine but we don't want lumps in it!



The frame yoke needs to be widened due to it having a couple of washers reinforcing the inside of the flanges



you can just make out the reinforced flanges in the shot above and below



Without spreading the yoke measured 30.59mm....or.....



...1.203"



The spreader bolt can be done either way round



Grease the eye up using the supplied Silicone Grease and insert a new polyurethane bush (the ones in the kits are now purple rather than red - the only difference is the colour!)



Put the other bush in and apply the same grease to the inside of the bushes. Spread it about using a Phillips screwdriver or similar.



Locate the leading edge of the centre spacer (it has a slight chamfer on it to assist fitting) and press it into the bushes





Using a 10mm socket centralise the spacer in the bushes



This is what it should look like





Drop the shocker onto the lower linkage and feed the reservoir, base first, into the frame. This can be a bit tricky!



Insert lower shock bolt and tighten



Slather the inside edges of the yoke with the grease....



and put loads more on the edges of the bushes



Gently feed the shock absorber top eye back into the yoke



Fits well doesn't it?



Use the Phillips screwdriver to line the yoke and eye up and insert the top bolt from the Left-Hand side of the bike.



Bolt inserted from the left



Tighten the bolt until you feel it pull the flanges of the yoke onto the new centre bush...then fully tighten it.



The shock absorber is back in place.



Photos over...refit the following The battery box and battery The airbox by rotating it back into it's space whilst attaching the elbow to the carb and the breather pipe to the breather. Attach the clips onto the shocker reservoir and clamp them up Refit the Left-Hand subframe support rail Refit the side panels and seat. job done, time for a cuppa!

Buy your kit here!

http://www.totallyttrs.com/ - everything you need (possibly!) for your TTR250 http://www.ttr250.com/ - all you ever wanted to know about TTR250s http://ttr250.activeboard.com/ - the forum for TTR250 owners http://www.totallywrs.com/ - for all your WR250R and WR250X after-market parts and accessories Reference within this site to any specific commercial or non-commercial product, process, or service by trade name, trademark, manufacturer, private individual or otherwise does not constitute or imply an endorsement, recommendation, or favour by Brian Sussex or Totally TTRs