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The TTR250 FAQ web pages -> TTR250 -> Modifications -> north american 2000 ttr250 plastic tank conversion
Post Info TOPIC: north american 2000 ttr250 plastic tank conversion
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north american 2000 ttr250 plastic tank conversion
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Hi

We have a 2000 blue TTR 250 . This is strictly a trail bike . The tank is garbage & one day it cracked  just sitting in the garage. Its been plastic welded & one time the bike fell over in the mud as my son lost his footing. resulting in 10 more cracks. We have had enough of this & want to switch to a steel tank. We are hoping a steel tank from a 96 TTR250 Raid  (white steel tank) will fit . I notice the frame is cross drilled in an area where the rubber cushons would probably go. I  ofcourse would need the complete tank./cap/pet**** cushons & any available hardware. Will this fit? Any thoughts & advice would be most appreciated. Again we have no interest of putting another plastic tank on this bike no matter who made it.

Thanks so much

Kevin in Canada

  



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Cubber


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Hi, Kevin, welcome to the forum.

I'm sure someone will be able to answer your query, but I'm sorry I can't. cry

You must be unlucky with your tank, mine's a blue plastic and has been thrown around the English countryside for 11 years with no leaks, yet! smile

Martyn



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As Cubber alludes, it is unusual for the plastic tank to suffer in the way that yours has confuse

There is quite a bit of work to do to properly fit a metal tank.

This is your existing plastic tank:

Petrol tank.jpg

 

and this is the metal tank version:

Petrol tank - metal.jpg

 

The parts shown in the breakout box top left would only be needed if you went for the bigger Raid tank. The downside of that is that ideally you would need the Raid seat to go with it or else modify your existing seat to fit the Raid tank.

Quite a few of the parts needed for a conversion are available in the Totally TTRs shop here

The frame mounts you are missing are shown in the photo below:

Metal tank mounting.jpg

 

I hope that helps.

Brian



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It Does
thanks Brian
Being a machinist these brackets are easy to make & I can tig them in place. The seat might be a pain. Is the Raid seat a bit thinner as to lower overall seat height. That would be good as this is my sons bike & he is a bit on the short side.
Sounds like a raid tank/seat & a few mods & good to go. if there is anything else you can think o please let me know
Thanks
Kevin

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This thread might be useful wink



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Brian
Do you think you can give me some measurements. I need to know the dia of the spigots for the rubber tank mounts as well as how long they are. Same for the small one on the seat end of the tank
Thanks
Kevin

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OE tank mounts 1.jpg

OE tank mounts 2.jpg

OE tank mounts 3.jpg

 

You are lucky I still have an old OE frame to look at Kevin wink

It wouldn't be difficult to drill out the spot welds on the front mounts.....

Can't see how the rear peg is fixed confuse

Brian

 

 



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TTRfan


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Front tank mounts.jpg



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rear peg might be secured from underneath. Wow thanks for all the info Brian I really appreciate it.
we have had the worst luck with those plastic tanks. I partially blame the fuel caps. In Canada they have some sort of spring /ball set up so if the bike fell over the fuel would not flow out of the vent. Truth is it jams for no reason & pressure builds up. I removed all the guts in ours after the 1st incident. I would recommend that to anyone.
you removed the front mounts? for sale?
kevin


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There is a thread about plastic tank caps - see http://ttr250.activeboard.com/t52353339/does-your-petrol-cap-breather-breathe-properly-the-question-/

Scroll down to my Jan 26 post.

If you are interested in the mounts then I will give them to Steve to put in the shop with the other tank fixings.

I managed to get the peg free but it fell into the frame. Didn't want to upset the neighbours using a disc cutter on the frame on a Sunday but will give Steve that one as well once I have recovered it!

Brian



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BM Steve


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I agree with cubber, mine has been bashed, scraped, scratched and generally knocked around, still great except it has a case of the uglies !

 



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2004 TTR250 - Highway Dirtbike Hand Guards, 38mm Bar Risers, D606 Front & Rear, Opened up Airbox with Twin Air Filter, Re-jetted Carby, B+B Bash Plate & Frame Guards, DIY 3mm Alloy Tail Tidy, 14/47 Gearing.

 
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I think now with my own blow test a year ago & after reading the cap issue Brian mentioned. Im certain repeated pressurizing/vacumn has flexed the tank & now that its 16 years old not to mention the crap fuel it probably had run thru it (methanol) before we bought it the tank is now brittle. I have no problem even though my son does putting another blue tank on it. Problem is finding one without cap issues . hate to go through all the expense to find it cracked sitting in the garage. I have told my Yamaha dealer my thoughts about Yamaha plastic tanks. Apparently the vintage IT models also had problems . So I would consider a plastic tank if there is one available. I am interested in the Mounts/fittings but wonder if I should hold off until I get a tank. What if I cant get one?> They are definitely not lined up ready to sell.

Thanks Brian & Steve

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