Upgrading the Suspension on a Honda TRX250R ATV - Improve Handling and Ride Quality

Upgrading the Suspension on a Honda TRX250R ATV

The Honda TRX250R quad was a revolutionary sport ATV when it was introduced in the late 1980s. With its liquid-cooled 249cc two-stroke engine, this lightweight racer could scream across the dirt at blistering speeds. However, the stock suspension left something to be desired, especially when compared to modern ATV designs.

Upgrading the suspension is one of the best ways to improve the handling and ride quality of an older TRX250R. While the frame and swingarm design are still capable, the shocks and A-arms are prime candidates for upgrade. Changing out these components can make a world of difference in how the Quad handles jumps, corners, and rough terrain.

Why Upgrade the A-Arms?

The stock A-arms on the TRX250R are made from standard steel tubing. While strong, these arms are quite heavy compared to more modern aluminum or chromoly units. Heavier control arms affect suspension performance in several ways:

• Reduced suspension action - Heavier arms restrict suspension travel and response.
• Increased unsprung weight - The suspension has to work harder to control the wheels.
• Decreased steering precision - More weight makes the front end feel slow to respond.

Lighter aftermarket arms address these issues and allow the suspension to work as designed. They also reduce strain on other components including wheel bearings, swingarm pivots, and shock shafts.

Choosing New A-Arms

When selecting new control arms, buyers have two main options - aluminum or chromoly steel. Here are some key considerations with each material choice:

Aluminum Arms

• Super lightweight - Reduce unsprung weight by up to 50% or more.
• Corrosion resistant - Ideal for muddy and wet riding conditions.
• Require less maintenance - Don't need greasing like steel arms.
• Softer material - Prone to bending in crashes or bottom outs.
• More expensive - Typically cost $200-$400 more per set.

Chromoly Arms

• Stronger than stock arms - More crash resistant than aluminum.
• Nearly as light as aluminum - Only about 10% heavier.
• Lower cost alternative - Around $200-$300 per set.
• Require regular greasing to prevent corrosion.
• Can bend from big impacts.

For hardcore racing, aluminum arms make the most sense if the budget allows. They offer maximum weight savings and great corrosion resistance for muddy conditions. For more casual trail riding, chromoly arms offer nearly the same benefits at a more affordable price point.

Custom Fabricated Arms

Beyond bolt-on replacements, some riders choose to have fully custom arms fabricated. This allows for complete customization of arm dimensions, materials used, and hardware selections. Joints can be redesigned to increase strength or allow added suspension travel. Complete one-off arms also allow for integration of accessories like shock guards, steering stabilizers and heel guards.

The downside is the cost and time required. Fully custom arms require extensive design and engineering expertise. Materials and manufacturing alone can cost over $1000 for a custom set. The benefit is a completely unique set of arms tailored specifically for the rider's needs and budget.

Installing New A-Arms

Replacing the TRX250R arms is a straightforward project for the home mechanic. No special tools are required beyond basic hand tools and a hydraulic press for installing bushings. Here are the basic steps involved:

1. Lift and secure the quad on a repair stand.
2. Remove the wheels, shocks and sway bar links.
3. Press out the bushings and sleeves from the pivot points.
4. Disassemble the arms from the frame mounts.
5. Clean and inspect all mounting points.
6. Press in new bushings and sleeves.
7. Install the new arms with fresh hardware.
8. Reinstall the sway bar, shocks and wheels.
9. Set sag and alignment to factory specs.

With the arms removed it's also a great time to inspect the frame structure. Check for cracks around the pivot points that may need addressing before installing shiny new components.

Arm Upgrade Results

Fresh high-end arms make a transformational difference in the TRX250R's handling. The quad will corner flatter and change direction more precisely. Front end response is improved through increased arm travel and reduced unsprung weight.

Landing jumps and harsh hits are less jarring with the plusher, more responsive suspension action. Bottom out resistance is also improved to prevent topping out on big impacts. The rear swingarm and tire stay better planted over rough terrain for increased rear wheel traction.

While the engine and frame may be decades old, modern high-performance arms allow the TRX250R to carve up trails nearly as well as much newer designs. The improved geometry, reduced unsprung mass and increased travel make the quad handle like a whole new machine.

Conclusion

Upgrading to aftermarket A-arms is one of the simplest and most effective ways to modernize an older Honda TRX250R ATV's handling. With a quality set of lightweight aluminum or chromoly arms matched to properly valved shocks, the venerable TRX250R can deliver stunning performance on today's trails.

FAQs

What are the main benefits of upgrading the TRX250R A-arms?

New arms reduce weight, improve suspension action, decrease unsprung mass, provide more precise steering, increase ground clearance, and improve overall handling and ride quality.

What materials are aftermarket A-arms made from?

Most aftermarket arms are either aluminum or chromoly steel. Aluminum is lighter but more expensive. Chromoly is nearly as light but stronger and cheaper.

Is installing A-arms a difficult project?

The arm replacement process is straightforward for a home mechanic. No special tools are needed beyond basic hand tools and a press for the bushings.

Can I customize the arms beyond bolt-on replacements?

Yes, fully custom arms can be fabricated to your specifications. This allows complete customization of dimensions, materials, and hardware.

How much difference do new arms make in handling?

Quality aftermarket arms make a huge improvement in cornering, steering precision, suspension action, and overall ride quality. The TRX250R feels like a modern quad with fresh arms.