1987 Kawasaki Tecate rebuild (lots of pics)

[ezmoney1979]

Hi everyone! Its time to finally post my 87 KXT (kind of long) story........ About 7 or so years ago I get a call from my friend (also neighbor). He says his friend needs some cash and wants to sell his three wheeler- " its green, two-stroke, 1987, runs and looks cool. Its got a big bore, extended swingarm, blah blah blah. He wants $500 for it." Knowing I am into three wheelers he says "you will want it." Although I didn't know much about Tecates at the time I say yeah I want it..... but I am kinda broke:( He says to help us both out he will spot me the cash:) I think I was at work or something but I came home to an 87 Tecate! Its front and rear fenders were destroyed but expertly stitched back together by what must have been the finest meth-head in the valley. The rear shock was blown (of course), it ran like crap, but it was intact and went through the gears. It had a DG pipe, decent shrouds, and an ok tank. I never met the guy who sold it so I had no history of the mods ect. just what was said on the first phone call. I took the carb off to find it still had the stock main jet in the mikuni (270 I think):wondering, so no wonder it ran like crap. I figure I would get it running good and go from there. I threw a much bigger main in it and got it to run better (still poor of course). I putted around on it just a little but decided to put it up before doing anymore damage to it (I could see cracks in the frame). So for the next few years it just sat behind my friends house, covered, waiting for me to revive it! Last year I decided it was time. This is what it looked like before I dissasembled it. http://i975.photobucket.com/albums/ae240/ezmoney1979/tecate018.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/tecate019.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/tecate012.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/tecate017.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/tecate015.jpg I know what you all are thinking and the answer is no, I will not sell the super-mega hi-flow ported/polished petcock:lol:

[scooterroo]

nice start, good luck with the build. always like to see the green ones getting redone. whats your plans for it?

[ezmoney1979]

Well initially I wanted to go as OEM as possible, but that didnt really fit my budget.lol. So I decided to make a very nice dune bike that looks kinda stock. Mostly powder/polish everything and replace all seals and bearings and buy OEM plastic. This is the frame after getting it blasted. Many more cracks were revealed in the known problem areas (footpeg/ swingarm mount.) I also had to fix the grab bar mount area (stripped threads). While I had some (ok lots) of spare time I got started on polishing! http://i975.photobucket.com/albums/ae240/ezmoney1979/2010009.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/2010197.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/2010010.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/2010163.jpg This was my first time polishing aluminum so I was pretty stoked with the results.

[thestud25]

Looking good. I like shiney things!!

[Bretmd94]

Very nice, Money!

[Xpress]

Very VERY nice! I love it when you need to wear a pair of glasses just to see your polished parts :D :beer

[ezmoney1979]

I remember it like it was yesterday......... UPS truck pulls up, dude gets out with huge box filled with new green plastic, I proceed to tear into it like a 10 year old spoiled brat at christmas.lol. I scored on the rear fenders. They were advertised as new with a seat that had been newly upholstered and new decals (although upside down). When they showed up there was a new stainless steel brace on them and all the rubber bumpers were in the seat base!! I still dont have a new right shroud but I should be getting one next week from a local guy that used to own a bike shop here. As it is the one I have is in ok shape its just had the top mounting tab repaired. I also ordered the 87 repro decal kit! http://i975.photobucket.com/albums/ae240/ezmoney1979/2010004.jpg

[fabiodriven]

Dude, how did you polish that stuff? I've tried like hell to do that and I have failed miserably.:(

[Xpress]

^Probably lots of fine steel wool to take all the crap off, then a lot of time with the polish, and a buffer. I'm subscribing to this. I'm interested to see the final product :)

[jpatey44]

where did you order the plastics from?

[scooterroo]

liking the progress. i like your case saver/ chain cover, is it aluminum as well? and is the swingarm an extended stock one? very nice job on the extension if so, and the polishing work too.

[ezmoney1979]

As far as the aluminum polishing goes I researched it a bit and just copied what everyone else was doing.(this site is awesome for that lol) Thanks 3ww! The swingarm and forks had major scratches and gouges that needed to be sanded out with a sander. I sanded every thing out (by hand) to about 1200-1600grit then threw it on a buffer with some white or green compound. To finish it off, good old Mothers aluminum polish! (which also works very good on gas tanks :) To achieve this level of shine I would also recommend having 1.Nothing to do 2.A patient wife/girlfriend 3.perhaps a sixer of your favorite IPA :) To be honest there was a bit of trial and error but I figure it was worth it. I think the tripples were the hardest to do (I never did get them as good as I wanted). Also before tackling the forks they need stripped of their clear coat. I used Ace paint stripper in an aerosol can. http://i975.photobucket.com/albums/ae240/ezmoney1979/2010158.jpg

[fabiodriven]

Do you need an angle grinder type setup to polish? Do you do it all by hand? Are there threads you can reference on here?

[ezmoney1979]

Fabio D- I just searched and I couldnt find the threads I was reading back when I did this, just bits and pieces. Some of the plastic sanding techniques remind me of aluminum:lol: No angle grinder! Nothing orbital until its a buffing wheel or buffer or you will just have more scratches to deal with. Some of the bad scratches I got rid of by using a small sander like a dual action 1/4 sheet with some 200grit, but that was only in the open areas. The rest was by hand in stages with the final stages wet sanding. It took lots of time!

[scooterroo]

hey any idea on the make of the rock guard? or is it a one of custom deal. i would love one of them.

[ezmoney1979]

The skid plate and spocket cover both came with the bike. There are no markings of any kind on either.:( The skid plate is pretty cool and if its a one off then someone did an awesome job. It came with little aluminum clamps and has a drain plug hole in it. I probably wont ever run it (it would probably keep sand trapped) but I might snap some pics with it on! http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecaterebuildskidplate043.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecaterebuildskidplate045.jpg

[ezmoney1979]

Before I sent the frame out for powder I wanted to decide on which shock to run. The stock shock wasnt usable as the shaft was pitted and the body was badly worn. So after a lot of research I went with the lt250r rear shock. I discuss this a little more on this thread- http://www.3wheelerworld.com/showthread.php?120051-First-gen-Tecate-rear-shock-questions/page2&highlight=t3+shock I will definitely let you all know how well it does as soon as I can. This is as close to bolt in as it gets and there are plenty of lt shocks out there. Once I had this much work into this thing I couldnt stand to have the frame done in the stock dull silver (slate grey I think its called) so I went with a little bit brighter silver with clear over it. http://i975.photobucket.com/albums/ae240/ezmoney1979/2010201-1.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/2010202.jpg

[sblt500r]

i've made up a few frame skids. a little different than that, but with clamps and a oil drain.

if your gonna use the lt shock. i would get a stiffer spring for it. the stock lt shock springs are kinda soft. unless your a little guy then you should be fine!

[ezmoney1979]

Well at one point had to do some pre-assembly to get an idea of how things were turning out.;) Those are the original fork boots after they were soaked in Meguiars! http://i975.photobucket.com/albums/ae240/ezmoney1979/2010169.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/2010166.jpg I also thought I should share this pic of most of my Tecate stuff! I have since purchased a Klemm pipe on Ebay that was mis-posted! http://i975.photobucket.com/albums/ae240/ezmoney1979/2010204.jpg

[Buster Brown]

Look'n sweet! Congrats on your hard work. Jealous for sure.

[hang&rattle]

Incredible! This is one of the top 2nd generation Tecate builds in the country. Your attention to detail is mind blowing, thanks for the step by step pictures. Wow!

[scooterroo]

looking good looking real good. like the polish work. only question... why did you put the rear fender decals on wrong? is this just the look you like?

[dcreel]

looking good looking real good. like the polish work. only question... why did you put the rear fender decals on wrong? is this just the look you like?

Post #7 They were like that when he bought the fenders.

[Xpress]

^This should answer your question:


I scored on the rear fenders. They were advertised as new with a seat that had been newly upholstered and new decals (although upside down).

Looking very VERY nice sofar! Now you need to get it together :naughty:

[code200k]

wow.looks amazing man.i still think they are the meanest looking trikes out their,even if they are apart

[D-dub]

Looks amazing!

[ezmoney1979]

Thanks for the compliments guys!:) It really makes my day! So onto the powerplant- bottom end checked out good (had a new flywheel) but the topend needed some help of course. It is a big bore with the head modified for a JS650 piston with extensive porting. The piston that came out of it looked like it got pretty hot a time or two- it was at 76.5mm- to clean up the cylinder I had to go up to a 77.5mm so if I remember right its 306cc (I did the math once):wondering. I went with a forged Wiseco and had a friend (engine builder- I dont have a lathe and he is way smarter than me:lol:) do the proper modifications (cut skirt, boost port). I had ordered a big bore gasket kit from Cometic but the head gasket was too small and hung into the cylinder so I think it is only good up to 77mm.:( I have a new gasket on the way- 78mm. I took the stock carb and threw it in the trash (jk- but I still dont know why it was on there) and bought a 38mm PWK and replaced the worn Boyesen two stage reeds with new carbon fiber reeds. I also got a 90's KX250 intake and to top it off I got a K&N (angled) with an outerwear (thanks bretmd94 for the filter and outerwear). The motor recieved a fresh coat of PJ1 fastblack satin case paint and freshend up fasteners (I still need a set of SS fasteners). And of course I polished a few things. I think next time I will get the cases powdered but I am still fairly pleased with the PJ1 (too flat IMO). Heres some pics. A curious US90 looks on..... http://i975.photobucket.com/albums/ae240/ezmoney1979/2010149.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecaterebuild025.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecaterebuild028.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/tecate11-6-10001.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/tecate11-6-10003.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecatemotor007.jpg Sorry for the barrage of pics. I have been waiting on sharing this with you guys for a while.:) Thanks again for the compliments.

[Bretmd94]

haha I like the jealous us-90 in the background.

[HondaRidr]

Wow! It is coming together great!

[posty2100]

good work, keep it up!!! I love the 2nd gen tecates

[petesatc]

nice job its going to look awesome!!!!!!

[Xpress]

Anymore news on this one??

[Bretmd94]

I got a call from Money just now. I have a feeling updates are coming soon. ;)

[ezmoney1979]

I must say there is nothing like firing up your newly assembled motor for the first time!! After a brief flooding issue and a bruised ankle (why wasnt I wearing boots?) Its Alive!! Im not gonna lie........ it was a pain to get fired up lol. (A few weeks ago bretmd94 came over and picked up my carb and was messing with it- I swear.) I will have completed pics soon with more details!

[Jeepermc]

VERY nice build... I hope mine turns out that nice some day.

[ezmoney1979]

Well its done for (for now)! I couldn't have done it without this site and all its awesome technical advice! Thanks guys!:D Not to get all corny on you but I also wanted to mention how amazing my wife has been with helping/putting up with me during this project! She lets me wash parts in the sink, assemble stuff on the coffee table, make a mess in the living room- I am lucky! I think she might even like three wheelers but just wont admit it:D I better get my YFZ in top shape for her to ride;) So here it is now- I was too lazy to swap tires http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecaterebuild001-1.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecaterebuild005.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecaterebuild003.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecaterebuild015.jpg Some old school gear aquired along the way! The sweater is from 1986 (still has tags), helmet is Bell MOTO-4. http://i975.photobucket.com/albums/ae240/ezmoney1979/tecateinthesun002.jpg I still need to get my hands on all the OEM stuff but I'm still pleased with how it turned out. I cant wait to get my other pipe restored and get rid of this DG.

[ezmoney1979]

A couple more- http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecaterebuild022.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecaterebuild014.jpg

[pantera1975]

Looks nice, I gonna be looking for one of these 86-87's in the spring cant wait

[bigbadktm]

nice build, good to see from start to finish

loving it

[dcreel]

It turned out great. You and your wife should be proud. There is no better bonding time with the wife than both of you on your knees together searching for that darned c clip that flew across the garage.. Been there done that.

[hang&rattle]

My heart is thumping for real. What a beautiful Tecate. Your detail is amazing and it even looks like a hellacious runner. Congratulations and great work. Makes me proud to own a Kawasaki.

[nd4speed]

that is really nice, wish mine looked like that. Great work!

[OZQUAD44]

that is really nice, wish mine looked like that. Great work!

I'm with you nd4speed, that has turned out great.

I love the cut and shut job on the swingarm, looks awesome. How does it handle?

[Xpress]

Holy cow, that is AMAZING!!!!!!!!!!!!!!!!1

Now you need to get your arse out to the invasion :lol: :naughty:

[sportvette]

great work. looks awesome man. good job on that swinger. came out great!

[Twilight]

Please, for the sake of that beaut of the machine... get a Uni filter and ditch the K&N

[oldskool83]

thats nice....and i dont even like tecates!

[sugarhead]

Good luck and congrats to a very very sweet job,take care of er;)I wonder where or why you dont see any 87 T3s? Were there like 500 made or in barns or wrecked or what? The 87 is my favorite bike of all time from 2 wheelers to 4,nothing comes close to the T3

[posty2100]

nice lookin Tecate you got there!

[Macs]

The skid plate and spocket cover both came with the bike. There are no markings of any kind on either.:( The skid plate is pretty cool and if its a one off then someone did an awesome job. It came with little aluminum clamps and has a drain plug hole in it. I probably wont ever run it (it would probably keep sand trapped) but I might snap some pics with it on! http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecaterebuildskidplate043.jpg http://i975.photobucket.com/albums/ae240/ezmoney1979/Tecaterebuildskidplate045.jpg

I have the same skid plate in a parts pile. i always wander what it went to.

[ezmoney1979]

Thanks for all the compliments guys! I have been side tracked a bit but I recently got settled into my new house and have had some time for the Tecate. I got a nice weekend in on the 310 motor a few months back. Probably ran it about 5-6 hours and it ran good except for breaking up on the top end. What I didnt like was starting it. Way too much compression. When I got around to compression testing it, the kickstart boss broke. Us Tecate guys know what a pain this is :(. So I recently got some parts- http://www.3wheelerworld.com/group.php?gmid=3560&do=discuss (no kicker boss though) and I got some ideas and one thing led to another and I decided to take it all apart again. I know kinda :crazy:

http://i975.photobucket.com/albums/ae240/ezmoney1979/Mcgrath%20parts/TecateRe-rebuild001.jpg

Included in the parts were two stock cylinders. One of them has a little wear the other is in perfect shape, both never ported. I also got a new Wiseco piston in the deal! So out of curiosity and for the sake of easy starting I am putting a stock motor together. I am excited to see how it runs with the large intake and Klemm? pipe I have. I am probably going to get the other cylinder re-plated and ported for extreme top-end, then I will have three combinations for all occasions! I have work to do- going to the dunes in two weeks. Also in the works is putting my new +6 axle in. Here are some pics comparing the big bore/stock.

http://i975.photobucket.com/albums/ae240/ezmoney1979/Mcgrath%20parts/TecateRe-rebuild004.jpg

http://i975.photobucket.com/albums/ae240/ezmoney1979/Mcgrath%20parts/TecateRe-rebuild003.jpg

http://i975.photobucket.com/albums/ae240/ezmoney1979/Mcgrath%20parts/TecateRe-rebuild002.jpg

[hang&rattle]

You're insane Money, lol. Perfection and patience, lol. That thing is gonna be so wicked!

[tecate 250rr]

Just read the whole thread and all i can say is wow. Great job and you have got to be the luckiest guy to come up on a 87' like that. good luck with the project.

[Eric250R]

Great job man, a true labor of love....

[Xpress]

Please, for the sake of that beaut of the machine... get a Uni filter and ditch the K&N

I still don't see the problem with K&N. 3+ years of using them, and not one issue with me... :wondering:crazy:

[IronBear]

Hello,

I'm fairly new to 3 wheeler world and also belong too 3 wheeler.org. Anyway, I just want to say that your bike looks awesome!

I just picked up an 87 Tecate on a trade but my plans are to replace all the plastic with OEM, find a OEM Headlight guard. headlight and rear tail light. Install OEM fork boots and several other things. Here are some pictures of it.

Pete

[ezmoney1979]

Nice find Pete! Best of luck to you on locating OEM fork boots, I dont think I have seen a pair for sell in over three years. I have an extra pair for you but they are not in the best shape. I might have some parts for ya also when you decide to start working on your T3. Thanks for the compliments once again guys! I will have some new pics up this week with a freshly mounted STU mohawk, Klemm pipe, new cylinder, and nice OEM right side shroud.

[justin4]

Hey i just got an 86 250 that would love to redo like yours.But money is tuff now because we just got a new house last week but i will be strate in a few weeks i want to start with the swing arm first any parts you could part with would be great. I want the after market stuff and my bike other than the plastics are stock and in very nice shape, i would be willing to trade or buy anything you want to get rid of. Do you know if it came with the twist throtle or was it the tumb? I dont know how to do it yet but pm me i will try to get and give you my number so we can talk. VERY NICE JOB by the way. Thank you for any help you can give. Justin4

[IronBear]

Nice find Pete! Best of luck to you on locating OEM fork boots, I dont think I have seen a pair for sell in over three years. I have an extra pair for you but they are not in the best shape. I might have some parts for ya also when you decide to start working on your T3. Thanks for the compliments once again guys! I will have some new pics up this week with a freshly mounted STU mohawk, Klemm pipe, new cylinder, and nice OEM right side shroud.

Thank you sir! I'm heading down to Connecticut to see my family tomorrow and plan on visiting Chaplin Kawasaki to purchase both the front and rear OEM fenders. I'm on the lookout for a complete headlight assembly, along with the switch and wiring harness. I also need the keyswitch and fork boots plus hardware. Let me know how much you would sell yours for.

Pete

[IronBear]

Do you know if it came with the twist throtle or was it the tumb? I dont know how to do it yet but pm me i will try to get and give you my number so we can talk. VERY NICE JOB by the way. Thank you for any help you can give. Justin4


Hey Justin,

These machines come with the twist throttle. I just picked up the new plastics in Connecticut and hopefully getting the radiator shrouds next week. I also need a rear tail light and headlight, along with the wiring harness and switch.

[fordnut79@hotma]

Why are the older pics showing up "photobucket" and blurred?

[gimmeamidget]

the thread was 8 years ago...this was before they had cameras...