1985 Kawasaki KXT250 Build Thread

[sjsst41]

Picked this trike up about a month ago with the intent to perform a semi-restoration. Nothing over the top, but address the items that need attention, and make a clean rider.

It's currently torn down to the frame - which isn't in bad shape, I had to re-weld the coil mount back in place (held in place with a hose clamp)

I received new KTX plastics kit, and a Clarke fuel tank (in Kawasaki green) new replacement stock graphics for the fenders and tank, and a replacement blue seat cover. I'll post of the fit/finish of all these parts once I get to that point (and I'll update this thread with pics)

I did ride the trike when I made the purchase, it ran well, but with the motor out I removed the top-end, looks to have a stock bore with Wiseco piston kit, and a Pro-X connecting rod - pleased everything is tight and doesn't look to have many hours on the build.

Also - the rear shock is blown, so that's out for rebuild (I hope it's in decent enough shape to rebuild) and I found out one fork tube is bent - so the plan is to straighten it out, then replace the fork seals.

As expected, there's a long list of small items that need repair - but I'll save that detail for another post as I make progress.

https://lh3.googleusercontent.com/drive-viewer/AEYmBYQkcb4JdFO-l8_AK9qkUWaOErHc1jR-wpohsI35oTMO94mbj3TQjrMMTGH2m9WlqjiIU3ydYowKiPPuJ9 VLf-11i-AOuQ=s1600

[HondaRidr]

Looks like a solid start! Are those fenders and tank painted? I have not seen that color before.

[oldskool83]

I can already tell you the forks are done for so there is no point rebuilding the forks with all that rust that will rip up the seals. You can have them stripped and re-chromed. Forking by Frank does make new replacement tubes. Getting somone to answer an email or a phone is going to be the hardest part.

[sjsst41]

Looks like a solid start! Are those fenders and tank painted? I have not seen that color before.

Yep - the PO mentioned he painted them as the plastics were faded to almost white. I have new plastics and a tank waiting to get installed.

[sjsst41]

I can already tell you the forks are done for so there is no point rebuilding the forks with all that rust that will rip up the seals. You can have them stripped and re-chromed. Forking by Frank does make new replacement tubes. Getting somone to answer an email or a phone is going to be the hardest part.

Yeah the fork tubes are definitely on the edge, if not over, of being usable. I have them soaking in Oxalic Acid as I write this - that will typically do a fantastic job at dissolving rust, I’ve used this technique on many chromed BMX parts that looked to far gone to salvage. I’ll post up the results.

[sjsst41]

I managed to strip the frame today of paint, which was a pain. Maybe tonight I’ll be able to get a coat of paint on it. The trike didn’t have the airbox installed (just one of those small filters with a hose clamp on the back if the carb). But the package deal came with a spare frame with an airbox, but no cage and no cover. I’ll have to fab a cage, but in a positive note, a fellow online has a 3D model he generated which is downloadable for a couple bucks. I did download and send it to a friend who 3D printed it for me, I’ll pick it up tonight and check the fit, I have my fingers crossed it works well enough.

[sjsst41]

Making progress - although slowly - but that's how it goes. Frame, engine and swingarm painted, new swingarm bearings, top end gaskets (just pulled to inspect, but all was in-spec), new shifter that I need to extend (it was supplied with the trike when I bought it, a new EMGO shifter, but for a mid-80's KX250). New intake boot and chain slider.

I'm headed to Norway for a month (business travel) on Friday - so I hope to have the triples and forks installed before I go, so the project will be stalled for a while until I return, but the rear shock should be finished by then. Also - I see the suspension dogbone heims are NLA - is there any recommended alternatives?

[sjsst41]

https://lh3.googleusercontent.com/drive-viewer/AEYmBYQat2TsH4PrMSptpU3D7ftXWdS-hSfc3AIQSHkqW-0eFCT2WxH5aW6dRZFChTE4XfG24BwOe5znNDlHB2MC_EJ62qHM =s1600

[sjsst41]

And picture of the 3D printed Airbox cover:

https://lh3.googleusercontent.com/drive-viewer/AEYmBYSnYOUr-PqgXeZ9sKBqY_4frCG5hZO9kTT1Hvocg1rFPf4FVvWqyl8vD4f CBo82yoZ7LlOIuK5y4QP9yLFlR4zjxbxLEA=s1600

[Red Rider]

Looking good. These things take time.

[sjsst41]

Looking good. These things take time.

As one of the engineers that used to report to me always said “Slow work takes time”.

[YTZ drew]

Looking good! I saw this trike a while back on marketplace, glad it's in good hands and getting the love it deserves!

[El Camexican]

As one of the engineers that used to report to me always said “Slow work takes time”.

Haha! One of my personal favorites is “you do nice work… not much, but nice”

Best of luck with your project :beer

[HondaRidr]

Off Road Innovation has a lot of parts for tecates including the dogbone bearings. Love to see another tecate getting some love!

https://www.off-roadinnovation.com/kxt250-84-85.php

[sjsst41]

Off Road Innovation has a lot of parts for tecates including the dogbone bearings. Love to see another tecate getting some love!

https://www.off-roadinnovation.com/kxt250-84-85.php

Thanks ! I did see ORI shows dogbone heims on their site, but they state they are discontinued with no stock available. I might have to get creative on a replacement.

[sjsst41]

271336

Test to see if this pic shows up.

[sjsst41]

Ha - it did. Not my trike, but does anyone know what low profile rear tires are on that Tecate?

I’m making ok progress - slow as usual. Rebuilt rear shock in place, went to install the rear axle last night and saw it’s also “tweaked” but not horribly, I’m going to try and straighten it out. The forks are installed, used the straightened tubes, I tried to source an alternate set (but failed unfortunately). I’ll post some pictures of progress in the next couple days.

[Red Rider]

Not my trike, but does anyone know what low profile rear tires are on that Tecate?18x11-10 Fast Trekkers.

[sjsst41]

Onto restoration of that radiator guard - can anyone give me recommendations on the paint code that should match up well to the new plastics? I’ve done some online research & read Kawasaki green paint k417 is a good match for late ‘80s lime green, but it’s not easily sourced stateside. All the PJ1 spray paints seem to be later colors as well (98+). Any feedback and experience is appreciated.

[sjsst41]

Making progress !271380

[sjsst41]

So I could tell the Mikuni carb that was installed on the Tecate wasn’t stock - it’s a flat slide - but figured I’d clean it up and see how well I can tune it (if needed) it seems to run well when I took the trike for a test ride - anyway the PO had removed the airbox and installed a small clamp-on canister filter. The extra parts included an airbox, so I reinstalled that, sourced a replacement cage (not easy) and installed a new UNI filter. Well as you may have guessed, the flat slide carb doesn’t fit in that stock space. Bummed to have to source a carb for this project, but I shouldn’t be surprised.

I don’t want to bother finding a stock carb that’s 40 years old (and it’s strange the prices being asked on eBay for non-complete ones). I did a quick test fit of the Keihin PJ off my ‘86 ATC 250R, and it fit perfectly. I’ve read to look at the 35 mm PWK - but I might try to fire it up with the PJ and see how it runs. Any recommendations?

Thanks !

Steve

[sjsst41]

Some photos

[legacy51]

My brother and I run 38mm PWK A/S carbs on ours and they fit with the stock intake boot and airbox. The airbox boot is stretched a lot, but it works. I'm not sure dimensions are much different if any from that PJ you test fit. I ran a 38 on my stock tecate and it was great and it's great on my ported tecate. I'm sure a 35mm would run great too, but you will give up a little power up top.

[sjsst41]

Thanks for the feedback - I don’t mind giving up some power, as I’m more interested in it being a good runner.

[sjsst41]

Moving further towards completion. Tank, exhaust and electronics installed. Hope to start soon with the replacement carb in place.

[Red Rider]

Coming along nicely. It's looking good.

[sjsst41]

Thanks ! Just finished up this morning before heading off to “mothers days” activities and I fired it up for the 1st time since the rebuild. Happy to say it started right up. Unhappy to say the aftermarket fuel switch leaks like a sieve. Any recommendations for a quality switch? The one that’s on there the PO installed, and a common eBay or Amazon $10 part. It doesn't look like a stock Kawasaki unit is available?

[Red Rider]

You're welcome. A few years ago, I rebuilt the OEM petcock on the Tecate I'm currently building. It was tested with water in the tank, and luckily it was leak free. We will finally be firing it up in the very near future, so gas will be going the tank for the first time, and hopefully it will still be leak free.

For your situation, I would try ORI: https://www.off-roadinnovation.com/index.php

Here is another helpful thread for Tecate owners: https://www.3wheelerworld.com/showthread.php/94809-Kxt250-Tecate-3-What-Parts-Fit-Swap-Interchange

[HondaRidr]

Some yamaha petcocks will fit on the tecate tanks as well. I think I used a timberwolf petcock or something like that on mine.

[sjsst41]

Thanks again for the reference - good knowledge/info !

I went with a Kawasaki petcock, OEM PN 51023-1342 for a KLX110 02-15, and it fit nicely.

[sjsst41]

I’ll consider this project “done” except I do need to dial in the jetting. I now realize it was a bad decision to use a Keihin PJ carb on the Tecate. The fit was great, but the idle being tied to the choke is flawed. Anyway the idle needs attention, and I assume I’ll need to fine-tune the pilot jet, at the moment and he trike runs well but the idle is not consistent. Anyway I am pleased at how it turned out, and I’m looking forward to handing it over to my uncle in Pennsylvania. The plan is to head back in August and deliver it then. Now I’m onto building the ‘86 ATC250R, with the goal to finish by August so I can ferry it back to PA for some trail action. Should be fun (as long as no one gets hurt)

[sjsst41]

Photo of the finished product ! Note I did install the “Tecate Uni-trak” and “250” rear fender graphics after the photo was taken a couple days ago.

[HondaRidr]

It looks great! Those PJ carbs are a pain. In my experience the pilot has to be a little too lean to get a decent idle. I still run one (it is about to get replaced though) and just deal with it not idling.

[rpeters]

I probably have a nice original carb. I have fork tubes that are probably good.

As far as the rear suspension goes, if you plan on hitting any bumps or doing any jumps, you need to change the rocker, dog bone, and shock to an 86 setup. It bolts right in and I have a few of them I would sell one if you want the rear to work somewhat on anything other than flat ground and not bottom out when you jump more than 2 feet in the air.

Also, the 86 shift mechanism is interchangeable and works better. I may have one I would sell, but you can find them on Ebay.
.

[legacy51]

Nice job! It turned out to be a good looking trike. I've never seen a bad looking tecate though :p

The 84 rocker isn't bad at all. It acts like a no link swingarm because it's not really progressive. It's really nice because it makes the rear end super predictable. It just doesn't do so well on bigger hits which most trike riders don't big jumps anyways. I changed from 84 to 85 on my tecate and I preferred the 84 for general trail type riding. I could hammer the whoops really hard too with 0 bucking. I really liked the 350x rear suspension too so maybe I am a no-link kind of guy. It all depends on what you like and how you ride.

[HondaRidr]

What do you mean the 86 shift mechanism? The shift lever or something else?

[sjsst41]

Thanks for the offer on parts rpeters, I’ll pass on the suspension though as I’m thinking this trike isn’t going too see much air time, my uncle is 65 now and probably shouldn’t be launching it, although he’s still a wild man. I’m looking forward to getting out on the trails with him (damn, reliving like 40 years ago). I just hope “no one” gets hurt. But let me know how much you’re asking for the carb. I’m going to try and improve the PJ, and might consider buying a PWK - which I like (I installed one on my ‘83 CR250 race bike & it is a nice carb to dial in)

[rpeters]

What do you mean the 86 shift mechanism? The shift lever or something else?

shift shaft assy and shift star . i have all the pats needed for sale.

[rpeters]

Ok I will take a look for the carb. The stock carb works flawlessly on a stock or near stock bike . if you go to an aftermarket carb the best one is an old school mikuni round slide. all these fancy azz $400.00 carbs will absolutely not get you to the finish line one iota so0oner.

[sjsst41]

Delivered ! Unfortunately the new owner (my uncle) gigged his ankle a few days ago, so we were not able to ride, I did leave the 250R at his place, so when I’m back in October we should be able to get out.271520

[sjsst41]

Both trikes 271521

[sjsst41]

Ok - so this Tecate RIPs, I did some riding around my house before packing it up and delivering to Pennsylvania, my uncle finally took it for a spin and commented on how intense the power delivery is. I noted the bottom end is mellow, starts to pull when you get into mid-band and has a “healthy” top end. Probably great for the track, but not the best for trail riding. Any recommendations on how to re-tune that motor to offset the top end while improving bottom end performance? The piston is maybe .010 or .020” over, Boyseen Rad Valve installed, DG pipe and Answer silencer, stock ignition with a Keihin 34mm PJ carb. I started some online research, but currently coming up empty. Thanks

[sjsst41]

One thing I thought of is to add the heaviest flywheel weight I can find. Anyone know if that exists for these older motors?

Edit: looks like Stealthy makes one for the ‘83 KX 250 motor ! So I assume it’ll fit the ‘85 Tecate?

https://www.steahlyoffroad.com/kawasaki-kx-250-83-89-flywheel-weight-603

[Footy]

One thing I thought of is to add the heaviest flywheel weight I can find. Anyone know if that exists for these older motors?

Edit: looks like Stealthy makes one for the ‘83 KX 250 motor ! So I assume it’ll fit the ‘85 Tecate?

https://www.steahlyoffroad.com/kawasaki-kx-250-83-89-flywheel-weight-603

This seems like a great place to start!

[HondaRidr]

The 83 kx250 flywheel fits on a tecate crank but the stock flywheel is much larger diameter than the kx. You could go back to a stock headpipe or even smaller carb possibly. Your build is already fairly mellow.

[rpeters]

Ok - so this Tecate RIPs, I did some riding around my house before packing it up and delivering to Pennsylvania, my uncle finally took it for a spin and commented on how intense the power delivery is. I noted the bottom end is mellow, starts to pull when you get into mid-band and has a “healthy” top end. Probably great for the track, but not the best for trail riding. Any recommendations on how to re-tune that motor to offset the top end while improving bottom end performance? The piston is maybe .010 or .020” over, Boyseen Rad Valve installed, DG pipe and Answer silencer, stock ignition with a Keihin 34mm PJ carb. I started some online research, but currently coming up empty. Thanks


It is impossible to "detune" a Tecate enough to make a significant difference in the power delivery. We designed them to to haul azz because the 250r engine was already xlnt for trail riding, so it made no sense to us to make our engine run similar.

The flywheel weight, and a woods type pipe will make the biggest difference, and possibly installing a slightly smaller rear sprocket, like 1 to 2 teeth.

Installing a smaller carb wont increase bottom end at all, it only slightly reduce the semi violent (light switch) hit that it has because it will reduce the horsepower.