I wish we had more progress to report, but everything is at a standstill due to this BVC inverted forks, tripleclamp kit. The goal is to get a rolling chassis, then start assembling everything else. Well, in order to get a rolling chassis, the tripleclamps have to fit correctly.
On our first attempt to assemble the front end, we had decided to leave the original bearing races in the neck of the frame (even though the BVC kit came with a new All Balls bearings/races set), as they were in good condition, and would be a pain to remove, as there is no way to drive them out easily. The BVC tripleclamps installed easily, using the new bearings, and old races, but it was quickly evident that the steering stops were too short to contact the steering stop tab on the frame neck. We disassembled, then reassembled, this time using the old bearings, and old races, but still no change. As it is, the steering stop on the lower tripleclamp just barely rubs the underside of the steering stop tab on the frame neck, and the bars would keep turning until the forks hit the radiators. BVC is already closed for the day, so mr tecate texted them, and sent pictures of the issue. The next day, BVC responded via a phone call, and they asked, "Are you using the entire bearings/races, that were supplied in their kit?" He told them no, we weren't. BVC said, "That's the problem. You have to remove the old races, and install the new ones, and then the steering stem will go in far enough for the steering stops to make contact." Mr tecate told them, "I don't see the new races making that much of a difference, but we will try it."
Several days later, on our second attempt to assemble the front end, we used a dremel to cut through the bottom race, then chiseled it out. The new All Balls race was installed, as well as the tripleclamps, and we have the same exact issue. The steering stops are not tall enough to engage properly. More pics were sent, via text, to BVC that night. The next day, mr tecate has a phone conversation with BVC, and BVC asks him to send the BVC tripleclamps back to them, as well as the OEM tripleclamps, and they will fix the issue. BVC has been very helpful, while dealing with their products, responding to texts, emails, and phone calls in a reasonable amount of time. It is apparent, that BVC has never had a Tecate in their shop before, to take measurements from, and confirm proper fitment of this kit.
About a week goes by, and we finally get the BVC & OEM tripleclamps back. We immediately notice, the redesigned, taller steering stops, as well as a bunch of nicks/chips in the billet aluminum, so we are optimistic, yet a little pissed off. We mount them up, and the steering stops are finally tall enough to work properly. Whether or not they are positioned correctly, to stop before hitting the radiators, while still allowing a good steering radius will have to be determined later, as the tripleclamps were once again removed, boxed up, and sent back to BVC for some nicer ones.
While we did have the BVC tripleclamps in our possession, we did notice that the front fender bolt pattern is incorrect for the Tecate, and there are no holes for the Tecate headlight mounting bracket. Via a phone conversation, BVC told us that their tripleclamp kits are designed to work with a Honda front fender (200X, 350X, or 250R, I can't remember), and most people run an aftermarket, strap-on headlight. Strangely enough, their website conveniently omits this vital information. We asked them about adding the proper front fender bolt pattern, and headlight bracket mounting holes, stating most Tecate owners would prefer the OEM front fender/headlight combo, but they didn't want to bother, as it would require a bit of reprogramming for their CNC machines. However, they did whip up, and send out, free of charge, a nice front fender adapter bracket (pictured), so we will see how that works out, whenever we get some nicer tripleclamps back again. At least BVC has been covering all of the shipping charges back and forth, while we essentially do some much needed R&D for them, so they can hopefully work out the issues with their product, before they sell anymore to Tecate owners.
While all of the BVC drama has been going on, we were also deciding what to do about the radiators. The originals on this Tecate were pretty ed, and I haven't read any good reports on the aftermarket Tecate radiators (improper fitment, brackets that break off, poor welds, & leaks), other than that they are available. So, we decided on a much nicer set of used radiators from Travis Gisclair @ D&A Restorations. We have nothing but good things to say about Travis. He communicates, is honest, offers fair prices, has been very helpful, and ships quickly. Once we received the used radiators, some aluminum adapter brackets were made up, and riveted on. These will allow us to mount up newer, green, radiator louvers from a 1993 KX-250, whose external dimensions are basically the same, except for the mounting tabs. The OEM black ones are fine, but you can never have enough of that Kawasaki green! Mr tecate also bought some TM Designworks powerlip chain rollers, and a billet, oil fill plug, all in Kawi green of course.