Kawasaki KXT 250 tecate restoration

[Antreas Sp]

Hello Guys, it's been a while but i'm still here trying to find time in between my daily routine to do some progress.It was a very busy summer for me.
Today i had a look on the kicker. As i mention before 1 engine i own has the kicker welded on the kick shaft. (not the oem one)
The second bike i bought had the kicker welded on the boss at the "open" position cause the boss had snapped and i think this is typicall on these machines as i have seen several cases where the kicker boss has failed.So i had a KDX 200 kicker laying around and the boss would fit the KXT shaft perfect,same splines! So i measure again and again and i cut the kicker from the old boss and tried to fit it on the KDX boss to find out that the KDX 200 boss is 1mm bigger in diameter!So i think it won't fail at the future like the Tecate one.So only thing i have to do is to bore the kicker and it will fit fine as i was lucky cutting it on spot!

[Antreas Sp]

Ok guys finally some progress! I fitted the kicker on the boss and i realized that the KDX boss is a bit shorter from the KXT one so the kicker had a bit of inteference with the shaft nut but that problem solved with a touch of the kicker on the sander!

[Antreas Sp]

Engine has been dissasembled and the cases have been welded at all the areas that were broken! One big chunck of aluminum was missing from the cases at the point where the engine mounts with the frame and swingarm. This happened from the previous owner when he tried to remove the engine loosening all the mounts, swingarm,head mount,front of the engine,# mount underneath-he never saw that mount which was covered with mud and he thought engine was stuck in the frame and took a and bit the out of the engine cases until he broke them! Video with the guy who helped with welding aluminum!

https://www.youtube.com/watch?v=fMkS...nel=Xalasis715

So here they are welded and ready for wet blasting!

Chain problems fixed! :-D


The kicker they welded on the shaft caused a hole at the clutch cover!

[Antreas Sp]

Next is gonna be the shift shaft which is totally destroyed and you cannot buy a new one anymore.

[350for350]

When I see things like you've found, I want to grab the person that did it, shake them around, and ask what they were thinking.

[Antreas Sp]

Okay guys 2022 is here.
I managed to restore the shift shaft using another shift shaft from a Kawasaki bike which is the same diameter for the oil seal and also has the same splines for the shift lever so a little bit of cutting grinding and welding and its done. The splines were damaged on mine from previous owner welding the shift lever on the shaft. So the part that is welded on the shaft and does the shifting when you press the lever was cutted of the old shaft and was welded on the new shaft and that was it.

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[Red Rider]

Pretty slick, nice work!

[Antreas Sp]

Thank you Red rider. This restoration takes some time cause really every little thing on this trike needs attention. I currently have some issues with the place i store and work on these so it will sure take a long way untill i finish this.

[El Camexican]

You’re fixing things many people would have sold for scrap metal, I think that’s awesome, keep posting your progress please.

[Antreas Sp]

You’re fixing things many people would have sold for scrap metal, I think that’s awesome, keep posting your progress please.

I want to thank you and all the other members here for the motivation you give to keep working on these old machines. That's the best to hear from you guys to continue work at stuff we love. Cause we live in difficult 'times' and sure mental health is the hardest to achieve.

So a small story for me is that i have worked in a lot of jobs throughout the years and one of them was at a machinist shop for 3 years. In these 3 years i learned a lot of stuff. And stuff i already knew how to do i managed to enrich my knowledge and thought about them. But the most valuable lesson i learned is that you can always rebuild,restore a really broken-damaged part that in first sight may look beyond repair. You just have to have the tools the time and the energy to do so. And i'm in that mood at this point so everything i see i try to make it almost like new and that's also a way to make myself better on making stuff.
So lets see if i can make this front brake master cylinder good. Someone tried to remove one of the bolts drilling it but he drilled the hole offset and now half of the bolt is stuck in there and the cap doesn't line up with that hole to do a new thread. That needs to come out.

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[Antreas Sp]

Some progress done. I managed to remove that half bolt from the hole by welding a nut on it so i can grab it. Third attempt got it out.


So then i had to fill weld the hole so a little preparation getting all the rust out and bring some new aluminum up the surface so i can weld on.

And after welding.


Then i sanded down the weld perfectly flat and i make the hole and threads and this was it.
Well i changed the sight glass also and the piston-seals. So i have a perfectly new master cylinder now.



Here it is next to another repaired one which had been broken at the point where the lever attaches on.

[350for350]

Wow! Great work!

[El Camexican]

Wow! I wish I had your touch for welding whatever alloy that reservoir is made off. A lot of guys would have turned that thing into a dog dropping shaped ingot trying to do make that repair.

[oldskool83]

I appreciate people who think "I already have this lets fix it" I know that take way more time. Keep it up.

[Antreas Sp]

Wow! I wish I had your touch for welding whatever alloy that reservoir is made off. A lot of guys would have turned that thing into a dog dropping shaped ingot trying to do make that repair.

Well you know, you must have a good welding machine with the ability to weld aluminium and practice again and again so you can deal with that kind of staff and 'win'.

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