Had about an hour to work on the project last night, nevertheless a little bit of progress. Didn’t get my shop manual yet, but I found this site with super duper expensive kz200 parts. I am talking about a front axle for $150. I just purchased the part on ebay for $14.00 with free shipping. The good thing about this site is that it has all the diagrams for the bike with OEM part names and serial numbers. I used some of those diagrams to look at the assembled front end that I have. I disassembled it, cleaned the front suspension with some soap water. Then proceeded to work over the fork with sand paper and managed to get almost all of the rust off. I finished it off with NeverDull wadding solution and now it's not quite like new, but in much better condition than before. I did the same to the steering stem and the washer-spring.
I took off all the controls from the handlebars, disconnected all the wiring and then stood there in silence scratching my head. Everything that I touch I notice has missing parts. Missing fork cover, missing axle (which I already ordered), missing bolts, missing washers, MISSING KEY?
Yes, missing key, which means that I am going to have to find a new ignition switch or see if I can get a key made for the old one. Anyway, that is for later. For now I must stick to the plan and get the wheels, suspension and handle bars assembled.
Yet, before all that I still have a lot of cleaning to do. Not to mention expanding my list of missing parts.
Will post new photos of the clean parts next time, for now here’s our new and improved garage. My wife and I spent 3 hours cleaning and rearranging. She also bought me a 260 piece Craftsman mechanic’s tool set, which is making my work on the project much easier.
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