kz200 snagged from barn-need parts and guidance

Hello all! found a 1978 kz200 in an old barn for my boy-hes 16..well try to rescue it! cheap gamble. its complete, even has shop manual, pretty simple bike. but looking for help to streamline all the same.


compression good.. even got spark. still apart until throttl cable, so no run yet!

pulled carb-fill needle stuck shut. all good to go.
bought new throttle cable-on its way

needs I know of, need to source
dimmer handlebar switch
little rubber grommets for side panels-theyre dry cracked.
fork seals? long shot.

anything else I should buy/do immediately? been awhile since ive messed with something this rickety im a german bike guy.

thanks for reading

issue:

hooked to power,voltage drops when i turn the key, but no gauge lights or headlamp,. does spark though...

Howdy.

Side cover grommets. Z1Enterprises.com >> OEM 92071-056

Possible alternative. Windshield wiper grommets or bushings from the auto parts store. From an old KZR topic someone used them to secure his side covers. I don't know exactly what he got, but probably something like this: Dorman - Help brand wiper motor bushings 3-pack. then remove the metal insert of course. I assume something similar can be found in Germany.

excellent, thanks.

clarification, I, personally, am not German. My bikes tend to be lol

New tires and inner tubes, fresh brake fluid and pads

Don't know where you live but if you want a back up bike this is a great deal on a kz200 with only 6 miles on it
chicago.craigslist.org/nwi/mpo/d/hobart-kz-200/7084040785.html

bluej58 wrote: Don't know where you live but if you want a back up bike this is a great deal on a kz200 with only 6 miles on it
chicago.craigslist.org/nwi/mpo/d/hobart-kz-200/7084040785.html

goodness thats almost worth it isnt it?!!!!!!

something ive not thought of...a headlight made of unobtainium. LOL thatll have to be a mod of some sort. is there an easy one?

Do you have the fork covers (fork ears)? The KZ200 had some of the same headlight stuff as some other models.

Alternatively, you might be able to go with an aftermarket headlight. something with an H4 bulb or LED or etc for better lighting.

What Martin said.

Unless you're planning to do a 100% correct factory resto, IMO there is no need to insist on the OEM style headlight. An aftermarket H4 replacement would be the safest bet: it will work with the stock alternator output (assuming it's working properly) and will avoid the weird lighting patterns that some of the LED headlights have. You should be able to find a complete headlight and mounting ears for under $100.

From the searching I've done, it's also more likely that the H4 models will be DOT compliant.

Yep its complete... all there, fork covers, headlight assembly and bezel... I dont give a damn about 100% correct. Just rescue from the scrap heap it was destined for.

yeah for sure replacing with H4. all day. thats what I meant basically.

it was just something I didnt think of...sealed bulbs not being made anymore.

Well she lives!

Head gasket blown. Good compression when cold...

The logical brain side says to stop, but I’m emotionally invested now since I heard it run. ... here we go. Lol

Wish me luck.

Peelz wrote: Well she lives!

Head gasket blown. Good compression when cold...

The logical brain side says to stop, but I’m emotionally invested now since I heard it run. ... here we go. Lol

Wish me luck.

edit that. Head gasket not the issue, though we still might rebuild it..... (oil on the head threw me off, it was cold)

shot battery and a short, caused weak spark. It would die under throttle. Changed battery, she took off. Itll do 60 with my chunky behind on it. Headlight still worked!!!(this was the short circuit-crusty wire crushed against frame by zip tie)

Im sure we could tune it a little more.... and it needs a top end, it smokes a bit....

but, 60, thats plenty.

I forgot the addictive feeling of reviving old bikes... I might be in trouble here.....

got the head off, waiting for parts. Head gasket was definitely shot...I was right the first time. It just didnt really get bad until it was really warm.. it was in a bunch of pieces... everything else looks good! we cleaned everything, lots of gunk from burning oil.... piston clean as whistle now. cylinder wall is beautiful. I didnt expect that.

the kid is loving the project, im creating a gearhead.....

electrical. most everything has woken up! starter, which I had planned on ignoring and making him just kick it is alive. that was a great surprise.
horn is back
neutral light is back(bulb)
brake lights on.. (short in front switch)
headlight works but hi low doesnt. ill just keep the swap in my back pocket. just leave it. kids not going to ride it at night out of town.

turn signals are vexxing me, i'm not afraid to admit, in part, because my vision sucks lol wiring diagram looks like linguini. power in (brown)from ignition to flasher is live, orange out to the switch, nothing.

the left switch pod is obviously bad. took it apart, cleaned/oiled it... it moves freely but still no power comes to the signal switch. thinking out loud here....

Power from ignition to flasher is there... i jumped from flasher up to the switch, the flasher clicks. but no lights.

gotta be the switch,? or in the spaghetti behind the headlight? or could flasher be bad but still click, ive never seen that....

i'm sure i'm overthinking. lol