SX200 Restoration Project
Test Assembly or Dry Fit
This is the perfect time to test assemble your bike. If you have purchashed replacement parts for your bike they might not fit as well as the original and now is the time to find out. Parts are never exacly perfect copies and each one can be slightly different from previous versions. Also, as parts 'live' together on a running bike they get comfortable with each other, introducing a new part can make things extra tight and you don't want to find out you bought the wrong part after it's been painted.
Take the time to mount your legshields, horn casting, horn grill, headset, and side panels. Mount the cylinder shroud and fan shroud on the motor. Go over each part and make sure it's not rubbing on anything, that it has the proper holes and everything lines up. Make sure the side panels fit on the bike and that the gap between the frame and the side panel is even all the way along the top edge. If you notice that anything is not quite right then now is the time to fix it.
Prepping For Paint
You're going to have to make some decisions about how you're going to get your parts painted. Are you going to rattle can them yourself? Pay a local car shop to paint them? Maybe you can afford to have Tim Stafford paint your bike. You'll have to determine a budget and go from there.
Ask your local scooter club, ask Google, visit your local body shop, and get quotes. Bring the parts with you so they know what you want painted. Make sure you're getting a quality paint job as you will be VERY bummed when the paint starts falling off as you build your bike.
Generally a painter or powder coater will strip the old paint off the piece for you. This is especailly true for powder coating but not so true for painters as the stripping proces can take quite a while and generally painters won't take the time to do it right which is why I spent a ton of time looking at every part before I gave it the seal of approval. I stripped the paint off using sand blasting which cleaned off all the rust as well as the many layers of paint. I then made sure there were no surprises under the paint and masked off areas that I didn't want painted so the painter wouldn't have to guess. I gave each piece of coat of etching primer to seal the parts as I knew it would be some time before they made it to the painter. During this time I studied each part that I was going to put on the bike. Since the hardest part of painting is the preparation I figured this was time well spent.
This was a cool time as I learned a ton about the parts I had and as you can see from the pictures I took. Some might consider me an anorak but I only wrote down these details as a way for me to document what I went through as I certainly won't remember all the details I found. I hope someone finds them interesting or gets some value from this article.
That's a lot of parts that need painting. I counted 40 for my bike. Make sure that whoever paints your bike is aware of the number of parts that you're going to bring them.
Your pile of parts might look something like this when you're ready for paint.
Next: Building The Bike!