Bashan BSR 250 Build/Chronicles - aka Enforcer/Hawk2/DB41H

[JerryHawk250]

Remove the air injection system and make a block off plate. That's more than likely the cause of the back firing.

[Weldangrind]

Looks like a nice, smooth transition in the exhaust inlet to me. Last time I did that, I used a die grinder, but a Dremel works with some patience.

[AresROC]

Originally Posted by JerryHawk250

Remove the air injection system and make a block off plate. That's more than likely the cause of the back firing.

Thanks!! I thought that was the EGR, didn't even know secondary air injection even existed. Reading up wiki on it - it sounded bad bad bad!

Was considering removing it previously and now it has got to go before I burn up anything.


Since it was late at night before the ride I had to invent something quick. Plugged air injection at the engine with a M8x1.25 bolt. Irrigation plug goes to the airbox with silicon sealant and a screw for the cut tube that goes into intake vacuum.


So far so good no backfires!


The exhaust has to be the best $100 spent on the BSR. It really wakes up the engine and the noise and stink is a worthy trade-off on the trail.


Last pic is the front tire. It looks very off-center, time to redo the spokes!

[AresROC]

Ordered a new foam air filter, but still undecided if the original airbox should be a keeper. I ride dusty in the desert and I do like the aribox design, with its separate compartment for air injection/crankcase ventilation. Has rear facing ports and a built-in drain hole. Also the original filter is a pretty good size and easy to find replacement.


With 600 km's on the bike, there were some fine dust already inside the airbox! Looks like I missed one of the plastic molding tabs and it is pushing up the filter surrounds.

Just noticed the rear fender is damaged from rides as well. I guess I ride pretty hard in the dirt the fender is bobbing up and down audibly during the ride and the tire ate into the fender. The project backlog just got longer!

[Deryl]

Do you have a link for those risers you have?

[AresROC]

Originally Posted by Deryl

Do you have a link for those risers you have?

Well the exact risers are not available from the store but here are the dimensions. And this one is similar: Riser

[AresROC]

Installed a new fender! See thread here

[AresROC]

The rear shock is not working. Took it off and a friend will look it over to see anything can be done to it.


Shock dimensions: Eye to eye 305mm. Top 30mm. Bottom 40mm.


Also noticed the rear brake line is pinched probably to the rear passenger foot peg... time for brake line upgrade?

Also air inject plug thread

[AresROC]

Broke chain guard! Looks like one more item to chop off the bike

[NzBrakelathes]

Have you thought about a digital speedo?
If you are and willing/able to assist in some basic info I’ll do you a very good deal on a unit of your choice.

[david3921]

Originally Posted by AresROC

Well the exact risers are not available from the store but here are the dimensions. And this one is similar: Riser

Does anyone know what the tapped holes are for on the top of these risers? I haven't seen this before.

[AresROC]

Originally Posted by NzBrakelathes

Have you thought about a digital speedo?
If you are and willing/able to assist in some basic info I’ll do you a very good deal on a unit of your choice.

Yes, my speedo wire is catching on the horn so a digital speedo would be nice! When the front forks compress the wire would catch the horn and prevent the handle bar from turning to the left. I put a zip-tie and it effectively prevents the speedo wire from catching.

Originally Posted by david3921

Does anyone know what the tapped holes are for on the top of these risers? I haven't seen this before.

My guess is for counter-sunk hex head plug to prevent handle bar from rotating? I also saw a guy who put a riser on top of the riser to raise the handle bar. Would be an interesting place to mount my NIB Evo SS Gimbal for GoPro. Almost had that Gimbal for a year now lol.

[AresROC]

Update - Lots more work going on the bike!

OCS (Oil Containment Separator Fix)
Rear swing-arm grease
Chain maintenance
Front sprocket relocate
New rear shock install
Digital gauge upgrade


Backlog:

Front wheel bearings seized... replacing bearings. If you start to hear squealing noise watch out! The front axle grease I put on during assembly are already dried up..
Change hazard switch to kill switch
Upgrade kickstand
Upgrade shifter

[AresROC]

Rear shock is now lengthened from 305mm to 320mm in the upgrade, so bike height have risen by ~1-1/2 inch. To compensate for the lean angle because the kickstand is now short, I found a piece of hardware that may offer a temporary solution

It was as simple as tapping a M6x1.0 threaded hole on the bottom of the kickstand and screw it in. The current kickstand is 13-1/2" tall, so I need to find a 15" kickstand. If this mod works well enough I might just weld it on... TBD.

[AresROC]

Ordered the digital gauge from site sponsor Tako aka NzBrakeLathes and it delivered in a week! I mapped out the Bashan BSR's harnesses with Tako and it is identical to a Bashan Brozz. The wheel speed sensor also fit perfectly!

Installation was a breeze. It was basically reconnecting the cluster wire 9-pin, and gear indicator 6-pin, plus power to battery. I added the rpm Blue/White wire with supplied pin and my crimp tool to the 9-pin connector, and it was done.

Thanks to Tako's clear documentation, setup was a breeze too! Only exception was my wheel speed sensor had only 2 magnets, not 4 as stated in the doc.

With accurate MPH and now RPM info, I will be able to tune my carb better. Plus no more annoying wheel speed wire that was being caught on the horn. I really wish I had done this upgrade much sooner!