2021 Bashan Brozz

[LightSmith88]

Originally Posted by Civire325

Hey Ya'll-
Still alive and workin on the bike. Been taking my time wire brushing the frame and swing arm and its been slower going than i expected. I did try to get in touch with Peace RE a cert of origin, but they told me that i would need to get this from the original owner (i'm the 4th.) I did order some parts from them and there were no issues on that front.

.....Wait, you were able to order parts from peace sports? that's great news!

[Civire325]

Yes, i was able to order 2 parts from them through their online store. They shipped fairly quickly with no issue. I will be trying to fit some parts from other bikes during my rebuild of my Recon though as Peace does not seem to list every part i need on their page. YMMV.

[LightSmith88]

Wow! That is a relief. I think I am going order a full replacement set of plastics then if I can. My biggest concern was if I wreck the plastics on my Recon, I was just going to have to live with it. I got the new Paladin but I kept the Recon as a back-up/buddy bike. A good friend of mine is going to do a motorcycle tour through Vietnam in a couple of months. I asked him "have you ever ridden a motorcycle??" he said no but hoped he would be able to figure it out HAHA! So of coarse, I volunteered to let him learn on the Brozz before he goes. My next though was. "oh crap. If he crashes it and messes up any parts, I will be out of luck". This new development, however, changes things! I tried to reach out to Jefferey from Peace Sports and got no response. I will just put an order in through the website then. Thanks for this! It is great information.

[Civire325]

So i looked at what they had, and they seem to carry a full set of Recon plastics in either Black for $200ish, or Army green for a little less. All of my plastics are completely toast so i need to replace them, but ill be looking at a different route as i am not interested in these colors (silly, i know), and my plastics look awful because someone painted them.

I plan on seeing what Hawk/DLX plastics fit, and so far the only thing i can tell that is different is the rear tail plastic/passenger handles. The single cast aluminum piece for the recon was broken in the the same place (the one that came on mine, and the replacement from Peace), so im wondering if this is a casting issue? (See pic for broken tab, i believe this is where the side panel is secured.) The Hawk has two separate handles and a different tailpiece. Gotta finish painting the frame first, will report.

[LightSmith88]

Now that you mention it, I would also consider some hawk plastics instead if that works out. I know that the headlight is very different but I would be interested to see if the plastics bolt up ok. Also, check this out. I was looking at other Brozz Recons and I came across one with a windshield that I thought was pretty cool. I bought one and I like it a lot.

[LightSmith88]

I have to thank RockCycle for giving me the link on that!

[Civire325]

Hey Riders-
Still chugging away at the frame, and got most of it stripped down to bare metal. For some reason, the larger gauge wires on my 4.5" angle grinder do not seem to strip the paint as quickly as a handheld drill wire brush. On the rainy days i've been working on cleaning up a few other things and found some additional customizations done by the PO-

It looks like the PO used a combination of 18F/45R with a 428, unsealed chain (RYC brand.) I dont know if it happened with this combination of gears, but it looks like it wiped out the front sprocket cover, the gear selector sensor wires and my case may be cracked. The bike did run, and isnt losing oil, but that looks pretty ugly to me. Not sure if id tell anyone to do this, but it seems to work.

Dan/Jerry - would you say (from a clearance perspective) that a 12TF/35TR with a 520 chain should give me better clearance? I am riding 100% offroad, so having more low end is what i was going for anyway. I plan on obsessively checking chain tension as well.

[LightSmith88]

Yeah that is ugly! I concur on the 12t front. that is what I did on my Brozz and it is great for low end grunt off-road. 18t front seems insane! I have heard of guys doing like a 15t but wow! luckily you can get like a whole new engine for these things for around $300 if you had to. I have a guy nearby on craigslist selling a cb250 unused for $250. I thought about grabbing it just to have around haha! I have definitely had to rock a JB welded case or two in my day. It should be fine. SEND IT!!! and keep the updates and pics coming!

[Civire325]

Slight update on progress-
Rear wheel - 2021 Brozz Recon, 17" diameter (4.60-17)

I had 3 broken spokes on my rear wheel, and i replaced these with spokes off of Amazon. The ones that i chose were 150mm in length and 4mm thick. These seem to be a little longer than the ones i had (~145mm) but i could not find those. I have re-trued the wheel to the best of my ability and replaced the sprocket studs with generic studs for the CG125 with dimensions of "Fitting: Dimension: 35 x 16.8mm/1.38" x 0.66"(L*D); Thread Size: M10 x 1.25." The description assured me that they're "durable." The studs i had on there were fairly loose and one had completely ruined threads.

[Civire325]

My goal for the engine was to:
1. Adjust valves
2. Drain oil
3. Upgrade clutch springs
4. New oil.

The takedown itself saw a few other things added to this list:
5. Valve cover gasket (Motocult)
6. Clutch cover gasket (CSC)
7. Clutch plate screw (CSC) - M5x20, grade 8.8
8. Gear selector switch/sensor? (TT250/Engine/Shifting Drum/ #17.)

Whatever happened with my front sprocket chewed up the wires of my gear selector switch/sensor. Markings on the switch say "CG125" but google searches of this had a lot with 2 dogs and not the single i see on mine. I ended up ordering the $5 one from CSC and it fit perfectly.

As i was removing the clutch plate/spring retainer *bolt*, i completed rounded the last one (of course) and was able to bite it with an extractor socket. CSC to the rescue again.

[LightSmith88]

Great work! Keep it coming! Yes, CSC is amazing! I got a really great engine skid plate from them that I use on my Brozz. It is surprisingly good quality. It is terrific to see that you are able to find parts to keep this bike alive! That gives me hope for the future of mine. It looks like yours led a pretty rough life before you got it, but I am pretty sure you are doing more than returning it to its former glory. Seems like when you are done, that thing will be better than ever!

[Thumper]

An impact driver is great for tightening or loosening Philips screws on a motorcycle. Less than $10 and it keeps screws from getting gnarled up.

[Civire325]

I do have a fair bit of tools for this work - including a cordless impact driver and one of the hand driven impact drivers. I had a bit of an "Oh Lort" moments when this happened and made it worse as i got frustrated. I had never used one of these extractor sockets before and really hoped it would work. The next steps would have been my acetylene torch (lighting all the oil on fire and the plastic gear in there) or drilling it out (snapping off the ez-out and spreading metal shavings in the engine case.) All of this was made more difficult because i have removed the engine fully and its resting on the floor of my basement.

[Civire325]

I guess i described the rounded bolts incorrectly. I did not mean the phillips head screws on the clutch cover, i meant the bolts that secure the clutch spring retaining plate. Picture from 360 power sports. They seem to have a lower profile head, and where they rest inside that plate makes it hard to get a box wrench on em. 5/6 were fine to turn with just my socket wrench, the last one went completely round because of my frustration.

[Thumper]

A mallet driven impact driver is awesome for breaking loose or making the final tightening on hex or allen bolts as well as philips head screws. It can extend the life of them!