2021 Bashan Brozz

[Civire325]

Hey All-
I decided to tear down the used Brozz i got a few weeks back and address a few things i noticed. Would you all be interested in a spreadsheet with bolt types/measurements as i re-assemble this? I planned to:
1. Strip everything off the frame.
2. Check valve clearance, drain/change oil, upgrade clutch springs
3. Chase all threads, replace hardware as warranted
4. Replace steering stem bearings, swingarm bushings and wheel bearings
5. Replace chain, possibly sprockets
6. Rebuild Calipers, replace pads
7. Repair/rebuild wiring harness (something is draining the battery)
8. Replace all plastics
9. Install oil cooler, crash bars and a new headlight.

Given that there are some similarities to the Hawk, but not on everything - is this information out there, been documented? I know of Dan/Jerry's posts with the Hawk, but what about the Storm/Brozz/Recon/DB-08?

[Civire325]

Here is the link to the quick comparison spreadsheet i did, i hope i'm doing this right. Its nothing earth shattering, i just found it annoying to flip back and forth between the distributor pages and wanted it in one place.

https://docs.google.com/spreadsheets/d/1ZI80W05kE0l1G-tuolOcE3GtNjX0jBxx/edit?usp=drive_link&ouid=101447160393990749013&rtpof=true&sd=true

[Civire325]

Starting from here, I identified:
1. a tab on the frame that was missing a welded nut
2. a welded nut was missing from the steering head for attaching the front fender
3. The steering head was missing 2 ball bearings on the upper race
4. the wiring harness was stripped bare down in a few places - mainly around the tail lights and rear blinkers.


To fix the missing fairing nuts - i found that McMaster-Carr has Metric Aligning Weld nuts the M6 Part number is 90955A101 and are about $19 for a pack of 10. Ill be using my wire wheel to strip the frame down this weekend and firing up the welder.

Note: This was a fully functional bike, i like a project and have enough tools to be dangerous.

[Civire325]

Hey All-
Hope you all had a happy new year, its been a bit since i posted but progress has been made:
1. I was not able to strip the paint off the frame in one weekend. Progress has been slow but is coming along.
2. I was also not able to push the swingarm bearings out. I tried hammering sockets in and even used my 12-ton shop press with a torch and was unable to push the inner sleeve out. I decided the swingarm bolt was tight enough so i cleaned up the side i had peened and walked away while i was still ahead.
3. This is a recon model - it looks like the plastics were tan at one point? I am seeing some sparkles on the satin black - was that something Peace did, or am i dealing with sparkly-farlkes here?

[Civire325]

Here are some photos. One is of the swingarm bushing - note this didn't technically need to be repaired i guess. I thought it would be easier to push out, but it was not. If anyone has any suggestions on how to do this, id appreciate it. i already tried a hammering, torch and hammering, and hydraulic press + hammer, i didn't damage it past the point of no return, i figured id stop while it was still usable.

Second photo is progress on stripping the paint, and specifically the one welded nut that had been torn off. Note that this is a mounting point for a piece of cover plastic on the right side just above the rear brake cylinder

[LightSmith88]

Keep up the good work. It's good to see these recons get a little love! I have a 2021 myself. Its a great machine. It will be fun to see what you do to it.

[Dusman]

I heard in a somewhat recent Motocheez video that Peace Sports isn’t going to sell the Brozz anymore. Is this true?

[Thumper]

I heard in a somewhat recent Motocheez video that Peace Sports isn’t going to sell the Brozz anymore. Is this true?

Inactive website for more than a year now. But the Bashan Storm is still sold online and in a few brick and mortar locations. It is an excellent CGclone.

[LightSmith88]

That is sad to hear. My experience with peace sports was amazing. the owner himself (Jeffrey, same gut on the you tube videos) would personally respond to every email. I was upset because i missed out on the larger rims and tires they updated for the 21 model and he sent me out a new set for like $100. rims and tires! That,s like shipping cost alone! I liked that you could get every single part for a Brozz off of their website. I even sent him pictures of the mods I made and he responded saying that he liked them. What a bummer. It was cool to see him come up with the paint scheme for the recon with spray cans on you tube. Then they actually recreated his original design and produced them. how cool is that. oh well...RIP Peace Sports!

[LightSmith88]

Funny! I just found this on Aliexpress! I guess you can still get a new Brozz! This one says 260 on it but I looked at the specs and it still has the 230cc lol


https://www.aliexpress.us/item/3256805917169440.html?src=google&pdp_npi=4%40dis%21USD%211698.64%211636.64%21%21%21 %21%21%40%2112000035756584147%21ppc%21%21%21&src=google&albch=shopping&acnt=708-803-3821&isdl=y&slnk=&plac=&mtctp=&albbt=Google_7_shopping&aff_platform=google&aff_short_key=UneMJZVf&gclsrc=aw.ds&albagn=888888&ds_e_adid=&ds_e_matchtype=&ds_e_device=c&ds_e_network=x&ds_e_product_group_id=&ds_e_product_id=en3256805917169440&ds_e_product_merchant_id=761193140&ds_e_product_country=US&ds_e_product_language=en&ds_e_product_channel=online&ds_e_product_store_id=&ds_url_v=2&albcp=20123152476&albag=&isSmbAutoCall=false&needSmbHouyi=false&gad_source=1&gclid=Cj0KCQiAy8K8BhCZARIsAKJ8sfTY_8kmA7g4ZrmopnKp RMeNLIvXXF6Z8Lb3XA9oNX9XTpOJDsDd9XIaAvLVEALw_wcB&gatewayAdapt=glo2usa#nav-description

[Bruces]

Peace sports was somewhat active on this site ,seemed like a great guy ,I don’t remember anybody having issues with those bikes and I am certain he would of stepped up and helped them out if needed .Not sure what happened ,hopefully he shows up again with some more good bikes .

[LightSmith88]

I sent an email out directly to Jeffrey on the same address we had been talking on back then. I'll let you guys know if he responds.

[Dusman]

I sent an email out directly to Jeffrey on the same address we had been talking on back then. I'll let you guys know if he responds.

Thanks! I’d like to know for sure if this is the case. The Brozz was/is a great bike for the $ and Jeffrey was always great about keeping the parts in stock and affordable.

[LightSmith88]

Well. Crickets guys. Sad to say I never got a response from Jefferey. Bummer, seemed like a good dude. Civire325 you making any progress?

[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.

[LightSmith88]

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!

32990

[Civire325]

Hey All-
I've got the frame to about 95% stripped down at this point and am just waiting for the temperatures to tick up enough to apply POR-15 to it. I have a bit of paint left to strip off the swingarm, but that's about it. The paint was a bear to take down with my cordless drill - this would have been a breeze with a sandblaster.

[Civire325]

I did chase the threads on everything i could find on the frame with either a 6X1.0mm chase or 8X1.25. I may put together a .pdf measuring fastener sizes and depths at some point as the PO of this bike used everything they could (stretched the tank tabs by using fasteners that are too long. I had one broken off fastener for the cargo rack that I was able to remove with an EZ-out (M8 fastener size, Irwin EX-3 Ez-out)

[Civire325]

I was able to weld one of the nuts that i had with the 1/16" E6013 (Fleetweld) rods and my inverter stick welder (25 amps) without making too much of a mess. Its not my best work, but there are a lot of really ugly welds on this bike to begin with.

[Civire325]

I've decided to go with the Army Green plastic set from Peace sports. Lightsmith - those photos you shared looked pretty good to me, and most of my plastics were in very rough shape. I started sanding things down to see if i could re-weld cracks (didn't know that was possible with Poly-propylene) but i decided id like to actually ride this bike at some point and just purchased the set. The description on Peace is not as detailed as i'd like: " This kit contains all Army Green painted pieces of the Brozz Recon body plastics", so i'll report back which actual pieces it includes - im mainly curious to see if it includes the headlight bezel, fork covers, tail cover and brake cylinder covers or just the fenders/leg covers.

[Civire325]

As a final question to anyone reading this - do you think adding rubber grommets to the fairings would be a wise idea? I know we're supposed to tighten down the fairing fasteners, but several of mine had ripped through the plastic fairings - would this be due to frame flex? I know i had rubber grommets on my Aprilia, and those plastics felt thinner (i think Polypropylene as well?) but were not cracked/ripped in any place. Has anyone done this? I figure $10 in grommets and $20 in Stainless panhead fasteners may make it harder to destroy the plastics?

[LightSmith88]

Wow! This is great! a full frame-off resto of a Bashan Brozz Recon....who would have thought! I am really excited to hear about the plastics kit. I am still planning on getting one to have as a back-up set. I had planned to do that already but I keep spending my hobby money on the Paladin. If you get them, don't expect them to look exactly like mine. I did some custom masking and painting with black in an American flag and star theme on most panels. I just kind of "ghosted" the images on the there so they are subtle. I do really like the green though. I hate to say it but that is what made me buy this bike over a hawk DLX at the time. That and the counter balanced engine, cargo rack, better swing arm, digital display, better seat and a few other things lol.

[LightSmith88]

I was able to weld one of the nuts that i had with the 1/8" E7018 rods and my inverter stick welder (25 amps) without making too much of a mess. Its not my best work, but there are a lot of really ugly welds on this bike to begin with.
:lmao:Yeah I think if you did a really nice weld, it would stick out like a sore thumb on this bike. You can tell for sure that it was not robotic arms doing this work. I call that "hand crafted"!

[Civire325]

:lmao:Yeah I think if you did a really nice weld, it would stick out like a sore thumb on this bike. You can tell for sure that it was not robotic arms doing this work. I call that "hand crafted"!

I totally mixed this up - i used 1/16" E-6013 -the 1/8 rods would have made a bigger mess i think. I ended up drilling 2 holes in the tabs and attempting a plug weld. I was also missing one of these welded nuts on the front fender plate . This weld isn't as awful as the other one - just know that i do not do this for a living.

[LightSmith88]

Oh yeah. It was more of a comment on how bad the factory welds on Chinese bikes are. I live by the "if your not a good welder, be a great grinder" principle myself! I never could get my stick welds to look good. I do fine with my flux-core or mig welder though.