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Matty`s Bashan Streetfighter Quad
As this forum doesn`t appear to have a separate project subforum I figured I`ll just slap this here.
https://www.customfighters.com/forum...b204f6c764.jpg So a quick brush over/recap from my introduction thread, bought this Bashan quad with the full intention of fixing it just enough to getting it running, gutting the rear suspension out of it and replacing it with a Honda VFR RC36 single sided swingarm for quick tire swaps as the said arm has a 4x108 bolt pattern so it readily accepts old narrow steel rims from say an old civic or so, ferry the thing across the gulf on Finland to Estonia next summer and thrash it & do burnouts until it blows at SMASH streetfighter festival, but when I went to get it I found out it has street legal reg plates which changed my plans somewhat. https://www.customfighters.com/forum...b204f87add.jpg The machine had caught fire under the previous owner due to a leaking carb and the idiotic routing of the exhaust mere millimeters under it so the wiring harness was completely melted and pretty much a one big short. I tried my best to repair it but without a wiring diagram it was half guesswork so when I finished and turned the key I wasn`t exactly surprised to find out nothing happens. https://i.uppaa.fi/2019/11/14/IMG_20...b42df79.md.jpg The PO had spraybombed the headlight cover black without doing any prep work what so ever and the paint pretty much fell off when I started sanding it. https://i.uppaa.fi/2019/11/14/IMG_20...e38cfcb.md.jpg I had a go at repairing the fairings too but quickly realized they`re beyond rescue due to paint flaking off in many places plus the mid section having sustained fire damage and partly melted so I ended up tossing the old plastics out. https://www.customfighters.com/forum...470bc3cda8.jpg Here`s how the headlight cover looks now and how the rest of the finished quad will be colored (not a KTM fanboy but happen to love the color combo) https://www.customfighters.com/forum...91efc79859.jpg The quad came with a brand new Keihin accel pump carb and an adapter boot but it quickly became clear they will not fit with the original exhaust because of the extra hump on the bottom of the carb clashing with the exhaust so the chimney had to move under the engine. Wasn`t exactly pleased to discover the state of finish on these things, FFS I`m probly losing a few HP on this weld seam alone... https://www.customfighters.com/forum...91efc7f90e.jpg Marginally better. https://www.customfighters.com/forum...91efc8d62c.jpg https://www.customfighters.com/forum...91efc86934.jpg Gotta say I`ve never seen a KAT that small before. https://www.customfighters.com/forum...91f1d50ad6.jpg Need to make a connection there or else the finished pipe will be impossible to get off the machine. https://www.customfighters.com/forum...99a8494014.jpg Some cockpit upgrades too, new clutch and brake levels&perches, new mirrors, new lower handlebar. Might have to replace the bar though as I bought it as an impulse buy not realizing the crossbar clashes with the gauge cluster so either need to replace the clocks (rather not, done it a few times on bikes, a royal PITA to get working properly) or re-replace the bars. https://www.customfighters.com/forum...82cda2d398.jpg Bought a .30cal NATO ammo box off an army surplus store for the battery which I will be replacing for a 14Ah one that got left over from my last streetbike build after I upgraded to Lithium. So that`s where we stand today. Parts already replaced so far: Handlebars, mirrors, levers&perches, wiring harness, CDI, coil, headlight, carb, c-boot, throttle cable, quick-twist throttle. Parts ordered but not yet fitted/received: chain, sprockets, complete new fairing kit, air filter, parts for a DIY electric chain-oiler Still in planning: reupholster/replace the seat, tape new fairings, have hub spacers made to accept car rims at back for burnouts :D, strobes lasers projectors etc for the fighter fest, replace destroyed tail light, update all indicators, weld a few cracks from frame and stop rust at places, repaint the front arms orange etc etc etc... |
Looks like that will be a nice quad once you're done with wiring and so on. I like the idea on the Ammo can/battery box. You might have enough room in there for so small tools too.
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The chain oiler reservoir and solenoid valve will be occupying the extra space in the battery box. New wiring harness is already fitted and the clocks do wake up but the general light relay connector was destroyed in the fire and still has to be replaced at the harness end to a different kind plus the wiring harness itself has minor differences to the quad as there are no connectors to hook up the engine start and kill switches but I believe to have identified the correct wires that need some minor re-routing once I get that far.
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The emperor`s new clothes have arrived...
https://www.customfighters.com/forum...79529ceb96.jpg https://www.customfighters.com/forum...79529d7891.jpg There was a huge box waiting on my pickup space at work this morning (I`m a mailman :D )and the contents of the said box turn out to be everything I expected and also what I feared... First of all the most obvious one which apparently isn`t quite AS obvious through pictures. The fairings aren`t black. Well thay are black but they`re not jet black, they`re more what I`d call trash-can black :D The headlight cover is the worst that`s just plain grey, luckily I refurbished the original one though now it`s a completely different shade of black as the rest. Buut I suppose after I get a few rolls of orange über tape on it, it hopefully won`t be as obvious. The fairings aren`t exactly a bolt-on fit either, some fitting tabs etc need some finishing work, deburring and stuff, some holes drilled that are missing... https://www.customfighters.com/forum...79529e0b33.jpg https://www.customfighters.com/forum...798ef0df30.jpg ...and there`s apparently some differences between the model versions, the basic shape of the fairings is correct but those ankle flaps need to be cut as they`re not in the original fairings as well as the fross brace up front is missing, or to be more precise cut off from the original ones so the headlight can fit in place as currently the reflector is clashing with the said brace. https://www.customfighters.com/forum...79529f03ac.jpg I`ve been sometimes accused of having an addiction to the color orange--- https://www.customfighters.com/forum...f5345840af.jpg https://www.customfighters.com/forum...bb7b7007cb.jpg I hereby declare such accusations quite very propostrous and offending :hehe: Rear sprocket and air filter should arrive tomorrow, I however do need to make at least one more order as I took the rear axel assembly apart last night and it appears the axel bearings are completely shot (at 4000km!) as well as the brake disc as it is in fact warped more than it`s own thickness. The brake caliper appears stuck or at least sticking as well but as a new one complete with pads cost 30eur I see little sense in trying to revive it. EDIT: whoops sorry this forum doesn`t appear to resize pictures, gotta keep that in mind henceforth... |
Looking good! Do you have a link to the body kit?
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Here`s the link, there seems to be two kits available when I post this so future viewers check availability. Seems to be the case with any part on these, all are running out as new parts aren`t available anymore so looks like I`m in the nick of time with this restomod.
The link: https://www.ebay.com/itm/362829523549 The seller is Happy Motor Parts Germany. https://www.customfighters.com/forum...8f45616645.jpg New jetcone air filter arrived from the UK today, was a bit of a challenge to find a 44mm filter with at least a 45 degree bend at the neck to make it fit as the new carb sits at a bit of an odd angle much closer to the frame rail than the original. https://www.customfighters.com/forum...8f4561dbae.jpg Fuel line fitted, I do have a petcock as well but that will have to wait as it needs a new bracket welded into the frame. The original tank is so ridiculously small I`m planning to make a "touring" mod and fab a second subframe to replace the twelve-o-clock bar at the tail end with a top box that will have a second tank to extend the range to reach a dear friend nearly 400km away (just hoping the quad can take that...) so the petcock has a two -way gate as if to have a reserve but the other intake will be routed into the top box. Tomorrow gonna hit the stores and get all kinds of fluids lights etc. But please someone tell me who was it that though it`s a great idea to paint the engine turquoise... |
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Gonna be slinging dirt in no time. Great thread. Keep the updates coming.
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Slingin dirt and rippin tarmac, I've come to learn you cannot register quads in the US, not the case here. Two oddities amidst the rules here are road going quads and there's no tax or MOT for motorbikes.
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Where you from? You can make them street legal here, might be different from state to state not sure. I know in AZ can register them but they need mirrors and I think a horn? I just have a offroad plate on mine.
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Asikkala, Finland. Yes lights blinkers mirrors the lot, hell this thing even has the most pathetic little catalyser I've ever seen.
This project just took a massive blow this morning... The SMASH streetfighter festival next july I'm basically building this thing for, has just announced there will be NO SMASH 2020. Major major bummed ATM... Don't get me wrong I will still finish it, just got a massive dip in motivation right now... The friend I was gonna go there with has alreay proposed an alternative event though... A six hour moped endurance race he wants to take part in but is lacking a rider on his team. Gotta say I'm tempted... |
I'd be all over a moped endurance race! :D
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Sod it, no point brooding over what`s not coming and focus on what is. Namely, the summer so wanna be ready so took apart the cockpit area to swap out the handlebar I bought that had the welded on crossbar and switched it with a Timeless Racing bar from which the said bar bolts off.
https://www.customfighters.com/forum...e3bcd57c47.jpg Started fitting the dash before taking a good look at it, all faded and blotchy sitting in the middle of all the new bling hanging from the horns so off and apart it came. Didn`t wanna paint it orange nor black so out came the über tape. First you gotta make a template with the clear sheet... https://www.customfighters.com/forum...e3bcd62bdf.jpg ...transfer that to the graphics sheet... https://www.customfighters.com/forum...e3bcd6bade.jpg ...and after forever of cursing cutting heat-gunning lifting re-pressing rolling off bubbles, two beers more cursing and pressing the corners you got a half-decent gauge cluster bezel, yay! |
You Sir have more patience and abilities then me. Good work so far. Can I ask what a SMASH Festival is? I searched Google but didn't seem to see anything or maybe I missed it.
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Karjala sounds interesting...
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Right, back to business. https://www.customfighters.com/forum...f8fbade56d.jpg I drilled the missing holes onto the fairings to start massaging them into place. They`ve quite clearly been sitting in a warehouse for a long time as they`ve bent the wrong way from a couple places. Gonna let em sit and probly apply some heat gun to startegic places to get them to assume the correct shape. Also it appears the tank damper rubbers are not original as the tank sits way too high so the infill panel won`t fit. Gonna fix that once I get this puppy going poot poot first. https://www.customfighters.com/forum...f8fbae6a79.jpg Couple more out the sticker factory (note to self get new sharp scissors) https://www.customfighters.com/forum...f8fbaed8ab.jpg and thattis all vee hav todei, tänks and pai pai. |
I had no idea about the Shelling of Mainila; further reading suggests it closely followed the Molotov-Ribbentrop Pact, where Nazi Germany and the Soviet Union agreed to be at peace with each other, while also planning the annexation of Poland, Lithuania, Latvia, Estonia and Finland. That was on August 23, 1939; Nazi Germany then invaded Poland on September 1, 1939. That gives me shivers. >:( The Shelling of Mainila followed two months later.
Excellent job on the graphics! I'm really enjoying this build. Please tell me what it says on the box of orange tape; I can only make out part of it. |
The product is called SFT Uber Tape. SFT comes from the Finnish show riding group StuntFreaksTeam and their main partner here is a car parts/supply store chain Motonet, though you can also order the sticker sets straight from their website HERE. It is quite expensive but it is very high quality, the material is much thicker than most china vinyls so it`s more forgiving when applying as it won`t kink near as easy, it responds well to warming up with a heat gun, just a small blast at low rating is usually enough to get through a tight corner and it won`t "snot up" when warmed as some cheaper ones do making it all stretchy and usually ruining the graphic. It also comes in several different designs and patterns, the one I`m using is called Mesh Orange. Oh and one more thing. When you`ve applied your graphic in place run over it a few times with the heat gun and wipe it down with your sleeve or sth and it bites down HARD. I mean it applied properly this stuff will not start peeling off.
https://www.customfighters.com/forum...0df1c9523e.jpg https://www.customfighters.com/forum...0df1c9df4e.jpg Couple more. Haven`t decided if I like the rear one on the fender yet, it was an offcut so had to make a compromise and at least since I know what to look for it shows... |
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https://www.customfighters.com/forum...778f80eb6c.jpg https://www.customfighters.com/forum...778f81644b.jpg Small update but still sth as I`ve more or less finished with the graphics. Surprisingly the narrow strips on the rear fenders were hands down the most difficult as both sides had to be made from two pieces, and only when I finished the left side and copied the stickers to the right side I realized the fairing is in fact asymmetrical which gave me a few grey hairs but I, just barely, got the vinyl to last to the end. At first I was thinking about adding the same kind of arches to the back as in the front but when I started modeling those I realized it`s a compound curve, takes up more vinyl that I have left and just doesn`t look right so ended up with this design. Got a message yesterday that my rear axel seal and bearings have arrived to a local tractor supply shop so gonna go fetch those next saturday, hopefully got the time to fab the exhaust this weekend and FINALLY get to try if this thing even fires up! OH before that I gotta fit the battery box and extend the power leads so no holding breaths just yet... |
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Swapped the sprockets and cleaned up the engine as well as I could tonight, quite unsurprisingly the front sprocket area as well as the rear swingarm bottom guard were absolutely caked with old chain grease mud and other nasties. https://www.customfighters.com/forum...8c4722a5ab.jpg Also took the rear axel carrier out for the bearing swap next weekend. Could someone with more mechanical skills than me explain one thing to me. The bearings in question are sealed on both sides and the spacer in between is just floating between them with nothing else to do than to be a spacer. WHY is there a grease nipple and the cavity in between is filled with grease?! |
To keep water out/keep the bearings greased. Normally the bearings on stuff like this have a seal missing on the inside, so that grease can easily be added.
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Soo when I replace the bearings with double sealed ones would you suggest removing the inner seals or leave as is and not have to pump grease in? I vote for the latter
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I'd leave the seals in place and I'd pump the space between them full of grease. Grease is cheap.
If you're ever riding for enough time to heat up the bearings and then cross a creek that will immerse the rear carrier, it will vacuum water in if there is space for it. The grease displaces the water. |
Ah that makes sense. Doubt I'll be doing any dipping though but my neighbor should still have my old grease gun I donated him when I quit trucking.
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Took the rear carrier apart today, somebody wanna tell me what the hell happened here?! Looks like as if one of the bearings had exploded and the balls have gone loose into the grease cavity, which would suggest the bearings have already been changed at least once, which in turn puts the odometer reading of 4200km under serious doubt. Either it has been disconnected for a long time or it has actually gone over and it`s on it`s second round! Had a bit of an event with the new bearings too. I looked online for them and found them in several places for anything between 5 and 15 euros plus carriage but waiting for a month for them didn`t sit right with me as I want to see what sits where before fabbing the exhaust so I ordered a pair into a local tractor parts dealer. You could imagine the "wait what" when I went in to get them and heard the price. They weren`t 5 euros. They weren`t even 15 euros. They were 63 euros. Per side. The ONE TIME I didn`t ask beforehand what they cost as I naively assumed they`d be around the same or at least not much over. With that money I could have ordered TWO new carriers and still have enough for the assembly beer!!!! https://www.customfighters.com/forum...cc79e182e8.jpg Having recovered from that for a day I decided to whip out the mig rig and start sticking bits together. First up was the new battery box and it`s bracket. At first my plan was to fit it so far back the box can actually swing open but it just didn`t look right sticking out that far so I figured it`s not that much of a hassle removing seven bolts/nuts to lift the rear fairing off, it`s not like you`re digging into the battery box every week anyway. https://www.customfighters.com/forum...cc79e1eb0d.jpg Somehow the muffler had managed to both rip out the front mount from the frame tube AND cracked the rear loop so those, among other fractures here and there, got welded. Judging by the cracks and the fact the right side fender bracket was bent this thing had been capsized at least once. Might at some point redo the twelve-o-clock-bar with either a skidplate or some rollerskate wheels but that`s a very low priority at this point. |
An ammo box for the battery is a neat idea. Do you plan to vent it?
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With a sealed AGM battery I don't suppose I have to. There will be rubber grommets where the wires and the chain-oiler hoses enter/exit the box that I suppose breathe somewhat but I wasn't planning on adding a dedicated vent. Do you think I should?
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Probably not necessary, but it wouldn't hurt to vent it. If you ever sold it, the new owner wouldn't be at risk if they installed a conventional battery.
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Think I'll just go with instructing them as the battery is mounted at a sideways angle so an AGM would be preferred, if not required, anyway.
Was planning to start fabbing the exhaust last weekend but I seem to have misplaced the right size boot of my bender so have to find that first, as well as get this fever/gough thing over with that's been pesting me for forever now... Also emailed the shop I've been waiting my rear brake parts from for two weeks now, somehow they've missed the order and promised to rush them to me. After that it's basically assembly, test, tweak, explode everything again, paint what needs painted and final assembly, provided the engine works and creates sufficient power (bit worried as it didn't put up as much of a fight as I expected it to when I turned the crank with a wrench) |
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New bearings and seal pressed into the rear carrier, got an email last Friday that my brake parts have left the Netherlands only after waiting three short weeks from ordering so postponed the axel assembly so I don`t have to do it many times. https://www.customfighters.com/forum...5f9728d272.jpg While waiting I`ve tried to tie up the loose ends, finished the exhaust reroute (well, still have to remove the front part, adjust the angle of the joint and weld all tacked pieces properly together.) The welds look horrible for three distinct reasons: I had to use parts of the original exhaust to size up at the connector, the original exhaust is a bitch to weld onto being thin walled and inferior quality metal, and most of all I`m not that good at welding. Also did some electric work extending the wires of both rear turning indicators and welded a bracket for the starter relay onto the battery box but didn`t see necessary to take pics of those. |
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https://www.customfighters.com/forum...884900c1e9.jpg ...And he said "let there be light", and there was light... Probly an insignificant post to anyone else but I really needed the moral win seeing the beast slowly waking up from it`s years of slumber. Everything`s connected with test leads at this point but slowly chewing my way through the connections by soldering connectors from the old wiring harness and replacing with other kinds where not available. Had to change the connector of the general lighting relay as the fire had destroyed the original one and couldn`t find the one the new harness used. Got it working 7/8 for now as of course I managed to drop one of the spade connectors into the sewer beneath the lifter table and the package only came with one mercy piece and that of course was a female one... https://www.customfighters.com/forum...88d7155b74.jpg The front indicators cannot yet be fitted as the bracket they will be fitted on does not yet exist, here`s a small teaser on what I`m planning to hang onto it as well, but that`ll have to wait for now. |
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Well that`s a bit of a double edged sword... The better you get with welding the less you generally have to grind, but yea welding small OD thin wall pipes together with a MIG rig no matter how expensive there will be cleaning up to do (I`m spoiled with a Kemppi MinarcMig EVO 200 which is a fully automatic digital unit, you only enter what material you are welding and the thickness and the machine does all the math. The guy at the shop did a tremendously good job selling the thing to me when I walked into the shop saying hi I need a welding rig but I don`t know how to weld, and the guy said never worry this machine does.)
https://www.customfighters.com/forum...9f0c3e7256.jpg https://www.customfighters.com/forum...9f0c3ec6ee.jpg Got started with the fog light circuit (since you know, we all got handlebar switches and relay sockets laying around gathering dust just in case right?) but got robbed of ability to think by a very persistent headache which I`m still nursing writing this so didn`t get far today. Still gotta finish welding the exhaust and rewiring the engine kill/start buttons before test firing as the connectors for those seem to be different in the new wiring loom and what I have dangling off the quad. |
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Haven`t posted much although been in the shed almost every night, mainly trying not to re-enact the famous garage fight scene from the movie House of flying spanners... Here`s where I`m at right now: -There`s no wiring diagram available anywhere for these things (at least one I`ve managed to find) -Not that it would have helped me much as the wire colors of the new wiring harness do not match the ones on the quad. -The new wiring harness has been wired... to clumsily translate a Finnish saying, "towards ass". I literally had to explode the remains of the old harness to find out which wire is supposed to go where. -The engine kill wire was hooked up as the positive for the horn -There`s one wire that has switched power but is not used so I`m guessing that`s what`s supposed to power the horn. -The horn negative is wired straight into ground so if I wire it like that it`ll scream bloody murder whenever the power is switched on, still haven`t gotten to figuring out where the horn wire DOES go and rather not push the button to find out -The engine start circuit was wired so that if I pressed the start button without the brake pulled the lights would go out, and the brake pulled in the brake light would light up, but only if the start button is pressed. -There`s still one wire that`s coming from the gear sensor and has switched power UNLESS the reverse gear is selected. At first I thought this was supposed to power the start relay but it only has 10v and too little amps to trip the relay so still got no idea what, if anything, that is for. As can be seen from the pic I wired the switch gear through superseal connectors but at that point got my head mixed up badly enough that I wired the connectors wrong so gonna have to re-re-re-re-redo those one more time... So yea it`s been a fun week but now the start button does indeed trip the start relay, and only does it when the brakes are applied as it should be. Still waiting on my rear brakes though, going on six weeks now... The DPD parcel tracker does show the package has left Meppel NL 31.1. but for some reason shows up in Oirschot NL two days later which is on the opposite side of the country and nowhere near Eindhoven where the airport is. Just sent an email to ALG-Moto if they`d kindly ask DPD where the hell is my package and why is it still not here. Slowly starting to run out of humor with that one... |
That reminds me of when I had to build a wiring harness for my old TW200. I had similar weird things going on and nothing made sense when a switch was activated. Turns out, you shouldn't use a blue LED flashlight to determine wire colour, when you're red-green deficient. After finding a white flashlight, my mistakes were quite obvious.
Not saying you made mistakes; I'm saying I can identify with weird results. |
FFS I'm a certified el-tech (though never worked as one) and it still took me a few nights to figure out what's going on as doing it without a wiring diagram is about the same as orienteering without a map... Gotta do it wire by wire.
That light thing is kinda funny though... |
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Turns out I got a ton of superseal pins and sockets but happen to be fresh out of the connector bodies so solder and glue-socket it is, the switchgear can easily be removed along with the harness if the need should ever arise. Also turns out there`s no point in searching for the horn wire as the new harness doesn`t HAVE one! The center pin in the 9-way connector to the left switchgear was empty! That was quickly remedied by a bypass and now I have a horn as well. https://www.customfighters.com/forum...32f9cb8651.jpg Done with electrickery for a while I decided to fit a new hose between the brake master and the reservoir as well as refit the said reservoir. Also fitted the chain although after thoroughly soaking it in 80w90 oil and letting it sit, it has sagged enough that I probly have to remove one more link, no biggie as it probly takes me more time to dig out the tool box again than to do the deed as this is a spring clip master chain. (I`ll tell you being used to 530xw chains this thing is worryingly flimsy but I guess it`ll be enough for the output this thing has...) |
It's remarkable how much punishment a 428H can take.
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Somehow I doubt this thing will make a hunnid an fordy horsies either ;) hell does it even do the 40? No idea what to expect TBH as I first bought this whole thing to be destroyed... Just got word that my brake parts have FINALLY beached in Turku, might get them for the weekend, might not. Probiy won't make it to the garage til saturday but then I got a very rare whole-day tinker-time as I got the house to myself, going to make every minute count.
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https://www.customfighters.com/forum...804ec889ee.jpg https://www.customfighters.com/forum...804ec8ef70.jpg She runs (man it always feels the best to write that :D ) BUT the battle is far from over quite yet... https://youtu.be/qVKXq-xbtuE Dismiss the horrible clatter I got spooked about that too but turns out it`s just loose things rattling around at the back (basically just threw this together after a very long day in the garage to try if it starts at all) Now I know how to do a lot of things, carb tuning is not one of them so if someonoe can identify from the sound or how it behaves (bogging/fluctuating revs at WOT) if it`s going lean or rich I`d much appreciate it. It does idle like a champ and revs up to about half throttle but when I open it up it goes hell no so I`m guessing main jet/needle position? |
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