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

[AresROC]

Since my new feeler gauge showed up early, its time for valve clearance check!


Removed a couple EGR tubes around the engine to get the valve cover off. 3 10mm bolts for the cover and 2 8mm bolts for the exhaust re-circulation.


Removed cover to crankshaft (top & side) with a quarter dollar. A half dollar might be better for the side cover but I havn't seen those for a while.

It was very easy to align the timing mark "T" to the notch. Turn the crankshaft with a 14mm socket clockwise. If you feel air compression while turning, that's the compression stroke you want. If you feel no resistance turning, you are on exhaust and keep turning a full circle.


My exhaust was already at 0.05mm, but intake had no clearance at all. When I move the intake rocker arm up and down, I didn't feel any gap.


It wasn't easy to adjust the valve clearance when it changes as you tighten the locking nut. I found what worked for me best was to:
1. loosen the locking nut, tighten the valve clearance adjuster by hand.
2. loosen the adjuster, rock the rocker arm and feel the tap.
3. while pushing down on the adjuster with one finger, tighten the locking nut by hand. feel a much quieter tap
4. tighten the locking nut fully, feel a very slight tap. Check with feeler gauge.


Using the method above I was able to get intake to 0.04mm.


On a side note, I noticed a little bit of rust on the kick stand spring post. Only the bottom half were welded, but not the top half. Might be time to break out my welder... Also there is a notch on that post near the base, I wonder if that where the kickstand spring should really seat.

[Chito]

Are TT250 parts compatible? Just wondering where you would source Bashan parts from

[AresROC]

Yes I would source parts from CSC TT250, since I am close to them in Las Vegas and their website is great. Or I would source Hawk or Honda parts if necessary. Roketa would also sell Bashan parts but you probably have to call them to find a vendor to sell it to you...



TT250 is made yet by another manufacturer so not all parts would fit...
It goes like:


CSC TT250 - Zongshen Moto 宗申
BSR DB-41H - Bashan 巴山
Hawk 250 - Haosen 浩森 of Hensim Motor Group

[AresROC]

Tried to install an oil temp sensor... there were just not enough clearance, engine mount bracket was in the way... bummer :(


Update: Just figured a way that may work... Remove the probe from cap first. Install the red cap and THEN install the probe. May not make a difference but worth a try. [Nope, didn't fit either...]

[AresROC]

Bike was having a hard time starting so I checked the spark plug. The plug was not tight at all it took very little effort with an 18mm socket to remove it. At first it was overly black as if running rich. So I measured the gap and it was a perfect 0.65mm. Factory spec is 0.6~0.7mm.


Unfortunately the spare plug I have at hand was a BR8, not a D8 .


Put it back in and the bike started right up cold first try. I must have cleaned the plug when measuring the gap.


Ran it for 25km and the tip color is now much better, maybe a bit lean being everything stock on the bike.

[AresROC]

Had some fun trying out GoPro

[AresROC]

Got my spoke wrench! Time to play with some wheels.
Someone recommended this wrench here. It works great, as front and rear spokes have different size...front 5.6mm, rear 5.8mm. Most of the spokes are nice and tight.



Not sure if front wheel was just bad or I already bumped it too much. It's got all kinds of side curves to it. Also front tire doesn't appear very round and even either. Rear wheel, however, is nice and round, and so is the tire. Front wheel upgrade needed sometime in the future...



Did wheel truing via the "Zip-Tie" method I just invented...


Also checked the rear wheel alignment. I measured from pivot arm bearing cap to center of wheel axle. Both sides measured spot-on 153.4cm. Yea the markings on the side are not correct at all, so don't use those as a guide.

[AresROC]

Noticed oil level was higher than high mark. Changed oil from 10w50 to 10w40 Synthetic at 100km/60mi.


Bike started first kick with new oil. Still stock everything on the bike.


Took the bike over a hill for more desert exploring!

[AresROC]

Someone recommended this tank bag on YT. Looks pretty good I think! Found some hard drive magnets and added them to the original for even stronger hold.

[AresROC]

Got some jets in for the Keihin, so time to play with my first carb!

Taking the carburetor out was fairly straight forward, loosen air intake hose and remove 2 10mm nuts from intake runner.

After dremel-out the factory screws, I replaced them with M4 16mm.

Factory main jet is K105, and pilot/slow K34. My jets kit came with the wrong slow jets unfortunately, so I only changed main jet to 115 with my stock bike setup. Inside of the carb, other than a little bit of rubber seal glue, is fairly nice and clean. Float seems to be level.

Removed the spring holding the needle, and raised the needle by 1 M3 washer. Still had to twist the throttle to cold start the bike, but I will wait for my pilot jets to come in before playing with the carb a bit more.


I wonder if there is a need for an aftermarket fuel mixture screw? Might be nice to be able to adjust for Summer/Winter time easily.

[NzBrakelathes]

Weird the screws can't be opened and the air buy pass is like the chainsaw type head that needs a special tool.

you might need a little less air at idle and the brass screw underneath usually solves tat but usually has a blade screwdriver slot

[Cravin01]

Here are your pilots, They are the same size. search cold start jet.

https://www.aliexpress.com/item/New-...a-7a7c2ac5df69

https://www.ebay.com/itm/Modified-Wi...Awe:rk:22:pf:0

[NzBrakelathes]

Originally Posted by AresROC

Someone recommended this tank bag on YT. Looks pretty good I think! Found some hard drive magnets and added them to the original for even stronger hold.

How much was your tank bag?

[NzBrakelathes]

Originally Posted by Cravin01

Here are your pilots, They are the same size. search cold start jet.

https://www.aliexpress.com/item/New-...a-7a7c2ac5df69

https://www.ebay.com/itm/Modified-Wi...Awe:rk:22:pf:0

Wouldn't it be easier if 1 supplier had the carb and all things for the 1 mod/upgrade? i was thinking about that this weekend.

might be easier if I made the kit or kits that had all the parts needed rather then buying here there and everywhere - just a thought and plz let me know your thoughts

[Megadan]

Originally Posted by NzBrakelathes

Wouldn't it be easier if 1 supplier had the carb and all things for the 1 mod/upgrade? i was thinking about that this weekend.

might be easier if I made the kit or kits that had all the parts needed rather then buying here there and everywhere - just a thought and plz let me know your thoughts

Kits are a great idea for some folks. I always recommend genuine jets though, which cost more, but the orifice sizing is accurate and consistent. I have bought quite a few cheap kits, and lets just say that they are either stamped incorrectly quite often, or just not held to the same quality standards.

Since the carb tuning for these bikes is rather well documented, the number of jets needing to be purchased is fairly minimal, with a realistic number required right around 3 or 4 mains and 2 pilots. In genuine jet prices that works out to around 30 bucks. Good quality "equivalent" (aftermarket to correct size standards) jets can knock that down to around 15-20.