Matty`s Bashan Streetfighter Quad

Oddball Matt · 01-03-2020, 04:43 PM

As this forum doesn`t appear to have a separate project subforum I figured I`ll just slap this here.

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.

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.

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.

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.

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)

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...

Marginally better.

Gotta say I`ve never seen a KAT that small before.

Need to make a connection there or else the finished pipe will be impossible to get off the machine.

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.

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

, 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...

01-03-2020, 04:43 PM	#1
Oddball Matt Join Date: Jan 2020 Location: Vääksy, Finland Posts: 401	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. 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. 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. 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. 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. 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) 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... Marginally better. Gotta say I`ve never seen a KAT that small before. Need to make a connection there or else the finished pipe will be impossible to get off the machine. 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. 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 , 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...
	4