I have a Bashan BS-200 s7, that i bought about 2 years ago and have riden her pretty hard.
With German TüV comming up, I have decided to bring her back to better than new.
After stripping her apart, down to the last bolt, and starting from the inside out.
We clean the motor (no pic available at this point),
wire bruch the whole frame to remove any loose paint and dirt.
Grind down all that nasty stuff the Chinese welded on to the frame.
We decided to paint the brake calipers to end our days work.
after a thruogh cleaning with acetone, they were primered 4 times.
After 3 coats of yellow, we decided to call it a night
Day Two of working on my Quad.
28 Feb. 2009
Today we went to Nevinīs Shop to do the hard core stuff.
We started with the swing arm.
We replaced the berings and drilled a hole for a grease fitting
We welded some bolts on the muffler to extend the gaurd away from it.
We did this to try and keep this plate as cool as possible.
This gaurd will be painted yellow on the flat black muffler ( i didnt have any heat proof yellow paint ).
While cutting the new heat gaurd out of a old exahst pipe,
the 12.5 cm cutting disk on our industrial cutter blew up and kicked it back right on to Nevinīs leg.
After applying first aid to the wounded, we finished the exahust system
and called it a day
Day Three
7 Mar. 2009
After stripping and degreasing all the parts that were to be painted yellow,
and applying three coats of primer, we applied five coats of yellow
and called it a day.
Day Four
8 Mar. 2009
Today being Sunday and my Granddaughter being Baptized today,
the only thing i got done was to apply five coats of heat resistance paint to the exhaust system.
Day Five
9 Mar. 2009
Now that the yellow paint has dried, its time to start putting her back together
Loctite on all the screws.
All bolts properly torqued, with flat and lock washers.
Motor wash, valve clearance check, carb cleaned and mounted.
We assembled some of the smaller frame parts,
replaceing every bolt, adding flat and lock washers and properly torqued everything,
Everything thats not yellow is primed and painted flat black.
After the framed was dry, we mounted the motor and exhaust system.
To give you a hint of what she will look like, we mounted the heat gaurds.
After that we called it a day.
Final Day (almost)
10 Mar. 2009
Today is the day we planned to have her back on her feet and running.
The day started off good, by me forgetting to stirr my coffee before I went downstairs to work.
Using a 13mm Proxxon wrench did the job and itīs time to get busy.
We started off with running the brake system.
As allways, using new bolts, flat and lock washers.
Got rid of those chinese wire wraps,
and replaced all clamps with the right hose clamps
Coil and Plug installed
Cleaned, intalled, and routed the wiring harness.
Intalled the handlebars and eletrical conections.
Connected the cooling system.
Can never remember what this is called,
but itīs supose to recycle unburnt gases back into the carberator neck to be reburned.
After installing everything we could and still get her up the stairs and outside,
we got her out of the work area.
Next came the rear end.
After finishing the brake system retaining bolt.
The rotor is installed and the axel filled with grease.
The brake calpers mounted,
And the rear end is finished.
The front shocks,
and the front brake calipers put back together.
After that we noticed that time was running out, but still "do able"
Do to our rush, we did not get any pictures of the A-Arm asembly
and drug her out side in the rain.
We asembled the rear end and shock.
As the last picture for the day, you see me intaling the last
new bolt, flat and lock washer on the front end.
After this we mounted the front tires, installed the brake lines and bleed them 2 times.
and after we realized it was too much to finish her on this dark and rainy night.
we concluded to add a half a day to the plan.
The final "Final" day 11 Mar. 2009
While waiting on Nevin to show up with the newly designed turned chain tensioner,
I started with rewiring the new speedometer,
All wires are sodiered and with heat shrink insolated.
The mounting bracket not being what we wanted, we cut it off flat and drilled a 5mm hole
We also drilled a hole in the swing arm and tapped it for a M6 bolt.
After torquing it down, we cut of the bolt head to make room for the sensor
Tail light, blinkers, gas tank, and everything else was mounted.
The front end alined
The body attached and last adjustments were made.
After 6 days of work the task at hand was acomplished and that was to
replace all bolts and nuts,
replace the berings,
paint the frame
and fix the exhaust system.
A special thanks goes out to my partner in crime,
Nevin, Who gave up a weekīs worth of work, to help me get my sh_t back on the road
and lookin good.
This project is not finished.
It has only been halted for finacial reasons.
In a couple of weeks (or monthes) i should have the money to properly repaint the body (and modify it?)
Midnight Blue.
Keep checking this site for additions ; )
This is what happens if you dont double check your Work.
