2008 DR650 Rebuild "Bronco"

Discussion in 'Thumpers' started by MotoBronco, Nov 24, 2019.

  1. MotoBronco

    MotoBronco n00b

    Joined:
    Nov 7, 2017
    Oddometer:
    3
    Location:
    United States
    Hello everyone,

    About two weeks ago I started my DR650 rebuild, I just wanted to share my experience in case anyone is looking for ideas, inspiration, or is just a DR junkie.

    I have had my DR650 for about 2 years and in that time I have mostly ridden it offroad, I am rebuilding it to prep it for some bigger longer trips next year.

    I'll report back here with a list of parts and things I've been doing to it.

    This google folder is where i will share photos of the rebuild. https://drive.google.com/open?id=1ST7zwkW_ApIjdZrCAi7XakiB_DxDev-3
    #1
  2. MotoBronco

    MotoBronco n00b

    Joined:
    Nov 7, 2017
    Oddometer:
    3
    Location:
    United States
    I took the bike apart over the last 2 weeks and have been cleaning all of the parts/ sending parts off to get work done on them. (see photos: 2 Breakdown 1.jpg through 2 Breakdown 4.jpg) As you will soon see on this thread I'm OCD about everything being clean sleek.

    I sent parts off to the powder coater (see photos: 3 Powder Coat 1.jpg and 3 Powder Coat 2.jpg) to have them powder coated the same color "magnesium" as my Warp 9 wheels.

    I sent the rear shock off to Cogent Dynamics so they can hard anodize the body black, replace all of the wear parts, and rebuild the shock. My shock has an aftermarket spring and gold valve already so it performs pretty well already, if not I would have had them re-engineer. The kit on my shock is from procycle (https://procycle.us/product/183)

    I have everything cleaned and prepped for when all of these parts are back to start reassembly!

    https://drive.google.com/open?id=1ST7zwkW_ApIjdZrCAi7XakiB_DxDev-3
    #2
    xaman likes this.
  3. MotoBronco

    MotoBronco n00b

    Joined:
    Nov 7, 2017
    Oddometer:
    3
    Location:
    United States
    Update (Dashboard indicator lights) I needed to figure out what to do about my dashboard indicator lights because I broke the previous ones that were mounted in my old Highway dirt bikes top clamp. Since I was getting a new Highway dirt bikes top camp anyways (for a fork swap I will talk about in a later post) I ended up also getting the HDB modular upper dashboard mount to put a baja designs key and indicator lights in. HDB makes these upper mounts for KTM specific lights but Trail tech recently came out with a set of universal indicator lights that fit the HDB mount perfectly! (see photos - 4 Dash Indicator Lights 1.JPG - 4 Dash Indicator Lights 5.JPG) Trail tech indicator lights https://www.trailtech.net/022-idb) shout out to HDB and Trail tech for helping me figure out if these lights would work!

    Photos are located on this google drive folder:
    https://drive.google.com/open?id=1ST7zwkW_ApIjdZrCAi7XakiB_DxDev-3
    #3