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[DirtFirst]

Check out this feature article in the April issue of Electric Bike Action.
Some good info on setting up the Zero DSR for serious offroad riding.
Here is a link to the digital article:
https://www.electricbikeaction-digital.com/electricbikeaction/april_2021/MobilePagedArticle.action?articleId=1662817#articleId1662817

[GoneToPlaid]

Well done!  Wonderful styling.  I'm working on my DSR for ADV travel.  I'm not going quite as far as replacing the whole front end (yet, anyway), but may want to chat with you about your shock.  Also, have you had any trouble from rocks hitting the motor, motor controller, or other bits back there?

[DirtFirst]

The rear shock on my bike was built by Race Tech in SoCal.
I brought the bike to them and they set it up for me.
The rear suspension is a problem area on this chassis- the shock is really short and there is no easy way to move the shock mounts.

I haven't noticed any rock damage. The 3/16" thick alum skidplate runs back under the motor and guards it well.
The stock plastic rear wheel hugger is still hanging in there- I thought it would get ripped off a long time ago.

Thanks for the compliments. I'll try and help anyone doing mods to their DSR.

[TheRan]

I'm surprised to hear the mudguard survived with so little clearance. I take it you removed the charger for extra ground clearance and use an external one? What footpegs are you running? I bought some RMZ450 ones but they don't sit level and I haven't got around to modifying them, and I don't fancy paying a ridiculous amount for the Pro Taper ones designed for Zero. Also are you not worried about the Power Tank being exposed, and could you not have raised the tank enough to cover it?

Great bike though, it's a shame that Zero's more off road focused (although still not as much as yours) bike doesn't go any bigger than 7.2.

[DirtFirst]

Yeah, I thought the mudguard/hugger would get destroyed because of the close fit to the tire, but it has held up well. Thanks for reminding me- I need to order a couple of spares, I think they only cost like $20 or so.

I removed the onboard charger for less weight and more ground clearance.

The stock footpegs and mounts are cheap metal, and I couldn't trust them to hold up. I wanted to use as many CRF parts as possible, so I used CRF mounts and pegs. I added an extension plate on the front of the CRF mounts to pick up the rear battery mount bolt. I think this is a pretty bulletproof design and I haven't had any problems with it.

The PowerTank is quite exposed, and I started making a perforated cover/guard for it, but it just didn't look good. The only thing I worry about is crashing and hitting the battery or plug on rocks, but I guess that's a chance I'm willing to take. The "tank" only looks/works good in the position it's in currently.