[Ljordan]

I started building another bike for my oldest son (11) because he wanted one with full suspension unlike his cag, so... I took a dr9 dirt bike rolling frame that I had and didn't want to go through the trouble of finding a stock seat. because well...... I simply can't. If someone here has DR9 parts (speficially seat and body and gas tank) let me know...
I was going to build a cateye bike but he really liked my dr9 that i have, Long story shortened.
I took the cateye seat fairing and welded a bracket onto the dr9 frame and started putting a engine together and also used the cateye exhaust with a custom hanger and this is my result so far...

as far as a gas tank my only option right now is using a small weedeater tank I have.
still waiting on the tranny to come in that I purchased off ebay and need to order a new clutch and remake 2 brackets for engine mounting since some dummy decided to cut/hammer the other ones.
what do you think?

 

[CAM2]

I think you made the right choice...Your son will grow into it in no time.......Keep up the good work............:thumbsup:

As far as the body goes...You can use one from a 39cc/47cc pocket dirtbike.............

http://www.ebay.com/itm/47-49CC-PLA...Parts_Accessories&hash=item438e05324e&vxp=mtr

You may be able to fit this kit aswell...

http://www.ebay.com/itm/YAMAHA-PW50...Parts_Accessories&vxp=mtr&hash=item53e7cee642

 

[Ljordan]

I've seen the 47cc pocket bike bodies on ebay but had no clue if they were even close to the size of mine so i didn't pursue any further..

a little more progress

I can buy the body for the dr9 new on ebay but finding a seat has proven to be very very difficult.

 

[Ljordan]

Well I got it done today. After the transmission finally showed up today I then realized that not only did the previous owner mutilate the engine mounts but he moved it over about 3 inches.. so after cutting it off and moving it back over and welding two new mounting tabs on it was running. Took it around the yard a few times and only thing I noticed wrong was the forks wasn't moving...

 

[CAM2]

Well I got it done today. After the transmission finally showed up today I then realized that not only did the previous owner mutilate the engine mounts but he moved it over about 3 inches.. so after cutting it off and moving it back over and welding two new mounting tabs on it was running. Took it around the yard a few times and only thing I noticed wrong was the forks wasn't moving...

Good to hear you got it rolling and riding,,,Nice job...........:thumbsup:

As far as the forks most dont like that wobbly feeling so they fill the lower half with RTV silicone to stiffen them up....Thats what I did to my x1 forks but I mixed the RTV with a lil motor oil to keep the RTV from hardening.....

Theres only a single M6 x 4" screw holding the forks together on each fork tube and a couple plastic guides that bust or wear down fast along with a weak spring to push it up and hold the weight..........

 

[Ljordan]

not even sure i'm going to mess with the forks right yet. I tried taking the one that was stuck apart with no success. it's pretty solid.... I will let him ride it for a while and if it bothers him then I will do something about it.
I've got the set that's on the cateye but they are a little shorter and haven't measured to see if they are the same diameter yet.

As it sits now.. I am going to simplify a wiring harness so he can run the headlight and have a brakelight along with the electric start because he can't pull start these engines since he doesn't have much meat on him.

 

[CAM2]

Looking Good to ride...........The cateye forks are the same diameter as the dirtbike and yes they are shorter....finding a new set will be a search and a half.....Id mod a set of x7 forks if you have to and lower the rear a lil to compensate.....

A wiring harness isnt too hard to accomplish....if ya need a hand LMK.I have a few already seperated and made up for those types of bikes......Keep up the great work and hope your son has a ton of fun on that D9......:thumbsup:

 

[Ljordan]

He got off the bus and we fired both of them up and went riding.. he loves it. Time to reassign ownership of the cag and gokart to the younger kids
The two harnesses I have are a big jumbled mess. Would be nice starting with something a little less complicated.