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Discussion Starter · #1 ·
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?
 

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Discussion Starter · #3 · (Edited)
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.
 

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Discussion Starter · #4 ·
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...
 

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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..........
 

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Discussion Starter · #6 ·
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.
 

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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:
 

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Discussion Starter · #8 ·
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.
 
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