08 drr90 xc build

[mfr422]

I thought I would post up our build for 09, I bought this for my nephew in september after we realized his dinli just was'nt fast enough anymore. Thanks Steve churchill and Gary Fallon.
Here's what we started with
http://i473.photobucket.com/albums/rr94/mfr422/DRR/Copy2ofLibrary-057.jpg

Coming apart, He managed to hit a tree his first race and bend the frame so I decided to fix it and gusset the frame. He's now 11 and nearly 5 ft tall and skinny. Besides I know you will sympathize that you can't be seen on a stock machine anyway. LOL!!:D I have QMS (Quad Modification Syndrome)!!
http://i473.photobucket.com/albums/rr94/mfr422/DRR/CopyofLibrary-062.jpg
http://i473.photobucket.com/albums/rr94/mfr422/DRR/Library-067.jpg
I sent him this picture in an email and said ( I'm almost done.):devil: , he didn't think my joke was funny.
http://i473.photobucket.com/albums/rr94/mfr422/DRR/Library-072.jpg

[mfr422]

Here's all his stuff going to the powdercoater. He really wanted and orange quad so the decision was made to go orange and blue. He really likes my KTM orange so we ordered some orange plastic from Gary and sold his red.
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-42.jpg

All the parts and plastic, picked them up sunday, I love the translucent blue with the orange. I modded his steering stem with a 2" raise and for anti vibe.
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-01.jpg

Time for me to get busy, He hit a tree and bent the frame in the front where the right upper a-arm mounts so I decided to put in a brace between the a-arms .
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-13.jpg
I used 1/2" tubing spaced to the top of the frame tube so the spark plug would clear and welded it about 1/2" from the end
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-13.jpg
Hopefully that will eliminate any problems with that area, I can't believe they don't support the frame better in that area the rear mounts are just hanging out in space. Maybe on the motocross tracks it's not a problem but you know how trees jump out in front of you in xc racing.:D One other thig I added was bracing for the upper bumper mount as these are flimsy
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-06.jpg

More later

[mfr422]

I put the motor in and took a pic of the spark plug
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-24.jpg
Swingarm installed
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-16.jpg
Frontend, We need some orange shock covers to cover those ugly red springs. I may put some shocks on her later in the summer after we see his progress.
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-21.jpg
I also gusseted the lower a-arms after his encounter with the tree (he bent his a-arm too)
http://i473.photobucket.com/albums/rr94/mfr422/DRR/Copyoflobb-19.jpg
Rear plastic and steering stem installed
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-37.jpg
I had to notch the battery box where my gussets were installed and covered the holes with tape
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-32.jpg

[mfr422]

Up next was the @#$#@^%%%$ coolant bottle, I've hated it since the first time that I saw it. I decided to come up with something better. I decided to use an old bottle from my 250r, it fits pretty good and won't splash all over the backend of the quad. I screwed up when welding and forgot to weld a bung for a bolt on the back side of the bottle so I had to make do with a tywrap.
Pic of the bottle
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-39.jpg
I drilled a hole in my gusset for the front bolt, if I was doing this over I would make this gusset larger and weld a nut to the back of it.
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-38.jpg
Pics of the bottle installed
http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-40.jpg

http://i473.photobucket.com/albums/rr94/mfr422/DRR/lobb-41.jpg
I still have to run the nipple and overflow hose out the top of the bottle but I'm very satisfied with how it came out.
That's as far as I've gotten but not bad for 3 days work.:D

[forgiven]

That looks great! Keep the pics coming.

[mfr440]

It's DONE!!!

Great job, Uncle Lonny!!!


Here he is hooking up the headlight - the final touch. Notice the bar height, the bars are +2 with a custom anti-vibe mount. This loosened up on the initial ride, so this may get tinkered with some more.

http://i473.photobucket.com/albums/rr94/mfr422/DRR/DSC001691.jpg

Close up of the BRM Offroad Graphics (http://www.brmoffroad.com/) graphics. "KDub" is Kellen's nickname.

http://i473.photobucket.com/albums/rr94/mfr422/DRR/DSC001671.jpg

First ride!
http://i473.photobucket.com/albums/rr94/mfr422/DRR/DSCN7724.jpg

[JAG Motosports]

That steering stem is loooong. We have plus 2 and it's alot shorter. I am afraid he will bend that off a good jump.... a tip over and it's a for sure. BTW nice looking bike!

[riding4fun]

ARS FX and ATV 4play make stem brackets that are much sturdier. Much needed on your set up.

Looking good.

[forgiven]

Stem bracket is certainly a must.

I may have to bring my quad to Indiana next winter for a little help ;>)

[forgiven]

BTW I PM'd you the other day with a question. If you get a chance could you take a look at it?

Thanks

[mfr440]

Steve, PM answered.

Others, thanks for the comments. We were a bit rushed to get it ready for the first race because of delays at the powdercoater, but we do plan to address the stem issue.

[mfr422]

Ok, so my brother couldn't wait and beat me to it, but here's the rest of the build.
Graphics going on.
http://i473.photobucket.com/albums/rr94/mfr422/DRR/DSCN7679.jpg
Kellen on it for the first time, I think he likes it.:D Dad looking on.
http://i473.photobucket.com/albums/rr94/mfr422/DRR/DSCN7685.jpg
I saved a few things for him to do so he could help put it together, we were supposed to finish it the weekend before but the powdercoating wasn't done yet. I let him put on the graphic behind the seat and wheels
http://i473.photobucket.com/albums/rr94/mfr422/DRR/DSCN7686.jpg
A few other details and we were ready for a test ride and some pics.
http://i473.photobucket.com/albums/rr94/mfr422/DRR/DSCN7701.jpg

http://i473.photobucket.com/albums/rr94/mfr422/DRR/DSCN7707.jpg

http://i473.photobucket.com/albums/rr94/mfr422/DRR/DSCN7718.jpg

Overall it came out better than I thought it would, I still need to address the shock covers, steering stem bracket, and should be getting a blue seat cover from Gary soon, but other than that, it's done. Now it's time to tune it to go as fast as it looks,LOL I guess it's like all my other projects, never done.:D Lonny

[mfr422]

We loaded up after our test ride and went to Plymouth Indiana for our local hare scramble series race on sunday.
Kellen and Colben at the start. (This was Colben's first race ever, on the sister bike to kellen's)

http://i473.photobucket.com/albums/rr94/mfr422/Plymouth%203-15-09/DSCN7767.jpg
Action pic
http://i473.photobucket.com/albums/rr94/mfr422/Plymouth%203-15-09/108_4896.jpg
All the kids with their trophies after the race. Kellen and Colben on far left.

http://i473.photobucket.com/albums/rr94/mfr422/Plymouth%203-15-09/100_0265.jpg

Kellen finished 7th and Colben finished 11th , a great time was had by all. There was also a photographer from CycleUSA taking shots of them so watch for a story in the magazine !!

Thanks again to Steve Churchill, Gary Fallon, Brm Offroad Graphics and Gale powdercoating.