fix(tray): kill child PID before IPC close to avoid macOS NSStatusItem orphan

Co-authored-by: Cursor <cursoragent@cursor.com>

cli/cli.js

@@ -685,6 +685,11 @@ function startServer(latestVersion) {
           const { clearScreen } = require("./src/cli/utils/display");
           clearScreen();
 
+          // Kill current tray FIRST so the new bgProcess can register a fresh
+          // NSStatusItem on macOS without conflicting with the orphan binary
+          try { require("./src/cli/tray/tray").killTray(); } catch (e) { }
+          await new Promise(r => setTimeout(r, 300));
+
           // Enable auto startup on OS boot
           try {
             const { enableAutoStart } = require("./src/cli/tray/autostart");

cli/package.json

@@ -1,6 +1,6 @@
 {
   "name": "9router",
-  "version": "0.4.44",
+  "version": "0.4.45",
   "description": "9Router CLI - Start and manage 9Router server",
   "bin": {
     "9router": "./cli.js"

cli/src/cli/tray/tray.js

@@ -255,10 +255,19 @@ function killTray() {
   if (instance) {
     try {
       if (wasWin) instance.kill();
-      // systray2.kill(true) defaults to calling process.exit(0) which aborts
-      // the rest of cleanup (server SIGKILL, MITM/tunnel cleanup). Pass false
-      // so callers stay in control of process exit.
-      else instance.kill(false);
+      else {
+        // systray2.kill(false) closes IPC but leaves the Go tray binary
+        // subprocess running, which keeps an orphan NSStatusItem on macOS
+        // and blocks a freshly spawned tray (e.g. hide-to-tray bgProcess)
+        // from registering. Kill the child PID directly first.
+        try {
+          const proc = instance._process || (typeof instance.process === "function" ? instance.process() : null);
+          if (proc && proc.pid) {
+            process.kill(proc.pid, "SIGKILL");
+          }
+        } catch (e) {}
+        instance.kill(false);
+      }
     } catch (e) {}
   }
 }

package.json

@@ -1,6 +1,6 @@
 {
   "name": "9router-app",
-  "version": "0.4.44",
+  "version": "0.4.45",
   "description": "9Router web dashboard",
   "private": true,
   "scripts": {