M1030B1 restoration in Oregon - Page 2 - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #11 of 94 Old 10-10-2016, 07:48 PM Thread Starter
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Got it down to just the frame and swingarm. Everything was rusted on. It took some MacGyver skills to get the handle bars and triple trees off. Anyone have any tips to get the "dog bones" off the swingarm? I should have done it when the rearend was together. now it's much tougher to get any leverage on them. I'll have some free time later this week to hit it again. Then the frame is off to sand blast and powder coat. The other bike remains untouched but the frame appears to be recently CARC'd. My buddy is going to keep that one green and I'll go for tan.
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post #12 of 94 Old 10-10-2016, 08:31 PM
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Quote:
Originally Posted by Johnnny13 View Post
Anyone have any tips to get the "dog bones" off the swingarm? I should have done it when the rearend was together. now it's much tougher to get any leverage on them. I'll have some free time later this week to hit it again.
Johnnny13,
An air HAMMER not an air wrench can be very Effective at vibrating PB Blaster into corroded areas and then vibrating the stuck parts OUT.

Start with Lower settings and work your way up to full power ONLY if needed. Patience is truly required for some issues.

pdwestman
Modify at "YOUR OWN RISK"!

Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #13 of 94 Old 10-11-2016, 09:07 AM
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Wow, great project!
Keep it coming please. Inquiring minds you know.
As my kid would say,,, Keep bringing it!!
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post #14 of 94 Old 10-14-2016, 09:38 PM Thread Starter
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Finally got the dog bones off with a air impact gun. I'm still having trouble with the pivot bolt. I removed the nut but the pivot bolt isn't coming out. I even used a pipe and hammer trying to bang it out. Any one have any ideas? We also blasted off some of the frame. Unfortunately we found that upper rear of the frame that the seat and air box mounts to has some rust holes. That will need to be replaced.
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post #15 of 94 Old 10-14-2016, 09:39 PM Thread Starter
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We also blasted off some of the handlebars. This USMC handlebars has mounts for the brush guard. The welds still look great. Until we can get the pivot bolt out we are moving on to the other bike. This one is in much better shape. It won't need to be stripped to the frame. Hopefully we can get it up and running an then move to paint.
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post #16 of 94 Old 10-16-2016, 06:34 PM Thread Starter
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While waiting on the multiple penetrating lube products to take effect on the pivot bolt I decided to paint my helmet. The original USMC helmet was a matte green Winex SR-X. They are a bit hard to find so I found a FOX V1 helmet on sale for $118 shipped. Unfortunately its neon green and blue. During the invasion most of the vehicles were green or woodland camo. The field expedient method was to just rattle can everything tan. I went ahead and used RAPCO 686 Tan. First I sanded down the original paint. Then I sprayed with RAPCO primer.
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post #17 of 94 Old 10-16-2016, 06:36 PM Thread Starter
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Then a few coats of RAPCO tan. Finally I used a matte black to stencil on a few things.
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post #18 of 94 Old 10-18-2016, 12:03 PM Thread Starter
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Still haven’t had the time to try removing the pivot bolt. The next option is still the brass drift, handheld sledge, Kroil, and the air impact. If that doesn't work we will cut it out.

We also found 6 M1030B1’s being auctioned by a sheriff’s department. I believe they received them under the LE program from the military. We threw out a reasonable bid and won! Not sure if we are going to part them out, sell them or restore a few to sell. Now we just need to work on getting them to Oregon.
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post #19 of 94 Old 10-18-2016, 01:13 PM
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Dang! lol

Are you assembling your own army?

If the SHTF Johnny is on my team...
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post #20 of 94 Old 10-26-2016, 12:42 AM Thread Starter
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I'm currently in Iraq so I won't be updating this as much. The builds are still going forward. My buddy will be taking care of it so I will be updating the builds and when the other 6 bikes arrive. More then likely we will rebuild a few of the six to sell, finish a complete restoration on our two, and sell the other ones off as projects. I don't want to part these out since they are hard to find.
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