M1030B1 restoration in Oregon - Page 5 - 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 #41 of 104 Old 05-09-2017, 11:00 AM Thread Starter
1st Gear
Join Date: Oct 2016
Location: Texas
Posts: 82
I have pretty much completed the first bike. There is a issue with the clutch not activating so I cant get the bike out of neutral. Iíll have a friend that is a bit more knowledgeable in that then me check it out. Then itís just covering a seat and itís done.
I decided to start on bike #2. I went through all of the wiring, cleaned up the connections, installed a new Deka battery, Raptor non-vacuum fuel petcock, replaced the fuses, rebuilt the carb and used the IMS tank set aside for my bike. The other two tanks lying around were really dirty and I didn't want to throw that problem into the mix. Anyone know the best way to clean out fuel tanks?

I was able to get all of the lights and black out lights to work. The bike wouldn't even attempt to start. All I would get is a click at the starter circuit relay. I then bridged the two connections on the starter relay and it tried to crank. After some coaxing I got it to start.

Iíll give it a rough once over before I take it out for a test drive in the dirt. It seemed there was a minor fuel leak at first but tightening down the petcock seemed to solve that. There was some oil coming out of the airbox drain. I assume this is due overfilling.
Bike #1

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post #42 of 104 Old 05-09-2017, 01:39 PM
2nd Gear
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Join Date: Jan 2017
Location: Panama City, Republic of Panama
Posts: 216
Good tread. You are doing a tremendous project. Congratulations. I will be following it to see the process and the rebuilt bikes.
Thank you for sharing the experience.

The man on top of the mountain didnít fall there.
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post #43 of 104 Old 05-13-2017, 07:40 PM Thread Starter
1st Gear
Join Date: Oct 2016
Location: Texas
Posts: 82
We took out bike #2 for a test ride. It went well the engine temperature ran high. I had flushed out the radiator and overflow. It was a bit dirty but easy enough to clean. I assume it's the impeller or the water pump that needs to be replaced. Other then that issue it handled well. We will now begin the paint and clean up process on it. It already had the exhaust sandblasted and painted with high temp paint along with the front fairing and blackout light.

I just received the military shock from F1 Engineering. These were the shocks that were placed on the diesel version (M1030M1) of the M1030B1. They developed the new shock around 2003 to replace the Progressive 420 shock they developed specifically fro the military. We also purchased a Progressive 465 shock with the RAP. Progressive is a awesome company and the shock looks great. I got the F1 shock from Noleen J6 Inc. I wouldn't give them a positive review based on the 4-month wait for the shock. We are going to go with Progressive 465 from now on.

I found another inventory tag on the upper fork covers of Bike #1 (this one is completed and painted). The UIC code indicates that it was last with H&S Company 2nd Battalion 6th Marines 2nd Marine Division.

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post #44 of 104 Old 05-21-2017, 04:29 PM Thread Starter
1st Gear
Join Date: Oct 2016
Location: Texas
Posts: 82
It seems bike #1 and #2 are almost complete at this point. The seats need to be recovered, the front forks seals replaced and forks painted, new tires and paint the wheels, and get some new turn signals. I am having a bike mechanic look them over one more time to ensure nothing was missed. On bike #2 there was only one upper sub frame bolt. Itís on to bike #3 to see if we can get it started and running then onto the tedious restoration process. I also have the DD Form 1348-1A Issue Release document from Hayes Diversified to the Marineís that shows the price of $6,518.

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post #45 of 104 Old 10-24-2017, 12:18 AM Thread Starter
1st Gear
Join Date: Oct 2016
Location: Texas
Posts: 82
And back! I have been back for about a month now and finished the first and second bike. With those complete I started to work on mine. I originally stripped it to the frame about a year ago in order to paint it tan. It took about 8 days to get it back together. Since it was originally a parts bike that was included with the bike my buddy got it was in rough shape. I was able to get a radiator, cooling system, and exhaust from ebay. I got a salvage KLR for the carb and some hardware. If this is your bike, thanks again and I hope your good from the wreck. I replaced all of the seals (pivot, swing arm, fork, etc).

I also found a brand new 2003 KLR650 engine a retired Marine was selling. He got it in a locker auction. He went out of his way to get it to me quick. It was definitely brand new and runs like a champ. The original two engines that came with mine we sacrificed to get my buddies top end back together. I couldn't find a natural color tank. I used the least green version but it didn't look quite right. I was able to paint one of the tanks tank and it holds up. I did a few mods: put the choke onto the carb directly, bigfoot kickstand, strobe LED brake light, grip puppies, and bolted the license plate to the bike with LED light bolts.

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post #46 of 104 Old 10-24-2017, 12:21 AM Thread Starter
1st Gear
Join Date: Oct 2016
Location: Texas
Posts: 82

I attempted to recover a older seat myself and it didn't go that well. I took my seat and replaced the foam and had it covered tan by stitch craft. I also got Bike 2ís seat recovered in green. I was able to recover another seat in MARPAT Desert for my bike as well. Iíll try and get some more updates up this week.

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post #47 of 104 Old 10-24-2017, 04:42 PM Thread Starter
1st Gear
Join Date: Oct 2016
Location: Texas
Posts: 82
Got Bike #2 done. The pictures are from a two-day 200 mile test ride. We hit the highways and trails (mostly trails). Since the pictures were taken I have repainted the forks, replaced the fork boots with new OEM Steel Grey, and fixed the rear turn signal. Iíll try and get some up to date pictures today. It really turned out awesome. Below is a list of what was done.

Cleaned all wiring connections
Rebuilt Carb
Replaced battery with Deka
Replaced fuses
Installed Raptor petcock
Installed new stencils
New oil filter
New air filter
Flushed coolant system
Replaced radiator
Titled and registered
Replaced rear tool kit
Installed subframe upgrade bolts
Replaced starter circuit relay
New Dunlop 606, inner tubes, and rim strips
New battery cover
New IMS fuel tank (unused old stock for USMC M1030B1)
New IMS tank hardware
New rear turn signals
New mirrors
New waffle grips
New fork seals
New chain
Replaced start switch
Replaced start relay
New OEM steel grey fork boots
Painted metal, plastic, etc in RAPCO CARC 383 green paint
And more that Iíd have to check my records for

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post #48 of 104 Old 10-24-2017, 06:48 PM
5th Gear
Join Date: Aug 2010
Location: Kelowna, B.C.
Posts: 2,574
Nice work; I've been following your efforts here and there. ;-)

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post #49 of 104 Old 11-25-2017, 07:43 PM Thread Starter
1st Gear
Join Date: Oct 2016
Location: Texas
Posts: 82
Finished my buddyís bike. This was one of the two originally ones we purchased. We had to do the normal restoration and rebuild the top end of the motor. Other than that it went really smoothly.

The 6 auction bikes have been a pain in the ass with everything. The second auction bike is now 100 percent complete. We are going to sell it in a few days and start on the restoration of auction bike 3.

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post #50 of 104 Old 11-27-2017, 01:51 AM
1st Gear
Join Date: Nov 2017
Posts: 79
Originally Posted by Johnnny13 View Post
I'm back in the US. I should get two of the bikes done. The one I originally stripped to the frame can now be put back together. I'm also snagging one of the 6 LE bikes from some engine work on Sunday. Attached is the next one I plan on starting as well. It only has 837 miles on it. From the UIC code it looks like it was 1/6 2D MarDiv.
where can i get one of these fat oversized fuel tanks for my gen1?!
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