Kawasaki KLR Forum banner

1 - 20 of 136 Posts

·
Premium Member
Joined
·
113 Posts
Discussion Starter #1 (Edited)
I just got a hold of two USMC M1030B1's. A buddy and I are going to restore them. I've already found so many helpful threads on this forum. Once they arrive I'll create a thread for the restoration.
 

Attachments

·
Premium Member
Joined
·
113 Posts
Discussion Starter #2
Bikes delivered

Got the bikes in today. They are both manufactured in June 1999 and the VIN states 2000 along with the USMC data plate. We started stripping them down. The plan is to sand blast and then powder coat the frame prior to painting everything in CARC tan.
 

Attachments

·
Administrator
Joined
·
8,368 Posts
Definitely subscribed.

Tom
 
  • Like
Reactions: Tym

·
Registered
Joined
·
529 Posts
Man, that is cool!

I'm new to KLR's , so still learning. So the USMC bikes had their own, unique frame?Or is that crash protection just something they added on?

Like Tom, subscribed and anxious.
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #6
Updated

Almost got it all the way down to the frame. We are working on the "parts bike" now. Originally two were purchased with one being a "parts bike". We plan on getting both up and running. I found out that the rear skid plate is missing on one but we can get a fab shop to copy the one on the "good bike".
 

Attachments

·
Premium Member
Joined
·
6,829 Posts
I just got a hold of two USMC M1030B1's. A buddy and I are going to restore them. I've already found so many helpful threads on this forum. Once they arrive I'll create a thread for the restoration.
I'm just guessing here, that the M1030B1 is the 1st generation Gasoline engined model of the USMC KLR, not the Hayes Diesel engined model? Easier for non-military personnel to acquire proper parts for?
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #8
The first was the M1030 gas KLR 250 the M1030B1 is the gas. Hayes then took them and added the Diesel engine and it became the M1030M1. I haven't seen any of those in civilian hands. Between both models their are military specific parts but most of civilian KLR parts. I was lucky enough to get all of the military parts.
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #9
Update

Most of the bolts are rusted on so the last few have been tough. I still haven't gotten the handle bars or swing arm off yet. I'm letting PB Blaster soak in overnight. It looks like the rear shock was a progressive 500/560. I know the newer version had the F1 engineering shock. I also ordered the stainless steel screw kit from Desmoparts. I will be replacing a few parts on the bike. I'm also going to use RAPCO 686 Tan. It's spot on for CARC. For the frame, bars, forks, and swing arm I'll sand blast and powder coat prior to painting.
 

Attachments

·
Premium Member
Joined
·
113 Posts
Discussion Starter #10
I just realized this is still in the intro forum. Maybe the MODS can move it to the 87-07 wrenching section.
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #11
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.
 

Attachments

·
Premium Member
Joined
·
6,829 Posts
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.
 

·
Premium Member
Joined
·
113 Posts
Discussion Starter #14
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.
 

Attachments

·
Premium Member
Joined
·
113 Posts
Discussion Starter #15
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.
 

Attachments

·
Premium Member
Joined
·
113 Posts
Discussion Starter #16
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.
 

Attachments

·
Premium Member
Joined
·
113 Posts
Discussion Starter #18
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.
 

Attachments

·
Premium Member
Joined
·
113 Posts
Discussion Starter #20
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.
 
1 - 20 of 136 Posts
Top