Usmc m1030b1

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Bradyrw625

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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. I’ll have a friend that is a bit more knowledgeable in that then me check it out. Then it’s just covering a seat and it’s 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.
https://youtu.be/G8rTzGfKJLo

I’ll 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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BIKE #2
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glcaines

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I really enjoy your posts and photos of the progress. You have made me want one really bad.
 

Bradyrw625

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We took out bike #2 for a test ride. It went well but 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. I already had the exhaust sandblasted and painted with high temp paint along with the front fairing and blackout light painted Rapco 383 Green.

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. Progressive developed the 420 specifically for the military. We also purchased a Progressive 465 shock with the RAP. Progressive is an 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 2[SUP]nd[/SUP] Battalion 6[SUP]th[/SUP] Marines 2[SUP]nd[/SUP] Marine Division. I also received the vinyl from Macs auto parts and it seemed way to blue / dark green.
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MWMULES

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Did you have Noleen J6 Inc rebuild your Progressive 420 shock that was on the bike? If so what did that run, also what is the reasoning on the 465 with the RAP?
 
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b1pig

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thats a nice looking shock. i have a 2008 KLR650. its WAY under sprung stock. ONE of these days i'll get mine taken care of.
 

Bradyrw625

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Did you have Noleen J6 Inc rebuild your Progressive 420 shock that was on the bike? If so what did that run, also what is the reasoning on the 465 with the RAP?
I didn't have them rebuild the Progressive 420 that was on the bike. I just had Noleen J6 build me a F1 military shock. Progressive said that the the shocks were not rebuildable.
 

Bradyrw625

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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. It’s on to bike #3 to see if we can get it started and running then onto the tedious restoration process. We even got a a company to copy the front google bag since the original ones were so trashed. I also have the DD Form 1348-1A Issue Release document from Hayes Diversified to the Marine’s that shows the price of $6,518.
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Bradyrw625

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thats a nice looking shock. i have a 2008 KLR650. its WAY under sprung stock. ONE of these days i'll get mine taken care of.
A member here recently sold all of his M1030B1 stuff to someone in Kansas. They are trying to see if Progressive can rebuild the 420 shocks. If so, I will have a few to sell off at a reasonable price.
 

Bradyrw625

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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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Salvage bike. It provided some useful hardware. I plan on using it for spare parts for some of the auction bike restorations.
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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 2’s seat recovered in green. I was able to recover another seat in MARPAT Desert for my bike as well. I’ll try and get some more updates up this week.
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Another Ahab

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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).
It's bad enough when you have to say that to someone who was belted into a car or belted into a truck.

It's generally never too good when you're telling someone who was on a bike the exact same thing (I was lucky, but ask me how I know).

Good looking restoration, Bradyrw625, nice.
 
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Bradyrw625

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I meant to phrase it “I hope you weren’t severely injured”. It was hit from the rear and went down on the right side. The damage wasn’t to bad but with a old bike new parts and labor totaled it fairly easily.
 

Another Ahab

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I meant to phrase it “I hope you weren’t severely injured”. It was hit from the rear and went down on the right side. The damage wasn’t to bad but with a old bike new parts and labor totaled it fairly easily.
The thing about bikes, ANYWHERE you get hit on one is not likely to turn out good.
 

Bradyrw625

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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. I’ll 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 I’d have to check my records for
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Bradyrw625

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Finished my buddy’s 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.
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vyxu1k.jpgThe 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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Bradyrw625

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Since the weather is a bit cold here its time to start on bike 3. The previous post showed what it looked like before we started breaking it down. Right now my jack is broken so I’ll grab my buddies tomorrow and take out the engine, the wheels, kickstand, handlebars, and the forks. Then it’s time for paint, reassembly, and replacing parts needed / troubleshooting. For those keeping track the restoration went like this. We started on the 6 auction bikes from the sheriffs department in Maine. We finished and sold bike 1 and fished bike 2. That one is still for sale. The first two we purchased (for my buddy and myself) have been completed. Now we are starting on the third auction bike.
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