I Bought a Diesel Dirtbike from the Marine Corps(1 of 214)

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I Cant believe I finally was able to buy the Diesel KLR that was made for the marine corps. and this bike has a few tricks up its sleeve.
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[@travismud5213]

For what it's worth, I am a mechanic in the Marine Corps. If you're able to find a USMC serial number on it, I may have some information. Also, the blackout lights display light not visible to the naked eye, they are designed to be used with night vision goggles.

[@travismud5213]

@@Bushlore1 I'll look it up when I get back to work and let you know what I find!

[@JusttheEdge]

It looked like the front light was open at the bottom. If they were meant for night vision wouldn't they be completely covered even the dim tail lights?

[@travismud5213]

@@JusttheEdge the front is shrouded because it shines infrared light onto the ground for the driver to see. The rear is not shrouded because it is for other people to see

[@travismud5213]

I bet there's a bunch of videos on blackout lights than can explain it better than I can

[@e.k.izzle32]

​@@travismud5213was curious if you ever got any info?

[@milleRC51]

I own one of these. DO NOT use ether to get it running. I learned that lesson the hard way by shearing the woodruff key on the flywheel (which coincidentally resulted in the exact same sound you're currently hearing when you crank the starter). I know the guy on ADVrider you're talking about, he's a great dude and a wealth of knowledge. Good luck getting her running! Edit to add- that motor sounds like it's spinning really fast to have full compression. Once you get the fuel and starter situation sorted out, make sure the decompression lever is fully disengaged when starting. On mine it has a tendency to stick so push it as far forward as you can on the side of the cylinder head; if it's partially open you should feel it snap into place and seat firmly. There is a very large bolded CAUTION in the operator maintenance manual saying the decompression lever is to "only be used for bleeding the injection system and for help in push starting" and "not to be used for normal, electric starting" (all bold, italic caps in the book). Good luck!

[@adam-g7crq]

Hi don't know much about diesel engines do some of them have two fuel pumps one from the tank and a higher pressure pump to the injectors is the one that's broken the lower pressure pump, I'm just guessing here.

[@KB3AOL]

That doesn’t sound good. 😕

[@milleRC51]

@@adam-g7crq It all depends on the location of the fuel tank relative to the engine. On the M1 the tank gravity feeds to the injector pump which is housed in what's called the "primary unit" iirc. I've been told that on the earlier models of the M1 this was a pretty well known point of failure and was modified later in the run.

[@elobiretv]

Don't know why people are so obsessed with using that stuff, it seems like every youtuber uses it. Just fix the fuelling issues instead of hiding it with starter fluid crap...

[@milleRC51]

@@elobiretv It's particularly temping on this bike because it's very cold blooded. I usually have to cycle the glow plug a half dozen times before the engine will fire when it's below 70 degrees out. A little go juice seems like a good idea but this engine doesn't respond well at all.

[@AaronzDad]

1 of 214?!?!? This is going to be a LONG series!!!

[@machupikachu1085]

underrated comment!

[@phylthamendment]

Right!

[@mr.l3gendz24]

Im not sure but i think he mean 1 of 214 bikes left ?! 🤔

[@-ELST]

​@@mr.l3gendz24it's a joke buddy :)

[@littytitt]

@@mr.l3gendz24 yeah go touch grass bud

[@davidcruz8667]

I'm a retired Marine. These bikes were all over the place being used by Marine Corps Scout Messengers. I'd say put out a call for a Marine Corps motorcycle mechanic to get his input. Also, every single item we used had a technical manual, even for something as basic as a bayonet, for example. They have everything you need to know about maintenance, troubleshooting, principles of operation, corrective actions, materials needed, part numbers for everything, step-by-step diagrams for each maintenance and repair action, important tolerances, measurements, torque values for fasteners, alternative methods if any to get the equipment running again in a pinch, tools and materials you need before you start each job... nothing is left to chance, everything is in there. You can usually download these as a PDF and print what you need to guide you as you work. Imagine you're at war and your mechanic is killed by enemy fire, and you need to grab some grunt and make him your new field-expedient mechanic. Just toss him the manuals and give him some tools with instructions to live and love his new position. You ever heard of the M2 Stinger machine gun used in Iwo Jima? Marines are pretty clever and capable tinkerers. As for the lights, those running lights operate in the infrared spectrum, and there are such lights on all our vehicles from HMMWV's to LAV's. You use them in combination with night vision goggles. Interesting that they used MarPat woodland digital pattern on the seat. It most likely originally had a vinyl seat in a solid green or maybe tan color. Semper Fi.

[@davidmeehan309]

There were a platoon worth of these bikes parked at Camp Pendleton near where 1st Recon Battalion was located in the 2000's last time I was on that base with orders. And agreed that everything in the Marines Corp and the military for that matter has an operations manual for the user and a repair manual for the mecha ic. Even helmet chin straps have manuals. Part of the requirement for the DOD to aquire new equipment. The whole Corp had been converting to adVD manuals by the time I saw these bikes. Which means there are PDF files in existence somewhere. Getting the DoD info on them will be key to getting eyes on a manual. The publications/manuals encoding system is incorporated with the DOD item number system. Any technician in the military would know how to look up that info or how to find the appropriate manual with that info. The bike will have a military model number that is not the same as the civilian model number. For example with Pistols: M9 (DOD) vs. 92FS (civilian)

[@Itsthebikeman]

What you said

[@TimeBucks]

This one will definitely be a cool one to get going!

[@mkgamingmlbb6558]

Good

[@mitonmohajan4941]

Vv nice

[@Vickythakurps512]

nice

[@nishatparveen4837]

👍

[@ajsweety4077]

Very nice

[@cplcarlman]

Those blackout lights are standard equipment on military vehicles. The reason there is 4 lights Lin the back is for proper following distance. If you were following too close to the vehicle in front of you, you would see all 4 lights. At the proper following distance, the lights on the left would appear as 1 light, and the lights on the right, the same. At too great a following distance, it would look like only 1 single light. Source: I was a motor transport driver for the USMC in the 90's.

[@xzx_sparky_xzx]

I was hoping someone had pointed out the tail light indicator purpose. I was a motor transport operator in the Army. Thank you for your service.

[@WhoWantsToKnow69]

motor tuh

[@cplcarlman]

@@xzx_sparky_xzx You too sir!

[@onseki1774]

Wrong. You are just wrong. They are not for any visible purpose at all, they are for riding with NVGs

[@cplcarlman]

@@onseki1774 I literally was Motor Transport by MOS. We were trained that proper following distance would show 2 lights on either side were just right, 4 is too close, and 1 is too far. Don't comment about things you don't know about.

[@TomSpurlock]

I personally knew the owner of the company that made these diesel motorcycles for the government, Fred Hayes. His company was located in Hesperia, CA. I was disappointed this endeavor didn't turn into something much bigger than it turned out. It's pretty awesome. Fred passed away about 6yrs ago, great guy, a smart entrepreneur.

[@paulpsyche42]

oh man sorry to hear of his loss, quite an innovator. God Bless him.

[@richbarnhurst4655]

yeah he was an innovator. I had a few interactions with him while he was perfecting the design for the multi fuel bike for the military

[@geezerguy6410]

I knew Fred, I owned funforsale in Hesperia. I moved to Oklahoma when the getting was good. Only thing I miss about So Cal and the high desert is the creative people. Funny thing is a lot of the Eucalyptus Street guys ended up here after me. Even my barber James moved here. I remember I first net Fred at Nutty Bolts.

[@mr.channel6467]

Looks like the bike had a hard time starting

[@tagadvance]

The diesel KLR has an almost mythical status in the community. I'm a little jealous. My first bike was a 2011 KLR650. Did the doohickey and thermobob myself. Love it!

[@Itsthebikeman]

I've seen about 10 of them over the last 15 years. Saw my 1st one while in the corps visiting another units motor pool junk pit. Also I've been a motorcycle mechanic for 17 years and actively seek them out. Look deep in the southeast for them..

[@krisholden5365]

The headlight is an IR light that is meant to be used while you are wearing NVG’s (night vision goggles). It’s invisible to the naked eye but when you’re wearing goggles, it makes it look like daytime. Same with the tiny little taillights. This was the same way that we flew helicopters at night when in combat.

[@Centermass762]

You're right, but a little tidbit is blackout lights on vehicles aren't IR. They use regular, off the shelf bulbs with a very dark lense to dim it. You can see the light if it's really dark out or you cup your hand around it. It's logistically easier and cheaper that way.

[@jayryan7473]

An easy way to determine if these are IR lights is to turn your phone camera on and aim at the lights. IR lights don't look red, they'll be very light purple/pink.

[@darylbryant3134]

You are absolutely correct sir!!!

[@jonw12]

​@jayryan7473 also a great way to see if your TV remote is working

[@jetstream454]

​@@jayryan7473 Yep, a very dull red to the eye and a bluey-purpley white/pink on camera 😂

[@gilesfarmer5953]

The decompressor lever is to enable you to spin the engine freely without compression on starting. Once the engine is spinning, release the lever so that it fires up on compression. You can also stop the engine by pulling the lever in.

[@jetstream454]

Theres a comment in here based off the manual that explains what the lever is supposed to be used for, which is bleeding the fuel lines or having to push stsrt it, and to leave it alone when electric starting...because as with most electric starters they can handle compression

[@JimBrodie]

@@jetstream454 Same thing is used on 2T Trials bikes. No starter motor, so have to be kick-started with a decomp lever.

[@kasuraga]

Also makes for a safe way to stop a runaway. no compression, no more run away.

[@deandee8082]

you can also pull it when you are moving and it will slow you down, compression brake, or jake brake

[@steve1978ger]

@@jetstream454 - I think most, if not all older, larger displacement engines with a kickstart had one. I know it from the Yamaha XT 500 and SR 500. There it just held the exhaust valve open.

[@retiredusmc9090]

Combat Motorcycle Scout Course 1989, Camp Pendleton we rode the KLR 250 4stroke. Perfect size, weight and power for scouting, I didn't think a switch to a 650 was needed. I thought they were way less maneuverable in the back country and literally off road terrain. That's was the most fun I had at any course over the years.

[@scout3058]

I watched some of those scout courses back then. My buddy was combat camera, and would go out to take photos so he took me along a couple times. I wanted to do the course or, as I thought at the time, pick that up as a B billet but was never afforded the chance. I was 0311. Rah, bro. 🦅🌎⚓️

[@alexanderhale7905]

The black out function is primarily used for night vision. With the phosphorus night vision optics/devices it’s way easier to see the small amount of light coming from the box. It’s comparable to the daytime light except only those who have night vision capability can see it.

[@MrWiseinheart]

Pretty cool 👍

[@ProbeGT2]

Also, by looking at the metal shavings, that thing worked while it was broken. You don't get that much shavings if it just break and stall suddenly. A good small diesels mechanic could probably figure this thing out in a few minutes. Also i'm pretty sure the company who made that thing used commonly available parts to keep the cost low, so the fuel pump, injector and all might be random kubota, yanmar or john deere stuff. The small diesels mechanic would be able to recognize those parts.

[@thebrowns5337]

How small are we talking? Do they have to be a legit dwarf or is like 4'10" small enough?

[@barrymccockner6450]

I thought the same thing . I live in the south , in an area where there are quite a few machinery repair places that have some great mechanics who can rebuild a small diesel engine like that in their sleep.

[@gwolf7716]

@@thebrowns5337 certainly of the leprechaun variety.

[@stephenconnors2111]

My thoughts exactly. Hopefully they can track those parts down.

[@hudsonstraight8628]

With 40 years experience driving diesel trucks, tow the darn thing round and round the block. ( after checking, oil, coolant). If it starts then open, strip ancillary and replace as needed.

[@equaliser2265]

Used this bike in the British forces, it's a land rover on 2 wheels, just Diesel. We had rifle racks and extra fuel tanks. Its bullet proof rode around with NVGs at night.

[@wretchedrider2157]

Literally, bulletproof? 😂 Very cool story, though. Seen them a few times but never had the chance to take 'em for a spin.

[@AM-bk9ei]

From my very brief KZbin experience with this bike, I disagree. 😂

[@thomasshepard6030]

@@AM-bk9ei my nephew rode these bikes in Afghanistan on loads of missions with the British army he said the guys who maintained them new what they were doing and he said it never let him down

[@jaytrock3217]

Do you ever use a RSOV?

[@stephensundet8472]

If it's bullet proof, then why can't a mechanic get it running 😂😂😂 what a piece of junk

[@user-sw2lv3zp6o]

I was going to say it looks like a KLR. Great video. There used to be a Dutch-built diesel adventure bike called a Track T-800 CDI. It was turbo-charged, the engine was an inline triple used in Smart cars. The company is now defunct, unfortunately. Have a look at it. What a brilliant bike.

[@mastaboog749]

Honestly love this channel. I have weird hobbies, I work asphalt paving but I'm a musician that uses synths, drums, grooveboxes, MPCs, and sequencers that i often need to tinker or rebuild but I love classic motorcycles and small engines (snow blowers rollers etc etc). IDK i like putting in the little bit of extra work that actually lets you control said device. And you get a feel of the past.

[@bordone]

I was Marine Corps Motor T in the early 2000's. I went to Camp Johnson in NC for Training on the Military Motorcycle. Back then most Marine units had the gas model but a select few units had the diesel model. the school was alot of fun and we got to tare them down to the frame and then put them back together plus ride them through the trails at Camp Johnson. I treated it like a paid vacation.

[@robertdickerson2821]

Semper Fi bro, I was USMC Motor T in late '60's-early '70's. They didn't have bikes back then so I drove duece and a half. Been riding bikes ever since.

[@UltimateEnd0]

Quote worthy

[@goldenratio5117]

Dang im Jealous ! Thanks for sharing and thank you even more for your service .

[@jmackinjersey1]

I was a courier, and had the opportunity to ride the multifuel dirts. Man they were a blast. Don't ask me how I was selected to be a courier, when I was already the Marine with the international DL. But then again, me being the Op's NCO, I had quite a few billets to fill. Man I miss those days. Also on CJ, but in '96, and then to LeJeune shortly after graduating from the MT school there. All of the M1030M1's were multi fuel, they phased out the M1030's so they wouldn't have one separate that ran on gas and one on diesel.

[@cplcarlman]

I was stationed at Camp Johnson from early 1991-late 1992. First as a student for DTS (Drivers Training Section) and then as an instructor at DTS (5 tons only). Yes, in the Corps infinite wisdom, they picked 4 students that had just graduated the school to go back and be instructors. This was not based on merit at all, just random assignment. At least I got some fleet time later in an Arty unit.

[@MatthewScur]

Haven't reached the end yet, but I would ordinarily crack injector lines to bleed the system on the old Yanmar generators. Also, Decompression lever is to drop the compression get low enough to spin the engine around fast enough to get it to fire. It's pretty common on old diesel generators to allow you to pull start them.

[@brentfellers9632]

You are correct! All kinds of diesels utilize a decompression lever, some engines including small gasoline engines use an acr (automatic compression release) .

[@robinsonrom]

@@brentfellers9632 Even the regular KLR has a decomp valve, via an automatic system called KACR. Looks like they needed a beefier system though to get the diesel engine's compression down enough to crank it with a stock KLR starter.

[@paulpsyche42]

This is awesome! I was a US Marine and ended up retired Army (Reserve). I remember seeing these in Iraq and thought they were sooooooooooooooooooo cool because they are. I had a KLR 250 wayyyyyyyyyyyyyyyyyyyyy back in the day, loved em, wanted to get KLR 650 but I am older and 53, and graduated to ...... Road Glide, thanks for all your reviews of them! This is great video so interesting about the diesel conversion, yeah JP8 universal. P.S. I wonder if the rot is due to the crazy heat in the middle east that made more brittle over time.

[@mach533x]

army reserve... gross...

[@travislewis9089]

One of the best videos I’ve seen I’ve heard about these bikes but the way he took the time to teach you something not very many know of! Love the videos keep it up Craig!

[@roszkowski89]

Marine Veteran here. This was the bike that got me into motorcycling! My MOS school was next to where other Marines worked on these, and I was always wanting to have that opportunity. So then I found some busted bike in a barn and the rest is history!

[@echohunter4199]

Well done Marine! I’m a retired Army Infantryman and what you described is similar to what I did when I bought my first M-151A2 back in 1993. I used to drive the MUTT because we mounted the TOW system on the back but they were replaced in April of 1987 on Ft. Campbell. I served 1983-2009. And it was all downhill from there, lol. I’ve owned and restored 31 old military vehicles since then including a Marine Corps M-422 “Mighty-Mite” that I sold to a Marine who wanted it which I felt was appropriate since I’m not a Marine. Most of us that own these are Veterans ourselves and we use them in parades sometimes. For me, it’s like bringing back a forgotten warrior back to its original glory which I enjoy the most. You saw one of my rigs in the we were Soldiers movie.

[@glenthompson207]

You Motor T on Okinawa?

[@echohunter4199]

@@glenthompson207 damn that sounds like fun! I envy you Marines who could be on places like Okinawa! And by God, you earned the right to have a base there! I wonder how a bike would handle on that volcanic sand at the beach? I heard that stuff was nasty to dig in.

[@roszkowski89]

@Glen Thompson you know its ol' Roszko here Glen! Nasty 9th ESB will forever be my home 🙃

[@glenthompson207]

How could I forgot you Roszko! One of the great guys! Motherfucking Nasty 9 ESB!!! Now those were the good ol days!

[@TheBrycemay]

I’ve had experience with a diesel KLR but it was by accident when I put the all 6 gallons of unmarked diesel in my 2015 klr 650 😂😂 ran great for one whole block.

[@volvo09]

I put diesel in my lawnmower once after I filled a gas can with it and said "I'll remember".... When it wouldn't start the next day I didn't notice until I drained the carb and it smelled a bit diesely 😆

[@Kickaha83]

I did the same also on a 2015 KLR650 a few weeks ago while touring Australia, I got nearly 3 blocks

[@vaibhavdlv]

The cliffhanger made me laugh so hard. After relentless work-filled 1.5 week, this felt good!! Thank you guys. Best luck with this (kind-of) unique motorcycle! On other note, I got my crappy 110cc scooter serviced today, so it rides a little better. Crossed 35K km, targeting 50K and then get rid of it.

[@jm0122]

Activa hogi bro

[@peytonmac1131]

The best bike is the one you have fun on. Nothing wrong with 110cc if it's got you 35k km.

[@maxxgraphix]

A diesel mechanic could help you. This engine is a mechanical injection system. 1. Don't use ether, you can blow the head gasket. 2. The first pump is a lift pump to make sure the injection pump has plenty of fuel. Verify that it works. 3. Injection pumps are high pressure and must be timed like a spark plug. 4. If there is air in the injection pump or injector lines it won't start. 4. If you can get to the injector line coupler, loosen the fitting to bleed the air while cranking with compression released. 5. The injection pump could be damaged if it was run dry and that's why those pins were sheared off. 6. The compression release should be used when starting then closed once the engine is cranking to start. This lowers the stress on the starter. 7. Does it have a glow plug? If so, should be a light on the dash that goes off when ready to start.

[@DeadFront1319]

Usually use the "Blackout" lights with NVG's. Pretty fun smashing around at night with NVG's on. 🤘🤘🤘

[@Doomer17018]

Yup was going to say the same thing, looks like those are IR lights. I feel like riding would be tricky with my single tube setup lol

[@cllintt]

I have been wanting to put a blackout switch on my T-dub. i feel like i can get used to it with my single tube. maybe...

[@Doomer17018]

@@cllintt same here for my KLR, man would make for a good video, I’d loan my helmet and pvs14 out to them

[@snowfreak207]

That would be sick is there a kit for the lights and what about the nvgs

[@Doomer17018]

@@snowfreak207 nvgs are an entire hobby themselves. Cost about 3k to get a decent setup. 2k for the tube and 1k for helmet and mounts.

[@christopherrobbins3018]

I LOVED the KLR-250! The tactical driving course at Camp LeJeune was a BLAST! Driving across Saudi Arabia with random invisible wadis that collapse into a “sand slide / sinkhole” when it’s too late? Not so much….

[@drd1924]

The KLR-250 is great, lighter and can be made to have same power with upgrades

[@thoakim673]

ok

[@frederickjeremy]

I read about these bikes when i was younger, i was fascinated by it, i hope yall can find parts to fix it, i have always wanted one of these, but was sure they were extremely limited military use only. I never expected to see one or even a video of one. I wish i could help you guys fix it up, this is a cool project.

[@demetriuscooksey7147]

That is SUCH a rad piece of modern military history. Can't wait till you guys can get it running... gonna be awesome!

[@epic_cat3724]

The decompression lever is used because the starter would have to be massive to over come the compression, so you let it gain some inertia and you release the lever and it should start.

[@TheGrobe]

Could riffing on the starter a bunch with the engine fully compressed cause damage?

[@Mikesorrento3344]

Scotty Kilmer has one. He has a KZbin channel.

[@scootypuffjr.]

​@@TheGrobewouldn't do it any good

[@TheGrobe]

@@scootypuffjr. Not that it does any good now but I was just thinking that if you don’t let that starter build up momentum like it’s designed to have, but instead trying to fully compress that diesel each rotation, it probably stresses that linkage that broke. That’s the kind of specialty engine you really need a manual or an expert to give you a procedure before you start trying to riding off into the sunset because they do so much to try to make them lighter, faster, longer range, jp-8 ect. “militarized” gear is really wacky sometimes.

[@scootypuffjr.]

@buttersstotch1002 Oh I know. They (people designing military gear) try to "idiot proof" what they can, but this engine would need redesigned from the ground up with a heavier starter and crankcase to take the cranking forces with no decomp. I'm sure it has either heavier flywheel or a flywheel weight and the procedure is likely wing it over with the decomp pulled and then give it full compression when spinning. Mechanical diesels especially, usually fire on the first rotation

[@applyingpurpose6011]

Blackout lights are also for driving with night vision. Night vision still requires some light to work, so for you night vision to work while driving you need some ambient light. Awesome video!!!

[@TheeWanderingAlaskan]

Now I am just picturing these two on USMC Diesel Kawasaki's with night vision goggles doing shenanigans and honestly, that's the content & experience we all deserve. lolol

[@inkloverdom]

I came to the comment section to share this same information.

[@tylerthomson7723]

Driving a track is hard enough with night vision. I could imagine driving a dirt bike.

[@raevennull]

@@tylerthomson7723 I remember doing night vision training in a 5 ton and all I could see is my own reflection on the windshield. All it took we the very dim gauge lights to light me up like a Christmas tree! I was pretty much blind to everything outside of the cab. I'm pretty sure a knocked a tree down during that FTX.

[@crudboy12]

Blackout lights predate night vision. WWII tanks, trucks, and even civilian cars used them.

[@Joshoptimus]

It's brilliant guys you do have to come out of your comfort zone eventually.....firmly delivered anticipation for part II

[@dudefuude7921]

The HDT JP-8 kit (esp the details fuel injection system) would be _extremely_ handy to know exactly how it worked as the gen1 and gen2 KLR are carburetor. Thanks for starting down that path! Many folks want to make a conversion kit but couldn't get access to the HDT parts list. Was not expecting the FI pump to be in the oil filter area--I wouldn't guessed it to be integrated to the balancer for engine timing. Makes me wonder where the oil filter was moved to? On the fuel spiel: There is another reason why everything moved to JP-8. Gas / Petrol / Mogas (marine gas) is considered a massive flammability hazard for everyone, but especially marine vessels. Neither JP-8 nor mogas meet safety of life at sea (SOLAS) requirements, so USN uses F-76 for ships and (more expensive) JP-5 for aircraft. USMC has to be flexible to meet USN safety requirements but desiring to run on Army / USAF procured JP-8 when on land.

[@davidmeehan309]

Also less violent when on fire from explosions compared to gasoline... But just a side bonus.

[@brianatkinson1398]

I was one of the last Marines to go through course to ride one in a combat zone. What a fun bike to ride!

[@bryanspanjer3213]

All bikes are fun to ride so I guess this one should qualify!

[@brianatkinson1398]

@@bryanspanjer3213 it is a blast not as much on the powerband like a 2 stroke but enough power that I was going over dunes in Iraq.

[@7eis]

Diesels typically run twice the compression of gasoline engines. It's like chainsaws with decomp valves - let you spin it over easier/faster. I imagine they still have regular klr starter on there, so the decomp will let them run that instead of sourcing a stronger one. Also easier on battery.

[@BikesandBeards]

I learned that after we filmed. Great info

[@dwightsmith4641]

@@BikesandBeardsScotty Kilmer had one he worked on and managed to get going. Call him. I thought all the You Tube guys had each others numbers.

[@Tolbat]

@@BikesandBeards See the comment from milleR above he owns one of these bikes and thinks he knows what you did to the bike - it sounds bad..... but also sounds like its fixable.

[@milleRC51]

@@Tolbat IF that's what happened it's a really easy fix. Pull the stator cover, pop off the flywheel (it'll be loose) replace the woodruff key and reassemble. I just wish I'd known that was the problem before replacing the starter, starter solenoid, starter relay, et al lol

[@mrsam9206]

@@BikesandBeards You got a scammer posing as you trying to scam people... you should address your audience before someone gets ripped off

[@_BAD_MERC_]

This is great!!! In 2003 I bought a brand new KLR650 that was olive green/black. I was ok with it until I was shopping for accessories and found an eBay seller that sold the bodywork from factory KLRs. I bough the entire set of new take-off plastics from a 2004 (red/black). It took the course of a weekend to swap them over but while I was in there I did a Bog Gun exhaust, removed the sidestand switch, installed serrated footpegs, and did the subframe upgrade. All my take off stuff was perfect and I was able to turn around and sell it and make back most of my money. I have heard of the military KLR but did not know it was a diesel.

[@canadiantechprep]

Probably already answered but the decompression switch is so you can run the starter and it will pressurize the fuel system to bleed the fuel without causing compression ignition. Bleeding needs to take place in stages, first the tank, then the pump, then the fuel compression pump, then the injectors. Once primed, the engage the compression switch to initiate combustion.

[@MrTenhighguy]

I'd get it all back together the way you first got it. Chances are its air locked somewhere in the fuel system. I know nothing about this bike but spent years working on diesel trucks and this is what i would do to start one of them that lost prime. Pull the suction/supply line off the injection pump then apply a small amount of shop air to the fuel tank (3-4 psi) just with a rubber tip blow gun and a wad of shop towels to seal the fill hole. That should at least get fuel up to the injection pump. Once that's done reconnect fuel line and look for a small plug (usually 6point 10mm)on the side of the fuel injection pump that is a bleeder, crack it and apply air again. If no bleeder plug is found crack the outlet line at the pump that feeds the injector and apply pressure. Work your way all the way up to the injector once you have fuel coming out the top of the injector at the fuel line threads it should be primed. Open up the decompression lever get 5-6 full rotations so a little heat can build in the cylinder than close it and hope it starts. Also almost all little diesels need a glow plug or intake heater to start so see if it has one of those and if so make sure they work.

[@ddhh6552]

This old bike does have a spot to bleed the air and pump it out. I had to use it in the field once and it kept me from having to push the bike back to the truck

[@dannywilliams3516]

A wise man once said don't buy a diesel bike. Unless you got a parts house around the corner. LOL. Hope you guys can get it all figured out at some point.

[@HebrewHammerArmsCo]

Did 6500 km (5000 miles) from Mumbai up through Nepal and down to kolkata and back to Mumbai .. did two oil changes, two filters.. did pretty rough terrain on a old Royal Enfield diesel .. Only real issue was with me and my gear top speed was about 60 kph (40 mph) Started every time within 4-6 kicks.

[@badchefi]

It would be easier to just use an old Royal Enfield and hook up a single diesel out of a generator. The above only makes sense as he is creating his desperately needed content for his channel. Any normal person would steer clear.

[@stephenmartin8331]

One of the guys I served with trained as a forward observer using these bikes. Before then, I never new the Marines had bikes. We were infantry so we rarely saw anything with a motor. Btw, the decompression switch is because the high compression can over power the smaller electric motor(compared to trucks) used to start the bike. If it won't turn over open the decompression switch to get the motor moving then close it again.

[@Jhraxlin]

The only time I've ever seen one of these in service was I believe 2015 at Camp Pendleton Del Mar area. I believe it was the MPs using them to maneuver around the beach (huge crowds for 4th of July celebration on the beach). I never got to work on them or use one as I was maintenance for a different unit. One of my dream bikes right here.

[@mikehoncho8722]

I rode the KLR 250’s and 650’s in the Marine Corps from 96-2001 but they were gas and there were talks about changing them over to diesel as I was leaving. Even in gas form they were way underpowered and under suspended for the terrain we used them in. They were bulletproof though.

[@lucabrasi8420]

They were always lack lustre and cumbersome.

[@easley421]

That's the whole point of the KLR. They're so cheap brand new. When I was standing next to one of the new ones at the cycle shop, I couldn't believe how large it was. A lot of bike for the price My buddys dad has one of the originals. It's been wrecked at least three times since I've known him and just keeps on charging. When we take long back country trips I always feel comfortable knowing ones around. Under powered, yes but still strong enough to drag a dead bike home

[@jediknight129]

the diesel was better off road because of the torque

[@kylem7708]

The marines ordered a few thousand EV dirtbikes already because they have a perfect torque curve, 0 shifting, and are totally silent. Problem is, they can't be used/stored in extreme temperature due to the batteries so they'd suck for the desert.

[@premo8564]

@@kylem7708 ev bikes are such a cool idea, but jesus that sounds like a waste of money. maybe with some military investment solar panels will start getting better or something, but i cant imagine ev bikes would be super reliable

[@barrymccockner6450]

I owned a 97' klr 650 for 5 years . That bike was amazing . Not too fast , not too complicated . Just perfect. I had the smaller acerbees tank that still took the fairing pieces from the metal tank .

[@lesklower7281]

The only diesel motorcycle built in large numbers l read about these diesel bikes when the Marines first started using them and didn't see one on another you tube channel l do hope you and your assistant get the diesel motorcycle. running

[@davidbryanttrucking]

I'm here for the tear down and rebuild. Send all the cliff hangers. Subscribed.

[@nathanaelhanson2412]

A lot of military surplus was provided to law enforcement all over the country. For instance, our local PD had a humvee with a turret. Very likely the sheriffs dept that had this bike had it given to them. I doubt they rode it much because they didn't have anyone to service it.

[@BikesandBeards]

Great info, I had no idea

[@RetUSNdude]

@@BikesandBeards Look into the Defense Logistics Agency (DLA) 1033 Program its the program Nathanael is talking about. You might be able to obtain records about the bike with a freedom of information act request with them.

[@robertbrunner4379]

Also they could of been bought for the purpose of search and rescue

[@chrispekel5709]

Why on earth do they think it's a good idea to use equipment like that. No idea...

[@RyTrapp0]

Yup, the militarization of police...

[@raevennull]

Another reason why they like to keep all of the fuels the same is to prevent confusion. I was on an exercise where we had some privates on a detail to keep our camp's diesel generator running all night. They grabbed gas cans from the back of one of the HMMWVs and proceeded to prevent us from having power for the rest of the exercise. Lessons learned dictates that it is best to keep things as simple as possible when dealing with large populations with varying levels of knowledge/experience!

[@pault151]

Asking anyone to do something for which they may not have been trained, is the recipe for failure.

[@markadkins9290]

KISS keep it simple stupid

[@mattmarzula]

​@@pault151 Especially if their last social interaction was high school, their reading skills are limited, and their fathers, teachers, and chosen deities have failed them.

[@kuiperdasniper]

Hummers are diesel...

[@ccooper8785]

Back in the day I REALLY wanted a diesel bike. Somewhere in my filing "system" there are letters (yes, it was that long ago) between myself and Stuart McGuigan (?) who was leading a university team developing a military diesel bike. Now, 40 years later, I am trundling around on an NC750X (wishing I had bought the DCT version)... Somethings never change.

[@bikerevolutiontv]

Loved the video. Can't wait for a part 2

[@CurtisDrew1]

I bought a KLR that was converted to diesel by a guy in Texas, and it was fun, but nothing like the Military version. It had a 418 cc Diesel Generator motor with a CV Go kart transmission. When I got it, I had to tweak it some to get it dependable and put out as much HP as possible. I could run 55 mph on it all day, but take offs were dismal. I built a real exhaust pipe for it that used a modified (gutted) KLR muffler and straightened the breather intake so it could use the KLR air filter and box. I converted the choke lever to the decompression lever and that made starting it a LOT Easier. The up side was it got me 95 MPG most of the time. But I live in the Country and I needed it to go at least 65. It was fun to ride, but never fast enough to keep up with even the 250cc gas bikes. (Think 50cc scooter performance) I sold it to a friend in Ohio and he loves it. Last I heard he was still putting around on it. I'm still riding my 06 gas KLR. 160K miles and running strong.

[@MachosAble_]

Dan, repeat after me: No more cliffhangers! 😂 Joking aside, I love your videos, and I look forward to seeing this awesome bike run!

[@PuerRidcully]

There was no cliffhanger. They got it to run and got on adventure in space.

[@Aksunkuvat]

idk how awesome it can be when mil specced low mileage bike brakes on ur hands

[@mioh23]

@@PuerRidcully now we all know that diesel bike > space x, absolutely no cliffhanger anywhere.

[@MachosAble_]

@Dennis McConnell Yo Dennis! Do I know you?

[@MachosAble_]

@Dennis McConnell oh ok 😂😂😂

[@ChaosWolfJoe]

My dad and I had one of these. They were powerful and handled everything. His had higher compression than the one I rode, and they were absolutely notorious for being -KZbin Friendly Words- to start. Using the Decompression lever was nice if we were on a hill. You could roll the bike holding the lever with little friction then release it and the bike would roar to life. Alternatively, if you needed to kick it the Decompression lever could be used to help find TDC before slamming the kick lever down to the ground. Both of our KLR's that we had, even the ones in the late 90's were kind of known for being ankle-breakers at least around where I grew up. That bike, once running nicely could handle pretty extreme weather, and the diesel engine allows it to crawl right up steep slopes hauling about anyone or anything they are wearing. There are things that a 250KLR from 1994 could do that similar CR/CRF couldn't simply because they were a little bit softer in the suspension area. The Honda CR and XR were more powerful feeling -opinion-, but the KLR was just plain smoother. Admittedly: I have never played with a diesel version. I've heard of them as a myth and rumor that's been proved and disproved a few times over. This is awesome to see. Love your channel.

[@bobverick]

The klr diesel. Love them. US Marines used to run those all over Ft. Bragg during Battery week.

[@MikeyMorentin]

I served USMC 2004-2009 in 2nd battalion 10th Marines. I seen about ten on them lined up while on my morning runs down Julian C Smith st. I used to joke with the boys how sick it would be to go to the field with dirtbikes.

[@christopherbice885]

I hope you are able to get it running soon! It was awesome meeting you guys the other day! I should have told you guys about my experiences with different bikes. This one will definitely be a cool one to get going!

[@quadererdd]

I drove one of those bikes before the Diesel conversion. Was a fun ride. Only rode it in Tunisia Africa and all over Camp Lejeune though. 2 / 2 Communications

[@drankthatpurple]

I haven't seen anyone say this but if its not starting and your not getting fuel out of the injection pump the pump or injector could be stuck or sticky. You can take a little diesel electric pump and push diesel suplement throught the injection pump for a few hours and it may help get it unstuck. Possibly check if your getting fuel out of the injector line you can try and loosen the line on the actual injector and turn it over until it bleeds the air out at the injector once it does you should have fuel in the cylinder. And the little thing craig flipped is the manual primer pump. You guys may know alot of this but im a diesel mechanic in illinois work on alot of old tractors and bulldozers that sit for a very long time and thought some of this may help as we have to do it all the time around here. Good luck! Love the content! @bikesandbeards

[@glenthompson207]

Being a Motor T Mechanic going overseas to Iraq, I only seen the Diesel KLR out in Ramadi and a couple gas ones in 29 Palms, CA. Never got to work or ride it but a very interesting video nevertheless. Hope you guys get it running. Maybe another jarhead who still has access to the Motor T Mechanics page can get online and look up the Service Manuals.

[@TroyFronczek]

When I was in the Marine Corps they were testing these across the street from where I worked for about 2 years. I got to see these things everyday I've always wanted one.

[@theskyizblue2day431]

I was at Lejeune 2010-2014 and I never saw these once, nor in country. They’re so cool!

[@birdsoup777]

Your channel is awesome. Thank you

[@anthony5227]

Man I get legitimate enjoyment from watching your videos. They’re entertaining, educational, and to the point. Good stuff ✊🏾🔥

[@ethanwedekind958]

This is so great I started watching your channel 2 yrs ago and bought 6 motorcycles when I was looking at a motorcycle in South Dakota there was one of these mostly parted it. I have a brother in the marine reserves that is a gear head I sent a pic to him. Long story short he has the mostly parted bike now and has been gathering parts for the last couple yrs in hopes of resurrecting it. Looking forward to watching you continue on with this one!

[@deplorabledave1048]

Dave knows diesels. I have a lifetime owning or working on small to giant ones. The small ones are simple. You MUST bleed everything and have air free fuel spurting out of the loosened banjo union on top of at least one injector. Huge tip. Remove air filter. Take a small book and completely block off the air intake. You just created a giant compression release because the motor is getting no air to compress. As a result the motor will spin over like a top with very very little stress on your starter. This is an old school trick, very much working today in anything that needs bleeding by turning over the motor. There often is a manual fuel pump with a diaphragm and a finger lever, to get fuel to the bleed screws in the fuel injector pump. Once the injector pump is primed, you need to spin over the motor to bleed the injectors. Its always a good idea to use a tad of ether first to assure that the motor will run, and the only thing you need now is fuel. If the motor will not even run on ether, then there are much more serious issues than lack of fuel. EDIT: I went back to watching the video and see you finally figured out the important "ether test". I usually start with that on unknow motors.

[@Synaptic_Synthesizer]

In diesel engines, compression plays a crucial role in the combustion process. During normal operation, the piston compresses the air inside the cylinder to a high pressure and temperature, which helps ignite the diesel fuel when it is injected into the combustion chamber. A decompression switch, also known as a compression release or decompression valve, is a feature that is sometimes found on diesel engines, including certain diesel motorcycles. The purpose of the decompression switch is to reduce the compression pressure in the cylinder during starting. By reducing the compression pressure, it makes it easier for the engine to turn over during the starting process, especially when the engine is cold. When the decompression switch is engaged or activated, it opens a valve or mechanism that releases some of the compressed air in the cylinder, reducing the resistance the starter motor has to overcome. This can be particularly helpful for kick-starting a diesel engine, as it reduces the force required to get the engine turning. Once the engine is running, the decompression switch is typically disengaged, allowing the compression pressure to build up again for proper combustion. It is primarily a starting aid and is not meant to be used during normal operation.

[@TrueRedneckGarage]

The decompression lever on this bike was designed to assist with bleeding the fuel system easily and also to assist with a no power start in an emergency situation. Our bike came out of Florida and the entire fuel system was clogged. Had to replace filter, lines and replaced the peckcock.

[@DieselbikeNet]

I had to replace the fuel lines on mine too. It’s an older prototype model & I also had to solder a few crimped electrical connections that were high resistance.

[@marksmallman4572]

You sure, fairly sure the lever manually cracks open one of the valves to reduce compression and allow the starter motor to rotate more easily.

[@TrueRedneckGarage]

Yes it is designed to crank over easier that is why it is used to assist with emergency push starts (since diesel engine naturally have more compression) and to cause less stress on the starter while bleeding the system.

[@jaystyles2241]

“This thing bleeds green. It’s marine corps through and through” *promptly plays the army song in the background*

[@rickybobby1055]

When i was in the Marines we had 4 of those bikes up at Bridgeport mountain warfare training center in CA. Never got to ride one but i can confirm that yes those bikes we had and had to do maintenance on.

[@jaytrock3217]

We acquired two in my unit in the Army. We used them a handful of times when we were setting up long range LPOPs when we couldn't be drop off by helicopters closer. Never had any problems with them. Also had plenty of fuel when we got back. I been looking off and on for one.

[@theone2be33]

What's an LPOP?? reply ASAP, RSVP, that's what speedy means to me

[@Pan_Yankess]

try disconnecting an injector line from the injector, stuff some hose on it and provide some sort of suction as you crank motor, it should deliver fuel to the pump and actually get it moving, not just spinning the air inside of it. I bled the old czechoslovakian 2 stroke diesel (tz-4k) that way and it works till today no problem

[@beaumcgaritymusic]

That’s awesome, Semper Fi Marines! Happy Memorial Day

[@beaumcgaritymusic]

Please let me know if y’all are selling this or giving it away, because this Marine would love an opportunity to buy this!

[@RobsNeighbor]

Very cool I had one of these in my shop a few years ago from the Wisconsin DNR they bought them from a surplus very cool bike

[@DancerOfClouds]

The last 30 seconds were the BEST. You guys Rock and thanks so much for all the hard work and FUN that goes into this Channel. I love KLR’s and cannot wait to see this one run.

[@scottydouglass1892]

I remember the mt500 sitting inside a secured fence at my last base before I retired. I also remember passing by 18k klr diesel, to buy a new klr650 with some of my Afghanistan deployment money in 2004 for 5500.00 out the door. I still own it.

[@WniGrup]

Oh man I have wanted one of those ever since I fondled one while I was a HD diesel mechanic in the Marine Corps! The blackout lights are surprising effective.

[@nikytamayo]

I've just watched two guys trying to unsuccessfully start a bike for twenty minutes. And I am entertained.

[@douglasfrompa593]

What I learned about those blackout tail lights is that when you see one red light you are too far away. When you see two lights you are Just Right and when you see all four, you probably hit the person in front of you already.

[@stevelacombe5291]

lol

[@tbusch63]

🤣😂🤣

[@bobsum1745]

You must served in Polish Army. All tracks were equipped with lights like that one. But if I can remember , they were green. When trucks were driving in blackout situation they were in use. One light visible -too far, two lights-OK, 4 lights -to close. I think all idea came from Russian Army.

[@bluejay31]

And if they're vertical you've flipped the vehicle

[@onseki1774]

That is not what they are for at all... They are for riding under NVGs, nothing else.

[@jayflow7949]

Love This Channel So Much!!! I’m Bed Ridden After an Injury So I Watch A lot of KZbin & I Always Watch Your Videos From Start to Finish Which Helps Take My Mind Off The Pain Etc…. So Thank You We All Appreciate You & The Effort You Out into the Videos With the Positive Attitude & The Big Guy ⛪️🖤🇺🇸🫡🦅

[@bwofficial1776]

Why Did You Capitalize Every Word? You only capitalize the first letter and proper nouns. Get well soon.

[@jayflow7949]

@@bwofficial1776 I Do it to Honour My Son Who Passed Away He Had Special Needs and Wrote Like This So I Started Doing it to Make Him Not Feel Like the Odd One Out Now Hes Passed I Do it to Honour and Remember Him if it Offends You Then Be Offended I Guess….

[@joethompson6362]

I was an operator for this system in 1987 as a Pathfinder/Scout FT Campbell KY, Fun but at that time not practicable for scouting. A minimum 300-mile travel distance for refuel and easy to load onto UH-60 Blackhawk!

[@RANGER73CPT]

I do feel bad for you guys but you guys NEVER FAIL!!! You CAN do it...

[@joeyahoo2438]

These were made in my home town (Hesperia) in CA. A friend of mine made many of the parts in his fabrication shop. He would have loved to own one, but he thought it was impossible. Evidently it is possible to own one if you have enough money!

[@SirSDG]

M1030m1 that’s the military designation for this bike. I’ve had two in my time in 22 years Active Army. ( mostly because they where unit issues and I was one of the few who rode daily.) they’re slow and sluggish off the line but once warmed up they’re solid. I’d strongly suggest getting a manual from DOD. Even Army wheeled Vic mechanics used the manual for everything. FYI there was some in the first gulf war and subsequent operation enduring freedom. We did not use them in Iraq or Afghanistan ( at least on Army side, no idea about Marines. Wouldn’t be surprised if marines had them rigged up to camo painted little wagons and built turrets on top.

[@mrnoname-lf7dr]

The decompression lever, also known as the decompression valve or decompressor, on a diesel KLR engine serves the purpose of reducing the compression inside the engine cylinder during starting. This makes it easier to turn the engine over and get it started. Diesel engines typically have higher compression ratios than gasoline engines, which makes them more efficient but also makes them more difficult to start. The decompression lever allows the operator to manually open a valve in the engine that releases some of the compression, reducing the amount of force required to turn the engine over during starting. Once the engine is running, the decompression lever is released and the valve is closed, allowing the engine to operate at full compression for optimal performance and efficiency. The decompression lever is typically located on the handlebars of the motorcycle for easy access and operation by the rider.

[@nicholassorensen9035]

The blackout mode is for operation with night vision. NVGs amplify it so it looks like normal functioning lights to the operator but not visible to the naked eye for the enemy.

[@applesauceisgood32]

Such a cool dirt bike, I hade one of these for my GI Joes when I was a kid, easily one of my favorite toys!

[@zacharycarlson4373]

Almost bought one of these on gov auction. But it went for like $17k and I just had bought a 2022 KLR. So wife didn’t approve, but think these are awesome (being a marine myself). Would be cool to have in a collection

[@xfire7]

Development for a klr diesel bike was carried out at Shrivenham in the U.K. I test rode it and it seemed very good .

[@jasonsierchio1167]

First video I've watched.... SUBSCRIBED. Fun channel

[@Suicaedere666]

I have never even heard of a choco-taco until now and I feel terrible for Klondike, they are running away from the rush! Unreal, what foolish lads. Great epi thanks boys🙌🤘🙌

[@kramwilliams9768]

Don’t worry about compression. The problem is all fuel related. That lift pump looks like it’s the same from a kubota L285. Both the injection pump and injector are based on springs.

[@chechubiker]

Love all your videos fan from Spain 💪

[@PoPatriot806]

I have the same stream light that he's using at 5:52. Love that little thing.

[@LuisSantos-dk1ox]

Last shot is impressive, this bike is going to bring this channel to new heights.

[@dadbike1100]

Sean: "I'm going to take this thing off. Everyone: "Why?" Sean: *Visible confusion*

[@thebigguy8306]

Thanks, love the channel, like 2Vintage, always a learning experience. Looks like a WW2 BMW bike the Germans used

[@bobvedder2451]

I have driven many miles under "blackout drive". The rear light is made so you can stay a specific distance from the lead vehicle: if you are too close you will see four lights, if too far behind you see just one, two lights was the goal.

[@Nikko780]

Looks like you got an early visit from the Ether Bunny. I've seen truck starters snap right off the block when the engine kicks back on ether. Ether isn't timed like the injection is, if it combusts too far before TDC (it can and often does) it will spin the motor backwards. In that fight, the starter is almost always the loser, especially on smaller engines that lack the inertia to fight the ether explosion pushing the piston back.

[@johnwalker194]

The Ether bunny ? 😆😅😆 I know the small twin cylinder mitsubishis that i worked on as an aprentice in the early nineties used to crack pistons when attempting to start on the damned stuff ! They run "rockwool" blowers for cavity wall insulation and the clever clogs operating it decided not to waste time having the pre heat circuit fixed !!!

[@Wooley689]

I was in contact with Hayes back during the introduction of these. He invited myself as a rep for the company to come see them. It was not a public event, but a closed Defense Government contractor type event. If I remember right, Hayes was making them to run on any type fuel.

[@3dartstudio007]

Some police departments have offroad vehicles for search and rescue. Hikers get lost. Not uncommon, neat bike! Great video!

[@zorvlatch]

Those are really good, and comfortable too!

[@mistersnipes6862]

I love how Craig’s asking permission to try to start it after his last accident start up😂