Bike specific tool kit

[Bob_Defly]

This is a question probably more so for ADV / dirt riders, or anyone that tours a lot. How do you put together a bike specific tool kit?

I can see what bolts are accessible from the outside, but is there any way of finding out what else I would need to do basic roadside maintenance, without taking everything apart?

I just want to carry only what is needed, no excess weight. Taking my tank off recently showed me a bunch of bolts et al that I wouldn't have known about from just looking at the outside. For example if the only allen bolts are 3mm and 5mm, then I don't want to carry the full allen key set if I can help it.

Any sources for this sort of info?

[Biker's Nemesis]

[nute]

That's a farmers tool kit, except ideally the hammer would be a lump hammer.

[Biker's Nemesis]

I couldn't find a better one, I included in my search an adjustable spanner, screwdriver and cable ties.

[Krikkit]

Bob_Defly said:

Any sources for this sort of info?

Depending on the bike they will have a standard tool kit when new, which might give you an idea.

Realistically I'd have a look at the bike and think which jobs you're likely to do at the road side, then draw up a list. For me that's very little as I've got breakdown cover.

Spark plug box wrench, Allen keys for the small fasteners, then maybe an 8mm and 10mm combo spanner?

[srob]

Just stuff as many tie wraps as you can in what space you have. Not much can’t be fixed with tie wraps on the side of a road.

[Gnits]

I use the KTM Multipurpose tool kit (00029997000) as a base and then I have added a few more bits and sockets.
On top of that I have added needle nose pliers, small adjustable wrench, sockets for the oil sump plug etc also some spanner/tyre spoons for taking off the wheels and replacing tyres. There are other bits and bobs - locktite, grease, tyre soap, wire, chain breaker, etc.
Also do the standard thing of only using this kit for all work on the bike and/or adding any new tools to it as I use them.
All fits into an Acerbis fender bag and the Nac-pak tool pack.

[Steve Bass]

Bob,

Kinda depends on what bike it is how far or remote you are headed.
A 1/4 “ T bar with a selection of sockets is a starter. Allen or torx heads as appropriate. Electrical tape, cable ties ,pliers and some spanners in the usual sizes and an adjustable that can manage axle nuts. Tyre repair kit and mini compressor are useful as well as a tiny can of WD40. Even a little voltage probe can be a life saver.
If you have a dedicated fender mount bag I’d fill it and take more than less.
Changing a friend’s rear sprocket in the middle of Malawi kind of reinforced the whole ’more is better’ (to a point).
Better to have it and not need it….
If it’s for the 450 a T with 3 or 4 socket heads, Allen keys cable ties and universal screwdriver will suffice if you’re not too far from your truck and suffer a puncture. Or use slime or mousses

My enduro kit fits in a Kriega pouch which is in my camel pack and has been ample to resolve most problems in the woods without weighing so much that it’s noticeable or an imposition.

Edited by Steve Bass on Friday 8th March 23:44

[Gnits]

Interesting to see what others pack!
I do agree with the above though - depends on the bike, I don't take a lot for the bigger bikes as I probably won't be able to fix it anyway plus have break down cover for serious things and will generally be in reach of civilisation.

For the escapades on the 500 exc I take a bicycle pump for the tyres which goes in the fender bag. Those tyres don't hold much air anyway.
Forgot to mention some other bits so here is a pic of the pack with its contents. There are also some spare nuts and bolts in there I think I have used everything in there except circlip pliers (for wheel bearings) tweezers and the spare clutch lever.
So far have replaced sprockets, chain, spokes, tyres 'in the field' but as I said, if I have used a tool on the bike it is in here. I also take a small can of WD40 and tiny can of chain lube/spray.
Fender bag not picture but is mostly tyre and chain changing gear and a plug spanner.
Good point on the voltage probe, I really should sort that out.

[Cambs_Stuart]

The other way to prepare is to look at what spares/gaskets/fluids you're carrying and make sure you've got the kit to fit them.
From experience, it's annoying to have a good tool kit and no parts to fit..

[hiccy18]

Cambs_Stuart said:

The other way to prepare is to look at what spares/gaskets/fluids you're carrying and make sure you've got the kit to fit them.
From experience, it's annoying to have a good tool kit and no parts to fit..

That's some sage advice right there.

My favourite "bodge it" tool is a pair of long nose molegrips.

[Bodo]

This is very bike specific, and also depends on what repairs you actually want to make at the roadside. Ie. you wouldn't remove a wheel if you have nothing with you to replace it.

1. What are specific repairs that might occur / adjustments I may have to make, that I can/must fix by myself on a trip?
2. What specific tools are required for this on my bike?

Some inspiration can be found in the user's or service manual - typical work to be carried out; but do I need to do this on the go?

Examples:
adjust tension belt/chain
remove fairing to get access to fuse box
remove mirrors to lower bike height
readjust items on the steering bar

[KTMsm]

The advice from the RTW lot is to use one set of tools on your bike and then carry them

Personally for my days out I carry the usual stuff to repair minor offs:

sockets to remove hand guards etc
a small tow rope which can also be used for tying things on
large adjustable spanner can also be used as a lever - mostly used for removing gate hinges of locked gates
Self amalgamating type to repair hoses
Electrical tape just comes in handy
Cable ties
JB weld or similar for case repairs
No need for inner tubes etc as I run mousses

After that it's a breakdown card, credit card and mobile phone

Very rarely used for anything on my bike - KTMs seem to crash well and are surprisingly reliable

[Alex@POD]

Just to add my 2p to all the above, if you have to make repairs at the roadside you're likely to be in a slightly stressful situation (fading light, inclement weather, etc). You'd probably benefit from taking things apart in the garage and understand how it goes together, and what tools you need, so that you know where you're heading if you break down.

[GriffoDP]

I'm just getting to thinking about this too. The nice guy who sold me the CRF already did most of the hard work thankfully, so I have good coverage in theory.

But my real plan is to start doing stuff at home to make sure I can do it with the tools that I'd have with me. I'll keep to the easy stuff first mind you. Ie levers and tyres, body panels.

[Playsatan]

There is a thread on the adv rider site on this very topic that runs for hundreds of pages. Opinions differ wildly from no tools and some breakdown cover to a full workshop on wheels. It can all get very bulky and expensive so the most common approach seems to bring just what you’ll realistically need and then bring the lightest and most compact version of that tool, ideally using items that can perform more than one function i.e. a tyre lever can also be used as a breaker bar on the end of a spanner.

Personally I have broken mine down in to 2 parts, the smaller can fit on my pocket and uses a sliding 1/4 inch T bar with a selection of sockets and 1/4 bits for Allens and screwdriver bits, a small multitool, knipex wrench pliers and of course zip ties. This I take on every ride and while it cant fix all issues covered me for the majority of minor issues and serves as a get you home kit. For longer or multi day trips I take the second part of my lit that is heavier and bulkier. Puncture repair items like patches, levers, pump, axle spanner’s (a real pain on one of my bikes), some basic spares and of course more zip ties.

I started by keeping it all in a single tool tool but it was just too cumbersome for a sunny afternoon blast so in reality it just stayed at home, now it’s much more likely to be with me when I need it. My theory is if I’ve got luggage on the bike then I’ll likely be far enough away that I need to be more independent but that’s ok as I’ll have the ability to carry what I need in said luggage.

[Bob_Defly]

Playsatan said:

There is a thread on the adv rider site on this very topic that runs for hundreds of pages. Opinions differ wildly from no tools and some breakdown cover to a full workshop on wheels. It can all get very bulky and expensive so the most common approach seems to bring just what you’ll realistically need and then bring the lightest and most compact version of that tool, ideally using items that can perform more than one function i.e. a tyre lever can also be used as a breaker bar on the end of a spanner.

Personally I have broken mine down in to 2 parts, the smaller can fit on my pocket and uses a sliding 1/4 inch T bar with a selection of sockets and 1/4 bits for Allens and screwdriver bits, a small multitool, knipex wrench pliers and of course zip ties. This I take on every ride and while it cant fix all issues covered me for the majority of minor issues and serves as a get you home kit. For longer or multi day trips I take the second part of my lit that is heavier and bulkier. Puncture repair items like patches, levers, pump, axle spanner’s (a real pain on one of my bikes), some basic spares and of course more zip ties.

I started by keeping it all in a single tool tool but it was just too cumbersome for a sunny afternoon blast so in reality it just stayed at home, now it’s much more likely to be with me when I need it. My theory is if I’ve got luggage on the bike then I’ll likely be far enough away that I need to be more independent but that’s ok as I’ll have the ability to carry what I need in said luggage.

Yep, exactly this. I'll take all the small stuff every day, and just the full kit on multi-day rides.