Tools and Spares - To Go - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 17 Old 03-26-2011, 02:59 PM Thread Starter
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Tools and Spares - To Go

Since there aren't near enough threads on what tools and spares to take with on a "longer" adventure, thought I'd show you what I have gathered so far for the 2012 CDT run. I'm sure that the final kit will be a bit different from what is pictured here, but it's a start and I'll work the bugs out this year. Comments from the veteran adventurers are welcome as always... I'm new at this!

Here's the tire bag:




• Front Tube
• Rear Tube
• Patch Kit
• Tire Irons
• Bead Buddy II
• Talcum Powder
• Air Compressor
• Tire Gauge
• Valve Stem Tool
• Valve Cores
• Rear Axle Cotter Pins
• Nitrile Gloves

Here's the tool roll:




• Combination Wrenches (7, 8, 10, 11, 12, 13, 14, 17, 19mm)
• 3/8” Drive Socket Set (8 - 18mm) with 3” & 6” Extensions
• 3/8” Drive Ratchet
• 8” Adjustable Wrench
• Needle Nose Vice-Grip – 6”
• Curved Jaw Vice-Grip – 7”
• 9 Piece Hex Key Set (1.5, 2, 2.5, 3, 4, 5, 6, 8, 10mm)
• 14mm Hex Key
• 4 in 1 Screwdriver
• Spark Plug Gap Gauge
• 12 ea. 8” and 16” Zip Ties
• ½ Round File
• Olfa Knife

Here's the spares bag:







• Permatex Medium Threadlocker Gel
• 15A Fuses
• 20A Fuses
• Fuse Puller
• Multimeter
• JB Weld – Kwik & Stik
• Super Glue
• Electrical Tape & Duct Tape
• 12’ ea. 14gau Red and Black Wire
• Misc. Wire Ends
• Wire Stripper
• Terminal Crimper
• Clutch Cable
• Clutch Lever
• Front Brake Lever
• Shift Lever
• Spark Plugs X 2 (Pre-gapped)
• WD-40
• Fuel Line – 3’
• Misc. Hardware
• Work Gloves
• Nitrile Gloves
• Shop Rags

09 KLR650
01 Jeep XJ w/ 200,000 miles as of 3-26-11
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post #2 of 17 Old 03-26-2011, 05:27 PM
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Looks great, you've got most everything covered seems like.

I wouldn't carry tools that don't fit the bike but maybe they would help out someone else.

I would have an additional way to pump up the tires, i.e. mt. bike pump, foot pump, etc. I use Windex to mount tires, WD40 works but I've had those little cans die pretty quick.

Have anything to fix a chain? Spare master link, chain breaker, some extra chain.

Didn't see wire on the list, safety type is very useful to hold stuff together!

Start another thread about bike prep... I've got opinions on that too!

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #3 of 17 Old 03-26-2011, 06:23 PM
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Great lists and excellent well organized images. Thanks much for the great post!

"No good deed goes unpunished"
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post #4 of 17 Old 03-26-2011, 09:02 PM Thread Starter
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Spec, can you recommend a brand of chain breaker? I see that KLR650.com has an inexpensive one but wonder about the quality. I'll throw my mountain bike tire pump in the kit but sure as heck hope I don't need it! As far as carrying extra tools, I plan to weed things out as I work on the bike over the next year. The black tool bags hold just enough to include what you need and aren't big enough to bring the kitchen sink, easily fit in the HT Tetons and were a good deal at Northern Tool for $7.50 each.

Adventure-Moto, thanks! You've had some great posts yourself.

09 KLR650
01 Jeep XJ w/ 200,000 miles as of 3-26-11
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post #5 of 17 Old 03-26-2011, 09:30 PM
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Quote:
Originally Posted by sardog1 View Post
Spec, can you recommend a brand of chain breaker? I see that KLR650.com has an inexpensive one but wonder about the quality. I'll throw my mountain bike tire pump in the kit but sure as heck hope I don't need it! As far as carrying extra tools, I plan to weed things out as I work on the bike over the next year. The black tool bags hold just enough to include what you need and aren't big enough to bring the kitchen sink, easily fit in the HT Tetons and were a good deal at Northern Tool for $7.50 each.

Adventure-Moto, thanks! You've had some great posts yourself.
I don't have one but the Motion Pro chain breaker gets good reviews.

You didn't ask but here's safety wire!

Great idea working on the bike with the tools you're going to carry.

Tire tube tip: keep the baby powered tube in a plastic bag, won't dry rot.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9

Last edited by Spec; 03-26-2011 at 09:33 PM.
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post #6 of 17 Old 03-26-2011, 09:53 PM Thread Starter
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Ordered the safety wire and chain breaker, thanks for the link. Great tip on the tube storage too! See, that's what I love about this forum, loads of great ideas and folks kind enough to share them.

09 KLR650
01 Jeep XJ w/ 200,000 miles as of 3-26-11
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post #7 of 17 Old 04-01-2011, 05:36 PM
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Great post, than you sardog1! I've been scratching my head trying to figure out what should go into the roadtrip tool box, now I have a better start.

Thanks!
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post #8 of 17 Old 04-01-2011, 08:14 PM Thread Starter
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No problem ADVdrming, were all in this to learn and have fun. I figure that my kit is complete enough to get me out of most binds. Still need to pick up a section of chain and a couple master links.

All of the tools and spares in the world won't do you a bit of good if you don't know how to use them or understand what went wrong. Adding farkle is a good start to getting to know your bike. Do the work yourself. Enlist the help of others if you stumble. But the main thing is, do it yourself, don't watch someone else do it for you. These KLR's are pretty uncomplicated. Armed with a service manual and basic tools, you can do most of the work yourself. Like the Nike add says, "Just do it!"

09 KLR650
01 Jeep XJ w/ 200,000 miles as of 3-26-11
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post #9 of 17 Old 04-01-2011, 08:28 PM
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Quote:
Originally Posted by sardog1 View Post
No problem ADVdrming, were all in this to learn and have fun. I figure that my kit is complete enough to get me out of most binds. Still need to pick up a section of chain and a couple master links.

All of the tools and spares in the world won't do you a bit of good if you don't know how to use them or understand what went wrong. Adding farkle is a good start to getting to know your bike. Do the work yourself. Enlist the help of others if you stumble. But the main thing is, do it yourself, don't watch someone else do it for you. These KLR's are pretty uncomplicated. Armed with a service manual and basic tools, you can do most of the work yourself. Like the Nike add says, "Just do it!"
Thansk sardog, that was my thought precisely.

Let's see:
1) service manual - check. Should be delivered on Monday.
2) basic tools - check.
3) farkles & mods - it's a dynamic & growing list.

Safe riding!
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post #10 of 17 Old 04-01-2011, 08:47 PM
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A comprehensive and conscientious tool inventory!

Guilding the lilly to some extent, perhaps, the Moose Racing moto-tool contains many motorcycle-specific tools for "metric" bikes, like hex keys, spring puller, valve core toole, etc.:

http://www.rockymountainatvmc.com/pr...FamilyId=19566

Will provide info on another compact super-tool; metric & SAE sockets, all manner of bits, in a compact package (it's in my handlebar bag of my covered KLR650; night-time and I don't want to go out and retrieve it for a picture, but . . . later!
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