KLR Tool Kit - Kawasaki KLR 650 Forum
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post #1 of 28 Old 01-14-2012, 06:16 AM Thread Starter
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KLR Tool Kit

Although I'm new to the world of the KLR650, I am not completely new to the world of motorcycles. In the past, bikes I have owned came with tool kits that were simply not up to par. The question I have for the fine folks on this forum is... Is the tool kit that came with my KLR up to the challenge? Have you found the tools to be adequate for roadside repairs? Are there tools you have added to your kit that you won't ride without? I'm looking for any suggestions, advice, tips, or just some good conversation.
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post #2 of 28 Old 01-14-2012, 06:35 AM
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Not exactly Snap-On quality, but . . . the OEM tools remain, "better than nothing at all!"

Pre-'08's had "Phillips-head" machine screws holding plastic side panels onto the frame (removal necessary for seat removal, etc.). Understand "Generation 2" bike side panel fasteners are hex-head bolts; not sure whether the on-board OEM tool kit has a deep socket or extension to reach those; just a thought . . .
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post #3 of 28 Old 01-14-2012, 08:39 AM
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I go a little overboard as noted below. Even if you don't go as crazy as I did, you might want to scan through this list for any ideas. A lot of my kit focuses on being able to repair roadside flats.

http://www.klrforum.com/showthread.php?t=11152

If you don't mind carrying more tools, the best thing to do is just sit down some afternoon and start tinkering. Figure out what fasteners and parts you might have to remove in case something goes wrong and put them in your kit.

Every time you work on the KLR, work out of your kit: that way you'll find out if you don't have something in there you need to add, plus a lot of other folks brought up some good ideas.

My theory is if you've got room to carry it, it's better to have it and not need it than to really need it and not have it.

LoneRider brings up a good point about the deepwell sockets for the side panels on a GenII: definitely necessary. You could also just replace them with some Phillips head screws from the hardware store.

For what it's worth, I also leave my seat bolts out so I don't have to remove them every time I pull the seat off. I think somebody on here said they found out the hard way and at a bad time that there's no wrench in the OEM tool kit that fits the seat bolts.




Last edited by planalp; 01-14-2012 at 08:55 AM.
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post #4 of 28 Old 01-14-2012, 10:16 AM
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The OEM tool kit is sufficient for minor repairs and does include the proper tools to remove the side panels and seat. That being said, I kept the spark plug wrench and tossed the rest! I made a tool tube for the front of the bike and it holds most everything. I do have a separate bag containing tubes (front & rear), tire spoons and all the other little things that make tire changing easier.

Tire Bag


Tool Tube


Tool Tube Contents


I have added a couple things since the picture was taken. Now includes a ball pein hammer with the ball part removed so it fits in the tool tube.

Also have a "Spares" bag with the following:
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post #5 of 28 Old 01-14-2012, 11:18 AM
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Quote:
Originally Posted by sardog1 View Post
The OEM tool kit is sufficient for minor repairs and does include the proper tools to remove the side panels and seat.
Good!

Just curious, what on-board OEM toolkit tool is used for the Generation 2 side panel fasteners?

-----------------

As I recall, the Generation 1 toolkit omitted one axle-hex size . . . no biggie!

Last edited by LoneRider; 01-14-2012 at 11:20 AM.
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post #6 of 28 Old 01-14-2012, 11:32 AM
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I always thought this was a good solution for the side panel fasteners and also provides some lashing points for cargo that uk trailer guy came up with:

http://www.klrforum.com/showthread.php?t=11533



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post #7 of 28 Old 01-14-2012, 11:37 AM
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Quote:
Originally Posted by LoneRider View Post
Just curious, what on-board OEM toolkit tool is used for the Generation 2 side panel fasteners?
Oops, my bad. Just looked and it takes an 8mm which the OEM kit doesn't include.

09 KLR650
01 Jeep XJ w/ 200,000 miles as of 3-26-11
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post #8 of 28 Old 01-14-2012, 12:03 PM
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I'm glad this thread got started, I've never looked in the factory toolkit, but I always assumed it would have the 8mm socket tool to remove the side covers. I think I'll be adding one in case I ever have to boost the bike. Lol, kind of an oversight on Kawi's part I would say...

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post #9 of 28 Old 01-14-2012, 12:16 PM Thread Starter
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This information is great and appreciated.

Sardog1, the pics are most helpful.
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post #10 of 28 Old 01-14-2012, 05:37 PM
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Sardog...can you share the info on that tool tube? Size of tube, length? I like it much better that the one I have on my bike.
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