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Discussion Starter #1
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
 

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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!
 

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Discussion Starter #4
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.
 

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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.
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.
 

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Discussion Starter #6
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.
 

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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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Discussion Starter #8
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!"
 

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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!"
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. :28:

Safe riding!
 

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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/productDetail.do?navType=type&webTypeId=140&navTitle=Tools/Shop&webCatId=22&prodFamilyId=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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Discussion Starter #11
Wow... Gilding the lily... that sounds so regal for a lowly KLR! Yeah, I have a habit of over-preparing, but I've never been in a situation that I can't get out of either! You should see my first aid kit!
 

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Wow... Gilding the lily... that sounds so regal for a lowly KLR! Yeah, I have a habit of over-preparing, but I've never been in a situation that I can't get out of either! You should see my first aid kit!
I failed to communicate clearly, sardog1!

By "gilding the liily," I was referring to MY commending additional tools to your thoroughly adequate assemblage, not YOUR "basic load" of tools!

I find the multi-purpose gadgets useful, when I don't want to dig into the tool tube or bag; most portable and capable of many tasks. For example, the Moose tool I mentioned, besides having the right metric hex keys and valve core tool and spring puller, has a sewing awl, too! Just the thing for stitching up your patient, after you perform the emrgency appendectomy from your first-aid kit!

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

And now, ladies and gentlemen, I give you the super-tool I mentioned, the NEBO ultra!

http://www.twocooltools.com/site/573454/product/4327

Let me tell you, friends; everything they say about this product is TRUE! I've performed critical roadside repairs with this set ALONE. (To adapt this one to KLR carry, I'd add metric hex keys (SAE included) and a 1/4" to 3/8" square drive adapter, so larger sockets can be used.)

I'm not knocking the full complement of on-board "regular" tools; only--gadgets like this one are portable, handy, and available, without rummaging about the tool box or bag.
 

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Spring puller? Spring puller? Splaina me spring puller. I don't have a spring puller. Do I need a spring puller? I may want a spring puller now.

T
 

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Discussion Starter #14
Now Damocles, your just being silly. I do my appendectomies via laparoscopic procedure and use the super glue and duct tape to close the incision. Much less invasive!

You're right, the multi-tools are a good addition to any tool kit.

Tom, take your pill and calm down, you don't need a spring puller tonight.
 

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Spring puller? Spring puller? Splaina me spring puller. I don't have a spring puller. Do I need a spring puller? I may want a spring puller now.

T
Ah, yes!

LOTS of young whipper-snappers ain't never seen nor heard tell of a spring puller, nowadays!

Look CLOSELY at the image shown below:



I think you might notice a hook-shaped device extending from the handle of the pliers.

See it? GOOD!

That, sir, is a SPRING PULLER!

Very useful, for example, should one address the BRAKE SHOES of a KLR250, or even a coil DOOHICKEY spring!

METHOD OF EMPLOYMENT: Fold spring puller outward from multi-tool. Hook SPRING PULLER end under loop or hook of coil spring wanting attention (i.e., connection, disconnection, adjustment). Pull handle of multi-tool, stretching spring to desired extension for procedure under way.

When finished, disconnect spring puller from spring, and fold back into storage position in multi-tool handle.

Rinally, Tom Schnitz, yes! You DO need a spring puller!

I appreciate this low-cost ($ 15) and versatile Moose Racing tool, I have one packed on each of my bikes (KLR650 and KLR250).

"Try it, you'll like it!"

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While I'm engaged in advertising worthy products, might as well show what the ULTRA toolset looks like:



As mentioned, throw in the metric Allen key bits, and you can practically OVERHAUL a KLR with this assemblage!

Oh, what are ALLEN KEY BITS? That's a story for another time, Tom!

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Aw, hek; I won't withhold, in cruelty, knowledge and information from you, Tom!

From Wikipedia:
A hex key or Allen key (also known by various other synonyms) is a tool of hexagonal cross-section used to drive bolts and screws that have a hexagonal socket in the head (internal-wrenching hexagon drive).
 

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'Oh. It's a gut-hook,' Tom said wrenchingly. I have a gut hook. It's useful for gutting small animals so that their viscera can be used to repair things. There was a time when I rode my KLR up Mt Washington in a blizzard and the T-Bob froze solid. I whittled some yew branches, gutted half dozen small animals with my spring puller and made some snowshoes. That done, I hiked down the mountain to buy firewood to take back and warm up the T-Bob. But I digress...

T
 

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"Yeah, that things for the birds", Tom said flightily.
 
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