KLR650 FAQ

Tool Pack File

This is very rough, as I wanted to get something up quickly. People wonder what tools to bring when they travel, and I'm working on compiling a general list. For now, here's what a few people have posted.  I'll try to consolidate the lists when I have time.  


Devon's kit:

An 8" crescent wrench replaces both axle wrenches + the cheater bar. A 1/4" drive ratchet with 8, 10, 12, 13, 14, a 6" 1/4" extension, and 3, 4, 5, 6 mm allen wrench sockets takes care of most everything else.

A set of small needle-nose visegrips

A leatherman

12mm combination wrench.

10mm ratcheting combination wrench from craftsman- try removing the shift lever without one of these, doable but deeply sucks.

A whole mess of other stuff, I should take a picture of it one of these days. It all fits into a Fox fanny toolbag, including quiksteel, clutch and throttle cables, shift lever..... 


Zack's kit:

In my MSR tool roll, which rides in a Marsee fanny pack:
*8,10,12,13,14,15,17 mm combo wrenches and sockets
*4into1 screwdriver
*Small Channelocks or needle nose Visegrips
*Pivoting sparkplug wrench (allows you to remove plug w/o removing tank)
*8" crescent wrench cut to open wider
*3/8" drive
*ATC fuses
*Spare cotter pin
*Locktite
*3,4,5,6,7,8mm socketed hex wrenches
*small Spyderco knife with serrated blade
*small hose clamp
*front brake pin

In my backpack/tankbag/somewhere:
*clutch cable
*brake lever
*clutch lever
*one tube Quiksteel
*shift lever
*brake lever
*brake bracket
*10mm tap/drill/bolts (for footpegs)
*QuikJak
*zipties
*electrical tape
*duct tape
*first aid kit
*small ziplock with bolts/nuts
*chain breaker
*chain press (lost!)
*spare master link
*pump

In my fender bag:
*21" regular tube
*film can of talc
*3 9" Motion Pro irons

With this kit, I can do most everything short of pulling the engine (but I could probably split the cases with this). When I am working in my garage, I usually don't even reach for the tools in my tool chest, I just grab my tool roll. That way I know that I can do it on the road, and that I have all the right tools. The only thing I might change is go with a 1/4" drive to save space and weight.

It's also good to know, from memory, what is in your toolkit, makes getting ready for

One of the handiest tools is actually not even a tool. Quiksteel, as you saw on Tumu's engine, is extremely useful, far more than JBWeld, as it's a putty and can be formed and molded. Not only can you patch your broken engine cases, but you can also fix your toasted radiator fan, and you can do it quickly (which is important when it's getting dark and you're tired and frustrated... Nobody wants to wait for JBWeld to cure, and then to find out a mile down the road that you didn't wait long enough).

If you watch Horrible Freight, they'll usually have metric socket and combo wrench sets on sale for less than $30. Buy two of each, cause with enough riding, you'll lose half your toolkit ;)

When offroading, I usually only pack my tool roll and select spare parts. No point in carrying around all that weight. 


 Most of the tools I bought at Home Depot and fit in a their tool roll / organizer.
* Stock Kawasaki tool kit spark plug wrench.
* Husky 8, 9, 10, 11, 12, 13, 14, 17, 19 mm combo wrenches
* Husky 10, 11, 12, 13, 14, 17, 19 3/8" sockets
* Husky 3/8" long handled flex head ratchet
* Husky 3/8" short handled flex head ratchet
* Husky 3/8" Allen keys
* Husky 3/8" extensions 2" and 4"
* ½" 27mm socket for counter shaft removal
* ½" -> 3/8" adapter for above
* Crescent adjustable wrench for axle nuts
* ¼" driver and 8mm socket
* 2 * 14" steel tire irons - Northern Hydraulics
* 6" tire iron
* Kmart 12v air compressor
* Vice-grips
* Channel Lock Pliers
* Channel Lock needle nose
* Husky small Phillips screw driver
* Husky large Phillips screw driver
* Husky small slotted screw driver
* Husky large slotted screw driver
* Tiny slotted screwdriver for mixture screw
* Metal file
* Digital voltmeter - must have auto power off
* Clutch cable
* Throttle cable
* 21" heavy duty spare tube
* 17" heavy duty spare tube
* Patch kit
* 2 tubes of vulcanizing tire glue
* JB Weld
* Dish detergent - tire lube
* 3 small shop rags
* Electrical tape
* Duct tape rolled flat
* Light gauge steel wire
* One trimmed coat hanger wire
* 8 hose clamps - various sizes
* Assortment of metric nuts, bolts and washers
* 20 zip ties
* Spare H4 bulb
* Spare tail light
* Several 6' lengths of 14G copper wire
* Wire nuts
* Valve stem remover
* 3 Kawasaki oil filters.  Didn't want to spend time trying to find one on the road.
* 9 spare fuses (3 of each amperage)  Maybe 5*20A would be safer.
* 2 Master links.  Possibly mend a broken chain.
* Small can of Chainwax Lube
* Small can of WD40
* 2 ft of vacuum hose
* 1 ft fuel line
* Spark plug


 Here is a tool and spare parts list for your consideration.  Each of you knows what you might need.  Look over the list and remember,  we will not be near any bike shops or spare parts source!

KLR650 Spare Parts/Tools List

- Shop manuals
- Chain Lube (small can wrapped in a plastic bag with rags)
- Extra fuel "in line" filter
- Air pressure gauge
- Three feet of fuel line
- Clutch cable
- Throttle cables (both)
- Heavy duty bicycle pump/CO2 cartridges
- Front and rear inner tubes (extra valve stems)
- Siphon hose
- Extra shift lever
- Extra brake lever
- Extra clutch lever
- Extra clutch lever "C" clamp and bolts
- Extra water hose clamps
- Length of water hose (to cut for repairs)
- Duct tape
- Coffee filters (for gas on the road or water for radiator)

- TOOLS
-- Craftsman box ends to fit all nuts & bolts
-- Tools from bike tool kit for front/rear axle nut removal (with leverage handle)
-- Screw driver with multiple types and sized bits
-- Set of Allen heads for all required sizes
-- Spark plug tool from original bike tool set
-- Small needle nose pliers
-- Small flash light
-- Link removing tool, spare master links and five inches of chain
-- Tire repair tools, levers, soap, rim protectors and patch kit
-- Bag of extra nuts, bolts, washers, cotter pins, etc.
-- Tube of silicone,  Tube of "Instant metal", Tube of  "Gasket in a tube"

 - ELECTRICAL
-- Volt meter (small credit card size)
           -- 12v probe
-- Six feet #14 wire
-- Various connectors
-- Electrical tape
-- Small can of Electrical water displacing spray (WD40)
-- Spare bulbs - headlight and brake / tail light
-- Spare fuses
-- Spark Plug
-- Small wire cutters and crimpers
-- Spare "in line" fuse holder
-- Small syringe for battery water servicing


Subj: Re: [DSN_klr650] stock tool replacement / slime
Date: Mon Jun 25, 2001 21:17
cc:   <DSN_klr650@yahoogroups.com>
At 7:46 PM -0600 6/25/01, eric & amy blissmer wrote:
>I have an 01 KLR and was wondering what REPLACEMENT TOOLS are ABSOLUTELY necessary to carry with me wherever I go <
 Tool-wise, I carry everything I need to work on my bike short of a torque wrench and feeler gauges.  These tools stay with the bike and are never used for anything else.  This all fits into a pack the size of half a sub sandwich.
Here's my list:
* 8mm, 10mm, 11mm, 12mm, * 13mm socket, 6" extension
* 1/4"-drive ratchet
* 5-in-1 screwdriver
* KNIPEX® pliers (these are very versatile)
* spark plug wrench
* 6" Vise-Grips®
* Allen key set
* 8-9mm, 10-11mm, 12-13mm, 14-15mm, 16-17mm, 18-19mm open-end wrenches
* two 7" tire levers
* and a Leatherman-type tool on me

>What do you guys think about SLIME for tires?  Should I put it in my tire now or carry around a can of fix-a-flat to get me home?  My fear of slime is that I will not know when it supposedly seals a leak, then it decides to give way at 90mph.
 Slime works great for me.
-- Mark B2 A2 A3


> does anyone know what is the essential tools you need to carry along on a off road trip, Yesterday I went on a of road trip on a 2000 KLR650 near Rosarito Baja California Mexico, it was a 120 mile off road trip and I was lucky because everything went OK but I was a little nervous because I wasn't carrying any tools. <
Ernesto,
 You've got a little tool kit in the plastic box in the rack.  If that's not there, I'd gather some pliers, a big Crescent wrench for the axles, a 4-way screwdriver, and 8mm, 10mm, 12mm and 14mm open/box end wrenches for starters (a 1/4" drive with 8mm, 10mm, and 12mm sockets is also quite handy).  Also, you'll want some tire irons and a spare tube or two, plus a patch kit and a bicycle pump if you're all by yourself.  And you can't go wrong with some medium sized Vice Grips, duct tape, and some Quick Steel epoxy.


> I'm sure there are folks out there who know what sorts of things to check on the bike prior to leaving and, of course, what to bring for parts too.  I started a list but I know I'm bound to miss something.  Does anyone have a list they would like to share?  The more detailed the better.
 Check the obvious first:
1) brake pads (maybe new fluid? depends when the last change was)
2) tires
3) change the oil
4) spark plug?
5) bolt tightening party (go over the WHOLE bike)
 Things to carry:
1) spare headlight/tallight bulbs
2) spare tube(s) -- depends how much you can/or want to carry, you can get away with just a front
3) bicycle hand pump -- it may be just enough to get you to the next gas station
4) full toolkit (including but not limited to; tire irons, 8/10/12/17mm sockets and wrenches, adjustable crescent wrench big enough for axles or axle wrenches, spark plug wrench, vise grips, pliers, needle nose pliers, screwdriver with phillips/flat tips,
small bottle of dishwashing soap or other favorite lubricant, small amount of baby powder, quiksteel, and a flashlight with working batteries)
5) spare shift lever
6) spare clutch and brake levers (unless you have proper handguards)
7) spare clutch cable (you could route it next to the current one if you want to guarantee that you won't need it -- Murphy's Inverse Law)
8) WD40


Subject: tool bag contents while away from home
 We are all in the same boat - building the perfect 'away-from home' toolkit..
Not just tools, of course, but little odds and ends for in-field replacement / repairs.
 I am working on this myself, again. The challenge of weight, tool strength,
and spares bits:
· One hose clamp,
· a light-weight front tube,
· 2 tire changing spoons,
· a tiny case-less air pump or bicycle pump,
· a bit of plastic for use as a rim guard,
· a small tube of metal putty,
· small batch of electrical tape (3m or better),
· 2' of 14 gauge wire,
· fuses,
· Snap-on or similar quality 1/4" breaker bar w/ small extension and 6-point sockets in 6mm, 8mm, 10mm, 12mm, and in my case, 13mm. 14/" to 3/8" socket adapter for 14mm, 15mm, 17mm.
 Also added
· a combination metric Allen wrench,
· combination Phillips and blade screwdrivers,
· sparkplug wrench and spare plug,
· spare headlight and taillight bulbs,
· near empty tube of silicone sealant,
· 3 feet of bailing wire (high-grade),
· factory 6/8mm, 10/12mm, a 13mm, 14/15mm, etc. open-end combo wrenches,
· factory axles wrenches/extension bar, lip balm container filled w/ grease,
· 2' of high grade duct tape wound on a 2" piece of 1" wide flat stock,
· mini-multi meter,
· spare chain link and master link,
· 1' of coolant hose, sized to fit fuel line and vacuum hose,
· fuel tank sealing putty,
· copies of electrical diagrams from manual sealed in a zip-lock sandwich bag,
· 1 quart of oil,
· small can of WD-40,
· 5 sections of blue shop towels,
· and misc. nuts and bolts.
 I am SURE that modifications will continue in the above list as I seek to further reduce weight and volume. I invite additional comments and suggestions as this subject warrants involvement by all listers.
-- Mike T, A16, Las Vegas


> -----Original Message-----
Well I guess anyone can start...from the toolkit and supplements:

1. wrenches...8, 10, 12, 14, 15, 17, and then whatever I need for the axle nuts...I ditched the stock nuts and bought some nylocs from DualStar that don't require pins...the stock tool kit does not have a wrench for the front axle nut.

2. 2 tire irons + 1 tire iron combo rear axle nut wrench, 2 plastic rim protectors

3. A spare front tube standard grade...

4. a nice kit from Dualstar that has a small ratchet with 8, 10, 12 sockets, 3 or 4 allen wrench bits, and 2 phillips and 2 flat screw bits...I added a 6 inch flexible extension.

5. needle nose vice grip

6. 6 C02 cartridges and mini-cartridge pump thingee (what the hell is it called Fred?)

7. the screwdriver blade from the toolkit and spark plug remover

8. Leatherman

9. Clean-up wipes, handi-wipes

Spares: I carry a length of wire, electricians vinyl tape, a bunch of plastic ties in different sizes. I need to develop an assortment of nuts and bolts....rear master stay, plastic thingee that goes into the rear master cylinder


Jake Jakeman's Tool List
· Combination wrenches: 8mm, 10mm, 12mm, 13mm
· Axle nut wrench from original tool set
· 6 inch Crescent wrench
· 6" fine-point Vise Grips
· fold-up metric Allen wrench set
· 6" Channelock pliers
· 3 10" tire irons
· Tube patch kit
· Multi-tip screwdriver
· 6 ft. of #12 automotive electrical wire
· Crimp terminals and pliers
· small mountain bicycle pump
· wipes
· 1/4 inch drive swing handle, 8mm, 10mm, 12mm sockets
· Valve stem tool
· fuses (10A & 20A)
· small flashlight
· batteries
· 1 Qt. of engine oil
· Fix-a Flat
· chain lube
· 4 ea. 1" hose clamps
· 6 ft. of soft iron (baling) wire,
· small roll of filament or duct tape
· Small probe-type voltage tester, or pocket digital VOM


Bill,
 What scares me, in Salt Lake City anyway, is that the Kawi dealers stock nothing. Everything is 10 days away unless it's special ordered from an online dealer (need roadside internet connection).  The stock toolkit isn't equipped to deal with the larger fasteners or the hardto reach ones.  A crescent wrench is just too sloppy and obtrusive.
-- Kevin A17

· An 8" crescent wrench replaces both axle wrenches + the cheater bar.
· A ¼" drive ratchet with 8, 10, 12, 13, 14, a 6" ¼" extension, and 3, 4, 5, 6 mm allen wrench sockets takes care of most everything else.
· A set of small needle-nose visegrips
· A leatherman
· 12mm combination wrench.
· 10mm ratcheting combination wrench from craftsman- try removing the shift lever without one of these, doable but deeply sucks.
 A whole mess of other stuff, I should take a picture of it one of these days.  It all fits into a Fox fanny toolbag, including quiksteel, clutch and throttle cables, shift lever.....


Subject: [DSN_klr650] RE: Re: help minimize toolkit
 Pretty complete, a bit more than I carry. However, I would like to add a couple items:
*Fredette Racing axle wrenches
*Length of Baling wire (about 10 feet, bundled up nicely) *Swiss Army Knife / Small Leatherman  (can replace a couple of tools you mention)
*6Ē Slipjoint pliers
*a few common spare bolts
 With a little creativity, you can pack stuff pretty tight.  i.e., wrap electrical tape around handle of screwdriver, wrap duct tape around barrel of bicycle pump, etc.
 With this kit, I can do most everything short of pulling the engine (but
I could probably split the cases with this). When I am working in my
garage, I usually donít even reach for the tools in my tool chest, I
just grab my tool roll. That way I know that I can do it on the road,
and that I have all the right tools. The only thing I might change is go
with a ¼Ē drive to save space and weight.
 Itís also good to know, from memory, what is in your toolkit, makes
getting ready for
 Losing your train of thought easy?
http://www.jmtools.com sells the same stuff for cheaper When offroading, I usually only pack my tool roll and select spare parts.  No point in carrying around all that weight.
-- Z, DC, A5X, A12X
 And if youíre in a group, no sense everyone packing a load.


A note on tire pumps: If you carry a bicycle pump, carry one that is mountain-bike oriented, that is, high volume, low pressure. If you don't mind the weight, and rig an electrical outlet, another alternative is a small electric compressor. Buy a one of the cheap little department store compressors, tear off all of the plastic housing and cooling fan, and pack that along.