What needs to get done?
Let’s be realistic, unless you are kitted out for a longer trip there is not that much you can do even if you have the tools with you. It’s unlikely you are carrying a replacement levers or inner tubes with you on those everyday ordinary rides.
Mostly what I want from my always-on-tool-kit is the ability to tighten anything that might get loose or knocked out of whack AND get access to places to do the above or evaluate the situation.
My philosophy is that I want to get the above things done anytime, anywhere and I want to have the tools needed ALWAYS on the bike. On the other hand, anything that does not fit inside the toolbox, doesn’t get to go on board.
Longer trips are a separate case entirely.
THE “ALWAYS-ON-KIT” THAT FITS IN THE TOOL BOX
HEX BITS ▸ | 4 mm, 5 mm, 6 mm, 14 mm |
SOCKETS ▸ | 7 mm, 8 mm, 10 mm,12 mm, 14 mm, 17 mm, 24 mm |
SPANNERS ▸ | 6 mm, 8 mm, 10 mm,12 mm, 14 mm, 17 mm |
OTHER BITS ▸ | Phillips head, flat head |
OTHER TOOLS ▸ | Ratchet, extension bar (3/8), extension bar (1/2 x 2), universal joint (3/8), 1/2 sliding adaptor |
MISC STUFF ▸ | Fuse puller, zip-ties, electrical tape, pliers, flash light |
WITH THIS “ALWAYS-ON-KIT” YOU CAN
(among other things):
- Change the oil & filter
- Tighten mirror stems
- Tighten, remove / mount hand guards
- Remove / mount brake & clutch levers
- Adjust / remove shift lever
- Remove / adjust handle bars
- Remove seat
- Remove battery
- Access air filter
- Access headlight bulb
- Access tail light bulb
- Access / change fuses
- Access / remove turn signals
- Remove / mount rear rack
- Remove / mount skid plate
- Access, remove / mount handlebar switches
- Adjust throttle cable
- Adjust clutch cable
- Tighten spokes
- Remove exhaust
- Remove tank
- Remove wheels*
- Adjust chain*
(*) You can do this, but not really ideal with this compromise of tool kit . Then again. a bit dodgy kit is better than nothing is you end up needing it.
4 mm HEX BIT | WHERE IT FITS |
▸ | Tail tidy mounting bolts |
▸ | Skid plate mounting bolts ( AXP ) |
5 mm HEX BIT | WHERE IT FITS |
▸ | Fork protector mounting bolts |
▸ | Headlight mounting bolts |
▸ | Fairing mounting bolts |
▸ | Exhaust shield |
▸ | Risers / handlebar mounts |
▸ | Rear sprocket (+ 14mm wrench) |
▸ | Handguard handlebar clamps |
6 mm HEX BIT | WHERE IT FITS |
▸ | Hand guard bar end bolts ( Acerbis ) |
▸ | Seat bolts |
▸ | Rear cowl bolts |
▸ | Rear brake cylinder mount |
▸ | Rear brake rotor |
▸ | Rear rack mounting bolts ( AXP ) |
14 mm HEX BIT | WHERE IT FITS |
▸ | Front axle |
PHILLIPS HEAD | WHERE IT FITS |
▸ | Hose clamps |
▸ | Handlebar switch housings |
▸ | Turn signal mounts |
▸ | Air cleaner cover |
▸ | Front brake reservoir cover |
6 mm SPANNER | WHERE IT FITS |
▸ | Spokes |
7 mm SOCKET | WHERE IT FITS |
▸ | Starter motor |
8 mm SPANNER / SOCKET | WHERE IT FITS |
▸ | Front brake cable guides |
▸ | Mirror mounts |
▸ | Throttle cable top & bottom (+10mm) |
▸ | Front sprocket cover |
▸ | Crank case covers |
▸ | Chain guard |
▸ | Battery terminals |
▸ | Oil filter cover |
▸ | Radiator mounts |
▸ | Water pump cover |
▸ | Tank mounts |
10 mm SPANNER / SOCKET | WHERE IT FITS |
▸ | Front fork clamps |
▸ | Gear lever pinch bolt |
▸ | Clutch & brake lever pivot bolts ( +12mm ) |
▸ | Chain adjuster ( +8mm ) |
▸ | Throttle cable adjustment top & bottom( +8mm ) |
▸ | Front axle pinch bolts |
▸ | Front brake rotor |
▸ | Chain quide ( + phillips ) |
12 mm SPANNER / SOCKET | WHERE IT FITS |
▸ | Front brake caliper mount |
▸ | Brake hose banjo bolts |
▸ | Exhaust clamp & mounts |
▸ | Oil drain plug |
14 mm SPANNER / SOCKET | WHERE IT FITS |
▸ | Rear sprocket |
▸ | Engine mounting bolts |
▸ | Rear suspension mount and links (+17mm) |
▸ | Mirror stems |
17 mm SPANNER / SOCKET | WHERE IT FITS |
▸ | Kick stand mounting bolt |
▸ | Rear suspension (+14mm) |
24 mm SOCKET | WHERE IT FITS |
▸ | Rear axle |
Great list. Thanks for saving others the time. 🙂
Looks like a fair bit of these can be left out for an on-the-bike toolkit. Do you use anything for holding the head of the rear axle bolt when tightening or just tighten on the nut side? I don’t see the bolt listed above.
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Yes, the 17mm spanner.
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Thanks.
So they changed it down from the 19mm of the 250? Interesting. But no objections — smaller = lighter.
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Hi, do you think that could be a good idea to realize a small tool case to replace the OEM?
I mean a smallest one only for documents and nothing else?
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A quick question:
How long is the toolbox – would it be possible to store 25 cm tire irons inside?
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No. The opening is roughly 16cm and the compartment is a tiny bit bigger. 17cm is likely the max length of a tool that would still for.
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Thank you!
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Great job. Any tricks to packing them into that space? i.e. wrapped in anything?
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No. Most of the stuff is in the original pouch.
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How are you going to drive the 14, 17 and 24 mm sockets if you only have 1/4 ratchet, and they require either 3/8 or 1/2?
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In the pic it looks like your screwdriver bits, smaller sockets, rachet and extension are 1/4” but the list calls for a 3/8 rachet and extension. Can you clarify
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It looks like your screwdriver bits, smaller sockets, rachet and extension are 1/4” but the list calls for a 3/8 rachet and extension. Can you clarify
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It looks like your screwdriver bits, smaller sockets, rachet and extension are 1/4” but the list calls for a 3/8 rachet and extension. Can you clarify?
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Thank you for putting this together, it’s ages since I found this first time, it was very helpful, my tool kit is growing and getting heavier lol, I don’t carry it much, just on longer trips but must think of putting some of it on the bike permanently. Thanks again
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JIS screwdriver is better than Phillips. The two are not the same.
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