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Motorcycle tool kits

I firmly believe in the adage that “The best tools are the ones that you have with you”.  With that in mind, over time I have tried to maintain a purpose-built set of tools such that I can always have them handy on the bike.  I have tried to keep the set to be as efficient as possible for space and weight savings, such that they will always fit in available on-bike storage that is not too cumbersome.  It is very easy to go overboard with what tools you are tempted to pack without giving more serious consideration as to what is critical and likely to be needed for on-trail repairs, versus what is probably more practical of a repair back in your garage or the motel parking lot.  When putting a tool kit together it is also important to understand the requirements for the specific bike you will be using.  Hex keys won’t help for much other than for those aftermarket farkles if you are riding a KTM or Husqvarna that has Torx head bolts.  What are the most likely repairs you will be doing out on the trail? Removing either the front or back wheel to fix a flat should be top of your list.  Fixing a broken control lever is also a likely scenario.

Also, I maintain an additional set of tools and parts that I optionally pack based on the length of the trip and where I am going. For example, if you will be riding in rougher terrain with a higher likelihood of mishaps, multiple days away from my car/truck, may not be in any places with an auto/motorcycle parts store within the next few days of riding, or somewhere like Baja with more limited resources, then it is wise to pack additional tools and spare parts in order to be more self-sufficient.

While I keep my baseline minimal tool set in my tank bag, given the space required for fixing a flat with a tubed type setup, I tend to carry the tire repair kit in a separate area in either my backpack or in a side/tail pannier bag. The same is true for the extended tool and parts kit that I may end up carrying or not.

Husqvarna FE450 tool kit
Given the lightness and agility of the FE450, the importance of going nimble is as important as ever. When researching off-the-shelf tool kits for the bike after first acquiring it, I found the Cruz roll-up tool set (Cruztools Roadtech RTKT1) seemed to provide the best match for a quality set of tools one needs that tended to thoughtfully match the specific needs for a KTM/Husqvarna dual sport bike

But after some riding time, I realized it was less practical to carry the full Cruz tool set. It weighs 3 lb, 3 oz, with a packed size of 9.5” x 3.5” x 2.5”. It is too big to fit in my small tank bag, and the weight in the backpack is a little much if you just want to just ride on some local technical single-track trails, but may be 10-20 miles from your car. So, I conjured up a custom tool set to try to go as light as possible and can also fit in my tank bag. This tool kit weighs just under 2 lbs, and fits in a bag from Home Depot that is 6.5” x 5” x 1.25”. The tools have been scrounged from various sources off Amazon, Harbor Freight, from my spare bicycle tools, etc. See the comparison in the figure to the left. This kit consists of:

6” open end adjustable wrench
Small needle nose vise grips
Small ¼” socket wrench
¼” socket extension bar
6mm, 8mm, 10mm ¼” sockets
T40, T30, T20 Torx wrenchs
Slim open-ended wrenches: 17/14mm, 13/11mm, 12/10mm, 9/8mm
Small combination metric hex key set with Phillips/flat-bladed screwdriver heads
(handy for various aftermarket add-ons like bar guards)
Zip ties
Small roll of duct tape
Master link (520 O-ring, clip style)
Tube repair kit with fresh unopened glue

In my tank bag I separately carry a minimal first-aid kit, small multi-tool, tire pressure gauge, tow strap, Rock straps, rag, latex mechanics grade gloves, and some baby wipes to clean up after working on the bike. For fixing a flat I carry a separate kit that is something I can move from bike to bike depending on what I am riding:

Medium duty front tube
Medium duty rear tube (optionally depending on length of ride)
2 aluminum tire spoons with wrenches to remove the wheel axle nuts
Small light duty 12V air compressor powered from the SAE connector on the bike
Valve stem puller
Tire lube and talc powder
Bead buddy (minimizes the need for carrying a 3rd spoon)

For more casual or less technical rides I may take my chances and skip carrying the tire repair tools. In one instance after getting a flat on my rear tire, but failing to successfully repair it due to a comedy of errors on my part (tire spoon gouged my only tube and my tube glue was dried up), I was able to ride it out for about 40 miles back to the car, by going slow and fortunate enough to have a rim lock installed and a very tough tire (Tusk DSport Adventure). For extended rides where I think there is a higher risk for failure or in an area with limited resources, I will carry an extended set of parts and tools:

Spare clutch and front brake levers
Spare shifter and rear brake lever
JB Weld steel epoxy
Blue Locktite
Spare bolts and nuts
Electrical wire, fuses, electrical tape, wire crimps
Small chain breaker & vice tool
Small bottle of extra engine oil
Small funnel
Spare fuel hose also useful to siphon gas
Plastic water bottle (holding drinking water) useful temporarily for a gas or oil
Hose clamp
Ratchet strap and more zip ties
Small tarp and rags
Second set of tubes (if a more remote trip like Baja or Death Valley)

For these extended trips I pack this stuff plus the tire repair gear in some small soft strap-on pannier bags balanced between the sides. My favorites are the 16L dual sport panniers from Rocky Mountain ATV as shown on the bike in the photo to the right.

Husqvarna 701E tool kit
Given I have had this bike longer and tend to take the 701 on longer multi-day rides such as BDRs, Baja, and the like; my tool kit evolved in a more ad-hoc manner over time. But in general it is relatively close in spirit to the FE450 but with a slightly larger compliment of tools, weighing in at 3 lbs, 2 oz, and all fits in a 9.5" long bag that I can store in its larger tank bag or in a side pannier bag. The following are contained in this tool kit as also shown in the figure below:

6” open end adjustable wrench
Medium sized vise grips
Small ¼” socket wrench with extension
8mm, 10mm, 12mm, 13mm, 14mm ¼” sockets
T40, T30, T25, T20, T15, T10 Torx socket bits
T25, T20, T15 Torx wrenches
Slim open-ended wrenches: 13mm, 11mm, 10mm, 8mm
Phillips & flat-bladed screwdrivers
5mm, 4.5mm, 4mm Hex wrenches
3 tire spoons (2 aluminum ones with wheel nut wrenches)
Zip ties
Small roll of gorrila tape
Blue LockTite
Master link (520 O-ring, clip style)
Spare bolts
Tube repair kit with fresh unopened glue
Valve stem puller
Fork seal saver (for cleaning fork seals in the field)

If starting fresh it would be tempting to just use the Cruz RTKT1 tool kit, and then compliment it with additional contents it does not have to address tire and chain repair.

Like the FE450, in my tank bag I separately carry a minimal first-aid kit, small multi-tool, tire pressure gauge, tow strap, Rock straps, rag, latex mechanics grade gloves, magnet (to fix kickstand failures), and some baby wipes to clean up after working on the bike. In general it is easier to duplicate these essential tools and parts and keep a dedicated set on each bike, than trying to keep track of which bike which tools are at, and then finding out later some essential tool is on the other bike.

BMW F800GS tool kit
This bike has been ridden on my longest trips including a 9000 mile ride to Tuktoyaktuk on the Arctic Ocean and back, Cabo at the tip of Baja, Continential Divide, and others.  As such it has probably seen the most use.  Like my other bikes I always have the kit on the bike and have it stored in a small Kriega bag attached with straps holding it to the right side of the frame below the seat and behind my leg such that it does not interfere with my riding either sitting or standing. The kit weighs 4 lbs and fits in a 10" long tool roll that also includes a zipper section for the smaller bits. The following are contained in this tool kit as also shown in the figure below:

6” open end adjustable wrench
Medium sized vise grips
Needle nose pliers
Small ¼” socket wrench with extension
8mm, 10mm, E8 torx ¼” sockets
set of Torx wrenches
set of hex wrenches
open-ended wrenches: 13mm, 11mm, 10mm
combo Phillips & flat-bladed screwdriver
small right angle combo screwdriver
3 tire spoons (2 aluminum ones with wheel nut wrenches)
Zip ties
Blue LockTite
Master link (525 O-ring, clip style)
Tube repair kit with fresh unopened glue
Valve stem puller

In the Kriega bag that holds the tool roll I also keep a tow strap, some duct tape, latex mechanics gloves, and a rag. One other important point is that often because you are riding with others, your tools will be needed to help fix somebody elses bike.  As a result, it can be more handy on these bigger trips to have a broader set of tools. For such trips I may bring some additional items such as a small chain press/breaker and spare brake, clutch, and shift levers.

Like my other bikes, in my tank bag I separately carry a minimal first-aid kit, small multi-tool, tire pressure gauge, and some baby wipes to clean up after working on the bike or just after a long dirty day of riding.