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uberthumper · # 2 06-02-12, 11:55

This is all for a Tenere, so you might want to check some of the sizes, but I would have thought the bulk of it would be the same.

Main sizes are:

Rear Axle: 22mm socket or spanner
Chain adjusters: 10mm and 12mm open-ended spanners
Front Axle: 14mm hex key
Front Axle Pinch Bolts: 6mm Hex/Allen Key
Most of the bodywork: 4mm allen key
Airbox/filter: Fairly big Phillips screwdriver.
Spark plug: 16mm (I think)

6, 8, 10, and 12mm sockets, and a 5mm allen key will do pretty much everything else on the bike.

My kit is as follows (as far as I can remember, may edit later). It doesn't fit under the seat, but it does all fit in a Kriega US-5. The Motion Pro gear is horribly expensive, but it does really cut down the amount of stuff you need.

Wheels and Tyres:

Motion Pro tyre-lever/spanners (22 and 27mm)
3/8" drive adapter for the 27mm lever.
(14mm 3/8" drive key for the front axle - I've ditched this now because I don't have standard forks any more - the 27mm spannerlever does mine now)
Hand pump
Pressure gauge
Spare front tube
Valve core extractor
Tyre patches, glue, etc.

General tools:

Motion Pro trail tool
Gerber Suspension multitool
3/8" extension bar
A few odd bits and pieces the MP trail tool doesn't have, like a 4mm allen key for the bodywork, and 10/12mm open-ended spanners for the chain adjusters.
LED Headtorch

General spares:

Fuses
Number plate screws
Screen screws
Zip-ties
Probably a few other bits I've forgotten

Edit: And a towrope!

I don't carry bulbs unless I'm going to a country that requires them. The tail/brake lights are LED on the Tenere, and if the dip beam headlight goes you can always swap the bulbs with the main beam. Anything else is optional. Probably doesn't apply to an XTR though.