Afternoon everyone,

We're currently prepping 2 XTR's for a UK to Oz and beyond trip to leave at the end of April. I was talking with a mate this week and we got on to the subject of what tools would go be going in the final kit.

This may have been covered elsewhere on the site but i couldn't see it (apologies if it was staring me in the face!).

We will need tools to allow us to do servicing on the bikes, change tyres and anything else you might expect, but to be honest I'm not too sure how much work on the electrical side I'll be able to do...

So, my question is this, given that I'm going to chuck/replace the standard kit on the bikes, what in your experience/estimation would you take to cover your needs? It would be great to have a list in this section available (if there isn't already one!...) for any future XT-based overlanders.

thanks

Theres a few guys who took there XTR/Z's for big distances and they should be along soon. As for me its the basic tool kit, plus any tools you need to do the regular servicing with, mostly good spanners (no cheese ones), good allen keys, screw drivers etc. As for the other stuff like electrics, bring the basics with you, a head lamp bulb, stop tail light, indicator, a few different spare fuses, a good length of spare cable, few connectors and a set of small wire snips (which can also be used as toe nail cutters along with other things).

Dont be taking all your tool kit with you as if you do break down (which hopefully will not happen) local people are normally very helpful and if they dont have the piece your after should be able to take you somewhere that does (only problem is this takes time)

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Plough on

I've been working on a replacement toolkit for a while (in prep for a short trip in May).

I'm not going to tell you what you need, as I think it's best all round if you figure it out yourself (this in itself is good prep for the trip).

Over the time you have, take your bike apart, little by little and copper slip all the bolts you take out (as you are putting them back in) - this will ensure that you will not suffer from 'stuck' bolts when you are far from a workshop. While you do this make a list of all the tools you use, wherever possible use the same tool, or better still get a tub and put the tools in the tub as you use them, always looking in the tub when you need a tool and only going to your tool box if it's not in the tub.

Clean all your electrical contacts, take them apart, clean with a contact cleaner and re-connect them securly, then grease all around to stop water ingress.

Check every nut and bolt you can and torque as the manual says.

Change the oil & filter,

Remove the spark plug, put it in your spares kit (as you know it works) and replace with a new one.

Clean the air filter, maby replace with a DAN or a foam filter, depends on where you are going and how much cleaning you want to do. Don't knock regular maintenance it gives you a chance to unwind and check the bike over for developing problems.

Consider an oiler, there are many. but think about where you are riding, many people argue that in the sand a dry chain is better and last longer than a well oiled one (sand sticks to the oil to make a lovely grinding paste!). In any case you will need to lubricate it at some time.

Replace the inner-tubes with HD ones, do this yourself as it's not easy learning the skills is the p!$$ing rain in the middle of warinistan, or a goatrack on a cliffside!

Once you have your box of kit, see what you can save on (there are some good tyre-levers with large ring spanners out there, so the same tool removes your wheel and the tyre!) or make, I made a tyre lever out od an old 3/4" extension bar with a hammer head and 3/4 drive on the other end, sadly it's died but the idea was sound (just not my ability to weld Chromevandium steel!)

You will be quite suprised at how little you actually need and can get away with, and all the checking will have you setting off down the road knowing your bike inside and out!

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Never underestimate the power of stupid people in large groups.

bravo for post !

very good question

Thanks for the replies so far! Glad it seems to be something of interest to people, definitely a need for it.

I'll definitely be giving the bike a service and putting aside those tools that I use, but I'm also thinking about the kind of additional tools that people tend to need or find useful on the road, for example tyre irons (type, length), wrenches etc..

So, what do people find is essential or unneccessary for a trip? What should I not leave home without?

hi bob
i rode my xt on "sibirsky extreme", probably the toughest road in the world, all told 10,000mls to home.
itook very few tools they all fitted in the hole under the seat, apart from 1 tyre iron. ktm do a nice cranked one.
If you,d like we could meet up or talk on the tel. and i,ll run through all the preps. i did.
The only thing i changed when i got back was put 15w oil in the forks, and bought a s/hand koni rear shock, ready for the next trip.
if your interested pm me.

Good to hear the Xt's so reliable!

I came across this great thread on advrider.

http://www.advrider.com/forums/showthread.php?t=262998

Once I've learnt what my travel tool kit is I'll post it, but in the meantime if anyone's already got one to show off....

There are also some tips on the "Tools" thread, buried here in the XT660.com archives:

http://www.xt660.com/showthread.php?t=8548&page=2

Plus I gave some ideas on the "Packing Light" thread a while ago when I was in the USA:

http://www.xt660.com/showthread.php?t=8901

J xx

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