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  #1  
Old 23 Oct 2008
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KLR 650 Tools Question
I recently moved and some how lost my tool set. I have to set that came with my bike but there isn't a tool for changing the tires nuts everything is too small. So instead of going out and buying a brand new set I am trying to piece together a set I can use on the road. I am leaving for South America November 1st so any help on constructing a bullet proof tool kit would be great!
Any other suggestions would be very helpful as well.
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Old 24 Oct 2008
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Tool kit for KLR
I came across this site for KLR info. http://klr.carguy.org/

Have fun on your trip.
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Old 24 Oct 2008
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Hey Phil,
I have already looked at that site. It is a good site but incomplete and it only tells you about the stock tool kit which I have already. Thanks for the information anyway and the actual link is gman's KLR650 Stuff
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Old 24 Oct 2008
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You can do a lot with the stock kit, as you know. I add to mine a little ratchet with a few sockets, 10mm, 8mm, and whatever size socket it is for the oil drain plug... 18mm? Get a decent set of pliers to replace the crappy stock pair and a wide array of hammers (kidding... but you CAN fix most things on a KLR with a good smack). Zap straps and loctite round out a basic kit.
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Old 24 Oct 2008
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My recommendation:

Open box spanners: (I prefer them to double rings as the double rings always come in the wrong combination of sizes with one end you'll never need)
10mm, 12mm, 13mm (only if you have nylocs on your drivechain tensioners), 14mm, 19mm, 22mm, 24mm (or 27mm depending on what KLR you have)
Allen 6mm for handlebar cap screws and brake calipers.
Add 3mm, 4mm and 5mm if you replaced all the crappy Philips bolts with allen head caps and button heads (you should!)
Sockets 8mm and 10mm plus a ratchet and extension.
Philips screwdriver in case you have any Philips scrap left on the bike (you shouldn't)
Spark plug wrench
Universal pliers

besides that the usual: 2 tyre levers (passenger car size), bottle with soapy water, inner tubes, patches, pump, plenty of cable ties, tie downs, duct tape...
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Old 24 Oct 2008
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Thanks for the info. I have found a great site with a great set up. Looks like these guys have done their homework. Blue Ridge Racing Products Motorcycle, ATV & Snowmobile Tool Kit Store
What sizes are the axel nuts on the 04 KLR650 I cant seem to find the sizes anywhere.
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Old 30 Oct 2008
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The axle nuts are 22mm & 24mm, the axles are 19mm & 22mm.

You also have to add a 17mm for the sump plug, no idea why I took that off the list ???
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Old 3 Nov 2008
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yoyo
Me and my friend are going to s.a. in jan we should meet up.
s.o.
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