roadside tool kit

[Mogo Bagginz]

Hi there, I'm trying to put a road side tool kit for my newly acquired Yamaha XT 600 43f. I currently have no tools what so ever (not even a screwdriver) as I brought it as a means to continue travelling.

What size sockets and alan key sizes and other tools would you need for dong all routine maintenance and essential roadside repairs including common faults?

What are the common faults on a Yamaha XT 600 43f?

What do you guys carry in terms of tools for long distance travel?

Nice one

[Hodgo1981]

G'day,
I'm surprised none of the regulars have chimed in yet. With regards to a tool kit, you could buy something like this http://www.ebay.ie/itm/Yamaha-XT600-XT- ... 2079494703 while its good for originality... it is a bit lacking. These are my suggestions:
-spark plug spanner.
-I have a cheap T-bar toolset with common allen key and screwdriver bits. plus common socket sizes 8,10,12,13mm ( bit like this http://www.ebay.co.uk/itm/22-PC-T-Handl ... 2273984212)
-spanners - get 2x 8mm/10mm open-end combo, 12mm, 14mm, 17mm
-shifting spanner which goes up to about 26mm should get everything else.
-tyre pump (bicycle)

extras to take when going remote area:
-chain breaker, and spare chain links and spare chain joiner,
-2x tyre levers and a 21" inner tube.

With regards to common problems, these are the commons ones I have had on my bike.
-carburetor manifolds coming apart, need replacing
-air filters not maintained/need replacement
-oil return valve failure (oil tank drains to sump when you stop)
-chain guides worn.
-Not a fault, but something people dont maintain is the suspension, consider replacing fork seals and oil, and if suspension feels 'bad' consider some upgrades there

[Mogo Bagginz]

Thank's Hodgo1981, that definitely gives me something to work with. I don't know how I didn't find that XT set on ebay, I was looking for something like that for reference. I found this set https://www.amazon.co.uk/Neilsen-Socket ... socket+set and was thinking of trying to expand it.

the spark plug in is 18mm right?

[Hodgo1981]

I think its 18mm, but I was reading another forum saying a lot of generic ones dont fit in the hole.
So I'd say buy a dirtbike specific one, or one of the yamaha toolkits like the ebay link before, or this (if you want cheaper and dont need the rest) https://www.motomike.eu/bitzforbikes/en ... le/390871/

[Mezo]

lot of generic ones dont fit in the hole.

None of my plug sockets fitted, i used the OEM Yamaha tool kit one.

Mezo.

[motorang]

Hi there,
get a spark plug tool that is rather long - and cut it to length. The spark plug sits quite deeply recessed inside the head.
You can use a standard socket if it is slim enough, as some 3/8-inch sockets are. 1/2-inch tend to be thicker. 18 mm is right, fitting a DPR8-EA9 spark plug. But you will need extra extensions to get the length right. I use NGK iridium plugs and find them more reliable than the standard ones.

Standard toolkit includes a Leatherman-type multi tool and some duct tape.

For the tyre work, carrying a rear tube always was enough for me (18 inch).
Originally you might need a 14-mm-socket too as japanese bikes do not have 13mm heads. But they tend to get replaced over time by easily aquirable 13 mm head sizes.
If you use a clip-type chain link a chain breaker comes in handy, but you will not need a chain joiner.
For getting the inlet manifolds off I always use a 5 mm allen key cut to length (cut the short end as short as possible). The carb is easier to handle with inlet manifolds attached.
Air filter is a washable foam filter which tends to get brittle over the years. I use replacements by Netherland company Twin Air, check with your local Motocross dealer.
For travelling I always had spare levers with me (clutch/brake) but now I find it better to have sturdy metal-core hand guards which not only prevent the levers from snapping, but the attached joints as well.

What else?
I fitted an oil temperature gauge (drain bolt replaced, electrical gauge by VDO or Racimex).
And I did put a direct choke knob on the carb instead of the cable operated one which tends to jam.
I have a small canister of chain lube with me and some multi purpose oil, some cable ties, wire. If you have no automatic fuse I would take a spare fuse with me, and fit a 12V socket for charging phone/navigation on the handlebar (with a fuse as well).

Many of these bikes have ruined thread where the bottom blt of the oil filter is - this is delicate and easy to damage.
Many of these bikes have damaged clutch vovers because they get kicked over sitting on a side stand or main stand. The very light cover is not up to that and the kicker shaft will ovalize or crack its hole.
These bikes have to be able to make use of their suspension when kicked over.

Do not overtighten the chain. With a helper, put the swingarm bolt in a line with the sprocket shaft and rear axle, this is the position with most tension on the chain, and this is where you set a minimal play of about 2 cm up and 2 cm down at the loosest part of the chain. Back to the sidestand and fully released you now can measure how much play that is NOW and take a note. It will seem very loose, but that will save the engine bearing.

Also it is advised to check the oil only after some km riding, just after killing the engine, with no idling on the side stand. Do not refill when the engine was not running before, as the level may lower and you then put way too much oil in the tank.

Get a workshop manual :D. There should be a digital version around somewhere.

For more serious expedition-type riding the list will be a bit more extensive, but for normal riding this will do.

If any cable, I carry a spare clutch cable with me. This was the only one that ever gave up. There are universal repair sets around which are smaller than a complete clutch cable.
For adjusting valve play you either need 0.08/0.12 mm feeler gauges, or if you can not get them use 0.10/0.15 on the tight side of adjustment.
Or you learn how to adjust the play by means of the adjustment screw angle.

Andy

[Mogo Bagginz]

Nice one guys, its mutch appreciated. motorang I heard about someone writing off a bike with like 4ks on the clock because they tightened the chain too much and jumping the bike. it's been on my mind after every speed bump, I'll have a test in a bit. I found this adjustable spanner when I was wandering around town http://www.bahco.com/en/p/side-nut-adju ... -59-c0-67/ I haven't used it yet but I'm pretty impressed with the design there's like 8th to a 10th of a mm play in the moving jaw bit, a little part of me wants to believe that this thing won't round every single bolt it touches.

I'm thinking about getting one of those 12v tire pumps like this one part of the lure is that I can pump up my air mattress. have any of you had any experience with these? the reviews on a lot of them say the pressure guage isn't reliable.

[motorang]

Hi,
this is a good pump for tyres, low volume and high pressure, and this is where a gauge makes sense. You will definitely ruin your air matress if you pump a long as you see no movement at the gauge :-).
The air matress is designed to be inflated with lung power, which is about 0.1 to 0.25 bar. So you can use the pump and your hand to feel the hardness of the matress. If you use the compressor to long the matress will balloon
For a classic air matress it will take several very noisy minutes to pump up. For a laminated foam matress (Therm-a-Rest and the like) it will go faster due to the smaller volume.

Special pumps for matresses or boats work the other way round: low pressure and high volume flow, more like a fan than like a pump.

Andy

[Kedishen]

I keep the following in my toolkit:

_Long distance_

- Locktite
- Cable ties
- 2x Ring Spanner - Size 10
- Socket Wrench
- Sockets 10, 15, 17, 24, 30 (brakes, axles, front sprocket)... think these are the right sizes...
- Mini Multi Screwdriver + star key bits + screwdriver bits
- Multi Tool (knife etc)
- Electrical Tape + Spare joiners
- Engine oil
- Brake fluid
- Chain master link
- Puncture repair gunk.

_Short_

- 2x ring spanner - Size 10
- Mini multi screwdriver
- Multitool
- Chain master link
- Engine oil
- Puncture repair