Tools for your VX800.

When I bought my VX, it came with what I think was an incomplete tool kit. No matter....I combined it with bits of my Kawasaki's tool kit as well as other wrenches and stuff.   I was one day reviewing my tool kit, which is getting a bit to bulky to easily sit under the seat, and started wondering if anything could be jettisoned. For example, I have combination wrenches from 7mm to 17mm, plus some sort of 24mm tool (I think it was for the Kaw's rear wheel nut).   I also bought a set of allen keys in the red plastic holder, plus some other sizes which I did not have (12mm for front axle for example, 13/16" for the windshield mounts, etc..).  I can't imagine that I need each and every one of those.  Hmmm.....I wonder if I'll ever use that 16mm I've been lugging around.

Sometimes when I work on my bike, I try to use only what is in the toolkit so that I can find out at my leisure what my kit is missing in comfortable surroundings. Unfortunately, I immediately forget which are the ones I used so I still don't know.

Recently Giselle purchased a stock Suzuki VX800 tool kit from the dealer.  I believe the price was around $26, part#09800-21015.  Thankfully, I was given an inventory and a pair of pictures of the kit in it's pristine state. 

So what exactly was in this kit?

Open end wrench 10mm / 12mm
Open end wrench 14mm / 17mm
Socket wrench thingie 19mm, presumably for rear axle
Allen key 3mm
Allen key 6mm
Allen key 12mm
Slip joint pliers
Spark plug removal tool.
Screwdriver handle
Screwdriver shaft with Phillips & slotted styles
Screwdriver shaft with larger Phillips  style only (longer shaft)

..........all packaged in an overly padded little vinyl pouch

     
click for larger images

I figured that it would be a good start for a "must have" list.   So one day I went out to my bike and started going over all the fasteners I could find, and logging which tool sizes were required.  I would list one or two parts for each size that you could conceivably have a need to use a tool for.  

I'm now starting to think that this replacement kit must be missing items from the stock kit.  For example, there was no 8mm allen key for the rear grabrail (should you need to remove the side covers), no 8mm hex wrench for adjusting the handlebar controls (if you have a tipover, you usually need to adjust)   Rick (J9andR) says his kit contained a thin 8mm with a little slot in the handle to accept the screwdriver bit, which the Giselle tool kit did not have.  There was no shock adjustment tool either.  I also suspect that there should be an extension handle for the 19mm axle removal tool and the missing shock tool, but have not been able to confirm that.  

Naturally, many of these tools are not necessary to carry on a daily basis.  I mean how often do you change the shaft oil on the side of the road?  Also, the only 7mm hex bolt I found was the starter cover.  I found that it is not possible to remove the starter cover without first removing the chrome coolant pipe.  This makes this unlikely to be done on the side of the road  so you may decide to omit that size wrench.  However I'd sure want the 4mm and 5mm hex keys and the 8mm hex wrench with me. 

Here's a more recent picture of my own toolkit.  Click for larger image.

Some of the extra goodies I added include  a shock tool, extra battery bolts and plugs, cotter pins, zip ties, electrical tape, feeler gauge, plug gap tool, zip ties.  I have a "AA" Maglite flashlight under the seat, leaning against the tail frame rails and tucked under the seat latch bridge.  I also carry small separate containers with 2 fresh sparkplugs, plenty of fuses, and various bulbs.  Extra spaces get a rag and a bungeenet.  Replacement brake and clutch levers are zip-tied and velcro-strapped to the lower tail frame rails.  However, I know there are still some other things I really should have with me.  Some will securely tape a spare ignition key to the frame somewhere.  I know that would've saved me some aggravation at least once.

On longer trips, I carry a modified 12v air compressor, similar to those shown at http://www.nohorizons.net/Micropump.htm and http://www.webbikeworld.com/Motorcycle-technical-articles/air-pump/index.htm. For even more fun, consider shortening the air hose, removing cigarette lighter plug and adding alligator clips, or maybe adding the same style plug that you use for your batter charger or electric vest.

Now THIS is a toolkit! (Click for enlargement.  Harvested from http://www.dansmc.com

Here's a handy wrench size conversion chart I found at Dan's MC site.

See these sites for more tips on what tools you may want to carry.
http://www.xs11.com/tips/misc/misc6.shtml ,
http://www.visi.com/~dalebor/pack_list.htm#Tools , 
http://users.pullman.com/viking/CampingList.htm#tools 
http://www.dansmc.com/tools.htm 

If anyone can find any reasonably important bolts or nuts that use sizes other than what's listed here, or any errors, please shoot me an email at the license plate below.

Brian Squibb suggests a 50mm C-spanner to facilitate head bearing adjustment.  Might be too big for an on-the-road tool, but good to have at home at least.  
I like the thought of adding some electrical wire and a fuse holder to the bike somewhere (for impromptu re-wiring jobs).  
Tony slo-mo stores some safety wire by winding it around the plug tool.
Here's some tool comments by Paul Fox.   

And whatever you do, don't miss Paul's homemade tool site.

emails to:    @optonline.net