Tool list for 05-08 dirt scooters

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jmscrttndn

jmscrttndn

Joined
Jan 28, 2015
Messages
277
Location
Winnipeg, Canada
Hello all,

I am trying to build up a specific tool kit for the Berg (mine's an '05). As I have played with the bike, I have determined that a tool kit for this bike should consist of (at least) the following tools:

-8mm wrench
-10mm wrench
-13mm wrench
-27mm wrench

-Phillips screwdriver
-Flathead screwdriver

-4mm hex key
-5mm hex hey

-Multi-tool; or
-Needle Nose Pliers
-Vice grip pliers

-x2 Tire irons
-Bead buddy
-18" Tube
-21" Tube

----- ----- -----

I do not have any tool kit for the bike at the moment, but I am trying to compile a comprehensive list. The goal is to be able to work on 95% of the bike should it break down trail-side.

Please review this list and add any tools you think would be helpful/needed AND WHY. Please list the location/item that the tool is intended to target. Those with a OEM tool kit should be able to chime in. Below is my reasoning.

-8mm wrench - Many bolts on the bike are 8mm (almost all engine bolts).
-10mm wrench - Certain bolts are 10mm such as rear fender centre bolt
-13mm wrench - Oil drain and screen bolts
-27mm wrench - Axles

-Phillips screwdriver - Fenders, random screws
-Flathead screwdriver - Hose clamps, general pry tools

-4mm hex key - Bash guard
-5mm hex hey - Control items (I think)... handlebar items

-Multi-tool; or
-Needle Nose Pliers - good for holding, grabbing items
-Vice grip pliers - Good for grabbing tough-to-hold items

-x2 Tire irons - tube changes
-Bead buddy - Facilitates easier tube changes
-18" Tube - Extra tube
-21" Tube - Extra tube
 
On the bike, just carry a 21" tube, it will work in the back as well to limp home.

Safety wire. small handpump, CO2 charger, or something to fill the tubes.

Something for the front axle, but a true "axle wrench" will have both front and rear sizes. Just get the correct one.
 
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Look at the motion pro t6 tire spoon/27mm wrench combo there is also a 3/8 drive ratchet that fits in to the wrench end.

Also put some epoxy putty in your kit. Putty saved my day a week ago. I used it to patch a hole in my clutch side cover on my husky.


If you are interested. Here is a thread on a local ride that is going on Saturday.


Orangeville-Creemore Dualsport and Aggressive Ride | Ontario Dual Sport Club Forum
 
Vise-Grips are subtly useful besides the obvious grabby benefits - They can serve as makeshift grips and levers. ... I've only seen pretty heavy ones. Thought: Maybe there are lighter-than-normal vise-grips available?


I'd advise having a spark plug socket. If the bike gets drowned, it's very good to be able to get the plug out and drain the cylinder.


The group should carry a liter or so of oil - at least a bike's worth - in case oil gets contaminated or a cover punctured.


Re. epoxy putty - Weicon Repair Stick is ridiculously good. High-quality german stuff. Convenient to carry too - it's a two-phase stick that you knead together, rather than the dual-tube liquid stuff that has to be stirred. I used the Aqua type to patch some pretty big holes in my DR-Z's steel fuel tank and it's still holding without even a drop leaking, what, 2-3 years later?


If there are no rocks where you are riding, bring something that you can use as a makeshift hammer!


Small can of penetrating oil? Stuck bolts suck. Also, if there is such a thing as a lightweight impact screwdriver, I'd consider one. Stuck bolts suuuuuuck. That said, shot of oil and hit it with something and it often comes free.


Knife blades, and maybe metal saw blades too. Wrap them up securely. The metal saw blades be used to pry and fix broken screw heads and generally unf..ck things that are far gone. Can be good in first-aid situations too. That's getting more random though, but blades don't weigh much.
 
Thanks, I will update the top post soon to reflect all the useful comments and suggestion.

KFS, unfortunately I cannot make it this Saturday... too bad. I emailed (Brian I think) from ODSC to get the GPS files off him so I can ride it later.
 
1 pack large and 1 pack small cable ties

spare brake pad retaining pin, some 1.6mm wire (eg tig rod) to retain the pins if needed
 
The gps file is a downloadable gpx file on the first post of the thread. Get it before Saturday as it will be removed on Sunday!
 
Extra fuses

Spark plug wrench (already mentioned, but worth rementioning!)

Sandpaper or small file. Useful for cleaning electrical (battery) contacts, . Triangle files can be helpful for cleaning up damaged threads on bolts.

Small assortment of extra bolts and fasteners

Tire pressure gauge

Electrical tape - patching up damaged wiring, limited first-aid applications

Lighter - for when you're really f*cked and need to keep warm or cook some dinner
 
3 tire irons work better then 2. Just to let you guys know 11mm same as 7/16 , 14mm same as 9/16 , 19mm same as 3/4 and a lot more! 8mm - 5/16 , 17mm - 5/8
 
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Hi there guys,

I used to carry-
money (notes) you never know
spark plug and spanner
chain link
spare metric bolt ,nuts ,screws ,etc
spoke spanner
mini lighter & compass, small amount of toilet paper
swiss army knife
Only carried front tube , as this will fit in rear wheel also to get you out of trouble.

I also cut down a 17mm ring spanner leaving the handle 40mm long, this is used to undo carbi drain plug and allow easier quicker turning of the nut. You can also use this for compression nut on PDS shock.
I also cut down an allens key to 40mm with 20mm bend, grinded a flat screw driver bit shape into the end on a particular angle so it can be used to adjust the rebound screw on the bottom of the PDS shock, can also put an 8mm ring spanner on the allen key bend for leverage on other allen key headed bolts.
I cut down a small flat blade screw driver to 20 mm in length, I used this for the mixture screw on carbi.
I cut slots under the seat plastic and used this to house, 2 lever levers, they sit there nicely and have easy access to them and never move.

On my 2014 bike, I have 2 pieces of high density foam cut 150mm long and 25mm+25mm ,with a slot cut in toward either end. I poke the tyre levers in the foam and sit it on the factory bash plate, then fasten the front retaining screw, they hold in place well, don't touch the engine casing or frame ,and sit low out of the way.

Its all about weight ,room,functionality with gear you carry , also try and get items to be used as a dual purpose.

Hope that helps
 

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