Everything you wanted to know about what you can and cant do with the std toolkit

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by mookymoo, Nov 5, 2008.

  1. mookymoo

    mookymoo Mookish Mook

    Joined:
    Aug 26, 2007
    Oddometer:
    4,397
    Location:
    Either UK or Australia ...
    Ive long been impressed with :
    a) the quality of the std toolkit.
    b) the attention to detail on the bike such that it requires so few tools

    Everyone wants to travel light and compact (at least I strive to), so carrying as few tools as possible saves weight and space.

    The std toolkit is my starting point. Having done a bunch of different work on my 950 Adv(s) now, in usually less-than-ideal conditions (ie outside my flat, by the side of the road :lol3 ), I have built up a bit of a list of what you can and cant do with the standard toolkit - and what 'missing' tools you need to complete a given task. The idea being people can make an informed decision on what tools they might supplement their std toolkit with for that minimalist approach.

    The point of this thread is not a "toolkit thread" (theres already a very good one of those).
    The point of this thread is to detail what you can do with the standard toolkit - and what extra tool(s) you might need for certain tasks. :deal


    I will endevour to update this first post with the details as they come to hand (via my own experience or via feedback)

    ==========================================
    Assumed:
    Obviously, all tanks, panels, ktm crashbars, ktm luggage racks & wheels can be removed with the standard toolkit.
    ==========================================
    Remove, service Carburettors
    All this can be done with the standard toolkit.
    Except for:
    • a 7mm spanner/socket required for the carb heater earth
    • a 3mm hex/allen key for the horn adapters and drains
    I found the stock screwdriver to be a good fit for the jets.
    You need to be careful with the phillips screwdriver though - the fit is ok, but not perfect.
    ==========================================
    Remove Forks
    All this can be done with the standard toolkit.
    No additional tools needed
    ==========================================
    Remove Shock
    All this can be done with the standard toolkit.
    Except for:
    • a 12mm hex/Allen key for the shock mounting bolts (950 toolkit owners). The 990 toolkit contains it.
    All bets are off though, if you drop that bolt inside the swingarm.:deal
    ==========================================
    Changing/Replacing Brake lines
    This requires a 14mm spanner/socket for the banjo bolts
    Also see Brake Bleeding
    ==========================================
    Brake Bleeding
    This requires an 11mm open-ended spanner for the bleed nipple
    ==========================================
    Remove Triple Clamps
    All this can be done with the standard toolkit.
    Except for:
    • a motocross boot as a soft hammer to encourage the top triple back on at the end :lol3
    • some kind of strap or rope to prevent the bottom triple and/or forks falling out when you take the top off. I wonder if the Aurel cable is long enough for this? :lol3
    The steering stem nut requires the use of the largest of the large spanners - and the handle of one of the smallest of large spanners. Place the handle end-in to make the bolt-head larger so the larger fits tightly.
    ==========================================
    Replace Front Brake Pads
    My technique might be shite here - but I am sure you need a fine pin-punch to get the pins out.
    ==========================================
    Remove Handlebars, guards and all hand controls
    All this can be done with the standard toolkit.
    ==========================================
    Remove/Change Drive Sprocket
    All this can be done with the standard toolkit. BUT you might well need some instruments of persuasion (hammers & levers) if its stuck on.
    You can loosen the nut if you keep the rear wheel & chain on - one of the tricks I learned of here (but not yet practised). If you place the large spanner on the nut with the stubby handle resting on the swingarm, then rotate the tyre to raise the handle and SLAM it back down. Effectively using the swingarm to hammer the spanner and loosen the nut. Dont forget the locking plate first ...
    ==========================================
    Rear Shock Compression/Rebound adjustment
    The 950 toolkit is missing a 17mm socket for high-speed adjustment
    The 990 toolkit has one!
    ==========================================
    Fork Preload Adjustmen
    Can be done with the smaller of the large spanners - but only if you dont have bleed valves.
    ==========================================
    Side Stand Removal
    Requires a 14mm Ring or open-ended spanner
    ==========================================
    Centre Stand Removal
    Requires a 17mm socket/spanner.
    ==========================================
    Oil Change
    A 19mm socket (or ring spanner) is needed for the sump plug. At a pinch, you can use the larger of the spanners in the toolkit, and the handle of the smaller spanner (much the same trick as the steering stem nut) - but you will be hard pressed to crack the seal with this combination.
    ==========================================
    Water Pump Seal Replacement
    If youre just replacing the seal & shaft, and not the bearings, this can easily be done on the roadside.
    Requires a 13mm socket for the exhaust header nuts.
    Requires circlip pliers
    Use the plastic handle of the T-handle to gently tap at the outer clutch cover to remove it without breaking the gasket.
    ==========================================
    Touratech Parts
    ... are a pain in the ass! They usually always introduce a new tool size requirement. That said, I think they boil down to:
    GPS Bracket: 3mm Hex/Allen & 4mm Hex/Allen
    High Fender Kit: Forget about it. All sorts of microscopic shite. But 4mm Hex/Allen is your main one.

    And here is the std 950 Adventure Toolkit (everything within that red box)
    [​IMG]
    And here is the std 990 Adventure Toolkit
    [​IMG]
    AFAIK: The 990 toolkit is missing the spark plug wrench, but has a 17mm socket (for the shocks) and has a 14mm open-ended spanner

    =================
    The 950 Toolkit contains:
    Sockets: 6, 8, 10mm
    Open-ended spanners: 8/10mm and 10/13mm
    Ring Spanners: 24mm, 32mm
    Hex/Allen: 5mm, 6mm (by way of T-handle), 8mm (for subframe bolts)
    Phillips/Flat screwdriver

    =================
    The 990 Toolkit contains:
    Sockets: 6, 8, 10, 17mm
    Open-ended spanners: 8/10mm, 10/14mm & ??
    Ring Spanners: 24mm, 32mm
    Hex/Allen: 5mm, 6mm (by way of T-handle), 8mm (for subframe bolts), 12mm for rear shock
    Torqz: ??
    Phillips/Flat screwdriver

    =================
    Extra tools you might need:
    3mm Hex / Allen key - for carb drains & carb horn adapters
    4mm Hex / Allen key - to remove the seat lock so you can get all the panels off!
    7mm open-ended spanner - for carb heater earth connection
    11mm open-ended spanner - for brake bleed nipple
    12mm Hex/Allen key (950 toolkit owners) - for Shock mounting bolts
    13mm socket - for exhaust header nuts (required for access to water pump seal)
    14mm open-ended or ring spanner (950 toolkit owners) - for brake banjo bolts, sidestand removal
    17mm Socket/Ring spanner (950 toolkit owners) - for shock high speed adjustment, centre stand removal
    19mm Socket/Ring spanner - for engine oil drain plug
    #1
  2. pilesofmiles

    pilesofmiles Life is an Adventure

    Joined:
    Jun 20, 2006
    Oddometer:
    775
    Location:
    Western NC
    :clap standing ovation! We need more posts like this....
    #2
  3. MY ADV

    MY ADV "ZERO.. POINT.. ZERO"

    Joined:
    Oct 20, 2005
    Oddometer:
    509
    Location:
    Greshtucky, Orygun
    Great write-up Mookymoo:

    So here are the extra tools needed to add to your standard 950 Kit:

    Sockets:
    1- Mini socket wrench.
    1 - 7mm Socket
    1 – 14mm Socket

    Wrenches:
    1 – 3mm Hex / Allen key.
    1 - 7mm Spanner
    1 – 11 mm Spanner
    1 – 14mm Spanner
    #3
  4. mookymoo

    mookymoo Mookish Mook

    Joined:
    Aug 26, 2007
    Oddometer:
    4,397
    Location:
    Either UK or Australia ...
    :nod
    Might be useful to list them like this too - with their corresponding uses.
    Thanks :thumb
    #4
  5. jamesbrown

    jamesbrown Lefty tighty.

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    Nice post. PM a mod and they'll change the title for you. :lol3
    #5
  6. Dru

    Dru Hardly an Adventurer

    Joined:
    Sep 25, 2006
    Oddometer:
    569
    Location:
    The Big Smoke
    Here's the 990 toolkit... a few more gizmos. Two 14mm ends on separate box wrenches?

    Attached Files:

    #6
  7. mookymoo

    mookymoo Mookish Mook

    Joined:
    Aug 26, 2007
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    4,397
    Location:
    Either UK or Australia ...
    Done. :thumb
    #7
  8. mookymoo

    mookymoo Mookish Mook

    Joined:
    Aug 26, 2007
    Oddometer:
    4,397
    Location:
    Either UK or Australia ...
    Ta. :thumb
    Added

    What are the open-ender sizes?
    8-10
    10-14
    12-14
    ?
    #8
  9. hilslamer

    hilslamer 2XRedheadedstepchild

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    Amen. Will post more when I'm keyboard-enabled.(No bluetooth keyboard for the BlackBerry yet...)
    #9
  10. Rabid Dog

    Rabid Dog Been here awhile

    Joined:
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    Where the Sun Don't Shine
    How about open a bottle of beer? Should be number one on the list.
    #10
  11. cpmodem

    cpmodem Orange Caveman

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    masa yee yah tee 59° 14' 9" N / 135° 26' 42" W
    Definitely the most useful/used tool in my kit.
    :freaky
    #11
  12. Krust

    Krust Adventurer

    Joined:
    Jun 2, 2008
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    Flagstaff, AZ
    Don't forget the jumper cables! :ricky
    #12
  13. w72315

    w72315 woody

    Joined:
    Aug 6, 2008
    Oddometer:
    113
    Location:
    Sydney NSW
    Quote "Ive long been impressed with :
    a) the quality of the std toolkit.
    b) the attention to detail on the bike such that it requires so few tools"

    I'm not quite so sure about the quality. My extension for the sockets snapped the 2nd time I used it. Wasn't really over-doing it when it snapped.

    The plug socket I have has split and the allen keys a pretty soft!

    The quantity of bits I find impressive (compared to a few other brands of bikes I've owned. (read this Mr Kawasaki!!))

    I've already gone out and replaced most of the kit with proper forged items that won't snap, break or bend when I need them most. I certainly wouldn't want to cross some the deserts in my back-yard with the standard kit.
    #13
  14. HappyGoLucky

    HappyGoLucky Goeie Grys Giftige Gert!

    Joined:
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    Oddometer:
    4,311
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    You must be really rough on your toolkit, or else every second piece is a dud, which just cant be.

    I have stripped bolts with the standard tool kit, and used it intensively for 3 years now, with nary a problem. Even bolts that were rusted shut (exhaust clamp bolts) were removed with the standard tool kit. Flexed, and held. Fantastic! :clap
    #14
  15. Dru

    Dru Hardly an Adventurer

    Joined:
    Sep 25, 2006
    Oddometer:
    569
    Location:
    The Big Smoke
    I'll get back to you on that. I'm at work today... can't always be playing right!:D
    #15
  16. aurel

    aurel Cheese&Wine!

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    Toulouse, France
    For sure :D

    Awesome post! Thank you very much! :bow
    #16
  17. AUS CRUZER

    AUS CRUZER Lets Cruz

    Joined:
    Feb 9, 2008
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    Location:
    Geelong
    Great write up.I have a 04ADVS purchased used and did not have tool kit,so was wondering whats in the origininal kit.
    Thanks in advance.:D
    #17
  18. PABiker

    PABiker Anywhere but here

    Joined:
    Dec 1, 2006
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    3,937
    Location:
    Pittsburgh
    You can get one from here if you want the original:

    http://www.ktmtwins.com/950adventure/58329099000.html

    No spark plug wrench though.
    #18
  19. Nailhead

    Nailhead Free at last!

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    Longmont, CO
    This might be a good candidate for stickydom...:thumb
    #19
  20. cpmodem

    cpmodem Orange Caveman

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    Nov 29, 2004
    Oddometer:
    7,103
    Location:
    masa yee yah tee 59° 14' 9" N / 135° 26' 42" W
    #20