Maintenance techniques, tools and working facilities
0-15
Maintenance and minor repair tool kit
The tools in this list should be considered the minimum required
for performance of routine maintenance, servicing and minor repair
work. We recommend the purchase of combination wrenches (box end
and open end combined in one wrench); while more expensive than
open-ended ones, they offer the advantages of both types of wrench.
Combination wrench set (6 mm to 22 mm)
Adjustable wrench -8 in
Spark plug socket (with rubber insert)
Spark plug gap adjusting tool
Feeler gauge set
Standard screwdriver (5/16 in x 6 in)
Phillips screwdriver (No. 2x6 in)
Allen (hex) wrench set (4 mm to 12 mm)
Combination (slip-joint) pliers - 6 in
Hacksaw and assortment of blades
Tire pressure gauge
Control cable pressure luber
Grease gun
Oil can
Fine emery cloth
Wire brush
Hand impact screwdriver and bits
Funnel (medium size)
Safety goggles
Drain pan
Work light with extension cord
Repair and overhaul tool set
These tools are essential for anyone who plans to perform major
repairs and are intended to supplement those in the Maintenance and
minor repair tool kit. Included is a comprehensive set of sockets which,
though expensive, are invaluable because of their versatility (especially
when various extensions and drives are available). We recommend the
3/8 inch drive over the 1/2 inch drive for general motorcycle
maintenance and repair (ideally, the mechanic would have a 3/8 inch
drive set and a 1/2 inch drive set).
Socket set(s)
Reversible ratchet
Extension - 6 in
Universal joint
Torque wrench (same size drive as sockets)
Ball pein hammer - 8 oz
Soft-faced hammer (plastic/rubber)
Standard screwdriver (1/4 in x 6 in)
Standard screwdriver (stubby - 5/16 in)
Phillips screwdriver (No. 3x8 in)
Phillips screwdriver (stubby - No. 2)
Pliers - locking
Pliers - lineman's
Pliers - needle nose
Pliers - snap-ring (internal and external)
Cold chisel - 1/2 in
Scriber
Scraper (made from flattened copper tubing)
Center punch
Pin punches (1/16, 1/8, 3/16 in)
Steel rule/straightedge - 12 in
Pin-type spanner wrench
A selection of files
Wire brush (large)
Note: Another tool which is often useful is an electric drill with a chuck
capacity of 3/8 inch (and a set of good quality drill bits).
Special tools
The tools in this list include those which are not used regularly,
are expensive to buy, or which need to be used in accordance with
their manufacturer's instructions. Unless these tools will be used
frequently, it is not very economical to purchase many of them. A
consideration would be to split the cost and use between yourself and
a friend or friends (i.e. members of a motorcycle club).
This list primarily contains tools and instruments widely available
to the public, as well as some special tools produced by the vehicle
manufacturer for distribution to dealer service departments. As a
result, references to the manufacturer's special tools are occasionally
included in the text of this manual. Generally, an alternative method of
doing the job without the special tool is offered. However, sometimes
there is no alternative to their use. Where this is the case, and the tool
can't be purchased or borrowed, the work should be turned over to the
dealer service department or a motorcycle repair shop.
Valve spring compressor
Piston ring removal and installation tool
Piston pin puller
Telescoping gauges
Micrometers) and/or dial/Vernier calipers
Cylinder surfacing hone
Cylinder compression gauge
Dial indicator set
Multimeter
Adjustable spanner
Manometer or vacuum gauge set
Small air compressor with blow gun and tire chuck
Buying tools
For the do-it-yourselfer who is just starting to get involved in
motorcycle maintenance and repair, there are a number of options
available when purchasing tools. If maintenance and minor repair is the
extent of the work to be done, the purchase of individual tools is
satisfactory. If, on the other hand, extensive work is planned, it would
be a good idea to purchase a modest tool set from one of the large
retail chain stores. A set can usually be bought at a substantial savings
over the individual tool prices (and they often come with a tool box). As
additional tools are needed, add-on sets, individual tools and a larger
tool box can be purchased to expand the tool selection. Building a tool
set gradually allows the cost of the tools to be spread over a longer
period of time and gives the mechanic the freedom to choose only
those tools that will actually be used.
Tool stores and motorcycle dealers will often be the only source
of some of the special tools that are needed, but regardless of where
tools are bought, try to avoid cheap ones (especially when buying
screwdrivers and sockets) because they won't last very long.There are
plenty of tools around at reasonable prices, but always aim to
purchase items which meet the relevant national safety standards. The
expense involved in replacing cheap tools will eventually be greater
than the initial cost of quality tools.
It is obviously not possible to cover the subject of tools fully here.
For those who wish to learn more about tools and their use, there is a
book entitled Motorcycle Workshop Practice Manual (Book no. 1454)
available from the publishers of this manual. It also provides an
introduction to basic workshop practice which will be of interest to a
home mechanic working on any type of motorcycle.
Care and maintenance of tools
Good tools are expensive, so it makes sense to treat them with
respect. Keep them clean and in usable condition and store them
properly when not in use. Always wipe off any dirt, grease or metal
chips before putting them away. Never leave tools lying around in the
work area.
Some tools, such as screwdrivers, pliers, wrenches and sockets,
can be hung on a panel mounted on the garage or workshop wall,
while others should be kept in a tool box or tray. Measuring
instruments, gauges, meters, etc. must be carefully stored where they
can't be damaged by weather or impact from other tools.
When tools are used with care and stored properly, they will last a
very long time. Even with the best of care, tools will wear out if used
frequently. When a tool is damaged or worn out, replace it; subsequent
jobs will be safer and more enjoyable if you do.
