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Discussion Starter #1 (Edited)
Photos Added - TheTwins' Underseat Toolkit

After 8 million iterations, a lot of trial and error, several hours of online and in-store shopping, and many fit tests, I finally have my Underseat Toolkit totally perfected.

As a preface, I'll explain how this kit came to be. I started with the factory toolkit which was kept on the bike, and an empty small plastic toolbox in my garage. Every time I have worked on my bike, I would make sure that I had the tools I needed, either in the factory toolkit, or from "new" items that were added to the empty box, from my main kit.

As time went on, the factory toolkit found itself staying on the bike, and the (once empty) plastic toolbox started filling up. Now, understand that I wouldn't simply add something to the box that wasn't needed. I was always in a "make do" frame of mind, to make sure the new kit was a small and capable as it could be.

Whenever I had a new idea to make something smaller, lighter, or more useful, either through a new idea I found here, a new product in-store or online, etc. I made the change needed. At this point, I feel it's optimized, because I can do all maintenance, repairs, changes, etc. that I've ever needed to do, with this toolkit.

Here it is:

1. Misc. Bag:
- Duct Tape, 6', rolled flat
- Lightweight Repair Gloves
- Spare Spark Plugs, 2, NGK CR8EIX

2. Misc. Placement Items:
- Electrical Tape, small roll, captured on the seat's release cable
- Zip Ties (assortment), rolled together and placed under seat

3. Buddy Kit:
- Fuses - 2 Each ATO30, ATM2, ATM10, ATM15
- Electrical - Misc. Ring Terminals, Splices, Battery Bolts, 14G Wire x 6'
- Jumper Cables
- Fuel Siphon Tube, 6'



4. Tire Repair Kit:
- Tire Plugs, 4
- Tire Plug Glue, 1 tube
- Tire Plug Tools, screwdriver style
- Valve Cores, 2
- Valve Core Tool, 1
- Valve Stem Caps, 2
- Tire Pressure Gauge, 1
- 12v Air Compressor

5. Adhesives Kit:
- JB Quik-Weld
- Yamabond
- Permatex #16B High Temp Adhesive
- Permatex Silicone High Temp Gasket
- Permatex Blue Loctite
- Permatex Dielectric Grease

6. Mechanic's Tool Kit:
- Channellock Pliers 6"
- Adjustable Wrench 6" (opens to 24mm wide)
- 3/8" Square Drive Sockets - 8mm / 10mm / 12mm / 14mm / 17mm / 5/8" Spark Plug, 24mm
- 3/8" Square Drive Extensions - 1" & 3"
- 3/8" Craftsman Breaker Bar
- Conventional Hex Keys - 2mm / 2.5mm / 3mm / 4mm / 5mm / 6mm
- Hex Key Bits - 8mm / 10mm / 12mm
- Screw Drivers - Phillips #3, #2, #1, #0 & 1/4" Flat



Some Key Comments:

1. The 6" Adjustable Wrench was used to eliminate open end / box end loose wrenches. I really wanted one single adjustable wrench that would "back up" the bolt end of a typical nut / bolt joint. I found a Crescent brand wrench at Lowe's for $10 that is a 6" length, and it opens to 24mm wide. This is enough to back up the rear axle.

2. The 24mm Socket, for removing the rear axle nut, is a 3/8" drive. This is extremely key - it allows you to use the 3/8" breaker bar, and eliminates the need for a separate 1/2" driver. I could not find this in-store, I had to buy one online instead. It is made by S-K Tools, it is 3/8" drive x 24mm and it is a 6-point type.

3. A good lead-in from above, I use a Craftsman 3/8" breaker bar for all sockets. It is stronger than a ratchet, yet still small enough (10" length) to stow under the seat. I chose the Craftsman because it had the strongest head I could find, yet it was only 10" in length.

4. The 8mm Socket, for misc. small bolts, is also a 3/8" drive. This eliminates the need for a 3/8" to 1/4" adapter, or a separate 1/4" driver.

5. The Hex Key Bits, in sizes 8mm / 10mm / 12mm are short bits that are 1" in length, that are driven by the corresponding socket. This works for front axle removal, the mag rotation cover, the mag position inspection cover, and the bolts on my GSX-R caliper mounts :) These are similar to the "nubs" that have been discussed here. This eliminates the need for the drive portion of a hex socket, saving that space and weight.

6. The screw driver kit is a small Kobalt brand that I got from Lowe's. It is a very small handle, with no shaft on it. It has a cylindrical storage tube built-in, inside, that can hold 6 bits that are all 1/4" drive. I had to buy the bits I wanted separately, but this way I have exactly what I need in a very small driver, with no additional weight or space wasted by several shafts, drivers, etc.

Packaging Details:

1. Pack #1 includes all the Mechanic's Tools that I listed. It is placed inside a Seagrams blue velvet bag, then wrapped inside a red shop rag, then placed inside a Ziploc gallon size freezer bag. It is placed under the seat, in the rearmost location, facing fore / aft.

2. Pack #2 includes the Adhesive Kit contents. It is placed first inside a quart size Ziploc bag, then rolled into a small roll, then taped around the perimeter to protect the contents from punctures. This is placed also fore / aft, in the rearmost location, under the seat, next to the toolkit.

3. Pack #3 is the Buddy Kit. The jumper cables I have (from Murray's / O'Reilly's) came in a small rolled package that was about 6" diameter x 2" height. I stuffed the fuel siphon line inside, and the spare 14g wire inside, along with the spare fuses & electrical terminals. This pack sits in the rearmost location, on top of the toolkit & adhesives kit.

4. Pack #4 is the Misc. Bag containing the spark plugs, duct tape, and repair gloves. This is stuffed inbetween the toolkit and adhesives kit.

5. Pack #5 is the Tire Repair Kit. It is rolled up into a small roll, inside a quart sized ziploc bag, then wrapped in a red shop rag. It is placed laterally, right behind the latch mechanism under the seat, and right in front of the toolkit and adhesives kit.

6. Lastly, the 12v compressor. This is wrapped inside a medium sized ziploc bag, and then wrapped with a red shop rag, and placed in the single space in front of the seat's latch mechanism. It just fits....its the smallest Slime branded compressor that I got from Meijer for $11. It works wonderfully well.

This kit is extremely capable. It is all I have used for the last several rounds of maintenance I have performed on my DL650. It is not designed to change a tire (with full removal), as I have a separate kit that I "add" when I am planning on bringing a spare tire with me, as I did on my last trip to Alaska. This "add-on" kit, for removing or changing a tire, contains simply (2) 8" tire irons, a small 3 oz. bottle of Napa lube, a medicine cup for scooping out my DynaBeads, and (2) small packs of spare beads at 2 oz. each, in case I drop / spill them.

And, one important point, all of this fits under the seat of my DL650. None of this is placed in a sidecase, pannier, tailbag, etc. So it can go with you, even on a "minimalist" ride if you don't want to carry luggage.

I'd be happy to answer questions, provide links to products I bought / used, etc. as needed. Respond here with questions or comments. Hope this is useful to you all.
 

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Hmmm... interesting... you carry way more than I do, and I do carry some stuff too.

I do have some space to spare under there though... was thinking of adding a few first aid essentials. Something against insect bites, some sun screen, perhaps few other small things.

I noticed that you have nothing related to this kind of stuff. Do you pack that separately? If I rode to Alaska I'd definitely do it...
 

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Discussion Starter #5
Hmmm... interesting... you carry way more than I do, and I do carry some stuff too.

I do have some space to spare under there though... was thinking of adding a few first aid essentials. Something against insect bites, some sun screen, perhaps few other small things.

I noticed that you have nothing related to this kind of stuff. Do you pack that separately? If I rode to Alaska I'd definitely do it...
Perhaps I should have been more clear, and made the title of this post more obvious to tools / maintenance / repair, etc. items only. I apologize. What I listed above, certainly isn't all that I carry on trips. This was only to address mechanical tools and repair items.

To answer your specific question, I do carry a rather substantial, but compact, first aid kit. I'm a firefighter / EMT, so that kind of thing is second nature to me. The kit is stowed in my tool tube, which perhaps, should be a separate post.
 

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Just a tip on the duct tape if you haven't already done it... Take a Bic pen that doesn't work, strip the guts out of it, chuck the body in a drill, and re-wrap the duct tape around the pen tube core. Then you can use a razor knife to trim off the excess tube, and viola! Easy compact duct tape roll! Use an old shoelace through it to make a hanging cord. :) (Saw that one on YouTube)
 

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Nice

Nice, complete kit.

Can't believe I'm saying this, but I would add three things:

Latex/nitrile disposable gloves (being an EMT, these are probably in your FA kit)

Reading glasses (can also be used as a magnifying glass)

Flashlight (I like the shake/Faraday ones)
 

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Mr. Vagicil believes that being prepared is a good thing. I'm running a Pelican 1150 on my license plate to carry chain lube/tools. I have a small slime pump, tire plugs and a bottle of slime under my seat. I carry a variety of extra tools. I have a 3/4" bolt/nut setup to remove the front wheel. I carry flashlights, latex gloves and rags
I bought a leather roll that I particularly didn't like. I also mounted a 2(1) gallan Rotopax cans on my ammo panniers. I may remove one if Rotopax comes out with a 1 Gallon tool kit or if I find an acceptable setup.
I really enjoy looking at anyone's ideas on how to make my Strom a better motorcycle to ride/travel. The days of me leaving the house unprepared ended years ago. If you look around I started one of the many toolbag threads.





Les
 

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Great thread! Thanks for taking the time to detail this. You have saved me a lot of time researching crap by putting in your rationale for the decisions you made on what to carry/not to carry.

Thank you!
 

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I have a Yamaha tool kit from a Venture Royale. Very complete, inculdes a 3/8 ratchet and sockets and axle wrenches. It and the Suzuki Kit will darn near do an over haul.

For multi day rides I put a pair of tire irons in, to go with the plugging kit and compressor. Fuses, snap ties, wire, posi tap and locks, a small selection of bolts, nuts, washers. And my leatherman. Don't leave home without it.
 

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You might also want to consider a small tube of two-part epoxy in putty form, available at West Marine and other boat places. Unlike JB Weld it's firm enough to cram into a hole in an engine case, and it cures very quickly (even underwater, because it's used to patch hull holes and cracks).

Don't know about the duct tape, either, unless you are planning on making a prom dress en route. Since the most likely use of tape is to repair a radiator hose leak wouldn't it be better to carry one of those pressure-resistant, heat-curing tapes designed for that purpose?
 

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I carry the putty epoxy, never used it but there just in case. I like the idea of it better than the tube stuff also.

Duct tape has a jillion uses like temporarily patching holes in air mattresses, tents, seats, clothing, holding together a cracked shield, used for securing by wrapping, etc untill permanent repairs can be made. Takes up very little room.

I've seen radiator and heater hose leaks wrapped with duct tape and then string last a very long time.
 

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I have a decent toolkit, not as complete as yours, but could I suggest a multi-tool and a pair of Visegrips? Indispensible.
 

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Discussion Starter #16
Nice, complete kit.

Can't believe I'm saying this, but I would add three things:

Latex/nitrile disposable gloves (being an EMT, these are probably in your FA kit)

Reading glasses (can also be used as a magnifying glass)

Flashlight (I like the shake/Faraday ones)
Gloves, both nitrile and latex, are in the FA kit. I carry (2) packs of matches, both waterproof, in separate locations. One in the tank bag, one in my tent kit (which comes along if I am camping). The flashlight, I also carry two of them. One small diameter penlight in my tankbag, and an LED head-mounted light, also in the tent kit.
 

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Discussion Starter #17
You might also want to consider a small tube of two-part epoxy in putty form, available at West Marine and other boat places. Unlike JB Weld it's firm enough to cram into a hole in an engine case, and it cures very quickly (even underwater, because it's used to patch hull holes and cracks).

Don't know about the duct tape, either, unless you are planning on making a prom dress en route. Since the most likely use of tape is to repair a radiator hose leak wouldn't it be better to carry one of those pressure-resistant, heat-curing tapes designed for that purpose?
The two-part epoxt is a good tip. I will look into that, and I do have some room for it. Thanks for that.

The duct tape can be used to secure a cracked pannier, like the plastic E41N models I use. It can also be used to seal up a ripped seat to keep water out. These are just two examples, of the million or so out there. I haven't had to use it on my own stuff, but it has come in handy several times.

The tip above on how to wrap it around the shaft of a pen - that's a good idea and I just may do that. Right now, I have it folded over on itself several times, so it's a slab of tape that's the standard width, about 2.5" in length, and about a half-inch tall. It can be stowed nearly anywhere.
 

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Discussion Starter #18
I have a decent toolkit, not as complete as yours, but could I suggest a multi-tool and a pair of Visegrips? Indispensible.
Those are both good suggestions. When I initially started this kit, I had both of those items included. Over the course of a few years, a few maintenance / repair events, I found that I never used either of them simply because I had the tool I was looking for, and didn't need the versatility (yet compromised, somewhat) of an item like my Gerber Multi-Plier, or a set of Vise Grips. So those items were removed from the kit. I do, however, carry the Gerber Multi-Plier on my belt, nearly all the time :)
 

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Oh, and one other thing: a small roll of safety wire, which can be used to bind up broken or loose pieces and even stitch plastic things together if you can punch holes for it. I had a friend who had a car accident while in Sierra Leone as a Peace Corps volunteer. The local hospital had no sutures so they used piano wire to stitch him up. I guess you could use safety wire for that, too, although dental floss might be a better choice.:yesnod:
 
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