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Old 09-18-2011, 08:18 AM   #11
space
a.k.a. Jake
 
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Joined: Jan 2006
Location: Pasadena, CA
Oddometer: 2,563
Here's my complete tool list for an HP2 with HPN tank. It's everything you need to tear down most of the bike, except for engine.

Yeah, this may seem a bit OCD. But it helps me organize when planning trips. Nothing worse than leaving an essential tool at home.


KEY:

* = always on the bike
+ = for long trips
. = for the home workshop


HP2 AND GENERAL USE TOOLS:

In my tool roll, roughly from left to right:

* LED flashlight
* 18 mm socket -- frame to engine nuts
* 19 mm socket -- front axle pull bolt, crash bar bolts
* 3/8" adapter for torx bits
* Tire pressure gauge
* 3/8" drive extension, medium length with u-joint
* 16 mm spark plug socket
* 5 mm hex bit -- cylinder head guards
* 6 mm hex bit -- bash plate
* 8 mm hex bit -- oil drain plug
* 10 mm hex bit -- front wheel (steel axle bolt)
* 6 mm socket -- removing tank breather assembly
* 8 mm socket -- upper tank panel, front brake line clamp
* 10 mm socket -- front axle clamp bolts, many others
* 13 mm socket -- exhaust hanger
* Loctite blue
* Socket driver, 3/8" drive
* 3/8" drive extension, long
* 8" side cutters
* Vice grips
* 10 mm wrench -- bash plate
* 13 mm wrench -- bash plate
* Adjustable wrench
* Needle-nosed pliers
* Heyco dual-tip screwdriver
* Box cutter / razor blade
* T25 torx bit -- assorted bolts
* T30 torx bit -- seat bracket, lower spark plug cover
* T40 torx bit -- cylinder head, front mudguard
* T45 torx bit -- brake caliper; common on frame and forks
* T50 torx bit -- rear wheel, paralink bolt
* T55 torx bit -- rear shock absorber
* E10 torx socket -- handlebar mounts
* E12 torx socket -- handlebar mounts
* T20 torx key -- tank breather line port; fuel pump holder
* T25 torx key -- battery holder; common for smaller bolts
* T30 torx key -- assorted bolts
* T40 torx key -- assorted bolts
* T45 torx key -- assorted bolts
* T50 torx key -- assorted bolts, Touratech oil filler cap
* 3 mm hex key -- tank panels
* 4 mm hex key -- bash plate
* 5 mm hex key -- assorted bolts
* 6 mm hex key -- assorted bolts
* Small flat-head screwdriver for prying stuff
* Small Phillips-head screwdriver

Also on the bike at all times:

* Air pump for tires, rear shock
* Tire repair kit
* Spark plug puller

For longer trips:

+ Oil filter wrench
+ Voltmeter
+ Tire irons
+ Leather scraps to protect the rims
+ Wheel bearing removal ring
+ GS911

In the shop:

. T8 torx key -- handlebar control housing
. 15 mm socket -- cylinder tie nuts
. 16 mm wrench -- rear paralink nut
. 18 mm wrench -- rear shock, frame nuts
. Feeler gauges for valve adjustment
. Twinmax
. Torque wrenches
. Rubber mallet


SPARES AND CONSUMABLES

* Zip ties
* Electrical wire
* Bailing wire
* JB Weld
* Blue loctite
+ Fabric tape
+ Ziploc bags & Sharpie
+ Wheel bearings
. Red loctite
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