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Discussion Starter · #1 ·
Hey all,

I'm starting a club activity at the school I work for to give kids some hands-on mechanical experience. We will be tearing down and rebuilding motorcycles in a corner of my classroom...should be fun :bigthumb:

I need some help, however, in getting a list together of the tools I'll need to accomplish an entire teardown and rebuild. I've done a couple myself previously, but we will probably attempt things I haven't done before and I borrow a lot of tools as well so I'm probably forgetting about some things I've borrowed. I need a complete list of everything I'll need so that, as I contact potential partners/sponsors, I can make give them a list of items we need to get started.

In helping me make a list of what we'll need, it may be important that we do have compressed air available where I'll be working if that makes any difference...

So, here's what I've got so far:
  • 3/8 drive spark plug sockets
  • 3/8 drive socket set – metric and US
  • Front and rear motorcycle stands
  • Box end wrenches – metric and US
  • Tire filler and pressure gauge
  • Screw driver sets – flat and phillips
  • Allen wrench sets – metric and US
  • Pliers and vice grips
  • Torque wrenches – 3/8 and 1/2 drive
  • Wire strippers
  • Spanner(s)
  • Engine compression tester
  • Valve feeler gauges
  • Carb sync tool

What else do I need? I've never done anything with forks, so what will we need for that work? I also haven't done a ton of engine or transmission work on my own (and never at my own garage), so I'm not at all sure what tools I need for some of that. This is just a list I threw together a couple days ago and then added a few things to here and there - I'm sure it's missing a lot which is why I need all your help :hail:

Any help/input is much appreciated!!!
 

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Here's to wishing I lived near Nitrus..sorry I couldn't be of more help:eh:
 

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Unless your working on a Harley, your probably not going to need any SAE size tools. Every bike built outside the US will be metric only.

Your going to need some select large sockets in 1/2" drive size, 27mm and 32mm plus a 1/2" breaker bar to go along with them. For axels and countershaft sprocket nuts and clutch basket nuts.

An impact driver is invaluable when disassembling old bikes. Most are 1/2" drive so a 1/2" to 3/8" drive adapter will be needed. Also, a 3/8" socket set of allen bits is very handy to have.
4 Pc High Visibility Socket Adapter Set
9 Piece 3/8" and 1/2" Drive Metric Hex Bit Socket Set
Impact Screwdriver Set with Case

Suspension tools will be mostly standard sockets and wrenches. HOWEVER, all suspension systems require at least some specialized tools. Forks and shocks all require special tools to work on. And a lot are very specific to a particular suspension manufacturer and model of suspension. For at least the first couple bikes, I'd work with a local shop to see if they will loan you the tools as you need them. Shocks are probably not going to be something you will be able to service without help from a shop. They require some fairly expensive tools to recharge the gas in them. Also, not all shocks are serviceable. Many inexpensive motorcycles and scooters come with shocks that are welded closed and are just thrown out at end of life.

I would also include a 1/4" drive metric socket set and a T handle or T spinner. They make things go much quicker. Also, when using 1/4" drive tools it much less likely someone will over torque a fastener and strip it.
T-Handle 1/4 Drive, 8.5" Long | Motion Pro
Spinner T-Handle, 1/4" Drive | Motion Pro

If you where closer, I'd give you some of my duplicate/spare tools. I've got lots of sockets and wrenches that you could have.
 

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Discussion Starter · #5 ·
Unless your working on a Harley, your probably not going to need any SAE size tools. Every bike built outside the US will be metric only.

My thought was that we should probably have SAE given that we'll be working on bikes that have been destroyed and probably messed with previously...so who knows what size bolts will be in there since some dingleberry messed with it :O

Your going to need some select large sockets in 1/2" drive size, 27mm and 32mm plus a 1/2" breaker bar to go along with them. For axels and countershaft sprocket nuts and clutch basket nuts.

We've got a breaker bar, but I figured I'd hold off on the bigger sockets until we actually need them and then maybe I'll just bring in mine. I don't want to go overboard before I know how successful the club will be long-term.

An impact driver is invaluable when disassembling old bikes. Most are 1/2" drive so a 1/2" to 3/8" drive adapter will be needed. Also, a 3/8" socket set of allen bits is very handy to have.
4 Pc High Visibility Socket Adapter Set
9 Piece 3/8" and 1/2" Drive Metric Hex Bit Socket Set
Impact Screwdriver Set with Case

Same as above for impact gun - I've got one that we can use when we need it and I don't want to go overboard right away.

Suspension tools will be mostly standard sockets and wrenches. HOWEVER, all suspension systems require at least some specialized tools. Forks and shocks all require special tools to work on. And a lot are very specific to a particular suspension manufacturer and model of suspension. For at least the first couple bikes, I'd work with a local shop to see if they will loan you the tools as you need them. Shocks are probably not going to be something you will be able to service without help from a shop. They require some fairly expensive tools to recharge the gas in them. Also, not all shocks are serviceable. Many inexpensive motorcycles and scooters come with shocks that are welded closed and are just thrown out at end of life.

My assumptions exactly for most of this - we'll deal with suspension issues as we get to them and probably through as shop (I've already talked to one locally that is interested in helping when/how they can and I'll be talking to two more today)

I would also include a 1/4" drive metric socket set and a T handle or T spinner. They make things go much quicker. Also, when using 1/4" drive tools it much less likely someone will over torque a fastener and strip it.
T-Handle 1/4 Drive, 8.5" Long | Motion Pro
Spinner T-Handle, 1/4" Drive | Motion Pro

I've never used T-handles or spinners at all. Interesting thought - I can see how they could make life a lot easier, quicker, and safer for some things.

If you where closer, I'd give you some of my duplicate/spare tools. I've got lots of sockets and wrenches that you could have.
See blue annotations above - thanks a ton for your input! I appreciate it greatly!!!
 

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Discussion Starter · #6 ·
- Fork service tools
- Swingarm castle nut socket
Could you give me some more detail on "Fork service tools" since I've never done any fork servicing before?
 

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1/4" drive torque wrench for all the low torque items like cam caps, spark plugs, engine cover bolts etc... of course a decent set of 1/4" sockets etc
I use 1/4" stuff far more than all my 3/8" and 1/2" drive combined

On damper rod forks- there is little in the way of "needed" tools besides basics and seal drivers (which you can make easily). On Cartridge forks you need a spring compressor for sure at a minimum (on top of the seal drivers)

Racetech sells a nice cartridge spring compressor (~120$) tool way easy to use- much better than the hand held unit (~40$) that requires 3 hands
Fork oil level measuring tool- (~20$) for the cheapo or (~130$) for a power unit

Spanner wrenches, the correct socket for steering head bearings so you can torque them properly, there are dozens to fit the gammit of jap bikes

wobble head allens 3mm upto 8 or even 10mm (although I rarely use anything but the 3,4,5mm sizes in the wobbleheads)

High quality screwdrivers in tons of sizes because you need them fit properly and have sharp crisp edges for a good grip

Vise with soft jaws, chain tools, various hammers and puches and chisels

micrometers, dial gauges, dial calipers

The list is virtually endless depending on how far you want to crawl down the rabbit hole of repairs.
 

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Discussion Starter · #9 · (Edited)
Impact DRIVER not impact GUN. See the links I put in my response, big difference.
Yes, thanks - I wrote gun, but have both - no worries (only I've got a pneumatic one, not like the one you linked)

1/4" drive torque wrench for all the low torque items like cam caps, spark plugs, engine cover bolts etc... of course a decent set of 1/4" sockets etc
I use 1/4" stuff far more than all my 3/8" and 1/2" drive combined

On damper rod forks- there is little in the way of "needed" tools besides basics and seal drivers (which you can make easily). On Cartridge forks you need a spring compressor for sure at a minimum (on top of the seal drivers)

Racetech sells a nice cartridge spring compressor (~120$) tool way easy to use- much better than the hand held unit (~40$) that requires 3 hands
Fork oil level measuring tool- (~20$) for the cheapo or (~130$) for a power unit

Spanner wrenches, the correct socket for steering head bearings so you can torque them properly, there are dozens to fit the gammit of jap bikes

wobble head allens 3mm upto 8 or even 10mm (although I rarely use anything but the 3,4,5mm sizes in the wobbleheads)

High quality screwdrivers in tons of sizes because you need them fit properly and have sharp crisp edges for a good grip

Vise with soft jaws, chain tools, various hammers and puches and chisels

micrometers, dial gauges, dial calipers

The list is virtually endless depending on how far you want to crawl down the rabbit hole of repairs.
Thanks so much for the info - I knew you'd end up having a list when you chimed in :sigh:

There were definitely a couple things in there that I just completely forgot about and a few that I never would have thought of. For instance, I don't think I've ever used 1/4" drive anything ever :O

I'll add a whole bunch of stuff to my list now :bigthumb:
 

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Oh, I guess I should mention it (I assumed it since your working in a school).

SAFETY GEAR!

Gloves, aprons, eye protection and hearing protection.

It may seem trivial when working on motorcycles but it can't be over emphasized. Eyes, ears and fingers are irreplaceable.
 

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Discussion Starter · #11 ·
Oh, I guess I should mention it (I assumed it since your working in a school).

SAFETY GEAR!

Gloves, aprons, eye protection and hearing protection.

It may seem trivial when working on motorcycles but it can't be over emphasized. Eyes, ears and fingers are irreplaceable.
Yes, thank you so much for mentioning that! We have a bunch of that type of stuff already that I make kids use for pretty much every little thing in my classes, but it never hurts to have a little larger stock :bigthumb:
 

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Just as some quick reference...

I have been working on motorcycles for some 33+ years, and I still buy tools.

I have no doubt the two rollaways I own have in excess of 100k in tools in them, then you still have the specialty tools not in the boxes

So, you could be buying tools for a very long time, but as far as basics and getting things rolling........ You have a decent list started

And yes eye/ear protection is a must---good catch !

check out the gofundme site I linked in your other thread.... I actually know a few people who have had great success in start ups, and in personal medical issues who have gotten a shit ton of funds from strangers
 

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I've never torn a bike down completely but the list looks pretty complete.

A couple of thoughts:

Fluids - The right motor oils, antifreeze, bearing grease, maybe some never-seize, loctitie, dielectric, etc.

Electrical: Multimeter, some crimping tools and terminals, maybe some electrical tape and zip ties.
 

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Discussion Starter · #15 ·
I've never torn a bike down completely but the list looks pretty complete.

A couple of thoughts:

Fluids - The right motor oils, antifreeze, bearing grease, maybe some never-seize, loctitie, dielectric, etc.

Electrical: Multimeter, some crimping tools and terminals, maybe some electrical tape and zip ties.
Fluids is definitely something I'll need to be asking for - not sure how that will end up working out, but I'm hoping I'll be able to form some long-term partnerships and will be able to continue to get fluids over the long-term.

As for electrical, we have a ton of that stuff around already for classes, so we're good to go on all of that.

Thanks for your thoughts!
 

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Discussion Starter · #16 ·
So, as of right now, this is my list of needed tools with an additional small list of things I'd like, but aren't necessarily needed:
  • Safety glasses
  • Work gloves
  • 1/4, 3/8, and 1/2 drive socket set – metric and US
  • Spark plug sockets
  • Box end wrenches – metric and US
  • Screw driver sets – flat and Phillips (lots of variety in size)
  • Allen wrench sets – metric and US
  • Wobble head allens - 3mm-8mm
  • Pliers and vice grips
  • Torque wrenches – 1/4, 3/8, and 1/2 drive
  • Wire strippers
  • Spanner wrenches
  • Micrometers/calipers
  • Various hammers
  • Punches
  • Engine compression tester (for small engines like motorcycles)
  • Carb sync tool
  • Valve feeler gauges
  • Cartridge spring compressor (racetech or similar preferably)
  • Fork oil level measuring tool
  • Front and rear motorcycle stands
  • Tool chest for all this stuff

Anybody who hasn't chimed in yet (or those who have) see anything glaring that's missing?
 

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So, as of right now, this is my list of needed tools with an additional small list of things I'd like, but aren't necessarily needed:
  • Safety glasses
  • Work gloves
  • 1/4, 3/8, and 1/2 drive socket set – metric and USwith numerous extensions, some wobble extension....deep and shallow sockets too
  • Spark plug sockets really only need 18mm and 5/8" for 99% of the bikes
  • Box end wrenches – metric and US 6 and 12 point
  • Screw driver sets – flat and Phillips (lots of variety in size) high quality, good handles, #0,#1,#2,#3 in phillips
  • Allen wrench sets – metric and US t-handle, regular L shaped (you'll inevitably cut some of these to be real short, some shorty on a socket and some long on a socket
  • Wobble head allens - 3mm-8mm 3,4,5 I would have in 1/4 drive and 3/8 drive
  • Pliers and vice grips side cutters, needle nose, duck bills, angled needle nose etc....
  • Torque wrenches – 1/4, 3/8, and 1/2 drive
  • Wire strippers
  • Spanner wrenches adjustable one would be fantastic and eliminate the need to have tons of them, but there are 6 main sizes
  • Micrometers/calipers
  • Various hammers rubber, dead blow, brass, ball peen
  • Punches and cold chisels and pry bars, even a 24" pry bar will come in handy more often that it should
  • Engine compression tester (for small engines like motorcycles)
  • Carb sync tool--home made ones work every bit as good and often better than the $100 bought units.... I would go that route
  • Valve feeler gauges
  • Cartridge spring compressor (racetech or similar preferably)
  • Fork oil level measuring tool
  • Front and rear motorcycle stands
  • Tool chest for all this stuff

Anybody who hasn't chimed in yet (or those who have) see anything glaring that's missing?
Air guns, 3/8 drive and 1/2 inch drive.... while I don't use them much- they do get used and when you need it you need it
likewise have impact sockets in 10mm, 12mm, 14mm, 17mm, 19mm and impact adaptors to go from 1/2 gun to the 3/8 sockets

Chain tool?
grinder for cutting of the old chain?
tape measure

You will end up grinding and bending some tools to make the tool you actually need, so doubling up on just about every tool is pretty much a must

That may get you started.
 

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Discussion Starter · #18 ·
Air guns, 3/8 drive and 1/2 inch drive.... while I don't use them much- they do get used and when you need it you need it
likewise have impact sockets in 10mm, 12mm, 14mm, 17mm, 19mm and impact adaptors to go from 1/2 gun to the 3/8 sockets

Chain tool?
grinder for cutting of the old chain?
tape measure

You will end up grinding and bending some tools to make the tool you actually need, so doubling up on just about every tool is pretty much a must

That may get you started.
Thanks again so much for the input! I maybe should have been a bit more clear about one aspect of my list - there are some items that I intentionally left off because we already have them, but I may need to edit that a bit to make it clear (just note the things we already have).

Again, can't thank you enough for your time and thoughts! :hail
 

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I figured you likely had some/much of this already....just trying to be thorough
 
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