The Tools Necessary for
Repair & Service of Dirt Bikes

Possessing and using the proper tools when working on dirt bikes is essential to professionally performing any maintenance, repairs or bolting on of aftermarket parts. Additionally, there are dirt bike maintenance tips and other articles throughout this site which may motivate you to head for the garage so you're going to need to have the proper tools for performing theses tasks. Furthermore, If you're well rehearsed in wadding up parts, blowing out wheels or keeping the bike on the pipe or rev-limiter, you're going to need standard and specialty tools as well since riding like this is kind of hard on parts.

Granted, the standard and specialty tools listed below should not be viewed as a complete list of all the tools that someone servicing motorcycles will ever need but it's a pretty good start. It's important to also understand that a mechanic can always (and should), continually add to the tool collection. You'll likely also notice that buying and acquiring tools is never ending so if there is a specialty tool necessary for a specific job, it's recommended that you stop and get the tool so as to not damage any parts.

When working around dirt bikes (Especially during use of any power tools, or grinding, cutting or hammering), it is very important to use face, eye and ear protection to prevent possible eye, face or ear injuries.

Additionally, Having the proper sized sockets and wrenches, as well as having an organized work area and other specialty equipment as listed below is important so as to prevent damage to fasteners or components.

The recommended tools listed below along with the Dirt Bike Maintenance Tips listed elsewhere should be everything necessary to keep a dirt bike running at it's best and reliable for some time to come, as well as save anyone a considerable amount in repair costs while avoiding the dreaded wait that comes with taking a dirt bike in to a service facility to be serviced by someone whom may have no interest or knowledge in the performance of off-road motorcycles and high performance dirt bikes.

Some places that are good for picking up the tools or supplies listed below are Sears, Auto Parts outlets (ask to see their special order catalogs), Home improvement stores and Motion Pro. (Motion-Pro products are available through local motorcycle dealers via special order).

The Basic Tools Required for Motorcycle Service

Metric Combination Wrenches
(Sizes ranging from an 8mm to a 32mm will usually cover everything.)

13/16" Open Ended Wrench

13/16" Spark Plug Socket

Metric Allen Wrenches or Drive Bits from 1.5mm to 12mm

1/4" Drive metric socket set 5mm to 14mm (deep and shallow)

1/4" Drive ratchet

1/4" Drive speed-handle or T-Handle with a 1/4" drive end

1/4" Drive nut driver (the type that a ratchet can be used with is best)

1/4" Drive x 6" Extension

1/4" Drive swivel

3/8" Drive metric socket set deep and shallow 8mm to 22mm

3/8" Drive ratchet

3/8" Drive x 3" Extension

3/8" Drive x 6" Extension

8mm, 10mm, 12mm and 14mm T-Handles

1/2" Drive to 3/8" drive adapter

1/2" Drive ratchet

1/2" Hand Impact

3/8" Drive Torque wrench

1/2" Drive Torque wrench

Awl

Pick

Pocket screwdriver

Screwdriver set

Hand impact driver

Vernier dial or digital calipers

6" steel rule

Metric tape measure

Channel locks

Needle nose pliers

Pliers

Diagonal cutters

cable cutters

Razor scraper

Razor cutter

Rat tail file

Flat file

Drill index

Straight punch set

Center punch

Chisels (1/4" width and 3/4" width)

Wire brush

Hacksaw

Cordless drill and flashlight combo

Air Compressor

Air powered rotary tools (grinders etc)

Portable air-tank

Face shield for use when grinding

Eye and ear protection

Air blow nozzles

Bench Grinder

Bench vise

32oz. Ball-peen hammer

Plastic tip hammer

Dead blow hammer

Tools Required for Maintaining a Professional Level Shop

Parts washer
Oxygen / Acetylene torch set
Tig welder
Shop press

Motorcycle Specific Tools

Factory service manuals specific to the motorcycle being serviced.

Motorcycle lift table

Motorcycle lift stand

Nitrogen

Nitrogen charging gauge and regulator

Engine building box
(See the article below on building an engine building box)

Flywheel remover (specific to dirt bike being serviced)

Case splitter (A common automotive harmonic balancer puller can often be used)

Long straight punch (for sag adjustments)

Sag Scale (or tape measure)

Safety wire pliers and stainless steel safety wire

Cable-luber

Sag Scale

Spoke wrench

Tire spoons

Low pressure tire gauge (the type with a hose and bleed valve)

Valve core remover

Front axle hex

Fork seal driver(s)

Ratio-rite cup

Common Supplies Necessary for Motorcycle Service

Clean shop rags
Nitrile gloves
No-Toil air filter oil
No-Toil air filter rim grease
No-Toil air filter cleaner
Simple green
Electrical tape
Duct tape
Teflon tape
Zip ties in multiple sizes
Safety wire
Anti-seize
Loctite (Blue and Green)
HondaBond or YamaBond
Dielectric grease
Chain lube
Silicone spray
Carburetor cleaner
Brake clean
Brake fluid
Engine coolant
Bel-ray water proof grease
2 Stroke oil
Engine oil
Mothers polish
Armor-All (or similar protectant)
Baby powder (to be used in tires to prevent inner tube chaffing)

How to build an Engine building box

If you're planning to do any lower engine repairs with the engine out of the frame, such as splitting the cases, you'll want to put together an engine building box so as to make your job easier.

Without an engine building box, attempting to service an engine while out of the frame can be a PITA due to the transmission mainshaft and countershaft, as well as the crankshaft protruding from the engine and making the engine awkward to handle or maneuver on the bench, as the motor will try to walk around on the table on the ends of the shafts.

Without an engine building box, you will find yourself chasing the engine around the bench every time you try to loosen, tighten, position or remove any component so this really is a must have and it's incredibly easy to fabricate.

All that's required for an engine building box is:

4 pieces of 2x4 approximately 12" and equal in length
A handful of 2" drywall screws, a few 1/2" drywall screws
A piece of plywood about 12x15"

Now with the minimal supplies listed above in along with a cordless or electric drill and a screwdriver bit, just fasten the 2x4's together to make a box securing the pieces together with the drywall screws. Once your box is complete and secure, attach your piece of plywood to one side of the box and that's it. Now you're ready to service an engine in a professional manner, as this box will now contain any loose parts that may fall out when rotating the engine around on the bench or while driving an impact driver, as well as making service of the engine much easier than past experiences.

Do You Have a Tool Box?

In addition to the recommendations listed above, you may also want to pick up a medium sized tool box from an outlet such as Sears for tool storage and organization.