Tool List

A common question from new owners of the Ninja 500R is, "what tools are necessary to do maintenance on this motorcycle?" This article is meant to be a complete list of all of the tools needed, as well as an explanation of what task requires the tool, if it is a tool that is not commonly used, such as a chain riveting tool. I will attempt to list all of the tools required, in an order that is both logical to readers, and which represents how commonly the tool is required, with more commonly-needed tools towards the top of the list, and tools which are not needed very often towards the bottom. If you are unfamiliar with a tool, just ask the person at the hardware store or make a post over in the forum.

If front-end cost is not a consideration, then a large metric toolkit is a great investment. If it is preferable to spread the cost of the tools out over time, they may be bought individually, but the end cost will be much higher this way. Individual metric socket wrenches and just about any other tool you haven't heard of can be found at automotive-type stores, such as Autozone or Pepboys. Other things, such as certain chemicals, or motorcycle-specific tools can only be ordered or bought at a motorcycle dealership. Finally, certain tools can only be found easily/affordably online, such as chain breaking/riveting tools.

Required Tools

 * Service Manuals - a DIY service manual. Most of the How Tos are best used with a DIY service manual.
 * Cable lube tool (usually run $10 to $20)
 * Set of metric Allen keys - fold out kit or kit with handles preferred as you will need to apply a lot of leverage for certain tasks
 * 10mm wrench (required for valve adjustment - there should be one in the under seat toolkit)
 * Ratchet Set (3/8 inch head preferred) (most ratchet kits contain all the required sockets except usually the 12mm Allen socket (required to remove the front wheel) and 24mm socket (to remove rear wheel) which may need to be purchased separately)
 * 8mm socket (coolant drain bolt)
 * 10mm socket (fairing fasteners and many common fasteners on the bike)
 * 12mm socket (gas tank bolt)
 * 14mm socket (for turning crank shaft)
 * 17mm socket (oil drain plug)
 * 18mm thin wall deep well socket (spark plugs - note the socket in the on board tool kit that comes with the bike can be used)
 * 24mm socket (rear axle)
 * 6mm allen wrench socket
 * 8mm allen wrench socket
 * 12mm allen wrench socket
 * 14mm Allen wrench socket (front wheel)
 * Large, medium and small Philips screwdrivers
 * Large, medium and small flat blade screwdrivers
 * Feeler gauges (0.024-0.028, 0.006-0.008, for spark plugs and valve adjustment) ~$5 to $10
 * Oil drain pan (also useful for catching coolant)
 * Funnel (coolant and oil changes)
 * Oil filter wrench
 * A ruler and/or tape measure (chain slack and misc)
 * Tire Pressure Gauge

Optional But Handy

 * Torque wrench (3/8 inch head preferred so it can use the same sockets as your ratchet set)
 * Heat Gun (optional but handy for heating stuck fasteners, melting locktite, removing decals, shrinking heat shrink, and forming vinyl seat covering, etc.)
 * Vise grip set
 * 99cent Turkey baster for setting fork oil level (see fork maintenance wiki)
 * Gear puller for taking front forks apart (see fork maintenance wiki)
 * Electric or Pneumatic Impact Wrench (invaluable for removing stuck bolts)
 * Compressed air
 * A carb sync tool. These are expensive ($100) but work well. You can also built your own for only few dollars in parts although these can be more difficult to use and slightly less accurate.

For Electrical Work

 * Digital Multimeter to measure voltage, resistance and current
 * Wire stripper
 * Soldering Iron
 * Solder
 * Electrical Tape
 * Heat shrink (optional - makes a neater insulated connection than electrical tape)
 * Heat gun (optional - for shrinking the heat shrink)

Common Chemicals

 * Chain lube - Dupont Teflon Multiuse Lubricant or Maxima Chain Wax are recommended.
 * Motor oil - 5W-40, 10W-40 or 20W-50 for really hot weather. It should not be energy-conserving to avoid clutch slipping issues.
 * General cleaner (like Aluminum safe Simple Green, or even dish detergent)
 * Cable lubricant and tool (for control cables) - I use RustCheck
 * Fuel additive (Seafoam recommended)
 * Gojo or other hand cleaner for cleaning greasy hands
 * Air filter cleaner, and air filter oil
 * Blue Loctite (handle bar ends and miscellaneous)
 * Sta-bil or other gas stabilizer for winterizing/storage of the bike. Not using this during winter storage will result in carb issues.
 * Penetrating oil like WD-40 is handy for loosening stuck bolts and cleaning chain

For chain replacement

 * A dremel for cutting off the old chain (other tools work too)
 * A chain riveting tool (Motion Pro makes a good one)

Tire Changes
Often it is easier and cheap just to take the wheel off and take it to the shop to have them install a new tire and balance it. If you wish to do it yourself you will need the following:
 * Valve tool to remove core.
 * Tire irons. At least two.
 * Rim protectors. Strips of plastic cut from a detergent bottle are my favorites.
 * Air source.
 * Bead lubricant. Laundry soap and water works for me.
 * Bead breaker.
 * Balance stand and wheel weights. A good balance stand operates on roller bearings with large rolling surfaces and little friction. People have balanced tires using the stock axles on the bike.

For Advanced Maintenance
List of Kawasaki special purpose tools with part number. These are not required for general maintenance. Unless you are rebuilding and engine you'll never need these.
 * Piston Ring Pliers: 57001-115
 * Bearing Puller Adapter: 57001-136
 * Steering Stem Bearing Driver: 57001-137
 * Inside Circlip Pliers: 57001-143
 * Outside Circlip Pliers: 57001-144
 * Bearing Puller: 57001-158
 * Oil Pressure Gauge, 10 kg/cm2: 57001-164
 * Fork Cylinder Holder Handle: 57001-183
 * Compression Gauge: 57001-221
 * Valve Spring Compressor Assembly: 57001-241
 * Bearing Puller Adapter: 57001-317
 * Bearing Driver: 57001-382
 * Piston Pin Puller Assembly: 57001-910
 * Hand Tester: 57001-1394
 * Fuel Level Gauge: 57001-1017
 * Compression Gauge Adapter, M12x1.25: 57001-1018
 * Valve Spring Compressor Adapter, Φ25: 57001-1019
 * Valve Guide Arbor, Φ5.5: 57001-1021
 * Spark Plug Wrench, Hex 18: 57001-1024
 * Fork Cylinder Holder Adapter: 57001-1057
 * Oil Seal & Bearing Remover: 57001-1058
 * Rim Protector: 57001-1063
 * Bead Breaker Assembly: 57001-1072
 * Steering Stem Bearing Driver Adapter: 57001-1074
 * Head Pipe Outer Race Press Shaft: 57001-1075
 * Head Pipe Outer Race Driver: 57001-1076
 * Valve Guide Reamer, Φ5.5: 57001-1079
 * Piston Ring Compressor Grip: 57001-1095
 * Piston Ring Compressor Belt, Φ67~Φ79: 57001-1097
 * Steering Stem Nut Wrench: 57001-1100
 * Head Pipe Outer Race Driver: 57001-1106
 * Valve Seat Cutter, 45° - Φ24.5: 57001-1113
 * Valve Seat Cutter, 32° - Φ28: 57001-1119
 * Valve Seat Cutter, 32° - Φ30: 57001-1120
 * Valve Seat Cutter, 60° - Φ30: 57001-1123
 * Valve Seat Cutter Holder, Φ5.5: 57001-1125
 * Valve Seat Cutter Holder Bar: 57001-1128
 * Bearing Driver Set: 57001-1129
 * Valve Seat Cutter, 45° - Φ30: 57001-1187
 * Oil Pressure Gauge Adapter, M14x1.5: 57001-1209
 * Rotor Puller, M16/M18/M20/M22x1.5: 57001-1216
 * Fork Outer Tube Weight: 57001-1218
 * Front Fork Oil Seal Driver: 57001-1219
 * Pilot Screw Adjuster, A: 57001-1239
 * Clutch Holder: 57001-1243
 * Bearing Remover Shaft: 57001-1265
 * Bearing Remover Head, Φ15xΦ17: 57001-1267
 * Fork Oil Level Gauge: 57001-1290 (or use a turkey baster)
 * Flywheel Holder: 57001-1313
 * Piston Base, Φ2.3: 57001-1336
 * Vacuum Gauge: 57001-1369
 * Hook Wrench: 92110-1019 or 92110-1173

For Traveling
Maybe this should be it's own article, but I figured I'd make a very short list of what tools I carry when traveling or riding any distance from home. Most people want to carry nothing, and some people seem to want to take their entire garage every time they leave home, but with a few purposeful tools you can handle almost any breakdown. I have two of every tool on this little list - one for my toolbox at home, and one that stays in my tankbag at all times.
 * A 10-in-one screwdriver: 2 phillips, 2 flatheads, a 8mm socket, and a 10mm socket, among other things.
 * 18mm thin-wall deep-well socket
 * Zipties
 * Duct tape
 * A fold-out set of allen wrenches
 * Electrical tape