I've wondered how far the GS500 toolkit will get me on a road-trip.  
I try to use it for routine maintenance (chain/sprocket replacement, etc.), just to see whether it has what I need.  There seem to be a few simple things that could be improved: the wrenches are OK (but too short), the screwdriver handle is too thin for leverage.

So what would you change about the GS500 toolkit?
I was thinking:
-get about 6' 8 ga. braided wire to jump-start (no clamps, just wire)
-get a screwdriver with hex tips, and metal through the whole handle, which could double as a drift punch.
-get a 12" 1/2" I.D. pipe, and some way to attach it to the wrenches (lateral box at one end?)... but how to store it?  Could double as a hammer.
-weld a locking pliers to some angle-iron with a hole in it, so that you can bolt it onto the bike in various locations to use as a table vise (horizontal or vertical).
-circuit tester light made from LEDs (can show voltage to within 1.5v).
-mushroom-style tire plugs
-12v air pump, removed from plastic casing
-spare shift, clutch and brake levers; headlight bulb.
-multitool
-LED flashlight

In addition to the standard kit I always carry a small set of spanners (wrenches) one of those screwdrivers with all sorts of bits stored in the handle, a swiss army knife, a small maglite, tyre preasure gauge and one of those aerosol puncture repair gismos. One thing I can absolutely gaurantee is that if ever I do get stuck I won't have the tool I need, thats life. Oh! and the tool that does everything, a cell phone.

Quote from: Cal PriceIn addition to the standard kit I always carry a small set of spanners (wrenches) one of those screwdrivers with all sorts of bits stored in the handle, a swiss army knife, a small maglite, tyre preasure gauge and one of those aerosol puncture repair gismos. One thing I can absolutely gaurantee is that if ever I do get stuck I won't have the tool I need, thats life. Oh! and the tool that does everything, a cell phone.

Are you able to store all of that under the seat or do you carry a separate bag?

All I keep under the seat is a couple of rags and a small accessory lock. Maglite and swiss army knife (and a recusiad+ rubber gloves to protect from the less social aspects of blood'n'snot) are permanently in a pocket of my "Bufalo" armoured jacket and the tools in a Givi topbox which is about 33litres and also takes full face helmet when I park or I put the helmet on one of the underseat hooks and can just about cram the scrunched-up Bufalo into the Givi. This allows me to park and walk around in almost human form.

On those rare occasions it is warm and dry in the bottom right-hand corner of England I may not use the buffalo in favor of a leather jacket in which case I don't normally bother transfering the pocket stuff. You sure won't get much under the seat of a GS!

I replace most of the tools with good quality ones (Craftsman etc), except for the plug socket/thingy and the shock spanner. The only really different tools I add are a multitool and a small pair of vice grips. A length of wire, electrical tape, some fuzes and tubes of JB weld are the extent of the spares I carry. 'Lita's GS uses the original tool bag with a little ziplock back for the extras. While I use a miniature nylon gym bag I got from somewhere I can't recall on the YZF, along with a mini first aid kit.

One thing I've learned is if you live in a damp climate (the south) is that your tools can corrode and rot after a time, so I put a pack of disassecant <sp?> in with them.

Yeah, and fuses, I forgot fuses, never had one go yet but sod's law dictates.............

It's "desiccant".

Good ideas here guys - keep 'em coming!

Quote from: Cal PriceYeah, and fuses, I forgot fuses, never had one go yet but sod's law dictates.............

Isn't that what the extra wire is for   ? j/k
How many kinds of fuses?  I just have the one included spare fuse.  

What kind of wire do you pack?  Preferably something thick-enough to jump-start. I think that should be under 100amps, or about 14 ga.?  Maybe some braided 14ga. A/C extension cord rated for 10amps (@120v A/C) with the ends snipped-off, snipped, twisted and soldered?  You can screw it down to the GS battery using the screws, and use the small locking pliers(*) to hold the positive end to the booster battery's ve+ post.

(*)you can make a spring clamp using pliers and a latex glove from the 1st-aid kit.  Vinyl and Nyplex don't stretch, though  :mrgreen: