I have a 97 sportster and just about eveytime I go to work on something I find myself needing a new tool. A #27 torque driver for the primary cover. a large torque drive for the rear break pad pin, a large allen key for the front break caliper, etc. I have a good set of standard and metric tools in common sizes. At least I feel I do! This bike is the only recent project that I keep needing new tools for. So can you list some of the off-standard tools that are needed for normal maintenance and repair of these bikes? I did try a search and didn't come up with much.

 

As of yet I have not had any metric fastenersntjat I recall. A GOOD set of torx sockets and hex sockets and some hex keys are main thing outside of wrenches. Snap ring pliers as well. Torque wrench is a must. Good inch lbs and Ft lbs.

 

ball end allen keys.

rocker box wrench
http://reviews.denniskirk.com/2388/p282560/reviews.htm

Large socket (I can't remember the size offhand) for the drive belt pulley.

A couple of easy outs for when you strip the HD bolts.

 

1 3/8 " socket for fork caps.
As mentioned foot & inch pound torque wrenches ( I like harbor freight) and GOOD quality torx bits.

 

Okay, if I add the hex and torque sockets to my collection and a 1 3/8" wrench; it sounds like I might have things covered. That's good to know that I shouldn't keep running into more tool purchases every time I try to do a bit of maintenance.

Thanks to those who replied!

 

Belt tension tool.. One I dont have yet but should proably own as I do all my own maintenance. And the clutch spring compressor tool, Im gonna need one of those soon too...

 

The #1 tool is the factory service manual. A couple other handy items not mentioned above are a motorcycle jack, feeler guages, filter wrench and funnel

 

My 2000 has a 1 7/8" nut for the front primary. agreed on the funnel for HD's and filter wrench.
Hey bootheat after you use the clutch spring tool can i borrow it so i can do mine. I'm a fellow Michigander i'm trustworthy, i think??????

 

Patience

 

A nearby hardware store with a good nut and bolt section where you can buy them individually and try threading them.