What: Chapman Manufacturing Co. Model #1916, European/Japanese/Indian Motorycle Tool & Repair Tools Set
Summary: Best on-the-go tool kit covering 1/4" socket, PH1/2/3, and metric hex bits 2.5/3/4/5/6/8 (7mm available not included).
I received today my order for a tool kit #1916 made by Chapman Mfg. CoE USA.
First the odd stuff, the stamped label on the bits themselves; 17, 19, 20, 21, 34, 42, 43, 4MM (sort of shallow stamp mark we'll see how this holds up over time), 45, 46, 48, S15, S20, S25, T27 (the metal on this bit looks noticeably blued compared to everything else), S30, CME-1, CM-13, "adapter pack" vinyl pouch, unlabeled rubber band toggle, and unlabeled drive spinner. The stamp markings and labels are not consistent so I'm left to wonder if new bits being made have changed marking styles.
Working on a Zero Motorcycles 2016 DSR typically starts with taking off the seat, a pair of Torx-45 (or 5mm) head bolts at 16lb-ft. Unfortunately there's no Chapman Mfg Torx-45 bit available. I did contact Chapman Manufacturing and got a prompt response thanking me for my suggestion, and that the reason there is no bit is because not enough demand. However this kit does already include a 1/4" socket drive part CM-24 so the kind-of-answer here is to grab a Torx-45 socket bit and 1/4" adapter from your existing tool kit. Loosening a bolt that is torqued to 16lb-ft it seems like the ratchet is well built and can take the stress. You won't want to tackle bolts tighter than about 16lb-ft (or 192lb-in) as this is between average working torque of 180lb-in and average breaking torque of 200lb-in for the CM-24 square drive bit.
Once the seat cover is off you will have access to the the fusebox and that might be enough. If you need to go deeper then you may be removing the tank plastics which needs 3mm hex bits on the provided extension bit (tested and approved! works great!), and later the PH2 bit also included. The PH2 fasteners used on the tank plastics are some of the more inaccessible angles and clearances I've ever seen, yet the Chapman ratchet and PH2 bit are sized to complete the task with ease. This tool kit is perfect as-is for confidently removing and installing Zero Motorcycles tank plastics.
Not yet mentioned, there's a range of torx bits included, but since they stop short of T45 size I'm not sure what usefulness they have on the Zero. Similarly the square end slotted bits seem to be a miss for the Zero. They don't weigh much or take up noticeable bulk, so there you have it they're in that kit should you need them.
If you own a Zero, or really any metric fastener using motorbike, you need this tool kit. Individual replacement bits (and actually an odd bit here and there not available in the master set) are available direct from the manufacturer for order on their website. I might suggest contacting Chapman Mfg and add your voice to the demand for an S45 (torx/star) bit, and also to order a screwdriver handle along with a 7mm hex bit.
Have you got a tool bit suggestion not offered by Chapman Mfg? Contact them and make it known!