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[Shadow]

What: Chapman Manufacturing Co. Model #1916, European/Japanese/Indian Motorycle Tool & Repair Tools Set
Cost: $37
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!

[BrianTRice@gmail.com]

Product page for reference: http://chapmanmfg.com/products/1916-european-japanese-motorycle-set

I looked that up to see the kit - which illustrates that it covers the "ratcheting side screwdriver" need for removing those screws mounting the front of the tank plastics, a rare toolkit feature.

FWIW I keep a small selection of T-handle allen wrenches, one open ended adjustable socket wrench, and a ratcheting side screwdriver in a tank bag, although a wrap that fits these would be better. I did also switch to the top rack bolts which use a 5mm hex allen key instead of Torx T45.

[Shadow]

In writing the manufacturer to ask about the stamp markings, Peggy from Chapman Mfg replied:

We are now in the process of marking the bits to their actual sizing. Customers like you have inquired about this as well.  The markings on the bits now were done since this company was established in 1936. 

We have not have had an issue with customers regarding the stamp on the bits.  Please let us know
if you have any problems with this!

We are finishing up our inventory of the T-27 bit.  Once that is complete, this bit will be
under the star catagory.

[ChapmanMFG]

First and most important: If the #1916 set isn't a perfect fit for Zero bikes, let's work together to develop a set that is, I'll list it on the website and post a discount code for you guys to use!

Thanks for reviewing our tools! To my knowledge you've written our first review for the e-bike market. We just celebrated 80 years in business, and initially our tools were used for industrial/firearms service, and now people use our stuff on e-bikes, NASA equipment and drones!

To address your questions: As Peggy said, we've been stamping our bits with the same arbitrary part numbers since 1936. Several years ago we, as a company (there's 15 of us here) decided to start marking them with the actual numbers. It takes a very, very long time to switch over our entire inventory because we have to give our wholesale/industrial customers advanced notice. However we've made a lot of headway and all the parts we're currently running are market with the actual size. I have sets from the 30's/40's that were/are used daily and I've never seen a stamped number that's worn.

Our part #S45 for T45 fasteners (Torx are a licensed product like Kleenex, we make star bits and they are higher quality than Torx bits) is a bit that's only my list to make with many other bits. Right now my highest priority are JIS bits as many people in several industries are clamoring for them. If you sign up for our monthly e-newsletter, you will be alerted as soon as we have new parts.

I'm excited about this,

Joel
Marketing at Chapman MFG

[Shadow]

Follow-up after 6mos+ usage:

I've added a "Felo 0715732076 T45 x 1-Inch Torx Bit, 026 Series" to carry in my set, since it could be awhile before there is an S45 Chapman Mfg bit compatible with the Torx 45 seat bolts used on my Zero DSR. The most used bits in the kit are the 3mm, 4mm, and PH2. Recently I helped a fellow EMF'er dismantle their Zero tail plastics, and while the CM ratchet was key to being able to do this, we also needed a standard PH2 driver for that task.

The CM kit is not a does-everything kind of kit. For the smaller fastener sizes and anything tightened to 16lb-ft or less it makes quick work of the task and stores very compactly.

Recently the CM-13 ratchet in my kit cracked under use.

I contacted Chapman Mfg and received a prompt reply that it is covered under warranty, and after confirming my address a replacement was sent.

That replacement arrived within the week:


I'm impressed with the quality of customer service. The CM tool set has earned its place with the tools I always have with my Zero.

[Crissa]

I recently bought a set, and it seems really nice!

Everything snaps together and the case was much, much smaller than I anticipated.

-Crissa