Ever fret over what tools and spare parts to bring on a long cycling journey? What to put in, what to leave out? Me too. There’s a myriad of options, with the lists being virtually endless, always striving to balance utility against weight. It boggles the mind. Regardless of what you settle on for your tool kit, it really boils down to “what works for you,” which should be the result of a little thought and analysis. Here’s my take along with a little of my decision-making methodology on the never-ending, ever-evolving, and sometimes hotly contested theme of building the “perfect” tool kit, if such a thing exists.
Think of Your Tool Kit as Part of a Larger Support System
The process gets a little easier and your kit a little more effective if it’s designed to support your trip’s goals, your personal riding style, the equipment you will be using, and the environment you’ll be traveling through. It helps to look at your tools and spare parts kit as integral components of a broader travel support system developed to provide specific capabilities to suit a particular set of goals, needs and operational conditions. Developing a clear understanding of how you are going to ride, what you are going to do with what gear, and where you are going to do it is key to assembling not only the right tool kit and spare parts list, but an effective, efficient support system that will give you the confidence and ability to go virtually anywhere you desire.
Implement “The Five P’s”
Prior Planning Prevents Poor Performance (P5) — good words to live by in not only adventure cycling, but life in general. Good support systems are build on solid values and decision-making methodologies. There are times to fly by the seat of your pants, but it shouldn’t be all the time. Fill free to live on the wind, following each breeze or gust to wherever it may take you, but have a solid plan to support yourself and to deal with any challenges that may arise along the way. Take the time and put in the effort to do a decent amount of research and preparation before you go. Setting the conditions to deal with problems ahead of time will save you a lot of pain down the road. Build a strategy for support. You’ll thank yourself later, trust me. Deliberate planning and preparation up front allows for greater freedom of movement down the road and acts as a solid base from which to disappear over the horizon rolling confidently in the direction of your dreams. Have a plan. Remember, it’s not a matter of if sh*t will happen, but when sh*t will happen.
Take the Time, Do the Homework
Research the journey ahead of time. Assess the route. Identify potential resources and possible hazards. Pinpoint and access potential problems, gaps in resources, and question marks on the map. It seems like a “no-brainer,” but many people don’t think this through or skip it entirely, opting to “make-it-up” as they go, and end up paying the price out on some deserted road in the middle of no where. Consider equipment failures, such as punctures, split tubes, blown tires, broken spokes, seized bearings, chain or belt failure, sheared rack bolts, frayed, kinked or snapped cables or worn cable housings, worn disc pads, and the list goes on, but you get the idea. Reflect on how you’re going to deal with critical and most likely equipment failures that could occur on the road.
Develop Capabilities and Contingencies
Once you’ve cultivated an understanding of the environment you’ll be traveling through and developed a clear picture of what could go wrong and how it can be fixed, develop a set of capabilities (actions you’ll take on your own) and contingencies (places or people you will go to and resources you will utilize) to mitigate potential problems that could occur along the way. In some areas, bicycle parts and shops are plentiful, so it’s not a big deal to travel with minimal tools and repair parts, while in other areas, cycling shops, tools and repair parts are scarce, creating additional challenges and planning measures that need to be addressed.
Build capabilities by developing your cycling maintenance and repair skill sets. Develop the necessary skills to maintain and perform most repairs on your bike and equipment by yourself. Be able to perform basic adjustments and service functions on all of your gear. Most are simple and require only an elementary understanding of your equipment, their components, and service procedures. At a minimum, be able to repair tire punctures and to fix or replace damaged or worn tires. Be proficient at basic servicing and performing essential adjustments on the bike’s drive train and braking system. Having the skills necessary to replace a broken spoke and make minor truing adjustments to straighten a wobbly wheel is a big plus. Know how to adjust the saddle height and handlebar position on your bike in the event they slip or need replacement. Know how to mark them with a paint pen once you get the adjustments dialed-in so that resetting them is simply a matter of lining up the dots. Know your equipment and how to use it. Be technically proficient. I’m always surprised to see how many people struggle to fix a flat tire because of inexperience. Pinched inner tubes and peeling patches can generally be circumvented with a little prior training. Avoid being “that guy.”
Develop contingencies. Address critical (showstoppers) by answering the “What I will do if…?” questions. Have an idea of what resources will available where and what actions you will need to take when problems arise. Usually, bicycle shops and common repair parts can be found in all but the most remote locations around the world (though quality is sometimes suspect), while unique, component specific and high-end parts and gear is not always available. Know what you will and will not have with you and plan accordingly. Bring hard-to-find repair parts with you, and/or make arrangements to have them shipped to you. If you rely heavily on available resources, you’ll be assuming a certain amount of risk.
Determine what you can fix and what you’ll need someone else to repair or replace, either locally or remotely by shipping the item back and forth. Develop a general understand of the resources that will be at your disposal at the various points along your intended route of travel. Use contingencies to cover gaps in your capabilities.
It pays to check with gear and shipping companies ahead of time to clarify and work through their repair/replacement procedures, and to workout shipping details ahead of time so that you’re not discovering them for the first time through trial and error after you’ve broken down out in the middle of nowhere. (See “The Five P’s.”)
Always try to have some sort of contingency in place — the more the likelihood or the criticality, the more detailed the planning and preparation. Assume the best is going to happen, but plan for the worst. Don’t wait until the fecal matter makes contact with the rotating blades to start trying to figuring out what to do. Have a fall-back plan in place you can implement when something breaks or needs a higher level of repair, instead of running around in circle with your hair on fire waving your arms up and down spewing a stream of expletives.
On my last trek through western China, I had two external hard drives (the primary and first back up) containing all my images and video (3,500+) fail a week apart, probably as result of the constant jarring from rough roads over the high mountain passes. But because I had two redundant back up drives in place, it was simply a matter of moving from one back up to the next (though the tension did rise significantly when the second drive crapped out), which bought me time to have two more robust replacement hard drives shipped to me on the road, thereby averting a digital catastrophe. (See “The Five P’s”)
Build Your Skill Set
As an adventure cyclist, you need to be technically and tactically proficient. Don’t let the first time you’re doing it be the first time you’re doing it. As a minimum, you should possess the technical and mechanical abilities required to meet the capabilities you’ve developed during your trip’s planning process. Short of major repairs requiring special tools or catastrophic damage to my gear, I pretty much maintain and fix my own equipment. I’m reasonably well mechanically inclined and have developed a sufficient skill set to maintain and repair just about anything regarding my bike and gear, mostly relying on myself to keep going. I am my first, best rescue team.
Inspect and Prepare Your Gear
Do a thorough inspection of your bike and kit. Get it in the best shape possible before departing. Fix any problems, replace highly worn components nearing the end of their lives, and ensure your kit is in the highest state of readiness before you roll out the door. Consider scheduled services and routine maintenance along the way. Incorporate them into your capabilities and support plan. Chains, tires, brake pads, etc. will eventually wear out or break and need to be replaced. Estimate where you will be on your journey when routine maintenance will be required and factor it in to your travel plans.
Tailor Your Kit to the Situation
Tailor you tool kit and repair parts to fit your support plan. Inspect your bike and gear to ensure that you have the correct tools for each fastener, fitting, connecting or adjustment knob, bolt, screw, etc. Depending on local availability, bring spare parts for critical components or hard to get items. For example, replacement tires, tubes, chains and the like can be “showstoppers,” and may not be available locally or can’t be shipped (or take to long to ship), so you may want to bring one or two spares of each. Think redundancy and fall-back plans that will allow you to keep you going and buy time or create “white space” to get replacements. If support is readily available, you can bring less. If not, bring more. The situation dictates.
Balance capabilities and contingencies against weight and space requirements. If the weight is too much, consider reducing tools and or repair parts by shifting capabilities to contingencies and assuming more risk. Don’t be afraid to carry a little more weight on the longer trips. You will naturally want to bring more gear on remote journeys. I tend to allow a little more weight for tools and parts, choosing to make it up by leaving other items behind.
As a minimum, I always bring items to deal with flat tires, which is usually a patch kit, a spare tube, a pump and a multitool, in addition to a little cash. If I go thin on the tool kit and repair parts (capability), I always have a way to get help, such as a cell phone (contingency plan). Setting up your tool kit is pretty straight forward. It just requires a little forethought, planning, and preparation. My luck usually dictates that if I bring two of everything, nothing will break. But, if I only bring one, it will fail at the most inopportune time.
What’s in My Tool Kit
Here is a rundown of my general tool and repair parts list, which is by no means all inclusive or written in stone, but a selection of tools and repair parts that I draw upon from trip to trip, adding to some while leaving behind for others as dictated by the situation. It’s a list based on my traveling style, the goals and objectives for the journey, and the expected traveling environment. As previously stated, situation dictates. I add or drop tools to meet trip requirements. Though riding a Rohloff Speedhub/Gates Carbon Belt Drive setup, I still carry some tools and parts for a traditional derailleur/chain drivetrain to be able to help fellow riders when necessary.
Tools – General
- Bit set, Leatherman
- Disc brake caliper block
- L – Hex wrench set (1.5 mm – 8 mm)
- Multitool (Leatherman Wave)
- Multitool, Lezyne 12 Multitool (bicycle)
- Pliers, slip joint
- Pliers, grip (Leatherman Crunch)
- Ratchet with bits (Topeak Ratchet Rocket)
- Screwdriver (with Philips, straight bits, etc)
- Spoke cup wrench (Mavic)
- Spoke wrench, Park SW-7
- Tape, measuring (1 meter)
- Tool roll
- Torx bits (anti-tamper)
- Wrench, adjustable 150mm
- Wrenches, open end (10mm/8mm, 9mm/8mm)
Tools – Puncture/Tire Repair
- Adapter, CO2 Cartridge (I don’t normally carry cartridges on longer rides, but inflate them with a mini-floor pump instead)
- Cement, 10g tubes (I keep several small tubes in two locations to prevent damage and all the cement from drying).
- Crankbrothers Speedier Tire Lever (x2) — superior to traditional tire levers.
- Gauge, tire pressure, Topeak D2 Smart Gauge
- Marker, tire (To mark puncture site)
- Patches (x100 stored in two locations) — I patch and patch until I can patch no more.
- Presta/Schrader adapter (x3, Make great gifts to fellow riders.)
- Presta/Schrader valve tool, Park Tool VC-1
- Stitcher and roughing tool — key to a quality patch job (My patches stick the first time).
- Tire boots (x3)
- Tire pump (x2) — Inability to air up tires is a showstopper.
Tools – Rohloff/Gates Carbon Belt Drivetrain
- Gates Klikit Belt Tension Tester
- Rohloff Cog Removal Tool, 4-Prong
- Spanner for S & S couplers
- Spanner, Park SPA-1, for eccentric bottom bracket
Tool – Derailleur/Chain Drivetrain
- Cassette lock ring remover (Park FR-5C or Cassette Cracker)
- Chain wear gauge, Park CC-3.2
- Chain whip/bottom bracket tool
- Chain-breaker, Topeak Chain Tool Head for Ratchet Rocket
Repair Parts – General
- Aquaseal Wader Repair Kit
- Cord, 50 ft.
- Duct tape (3 meters) — Like the Force, it has a light side and a dark side, and holds the Universe together.
- Lacing wire (2 meters)
- Patch kit, air mattress and pillow
- Sewing kit
- Tenacious tape
- Zip ties, long (10) and short (10) — don’t weigh much and are very handy.
Repair Parts – Cycling Specific
- Allen screws and washers for racks (stainless steel)
- Aquaseal (x2) to patch panniers
- Cable end caps (6)
- Cable ferrules (x6)
- Cable guide, Rohloff (x2) — can easily be damaged from a bike fall.
- Cables, cable housings, derailleurs, brakes
- Carbon belt or chain (x1)
- Derailleur hanger
- Disc brake pads (2 sets)
- Grease (1 tube) — can take smaller portions in a smaller container.
- Inner tubes (x2-3) — usually two, sometimes three.
- Loctite (x1)
- Lubricant, chain (x1-2 bottles) — one bottles lasts about 60 days.
- Master link, chain (x2)
- Ortlieb Inserts for pannier rack hooks, 11mm (x4)
- Ortlieb Rack Hooks (x1)
- Rags
- Rohloff shifter cable kit
- Rohloff Speedhub oil change kit
- SPD cleats (x1)
- Spokes (8-10)
- Super glue (1 tube)
- Taillight, Bontrager Flare 3
- Taillight clip (x1)
- Tire, folding (x1)
Pack it Right
Develop a load plan for your tools and repair parts. Put the items you need most on top. Keep them readily accessible.
Protect sensitive repair parts from damage in transit: cement tubes, inner tubes, patches, super glue tubes, cable housings, cables, carbon drive belts, etc. Keep liquids separated from other items to protect against damage and guard against spillage, as road vibration and rubbing can wear holes in tubes, loosen screws, and unscrew caps. Things come apart or work loose from being continually bounced around.
Store the puncture kit, air pump, and perhaps an inner tube on top for easy access. Flats happen. You don’t want to dump all you kit out on the side of a busy road just to fix a flat or replace an inner tube. I keep a small tool pouch in the front top bag for quick access as well, with the tool roll containing less used or special tools stored in the right rear pannier.
Additional Tips
- Carry enough spare parts to get you through the designated sections of your ride or to your next resupply point, if you’ve established one.
- Consider organizing your kit by system and immediacy of use, with the most used items being put together and packed for quick access to avoid peeling open every pannier and rummaging through all of your gear to find a particular tool or repair part.
- Schedule time to clean, service and maintain your bike and kit. Take care of your gear and it will take care of you.
- Carry tube cement in several small tubes in multiple locations, rather than in one. Do the same for patches too. I used to carry one larger tube of cement until I noticed that it began hardening over time after opening. If it gets punctured, and leaks out, you have nothing to fall back on. Don’t put all your eggs in one basket. When one runs out or hardens, I open another one. When visiting local bike shops, I pick up a replacements.
- Protect repair parts from damage. Keep them in their original packaging, if feasible. Rotate your stock to avoid dry rot or damage to due to wear and tear from being carried in the panniers over long periods of time.
- Consider carrying two tire pumps. They don’t weigh that much and I consider them a critical asset. Losing the ability to inflate your bikes’s tires could be a showstopper.
- Ziploc bags save weight and are useful in organizing your kit, but puncture easily.
- Where possible, have tools do double duty to save space and weight.
- How-to-videos on bike maintenance or repairs downloaded from YouTube make great refreshers and can easily be stored on your computer or external hard drive.
- Save weight by digitizing manuals, instructions, parts lists, contact lists and store them along with how-to videos in multiple locations on your computer, iPad, online, etc. for future reference.
- Service your tools, such as lubricating the inner barrels of your air pumps. Keep them clean and organized.
Home-Base Support Kit
As part of my support plan, I have a set of critical and key back up parts and supplies organized and stored in numbered Ziploc bags in a box kept at my home-base with an accompanying reference packing list. Should the need arise for a particular part, I can simply send a request to my lovely wife specifying what bag to drop ship to me once I’ve nailed down an accurate shipping address. After my wife sends me a “care package,” she replenishes the items so that more will be available should they be required.
This simple system provides timely access to essential gear and keeps me from going through the hassle of searching for replacement parts online from retailers and then having to work out the shipping details them, which is especially useful in areas with limited or no internet connectivity. My wife and friends know the drill and simply work out the shipping after I give them the address. Additionally, I know I’m getting the right part.
Pay additional attention to special or hard to get parts for the area you will be traveling and plan accordingly. For example, I ride a 29er, whose parts widely available in the U.S., but are rare, if not impossible, to come by in most of Asia due to the popularity and proliferation of 27.5” wheeled bicycles. So, make sure I have access to plenty 29er specific parts, such as tires, tubes, spokes, etc. Anything more than that and I’ll it have shipped from my home base.
The home-base support parts cache generally consists of the following but is not limited to:
- Tires, folding (x3)
- Inner tubes (x3)
- Rohloff oil change kit (x2)
- Gates carbon belt (x2)
- Disc brake pads (4 sets)
- Cable housing (brake x1, Rohloff shifter, x2)
- Cable (brake x1, Rohloff shifter, x2)
- Cable guide, Rohloff (x2) — can easily be damaged from a bike fall.
- ESI Silicone Grips (Extra Chunky) (x1)
Take Action
- Make you tool kit part of a larger support system.
- Build your support system based on an analysis of your style, equipment, goals and the environment.
- Employ “The Five P’s” — Know them, love them, live them.
- Develop capabilities and contingencies to support your system, which supports your journey.
- Be technically proficient with your bike and other kit.
- Tailor your tool kit and repair parts supply to fit your capabilities and contingencies.
- Consider employing a home-base support system.
- Get on your bike and ride.
Final Thoughts
A detailed trip analysis backed up with solid skills and viable contingency plans engenders a high degree of self-confidence and sets the conditions for a trip’s success with minimal pain, not to mention enhancing personal safety as well.
Have a plan so that when something breaks or happens on the road, you simply employ your skills or fall back on a well thought out contingency plan to resolve or mitigate the issue, other than hitting the panic button and begin running around in circles with your hair on fire spewing expletives and waving your hands in the air.
As with all things, some adventure cyclists bring more while some bring less, and some none at all, while others have a different approach entirely, which is one of the beauties of adventure cycling. As Carl Jung said, “A shoe that fits one, pinches another.”
This is my system; it’s what works for me. Take what you like and leave what you don’t. Develop your own. It really comes down to “what works for you.” Consider your riding style, where you are you going, what you’re riding, other equipment you’re using, and what you’re trying to accomplish. Build a tool kit, a repair parts list, and a support system that supports these factors.
Enhance your freedom of movement on the road through a little deliberate planning before you begin. Tailwinds and long descents.
Note: Not all items contained in the tool and repair parts lists were included in the images.
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