what spares would you carry . . . .
 

As the mantra for any long distance trip is always light, light, light! . . . what spares would you carry?

In my case, thinking of an unassisted, solo, lots of dirt roads, across Australia trek (say 7000km over a couple of months) with relatively long distances between towns but with reasonable size towns at the end of each stretch on a relatively new bike, I like the idea of minimalist travel but also like the security blanket of some spares (even if I never use them).

So option 1 - the minimalist; carry no spares but a simple, very basic puncture repair kit (few patches, bicycle pump, tyre levers) and nothing else and virtually no tools.

Option 2 - The Rolls Royce option; including a good puncture repair kit (spare tubes, patches, 12v pump, 3 good tyre levers, G clamp help to break the bead), spare sprockets and chain, chain breaker, spare battery (LiFe type, very light), spare rectifier/regulator, spare levers, spare cables, few spare bolts and the usual bodge stuff (gaffa tape, cable tyres, oil, grease, wire, bulbs, fuses) combined with a good (fit for purpose) tool kit. Plus any other specific xt660z recommended spares. I figure most of this option would fit comfortably in the bottom of a soft pannier but the sprockets and chain are heavy!

On my last trip (many, many years ago) on a very second hand old 2 stroke dirt bike (Yamaha DT250) I carried no spares (not even a puncture repair kit! . . . more though ignorance and poverty rather than any well thought out plan! and it all worked out okay. Not that we much room on these small light bikes anyway.

So what would/do you carry?

At minimum for most trips ive made sure to carry the standard tool kit, gaffa tape, extra cable ties, good pen knife, two lengths of electric cable the length of the bike, couple of different sized bolts and nuts, some spare oil, puncture repair kit and levers and small hand pump to get even the smallest amount of pressure in the tyre.

I normally like to keep it simple, light and small. As long as you can get the bike up and running again, even at say 20-30mph you will get to somewhere or someone in most places who could help you out, put you up for a while, or help with tools etc.

So my option is simple, light and small. Test out a few of the bits and bobs before you use them, no point having something you dont know how to use.

I think the main criteria has got to be what you can actually fix, no point in bringing a spare piston if you can't realistically change it! However, things like wheel bearings, steering head bearings, etc, are fixable on the side of a road if you need to and could bring you to quick and abrupt stop if they fail - and given that they are relatively small and light might be worthwhile bringing.

The next thing is to bring spare parts for items that could actually fail, no point in bringing a part if it is highly unlikely to fail in the first place.

And finally the part isn't too heavy or bulky.

Ditto for service and wear items if you are going to be away from 'civilization' for a time (although in Aus you could realistically get most of what you need in any decent sized town so I wouldn't bother).

So my three main criteria would be that;
1. you could actually fix it,
2. part has been known to fail and if it did could leave you stranded, and
3. the spare is not to heavy or bulky.

So what should be on the list for an XT660Z?

Very good post. I guess I'd probably add "how much time pressure are you under to complete your trip" as something to think about as well - as long as you can at least limp to a town then even if there's no bike shop you can sit tight for a few days while someone at home gets the part and ships it to you. Might end up paying more to FedEx (or whoever) than you actually paid for the part, but it's an option :D

I'd probably put things like wheel bearings on that list - as long as they're in good condition when you leave, they shouldn't fail unless you're away for months and thousands and thousands of miles. But they're small and light enough to post cheaply, so maybe buy a set and leave them somewhere a friend can retrieve them and sent them to wherever you are.

I probably wouldn't bother carrying a whole chain, as it's quite a bit of weight. A short length and a few soft-links might allow you to reattach a snapped chain and limp to the nearest town, and any bike shop will have 520 chain.

I will be carrying a spare front sprocket when I set off on a 2500 mile round trip to Spain in a few weeks. I think my chain/sprockets should be fine, but it's always the front which goes first, and it's pretty small and light. I'm actually going against your point 1. above, as I won't be carrying the tools to change it - because they're big and heavy and I'm not expecting to need them. But if I do, I know that in Western Europe I'm unlikely to be more than a few miles from a garage with a 32mm socket and a rattle gun, whereas I might be a long way from a Yamaha dealer, and a couple of days wait for parts can spoil a two-week holiday.


It's all an assessment of risk vs weight, and you can be sure you'll only need the spares you didn't pack :D

Interestingly, the chain (and the associated tools required to properly brake and rivet a chain back together) and sprockets as well as a spare battery are the 2 items that are causing me the most angst - heavy to carry but both could fail unexpectedly (especially being bounced around in the Aussie outback).

I could get around the battery scenario by buying 2 Shorai LiFe batteries (very light and small) and wiring them in parallel with a switch (dual battery setup similar to the way most outback 4wds are wired up here in Aus). The chain and sprockets could end up as one of those "one unlucky rock" and your stuck scenarios, so I'd probably get spare Al sprockets and a new chain (sacrifice one can of beer to make up for the weight!), relatively light except for the chain.

Another way of looking at this is.....

Get to know your Bike Well.

If your going touring and intend doing 4 to 5 thousand miles on the trip dont set off on a worn out chain and sprockets , or 2 mm on your brake pads .

If you prep your bike before the trip you should not need to carry much at all.

Consider fitting new C and S and Pads before you leave, also start the trip on new tyres. { my C and S on my Tenere have now covered 12.000 miles and are still OK} I did change half worn pads which I kept to refit at a later date at 7000 miles because we had a 4000 mile touring holiday to do.
If your bike as already done more then 15,ooo miles consider fitting new wheel bearings and strip the rear linkage and head stock and repack with high melting point grease.

The only problem XT's seem to have is the R/R which now we know about this can be fixed by a small Mod to the top of the plug.

I have only ever snapped one chain in 35 years so as long as your chain is adjusted correctly and looked after they should be no problem.

A extra clutch cable along side the one in use is a good idea.

So I only carry what cant be bought from a DIY store

My spares Kit...........

Brake and clutch lever
front and read tube
12 volt pump
puncture repair kit
clutch cable
tow strap
AA card.

I would also carry front and read wheel bearings, if I were going through Africa/ south america / Far eastern Russia.

As above..travel light.

First kit to sort should be a basic First Aid kit for whenever a blue rinse or flat capper pulls out in front of you...enough to deal with road rash and maybe an army type field dressing to deal with bigger 'openings'...the usual applies...sprays,tablets,foil blankets,CPR mouth piece and triangular bandage etc etc .

On the safety aspect...if room permits...a small fire extinguisher...if at all....if you can carry a bottle of water then you can carry one of these too?...the reason is say this I have used one in the past to put out a moto with an electrical fault and with the flames close to the petrol tank...again not that common a thing to ever come across...(touch wood)...

I'll be going back to Morocco at the end of October and before I leave I'll take what tools go in my bum bag. Try to work on your moto with these tools as every day maintenance then you'll know what tools you don't need to bring.

I'll be riding with two side panniers only and no top box and the only thing on top of those at this time will be a tarp(the type you can buy in Decathlon for €25)...If there's a break down of any length of time you can shelter from the sun or rain,thus making any repairs less strenuous....(even if you have to stay for along time,e.g. over night...you'll not die but be kept dry at least) These roll into a compact bag and I have used them to great effect before just to eat lunch and relax for an hour or two under the desert sun.

I usually put the majority of my small stuff in a long CIF/JIF plastic detergent bottle with the top cut off. It keeps them from moving about in the bum bag and you can also wrap heaps of duct tape around it thus eliminating the need to bring a large roll. Also pack super glue. This works really well if you get a hole in any radiator hose. Dry it off...fill with super glue and then wrap with duct tape.I can vouch that it works and will let you limp home!!

As stated a clutch cable zip ty'd to the existing and a throttle cable too. Tape the ends up with duct tape to keep the crud out.Again if it snaps not a long job to undertake.



Brake pads will checked and changed if need be and wheel bearings are small enough to stash anywhere. Even if one fails it's only a 30minute job to change them and ride on.

A 12v pump takes the effort out of inflating a tyre and they're small enough nowadays to stash also. Use your side stand to break the bead so that eliminates a special tool for that.

A tyre grip installed on each rim before leaving is a cheap addition too...if you need to limp on with a flat you can do so at a slower speed. Speaking of wheels....fit a new set of dampers in your rear hub before leaving to avoid any issue there.

A front tube will fit the rear too so only one tube IMO is needed.

Chains and sprockets (if made of steel along with a good O ring chain) replaced before you leave means you don't have to think of that. Maybe a front sprocket if you're uneasy about it As stated a few chain links and a split link along with a chain breaker tool ( I clip my split link onto my throttle cable and also paint the clip white with Tippex...this means when it pings off,if and when needed,and as it invariably will you'll be able to find it!!)On that subject...if you mark your main bolts,e.g. sprocket bolts ,brake pins etc with Tippex then when you're standing about eating or chatting you can visually check them with out ever having to wield a spanner at them.

Also take that little box of nuts and bolts as mentioned,and throw a few fuses in for good measure.

Also any farm supply will carry various chains(for use in various harvesters etc) if you don't find a moto shop...might not be the correct width but the pitch should be close enough....again in 40yrs of riding I've never had a chain break.

A tow strap also is essential...doesn't have to be long....I usually use(and have used in the past, a normal moto tie down strap with a hook on each end)tow from foot peg to foot peg to avoid any fighting with the handle bar,i.e.,if you're being towed...from your left foot peg to the tow bikes right hand foot peg....he'll be able to change gear easily and still brake....and you can steer an still brake with no effort required.

A good strip down and grease of all pivot points will indeed ensure that that's not an issue and you're good to go. An oil/filter change with fully synthetic oil would also give peace of mind...along with a washable replacement air filter and can of spray on filter oil. A small tube of grease(like you buy in cycle shops,the same as a toothpaste tube)means you'll be able to grease the air filter seal to plastic air box.

A regulator spare...a second Yamaha Fazer one fits...fit it before you go to make sure it works...remove and it's small enough to stash....The plug from the original......,as I have done on mine,is to fill it with grease and cover with a section of bicycle inner tube to keep it waterproof(zip ty it tight with several zip ty's)....Thanks to the forum this tip was discovered.. :)

If a long journey is planned and there's lots of kms on the engine....why not replace the clutch discs with new ones to eliminate that also?....Even bring new discs if your clutch hasn't too many klicks on it....stash them in the air box?

Most stuff that will stop you and your moto in your tracks has been covered...after that 'Necessity is the Mother of Invention' as they say...and you can put your hand on your heart and not blame yourself for being a donkey head after wards...even more importantly...you can't leave yourself open for endless pub bantering from your buddies for the next 10yrs....which of course,is even worse than a breakdown!!! LOL

:)

On my XTR...
2 tubes "fit quite nicely on top of the air box under the seat"
DRG mini foot pump "in the tail box"...
Front guard tool bag... 2 x 200mm tyre levers/spanners/pliers/screw drivers/allen keys/punchure repair kit/small can of CRC/etc...
Small bottle of chain lube "in the standard tool try under the seat"
Be surprise what can be fitted in a front guard tool bag...

Pete, are you fitting standard sized tubes above the air box?