How to make a travelling toolkit for adventure bike rides

Rule 4: Evaluate the risk, then prioritise your toolkit accordingly

If you know your bike well enough, then you’ll also have an idea of its potential weaknesses or areas of high maintenance need. Being aware of these factors also helps in the decision-making process for taking the appropriate tools – for example, if you know you’ll be riding a lot of miles on rough surfaces or other rocky terrain, a puncture repair kit is essential. Some bikes have known weaknesses: immobilisation antennas or wheel bearings for example. If you know there’s a higher- than-average chance of a problem, be sure to take appropriate spares and the tools needed to fit them.

Diagnostic tools

CAN-bus, like it or not, is a growing technology and is to be found in all high-end adventure bikes currently available. While this technology brings a flexibility and sophistication beyond the capacity of conventional hard-wired electrical control systems, it also means that fault-finding is a lot more difficult as the computer-controlled ‘brain’ will more often than not simply shut the whole bike down.

The computerised control systems found on many modern cars and motorcycles these days are extremely complex and require sophisticated equipment to use them effectively. Using a full diagnostic computer is a skilful task, requiring not only the hardware but also the software needed to read and interpret the fault codes, and ultimately reset the system or component to function within its required parameters. The complexity of these systems is advancing constantly, with the most current systems being able to download bike-specific data on to a central database. This degree of connectivity allows vast amounts of information to be stored and will let any networked dealer access the bike’s history, identifying all service operations and upgrade or recall work conducted.

Thankfully, a simplified device for reading the fault codes stored in the bike’s memory is available at a fraction of the cost. Known as a ‘code reader’, it allows the user to interrogate the diagnostic system to see what fault codes have been flagged and which system has been compromised by any failed component. Model-specific readers will also display real-time data, and allow certain components and systems to be tested in isolation, as well as identifying any anomalous readings which might generally indicate an imminent failure. Their real benefit will come if ever a component fails while travelling, and using one to interrogate the system will allow the user to identify the problem rapidly and, if necessary, make arrangements for replacement components to be ordered and shipped.

Most Japanese motorcycles can display fault codes on their dashboard if a ‘service plug’ is connected to the diagnostic socket. The same result can very often also be achieved by ‘jumping’ specific terminals of the diagnostic socket with a wire link, although you must be sure that you know which terminals to connect. The resulting codes can be shown as a number in the display panel, or occasionally a sequence of warning light flashes. Interpreting these codes can sometimes be difficult, but a little web-based research will usually reveal the answer.

Spares

There will always be a few key items that will be essential to pack, although it will always be difficult to predict what you’ll need. Try to keep whatever you take to a minimum, certainly only taking those items that you know might or will be difficult to source in the area where you’ll be travelling, but remember that smaller items such as spare brake pads and wheel bearings take up no room at all in your luggage. Research your route, identifying points on the way where you can access garage services or dealer facilities. Check with the various owners’ groups to research your bike’s weak points and use that knowledge as part of the preparation process to replace items that have a history of failure, or those which will wear out before your return. Thankfully catastrophic mechanical failures are relatively rare these days, especially if you are diligent with your service schedules, but smaller items such as control cables are always at risk. Buy replacements for your key cables, and fit them before you leave, but leave the ‘old’ ones in situ. That way you know for sure that the spare works (because you’ve already fitted it) and you also have a guaranteed suitable replacement already in place (the ‘old’ one) in the event of the new ones failing.

Spare bulbs for your main lights are essential, and are a legal requirement in some countries. Keep a set in your electrical toolkit, along with a selection of fuses. One of the most vital spares to take is a duplicate ignition key. Surprisingly, many motorcycle travellers leave home with just one key, but in this day and age of hyper-sophisticated alarms and immobilisers, if you lose yours it is very unlikely that you’ll ever get the bike running without it. There are suitable hidey-holes on every bike that can be used to stow a spare key – you just need to remember where you put it!

When securing a spare key, make sure it’s not going to become dislodged, or fall out easily. Don’t chose an obvious place like under the seat, or behind the number plate, or secure it to anything that might become detached from the bike, like a rear mudguard, for example. Ideally, it should be in its own small waterproof container, one that can be either zip-tied or fixed to the bike’s bodywork.

Self-preservation

There will always be the rare occasion when you break down and are unable to make any progress at all. In these situations, never leave your motorcycle. You and it are far more visible together. While it might seem that you’re in the middle of a wilderness, the reality is that you’re quite likely to see someone coming along the road before too long. Don’t be afraid to be assertive when trying to get them to stop, although once they see your plight most fellow travellers will be more than happy to help. Hitch a ride to the nearest town, and you’ll probably find that your travelling friend will help you here too, in seeking recovery and repair of the bike. Most mechanics in remote areas have learned how to keep almost any vehicle running and they might well be able to offer a solution. At worst you’ll be able to find a phone and call home for spares to be freighted to you.