Once upon a time, if you can believe it, every motorcycle left the factory with its own tool kit. Sounds crazy, I know, but in the not-so-distant past, manufacturers both expected and encouraged owners to handle basic maintenance and repairs.
Why motorcycle tool kits fell out of fashion is up for debate. Optimists say motorcycles became more reliable. Realists say it was a cost-cutting measure.
Pessimists say greedy service departments don't want you wrenching on your own bike.
As for us, we stick to the facts: If you're gonna own an ADV bike, you're gonna need your own adventure motorcycle tool kit, and if the OEMs won't do it for you, you're stuck building one yourself that's specific to your machine.
Here's our take on what you need (and what you can skip) in your ADV tool kit after a decade or so of riding and guiding adventure tours all over the world.
Some of these items will be no-brainers, while others we've learned the hard way through trial and error. Unless you're guiding tours yourself or supporting all your riding buddies, add to this list at your own peril.
This is a catch-all for your core hand tools, or all the things you use most often for basic day-to-day maintenance of your bike.
That'll include screwdrivers, wrenches, hex keys, and pliers, plus a compact adjustable wrench and a set of vise grips.
Take some time in the garage to pull all the bolts you may remove during actual trailside repairs, then make sure your kit includes those specific tools.
Many bikes also need Torx bits, while a mini-ratchet and a few sockets can come in handy too.
If your bike came with a factory tool kit, that can be a great place to start. If it didn't, we're fans of CruzTools pre-made kits, which are fairly comprehensive and often built specifically for individual brands/models.
CruzTool Motorcycle Tool Kit
REVZILLA | AMAZON
Once you've got your basic hand tools together, the next priority for any adventure rider is an effective tire repair kit, because flats are part of life in the dirt.
This includes wrenches for both front and rear axles, tire irons, and tire repair supplies.
The wrenches are self-explanatory. Figure out the sizes you need to pull each of your axles, and add those to your kit.
You'll need at least two tire irons, and we highly recommend dropping the cash on Motion Pro's BeadPro levers if they're in your budget.
As for your tire repair supplies, the easiest "catch-all" repair item is a spare 21-inch tube, as you can stuff one into any size tire on any wheel (tubed or tubeless) and limp your way home. If you're running tubeless, you'll want to carry a plug kit as well.
Last but not least, you'll need a way to re-inflate a repaired tire, and depending on the repair, you may also need to reseat the tire bead. Compact 12V pumps, CO2 inflators, and even hand pumps can do the trick; just make sure you carry something.
We'll also note that adding a tube patch kit to your repair supplies is a smart move. Getting two flats in a day is unlucky, but it happens.
A $5 patch kit takes up next to no space and could save your bacon.
Motion Pro BeadPro Tire Irons
REVZILLA | AMAZON
Chain failures are rare, but they do happen. Luckily, the fix for most chain issues is as simple as carrying a spare masterlink. We recommend carrying a simple clip-style masterlink, as it can be installed with basic tools and will get you into the next town.
That being said, clip links aren't intended for big ADV bikes doing highway speeds, so a rivet link will need to be installed sooner than later.
Some riders opt to carry a chain tool and rivet link for this reason, but we wouldn't consider either a priority.
BikeMaster Clip Master Links
REVZILLA | AMAZON
We don't expect anyone to hit the road with a multimeter or soldering iron, but a few basic tools go a long way to dealing with common trailside electrical issues.
Spare fuses of the correct size/amperage for your bike, for example, should be in your kit.
We'd also recommend packing electrical tape for any wire repairs, and even a short length of wire itself in case you need to bypass something to get running again.
Things rattle around, come loose, fall apart, and need to be put back together all the time on the dirt.
Zipties are truly the unsung heroes of any motorcycle tool kit for adventure riding, but they have a few accomplices worth mentioning too.
Safety wire, hose clamps, duct tape, and JB Weld all belong in this same "quick fix" category. Carrying a few extra of the most common nuts/bolts/washers on your bike can come in handy as well and save you some time getting creative with zip ties.
A fuel siphon, a.k.a. "a non-descript length of hose," is one of the most versatile and useful items you can have in your adventure motorcycle tool kit.
Use it to bum gas from passersby when you run out yourself, or to share gas with your ill-prepared friends.
This literally doesn't need to be anything other than a few feet of clear hose, however, if you prefer to keep fuel out of your mouth (highly recommend), consider a "safety siphon" style hose, which can be self-primed by simply shaking one end up and down.
CHECK PRICE:
Shaker Siphon Hose
AMAZON
We know this might sound silly in the age of smartphones, but when the electronics fail, a paper card with info like torque specs, fluid types, tire pressures, common part numbers, and chain tension can be worth its weight in gold.
Write the important stuff you might need down, laminate it, and throw it in your tool kit.
It weighs nothing, takes up no space, and in a pinch you can even use it to clear out a leaking fork seal.
A good motorcycle tool kit for adventure riding is thoughtful without overthinking it.
Unnecessary weight and bulk cut into the fun factor on any adventure ride, so here are a few things we'd recommend leaving out of your repair kit.
Torque wrenches are large, heavy, and rarely needed on the road. There are a few jobs where precise torque provides peace of mind (axle nuts, sprockets, etc.), but "torquing by feel" will get you through 99% of situations and on to a garage if needed.
You'd be shocked how many folks we see out on the road with one of those bulky plastic socket sets with one of every size imaginable.
A mini ratchet and a few choice-size sockets are nice to have, but the whole kit and kaboodle is overkill.
Bring the bare minimum number of tools you need and leave the rest at home.
We see a lot of riders with both metric and imperial wrenches in their kit "just in case," and they never get used. Save the weight, save the space.
A few extra pieces of useful hardware (a few extra common nuts and bolts) is one thing, but bringing along extra levers, cables, and plugs is another.
You'd be surprised what you can do with a pair of vice grips and a handful of zip ties.
Carrying spare motor oil, coolant, brake fluid, or really any spare fluids is almost always overkill.
Top up fluids can be purchased in any town you ride through, and a single quart of oil isn't going to make a difference if you punch a hole in something crucial.
Did we miss anything? Leave a comment below and tell us what you’d bring or leave at home!
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