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Tips for reducing weight (and volume) on a cycling journey

by   Igor Kovse
Last updated ("NEW" in text): April 2010

Here's an ultralight cycling setup that could get you right across the world:
Ultralight cycling setup at 4200 m. Indian Himalaya, 2006
Fancy it? If yes, please read on. However, if this doesn't seem "self-sufficient" enough for you, you can stop reading and go directly to fullyloaded.

Practically all touring cyclists seem to be weight conscious, both those who cannot survive without 40 kg of luggage, as others, who don't carry much more then a credit card. Earlier, I wrote some thoughts about weight saving on a cycling trip and for those interested, here they are.

The philosophy behind the light weight style was inspired by frequent breakages of spokes on rear wheel. This happened on second hand bikes of questionable quality, but the idea of weight reduction survived up to today when broken spokes became a very distant, unpleasant memory. I am, ... or rather I was ..., religiously convinced - which means without evidence - that little weight reduces the number of mechanical problems, decreases energy requirements and fatigue and increases average speed, distance and enjoyment of cycling. It probably decreases off-bike comfort, but it is not me who will point out the disadvantages.

If you're still interested, here are some tips:

Packing lists

Lists from my last trips

Below is a list of things from my last cycling trips.
I try to weigh everything I have, e.g. also shoes, glassess, passport, etc. I think it's the only objective way to compare different setups. Food and water weight is a maximum that I am likely to carry at any time. On a tour you might pick up additional weight - one notable example is money in coins. Conversion factors: 1 lb = 453.6 g, 1 oz = 28.35 g, 1 g = 0.03527 oz, 1 g = 0.0022046 lb.

            I T E M                                        W E I G H T [grams]
                                      Kyrgyzstan  Tibet  S.America  India   Alps  Middle Canada
                                                                                   East
FRONT
Handlebar bag.                           510       450     510       -       -       -      -
2 small bungee cords.                     -         -       30       -       -       -      -
Underseat bag used as handlebar bag.      -         -       -        90      90     90     90
SLR film camera with battery.            885       885     950       -       -       -      -
Digital camera with battery.              -         -       -       325     325    325    325
'Monocular' - the right part of small     80        -       -        -       -       -     80
binoculars with dioptry adjusting ring
used for focusing.
Potocopies of maps, town maps,            10        10      10        5       2      2      2
and distance table (2 A4 sheets).
Parts of maps.                            30        10      -        -       -       2      -
Gloves.                                  100       110      50      190      64     56     56
Woolen cap.                               55        55      -        -       -      34      -
Neckerchief.                              20        15      -        15      -       -      -
Rain pants.                              140       140     140      140      -     135    135
Overshoes.                                -         -       70       70      10     78     78
Tooth brush + paste.                      20        20      20       10       6      6     12
Soap.                                     25        25      25       -       -       -      -
Skin cream.                               20        20      20       20       6     10     10
Sun screen.                               20        20      -        10      -       -      -
Razor.                                    10        10      10        5       2      6      6
Dish washing cloth used as a towel.       10        10      10       10      -      10     10
Lighter.                                  15        15      15       15      -       -      -
Pen water filter.                         30        20      -        20      -       -     20
Plastic bags.                             20        20      20       10      10      6      6
                                        2000      1835    1880      935     515    760    830
REAR
Backpack.                                830        -       -        -       -       -      -
Waterproof bag.                           -        445      -        -       -       -      -
Stuff sack.                               -         -      160      160      28     78    160
Tent.                                   1350      1350    1880      905      -       -    888
Bivy bag.                                 -         -       -        -       -     262      -
Sleeping bag + plastic bag.              840      1190    1090     1090      -       -    592
Silk sleeping sheet.                     210        -       -        -       -     174      -
Bungee cords (1 or 2).                   160        80      80      100      70      -     70
Nylon straps.                             -         20      20       20       4     30      -
Foam sleeping pad.                       155       155      -        -       -       -      -
Strip of bubble wrap.                     -         -      120      120      -       -     72
Underwear (1 or 2).                       60        30      30       30      30     30     30
Socks (1 or 2).                           80       100      30       40      -      40     76
Polar fleece jacket.                      -        400      -       245      -     250      -
Light fleece jacket.                     185        -      185       -      202      -    185
Cotton pullover.                         330        -       -        -       -       -      -
T-shirt.                                 120        -       -        -       -       -      -
Long trousers.                           320       300     300      300     312    295    295
Tyvec protective suit.                     -         -       -        -       -      -    172
Nylon stockings as leg/arm warmers.       -         15      15       15      10      -     10
Spare glasses in soft case.               50        50      35       35      35     40     40
Medical kit. Sewing kit.                 120       120      85       70       8     20     26
Spare camera battery & charger.           30        -       -       170      -       -     86
Spare camera films (6 to 8 rolls).       175       160     125       -       -       -      -
Spare cycling computer.                   -         -       -        60      -       -      -
Spare tubes (2 or 1)                     200       200     200      200      94    100    100
Mini flash light.                         25        25      25       25      42     18     18
Fishing line.                             -          -      30       -       -       -      -
Mosquito net.                             -          -       -       -       -       -     14
Cell phone.                               -          -       -       -       -       -     70
Plastic bags.                             90        90      90       50      30      6     40
                                        5330      4730    4500     3635     865   1343   2944
MIDDLE
Underseat bag.                           110       150      -        -       -       -      -
Spare tyre                               200       250      -        -       -       -      -
Cable lock.                              170       170     170      170      46     48     48
Spare spokes + nipples.                   40        40      20       20      -       -      -
Duct tape.                                30        30      30       30      -      16     18
Tools: Mini tool kit, screwdriver,       390       370     345      400     170    206    236
knife, Tranz-X, pump, patch kit,
pedal+small wrench or adjustable wrench,
spoke tool, tyre levers, hypercracker,
bolts, oil.
                                         940      1010     565      620     216    270    302
MYSELF
Hat/cap/helmet.                           90        90      90       90      40     28     30
Glasses.                                  40        40      40       40      40     40     40
Cycling jersey.                          175       175     175      160     170      -    230
Long sleeved jersey.                      -        275      -        -       -     204      -
Cycling gloves                             -         -       -       45      34     34     28
Arm warmers.                               -         -       -        -       -      -     62
Rain/wind jacket.                        220       225     500      500     112    112    114
Windstopper.                              -         -       -        -       -     160    160
Cycling shorts.                          185       185     185      135     152    152    152
Passport, air tickets.                   110       110      90      100      10     48     60
Notebook, calendar and a pencil.          60        50      50       50      12     20     28
Socks.                                    30        30      30       30      46     20     20
Ankle/knee straps.                        10        10      -        -        4      4      4
Shoes.                                    -        925      -       660     734    688    616
Sandals.                                 635        -      635       -       -       -      -
                                        1555     2115    1785      1810    1354   1510   1544
FOOD & WATER
Water in one or two plastic bottles.    2590      2590    2590     1545     925   1045   1045
Food.                                    200       700     500      300     100      -      -
                                        2790     3290    3100      1845    1025   1045   1045
BICYCLE
Bike, rear rack, two bottle cages,     12000     12800   10400       -       -       -      -
kick-stand, computer, altimeter.
Bicycle alone.                            -         -       -      9600   1090    9600   9600
1/2 bottle cages with bolts.              -         -       -       140     120    135     72
Rear rack with bolts.                     -         -       -       520      -       -    454
Computer.                                 -         -       -        25      25     30     36
Altimeter.                                -         -       -        30      -      30      -
Kick-stand.                               -         -       -       220      -       -      -
Mirror.                                   -         -       -         -      -       -     35
                                       12000     12800   10400    10535   11045   9795  10197
---------------------------------------------------------------------------------------------

TOTAL: GEAR                             9825      9690    8740     6970    2950   3883   5792
TOTAL: GEAR+WATER+FOOD                 12615     12980   11830     8815    3945   4928   6837
TOTAL: GEAR+BIKE                       21825     22490   19140    17505   13995  13678  15989
ALL:   GEAR+WATER+FOOD+BIKE            24615     25780   22230    19350   15020  14723  17034

List by category

The following is a list of items sorted by category. It is based on a 21-day cycling trip in Indian Himalaya and is typical for my "fully loaded" tour.

ITEM                                          WEIGHT   POSITION     Frequency
                                              [grams]               of use [1-5]

BICYCLE
Bicycle alone.                                 9600    bike            -
2 bottle cages with bolts.                      140    bike            -
Rear rack with bolts.                           520    bike            -
Computer with holder, magnet and reciever.       35    bike            -
Altimeter.                                       30    jersey pocket   4
Kick-stand.                                     220    bike            -
Lock.                                           160    bike            2
                                              10705

CARRIERS
Underseat bag used as handlebar bag.             90    bike            -
Main stuff sack (30 L).                         160    rear rack       -
Stuff sack for tools.                            20    tent            -
Stuff sack for medical kit, spare glasses, etc.  20    stuff sack      -
Bungee cord for the main stuff sack.             70    rear rack       -
Spare nylon belt.                                20    stuff sack      3
Spare velcro straps.                             10    stuff sack      1
Plastic bags.                                   100    stuff sack      2
                                                490

TOOLS & SPARES
Flat screwdriver                                 30    tool sack       2
Mini tool kit with spoke key, allen keys         25    tool sack       2
and philips screwdriver
Knife                                            25    tool sack       2
Pump                                            100    tool sack       1
Patch kit                                        20    tool sack       1
15 mm pedal wrench (cut in half)                 40    tool sack       1
8 mm & 10 mm wrench                              20    tool sack       1
2 tyre levers                                    10    tool sack       1
Bolts and nuts                                   20    tool sack       1
Oil                                              10    bike            2
Duct tape                                        10    tool sack       2
3 spare spokes                                   10    rear rack       1
2 spare tubes                                   200    stuff sack      1
Spare tyre                                      300    rear rack       1
                                                820

CAMPING
Tent.                                           905    rear rack       1
Sleeping bag.                                  1090    stuff sack      1
Strip of bubble wrap (sleeping pad).            120    stuff sack      1
Mini flash light.                                25    stuff sack      1
                                               2140

FOOD AND WATER
Water in 1.5 l plastic bottle.                 1545    bike            -
Emergency food.                                 300    stuff sack      2
                                               1845

CLOTHES
Hat.                                             90    myself          5
Glasses.                                         40    myself          5
Cycling jersey.                                 160    myself          5
Cycling shorts.                                 135    myself          5
Cycling gloves                                   45    myself          4
Socks.                                           30    myself          5
Shoes.                                          660    myself          5
Rain/wind jacket.                               500    rear rack       4
Neckerchief.                                     15    stuff sack      2
Polar fleece jacket.                            245    stuff sack      2
Long trousers.                                  300    stuff sack      1
Rain pants.                                     140    rain jacket     2
Underwear.                                       30    stuff sack      1
Plastic kitchen gloves.                          50    rain jacket     2
Light fleece gloves.                             50    rain jacket     3
Overshoes.                                       70    handlebar bag   2
Spare socks.                                     40    stuff sack      1
Nylon stockings as leg/arm warmers.              15    jersey pocket   3
                                               2615

PHOTOGRAPHY
Digital camera with battery.                    325    handlebar bag   5
Spare camera battery & charger.                 170    stuff sack      1
Bubble-wrap protection                           10    handlebar bag   5
                                                505

PAPERWORK
Passport, air tickets.                          110    myself          -
Notebook, calendar and a pencil.                 50    jersey pocket   5
Potocopies of town maps and distance table.      10    jersey pocket   5
                                                170

MISCELANEOUS
Tooth brush + paste.                             10    stuff sack      1
Skin cream.                                      20    handlebar bag   4
Sun screen.                                      10    handlebar bag   2
Razor.                                            5    stuff sack      1
Dish washing cloth used as a towel.              10    handlebar bag   2
Lighter.                                         15    stuff sack      1
Pen water filter.                                20    stuff sack      2
Spare glasses in soft case.                      35    stuff sack      1
Medical kit & sewing kit.                        70    stuff sack      2
                                                195
--------------------------------------------------------------------------------------
TOTAL                                         19485
TOTAL without bicycle, water and food          7035
Light setup in India, 2006
My tool and patch kit - 300 grams, 2007

Light Evolution

Below you will find history of light evolution: what I changed during the course of last 7 years of cycle touring, mostly in persuing the reduction of load and volume. This might be more insightful then reading the above tips. It may save you some money too: learn from my mistakes and don't repeat my evolution by bying several bikes, sleeping bags, tents, etc.

2002  Mongolia, 2002 This was the setup in the summer of 2002 in Mongolia and China. Steel road bike with big 630 wheels, front and rear racks, two front panniers, two bottle cages with 0,75 l cycling bottles, 2 kg tent bungeed atop the front rack, 40 l backpack and 5 mm foam sleeping pad on the rear rack and big handlebar bag (which is not on the photo). I wasn't weighing my stuff yet at that time, but the setup was already light in comparison with most of the cyclists.
2002/3  Mexico, 2003 In the winter 2002/3 I rode in Mexico. I had lighter road bike, this time with the usual 622 wheels. I got rid of the front panniers, but still kept the front rack to bungee the (same) tent on it. The setup at the rear is unchanged. The handlebar bag is still the same.
2003/4  Cambodia, 2003 In the winter 2003/4 I rode from Phnom Penh to Kuala Lumpur. I bought a new lighter steel road bike for this occasion. I wasn't camping on this tour, so I had no tent and sleeping bag. I removed the front rack. The setup at the rear and the handlebar bag are unchanged. I still wasn't weighing my stuff.
2004  Kyrgyzstan, 2004 Summer 2004: 1 month in Kyrgyzstan & China. The bike is the same as the trip before. The setup is also the same with the exception that I had a tent and sleeping bag (in the backpack on the rear rack). I also included an underseat bag (yellow one) for carrying tools. This trip marks the beginning of light weight awareness (and maybe folly?). I started weighing everything, trying to find better (=lighter) solutions. At the end I managed to get the weight of all my stuff down to 9.8 kg, or 21.8 kg including the bike. At that time cycling community considered this as extremely light.
I cut the waist belt of the backpack and removed several straps, leaving only shoulder straps so that I can use the backpack for hiking. It lightend the backpack for about 300 g.
The plastic cycling water bottles (0,5 and 0,7 l) were replaced by ordinary 1 litre PVC bottles. You save 40 grams per bottle.
I bought new 1-person single walled tent weighing 1365 grams. That was 500 grams less then the old tent.
I stopped taking tourist guides on tours. At least 300 g saved.
I cut the map and took only the part where I planned on cycling. Big saving in volume and about 50 grams in weight.
I bought smaller and lighter SLR film camera with 28-300 mm lens. 80 grams less, or 600 grams less if I count also the old telephoto lens, which I normally took.
I started using dish washing cloth instead of towel. About 50 g saved - and huge amount of space.
I bought very light foam sleeping pad. It was as big as old one, but weighed 155 g which was 150 g less than the old one.
I bought a small, 25 g flashlight. That's about 80 grams less than the old one.
I used sandals instead of shoes - about 150 g saved.
I had a pen water filter - the first time (30 g with the container).
2005  The bike for the Tibet tour, 2005 Tour in China (Xinjiang, Tibet) in summer 2005. I made several changes. This was very demanding tour because of altitute, low temperatures and rough terrain, but I still managed to cut down the stuff by 130 g (to 9.7 kg) - mostly because I used a waterproof bag instead of the backpack. Overall weight including the bike was bigger: 22.5 kg, because of heavier bike.
Replacement of the backpack with a waterproof bag. The bag was 445 grams, which was almost 400 grams less than the backpack.
New down sleeping bag. At 1190 g it was heavier then the old one by 210 g, but was rated at -5 C (old one at +5 C). It packed a little smaller.
No silk sleeping liner: 210 g less. It was not necessary with the warmer sleeping bag.
I used only one bungee cord instead of two: 80 g less.
Only one underwear - 30 g less.
Smaller mulitool: 50 grams less.
I had no maps - not even cut-outs, just a paper with riding directions.
I gave up on "monocular" - a part of small binoculars for birdwatching. 80 g less.
I left the container for pen water filter: 10 g less (+volume).
I had about 50 grams more of warm clothes and 300 g heavier shoes.
I lost the bike and practically all the stuff in Tibet, so I could start building up my gear from the scratch.
2005/6  Argentina, 2006 There were some radical changes for a winter tour 2005/2006 in South America. The overall stuff weight was cut down by 950 grams, counting the bike even by 3350 g from the previous trip to China and 2685 grams less from the lightest setup so far (in 2004). Stuff weight 8.7 kg, with the bike 19.1 kg.
I bought new, 2 kg lighter bike.
Stuff bag (160 g) instead of waterproof bag (445 g) - saved 285 g.
Bubble wrap as sleeping pad and waterproofing material for the stuff bag. Not much saved in weight (30 g), but an enormous change in volume and the whole lightweight philosophy.
Lighter gloves: I had only plastic kitchen gloves. 60 g less. This was not a good idea - I suffered from ulnar nerve inflamation.
No woolen cap and neckechief.
No pen water filter.
Only one pair of spare socks, 30 g less.
Much lighter top clothes than in China - it was summer in S. America. Around 220 g less.
I also had some stuff which was heavier: camera (80 g), overshoes (70 g, new addition), tent (530 g more! - I used the old tent from before 2004).
2006  India, 2006 The trip to Indian Himalaya was the peak in the evolution and it set a standard for my ultralight setup. I dropped the weight of the stuff by 1770 g, down to 6970 g (or 17.5 kg with the bike).
Compact (ultrazoom) digital camera instead of SLR film camera. The camera itself with charger and spare battery meant 390 g less.
No spare film rolls: 125 g less for 6 rolls.
Underseat bag used as a handlebar bag: 420 grams less. Since I had small camera and no spare films, I didn't need the big handlebar bag.
Lighter, single skin tent, only 950 grams. Saving of about 900 g from the previous tent and 450 g from the lightest tent I ever had.
I trimmed down the tent for additional 45 grams (removed inner pocket and straps from its bag).
No soap. I relied on the soap in hotels.
I cut the handle of the plastic disponsible razor. Not a big weight, but quite some space saving. Besides, you really need only a small handle for a razor - unlike the tooth brush.
I cut down the medical/sewing kit by 30 g.
Also the amount of plastic wrapping bags was smaller for 40 g.
I bought new light shoes: shoes for in-door football (soccer). At 660 g they were just 25 g heavier than sandals, but infinitely more comfortable and warm, both for cycling as well as walking.
I had some heavier/bulkier stuff: warm gloves (+140 g), fleece top (+70 g), tool kit (+55 - chain tool), cycling gloves (+45 g).
With all these savings I could indulge in a bit of luxury: I mounted a kick-stand (200 g) for the bike.
2007  Australia, 2007 The trip to Australia was done with similar setup. I dropped the weight of stuff down to around 6200 g, mostly because I expected much warmer weather then in Indian Himalaya.
I used very ligh rain jacket (140 g) instead of my standard 500 g jacket.
Fleece top replaced with lighter one, saving 90 g.
I removed kick-stand. It does provide some luxury by not having to lay down and lift up the bike, however it doesn't provide a stable support (a few times the bike toppled down), so I will not use it again. 200 g less.
I cut the pedal spanner in two - 50 g saved. You don't need a big handle for the pedal spanner: just find a stone and hit the short handle a few times to unscrew the pedals.
I cut 8 cm of seat post, saved about 50 g.
Ligther lock: I bought a tiny combination lock which weighs only 48 grams. 130 g saved. The philosophy is that any lock could be broken by a dedicated thief, so take the lock that just ensures your bike can't be ridden away by occasional passer-by.
No camera battery charger. I estimated that one spare battery will be enough for 1 month trip - and I was right.
Only one spare tube. I relied on availability of those in Australia.
No tooth paste. I brushed the teeth just with water.
Instead of a knife I used razor blades. Quite a volume saving and about 40 g less.
Less pages in a notebook - minus 10 g.
Shorter and lighter wicking cycling socks: 30 g less.
I did use a helmet this time (280 g more).
2008  Tadjikistan, 2008 The trip to Central Asia (Tadjikistan, Kyrgyzistan, China, Pakistan, India) was done with practically the same setup as from 2006. There were little changes, resulting in about 300-400 g less: stuff 6.7 kg, with the bike 17.1 kg.
I bought new down sleeping bag - smaller and almost 100 g lighter, with the same rating (-1 C comfort) as the old one.
I cut off the inner mesh lining form my rain jacket. The weight dropped from 500 g to 370 g. I am still undecided whether this was a good idea or not.
New strip of bubble wrap. The new one was 60 g lighter. I don't know if this comes from different construction or from the dust that collected on the old one.
A hat replaced with a cycling cap: 30 g instead of 90 g. The cap is also an excellent tool for killing flies and mosquitos (a hat would be too heavy for that).
Lighter rain pants - 30 g less, but worse quality. I will go back to heavier ones.
Heavier stuff: there was a spare tyre (300 g) this time.
2009  Jordan, 2009 In the January 2009 I was in the Middle East. This was a rather radical experiment regarding the ultraligh cycle touring. I tested how it would be to tour with just the bivy bag, carrying all the stuff on the bike, without the racks or backpacks. With 3.9 kg of stuff and 13.7 kg including the bike, it meant about 3.7 kg less from my usual "fully loaded" setup as in 2008.
Tent, the sleeping bag and bubble wrap were replaced with a bivy bag and a silk liner. I saved 1.5 kg there. The bivy was carried in the bottle cage holder.
I kept most of my stuff in the compression bag behind the seat. I saved 100 g because of lighter bag and another 40 g by using nylon straps instead of bungee cords.
There was no need for a rear rack. 570 g saved.
The rain jacket was replaced with two items: a windstopper and a light rain shell, both of them together were almost 100 g lighter then the old jacket.
There were a lot of small things that I left out: water filter, sun screen, neckerchief, lighter, battery charger, one spare tube, spare spokes, chain tool, hypercracker, one water bottle. All of this meant about 500 g less.
2009  Canada, 2009 In the summer of 2009 I rode from Vancouver to New York City. It was a full-kit camping tour with the least weight so far; I managed to cut down my touring weight by almost a kilo. I had 5.8 kg of stuff and 16.0 kg including the bike.
Smaller and lighter rear rack. It's 450 g or 120 g less then the old one. Besides that it attaches to the brake bridge screw and enables me to adjust the brakes without the need to remove the rack.
Lighter road tyres 25x622. Almost 300 g lighter then the 32x622 Schwalbe Marathons. Only one tube - 100 g less. No spare spokes. No spare tyre.
I bought the lightest pump there is: 25 g, means almost 50 g less. It's also a bit smaller.
Only one bottle cage and one water bottle: 110 g saved.
I bought a new summer down sleeping bag. With 600 g for a bag with light compressioin bag it was 350 g lighter than my 3-season sleeping bag.
I had new lighgter shoes, 60 g less.
A few things left out: beanie, battery charger, card reader, altimeter, hypercracker. Smaller first-aid kit. In all about 150 g less.
The clothes were different from the last year's tour, but the overall weigth was practicaly the same. Rain gear and cycling shorts were lighter, but the merino cycling jersey and arm warmers were heavier.
I did have some new additions. Rear view mirror. I took a 170 g tyvec protective suit (meant as rain gear). Cell phone (70 g) and "monocular" for watching birds (80 g) didn't work at all and were never used. I threw monocular away on the 3rd day.
NEW 2010   I am planning a new tour in august/september of 2010. It would be a mini "Africa's coast-to-coast", through Namibia, Botswana and South Africa. To start with, I am taking stuff from the 2009 trip in Canada and then reducing it for about a kilo: 4.8 kg of stuff and 15.1 kg including the bike.
After having illusions for 20 years about me becoming the National Geographic's featured photographer I finaly realized that it is not going to happen. So I bought a very popular "travelling ultrazoom compact" and I am quite happy with it. It weighs 220 g and saves me 150 g, counting in the charger as well.
I am thinking of using "crocs" as my only footware. They are incredibly light (320 grams a pair), comfortable, have excellent pedal grip, can be used for fording rivers or as bathroom slippers, and they dry in a second. Complemented with some kind of waterproof/windproof socks, they may be the ultimate cycle-touring footware. Saving 340 grams!!!
The things left out: rain shell, rain pants, fleece gloves, overshoes, tyvec suit, "monocular", mosquito net, spare socks. I don't expect much rain this time, so my windbreaker jacket (160 g) will have to suffice. Will mean 660 g less.
Lighter synthetic jersey: 70 g less. Merino jeseys are excellent, they are warmer and quicker drying then synthetics, but heavier. This time I really wanted to cut the weight to minimum, so I decided against the comfort of merino jersey.
Additions: second bottle cage and water bottle, heavier front tyre, beanie: 240 g more.


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