How to Fix a Tubeless Puncture with a Plugger Kit
By Bicycle Superstore | Published: 2026-10-31
Category: How-to Guides
Learn how to plug a tubeless tyre puncture on the trail using a plugger kit, when to add sealant, and how to check the repair before riding on.
Quick answer
For a puncture that sealant won't close, stop, remove the object, and push a plug into the hole with a plugger kit, then inflate and ride gently. A plug is the right tool when the hole is too large or keeps reopening; sealant alone handles smaller thorns and pinholes.
When a plug beats sealant, and when it doesn't
Tubeless sealant works by coating the inside of the tyre and clotting at small holes, usually up to a few millimetres depending on the product. A plug is a mechanical fix: you push a rubber strip into the puncture so it stays closed even if the sealant is low or the hole is too big for the sealant to close on its own.
Use a plug when the puncture is a clean slit or round hole that sealant can't seal after a minute or two of rotating the wheel, or when the hole keeps weeping. Don't plug a sidewall tear, a pinch cut longer than the plug can fill, or a hole near the bead — those need a tube or a new tyre. If you're unsure of the hole size, inspect it before inserting anything.
What to carry so the repair actually works
A plugger kit is only useful if you can also inflate the tyre afterwards. Carry a pump or CO2 inflator, and check that your plugger still has plugs in it before every ride — it's easy to use the last one and forget to restock.
If your tyre has been running low on sealant, a plug may stop the leak but leave the tyre slowly losing air. Topping up sealant at home is the longer-term fix; on the trail, the plug plus inflation gets you home.
How to plug a tubeless puncture, step by step
- Stop and find the hole: Get off the bike, spin the wheel slowly, and look for sealant bubbling or a wet spot. Mark the spot with your eye or a dab of mud so you don't lose it. Checkpoint: if the hole is in the sidewall or near the bead, stop here and fit a tube instead.
- Remove the object and clear the hole: Pull out the thorn, glass, or flint with pliers or your fingers, then push the plugger's reaming tool through the hole once or twice to rough the edges so the plug grips. Common mistake: skipping the ream — a plug pushed into a tight, smooth hole can pull straight back out.
- Load a plug into the tool: Thread one plug strip through the eye of the insertion tool so it sits centred, with roughly equal tails on each side. Checkpoint: don't bunch the plug on one side, or it will push in unevenly.
- Push the plug into the hole: Press the tool firmly into the puncture until the plug is seated, then withdraw the tool straight out, leaving the plug tails sticking out. Common mistake: twisting the tool on the way out can drag the plug back with it.
- Trim and inflate: Cut the plug tails flush with the tyre surface, then inflate to your normal pressure with a pump or CO2 inflator. Checkpoint: if the tyre won't hold pressure, the hole may be too large for one plug — add a second plug alongside the first.
- Check the repair and ride gently: Spin the wheel and look for sealant weeping around the plug. If it's dry, ride on at a moderate pace and recheck pressure after a few minutes. Next action: at home, top up sealant and inspect the plug before your next ride.
Product facts
- Blackburn Plugger Tubeless Tyre Repair Kit: The Blackburn Plugger Tubeless Tyre Repair Kit weighs 27 grams and ships with 10 tyre plugs. It's light enough to strap to your frame or ankle, and the 10 plugs give you several attempts before you need to restock.
Blackburn Plugger Tubeless Tyre Repair Kit - Muc-Off No Puncture Hassle Inner Tube Sealant 300ml: Muc-Off No Puncture Hassle Inner Tube Sealant is designed to seal holes up to 4mm in inner tubes. It's a tube sealant, not a tubeless tyre sealant, so use it to keep a spare tube working rather than as a substitute for a plug in a tubeless tyre.
Muc-Off No Puncture Hassle Inner Tube Sealant 300ml
