How We Prepared Our Motorcycle for a Round-The-World Trip

Our beloved 2010 Yamaha XT660R is no stranger to travel; back in 2011 I rode it from Slough to Iraq and back, it’s been in sandstorms, swamps, crashed, completely submerged and abused. It was well prepared for that trip, or so I thought. Since then I’ve learnt a lot about motorcycle travel and what needs to be done to a motorcycle – and what doesn’t. Here’s the complete list of changes that we made to our XT for our round-the-world trip.

yamaha xt660r


Dumb it down. The XT came in bright red and white colours with decals plastered all over it. I quickly swapped them out for plain black fairings and removed all the stickers. I like the battered and bruised look, it doesn’t attract as much attention. Riding through a poor African village on a gleaming £20,000 motorcycle will attract a bit more attention than on this old girl and doesn’t make you look as appealing to thieves.

adventure motorcycle hacks


The XT originally ran two pipes and the headers were routed underneath the bike – perfect for smashing on rocks. Swapping the unit for a Metal Mule two-into one-system shaved 10kg off the total weight and now has the pipe running alongside the bike. I’m still undecided on the system, it sounds and looks great but it’s very close to the swingarm and can hit it. The Exhaust has also snapped off (after six years) and had to get welded back on in Slovakia. I also grinded off the bolts for the carbon fibre plate and heat wrapped it to stop the bolt from melting my trousers. Check out our Metal Mule review here.

adventure motorcycle exhaust


The standard rear shock was swapped out for a Nitron unit. I didn’t think I needed a replacement rear shock for the Iraq trip. But I had the original swapped out for a British made Nitron shock due to having a pillion and extra luggage – and I wish I had done it sooner. The Nitron shock has made all the difference in handling and confidence when on the rough stuff. It originally came with a remote preload adjuster, which made flitting between preload settings smooth and easy (an unfortunate chain accident cut the cable and now it’s manually adjusted instead). Still, a fantastic bit of kit. The front forks have stayed the same, I did buy and fit a pair of gaiters from eBay for £15 to protect the seals from dust.


  • Bashplate from German company Off-the-Road
  • Crash bars from SW-Motech
  • Handguards from Bark Busters
  • Collapsible gear lever from Off-the-Road and clutch casing protector
  • An old piece of hose pipe protects the coolant pipe from stray stones
  • Foldable mirrors off a KTM (stops them snapping when crashing) from eBay

adventure motorcyle handguards barkbusters


  • Grippy footrests from SW-Motech with removable rubber. I decided I wouldn’t need the rubber and have since chucked them.
  • Renthal handlebar and SW-Motech bar risers
  • Renthal grips
  • The old seat was taken to Sussex Motorcycles and fitted with memory foam padding for both rider and pillion, it was widened and shortened too and I had new material put on all for £150. The padding has proved excellent, but the new seat cover isn’t particularly tough. It would be a better idea to opt for foam inserts and keep your own seat cover.
  • I used to have a tall screen, which was brilliant but I swapped it back for the small one because I liked the look better. In cold conditions I wish I hadn’t.

adventure motorcycle renthal bars


  • Top box and luggage plate from SW-Motech
  • Rotopax petrol and water containers (6.6 litres each)
  • Pannier rack from SW-Motech (to keep the soft bags away from the rear wheel and exhaust)
  • A holdall shelf was welded onto the rack to take our camping bag
  • Tool box is an old army ammo tin, bought for £12 from eBay and bolted to the sumpguard and padlocked
  • Pipe luggage is made out of cheap guttering and attached to the rack with cement glued screw on caps. It carries liquids and spare fuel

adventure motorcycle rotopax luggage

Handy stuff

  • The XT didn’t come with a centre stand, so I fitted an aftermarket one from SW-Motech (which as you can tell, has quickly become my go-to for XT parts)
  • When fully loaded the rear compresses and the sidestand is too long. So, it was cut down and a stronger piece of tubing was inserted inside with three holes. Two nuts were welded onto the original sidestand and one hole drilled through. Now it has three changeable height settings. A wider footplate was also welded on to stop it sinking in soft ground.
  • Tom Tom Sat-Nav and lockable RAM mount

adventure motorcycle fat food wide side stand

Nifty stuff

  • The brake pins have both got a piece of steel wire wrapped around them and the bike so they won’t get lost
  • The airbox has been greased with silicone to capture any dust and the air filter was changed for a K and N unit.
  • All electrical connections were greased up
  • Scottoiler high capacity reservoir system with dual injectors is attached behind the number plate
  • The original horn was swapped out for an extra loud one.
  • The cush drive rubbers are notorious for wearing out quickly on XTs, so square pieces of inner tube were cut up and laid across the cush rubbers to pack it out. A handy mod found on the XT660 forum

cush drive rubbers

Tools and spares

  • Tools were all placed into the army ammo box up front. Click here if you fancy making your own!
  • Spares are all kept in a Kriega bag which has been strapped onto the inside of the rear rack and rests on the gutter luggage.

diy motorcycle tool kit

If you have any questions, comments or anything to add to this page (or even if you just want to say hey) then please get in touch, we’d love to hear from you! Drop us an email at [email protected]

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