Originally Posted by Algarve Nick
XT660R. Wonderful choice of overland bike. I'm thinking of getting one. Any problems with yours? Nick...
I had one of the two wires into the back of the starter switch de-solder itself. That required I be towed 17km into the next town to find a man with a soldering iron. The act of being towed, I think, damaged the fork's oil seal which finally went a week or two later in Kyrgyzstan (which required an extra visa and three day side trip to Almaty).
Other than that, I swapped the stock exhaust (which rather stupidly go under the engine) for a 2-into-1 round the side like the Tenere and stuck a big old bash plate on. In fact, then entire replacement exhaust at 2.75kg was less than each original can (5.5kg)! Oh, and put some handguards on with metal in them (eg. Acerbis Rally Pro) for when you drop it
As noted above, pick up a used 5ltr plastic oil can as your fuel can. The XT660R stock tank at 15ltr is small and the engine isn't the most fuel efficient (I got 25km/ltr).
Other than that, the bike worked a treat including being hammered by some awful Indian roads and never missing a beat up to 5375m (the road went back downhill after that).