Just come back from a test run in Iceland (3 weeks mostly on the tracks) on my 650r. I used Ortlieb panniers and a rack pack which is about 95 litres in all of luggage capacity. The pannier front strap fitted neatly under the back of the seat and I made some tie down loops from nylon webbing to allow the bag to be attatched. The luggage never moved and was secure off road. I reckon I used about 75l of the 95 available and weighed the luggage at 25 kilos. The luggage included all I needed to camp and cook. I did not modify the subframe in any way and it has performed without probs. The tracks were rough and rocky and the bike got a good work out. I was thinking of getting a steel subframe made but at about 300 quid I am now thinking that the alloy one may be up to the job if I keep the luggage light and the heavy items low. The tools will be moved to the bashplate so I reckon 20-22kgs should see me right. The plastic panels are now looking a little rough due to the abrasion of the dirt in between the bags and the plastic but to be honest as long as the system works I couldnt care less about the cosmetics. In my opinion having a rack on the back would only place the weight further back on the subframe and increase the chance of breaking something. My bag sat on the back seat and on the plastic mudgaurd just in front of the rear light. Am off to Mongolia via Iran and the stans next year and think that I will carry a couple extra long bolts that secore the top of the subframe and hope it all works out. If you need to carry more than lightweight luggage on the XR I think you negate any off road advantage the bike will offer and you would be better off on a heavier bike that has a sturdier subframe.
Cheers
Oz
nearly forgot to mention that I fitted a 15 tooth front sprocket that made cruising at 70mph about bearable and also worked for slow speed technical riding that is needed in the lava fields.

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