Regarding the Malawi-Moz crossing the road you are thinking of taking (via Cuamba / Namwera) is apparently a right bugger. I say 'apparently' 'cause every time we asked anyone (in Nampula, the closest biggish town to the route) they just laughed at us.

It is marked as a major highway on official Moz maps but DO NOT BELIEVE THEM.

We met a couple of people later who had taken that road and they said it was hell and took three days. Apparently though it has a certain 'remoteness' to it though which is nice if you like that sort of thing.

There is also a train that take that route, so if you definately want to enter moz by that border crossing it is an option. Pretty shoddy train though and you would need to provide everything to secure your bike yourself..and keep an eye on it.

We ended up going south via Murrupula, Mocuba then up to the Mulanje border crossing. The road is tar, and varies from decent to appalling potholes. If you take this route then fuel up whenever you can, even if it's from drums (which it is likely to be) The last 200km is dirt (but ok) and there is very little chance of fuel. It is still an 'adventurous' ride/drive but probably not as arse-breaking as the Cuemba road.

On a side note, if you have the time then crossing into Tanzania, and heading down the coast to the Mtwara crossing with Moz then it is well worth it. Classic border crossing, deep bush, remote, fantastic.