Hi.
Im doing the same thing as you at the moment it seems.
Steve at XR Stuff sorted out an 22l acerbis tank (they are getting hard to come by now) for me and stocks all sorts of goodies for the XR series Hondas.
I'm a qualified mechanic and am doing the prep myself so if I can be of any help please feel free to email djorob@aol.com.
The rear subframe can do with some bracing, and if you are making your own racks incorporate this bracing into them.
A crush drive hub from a dominator would be kinder to the cluch basket and chain but you'd have to get it built up by a wheel builder. Keep the 18/21 sizes as tyres are easier to come by for 18" around the world.
You can get re-useable oil filters for this model which ,depending on how long/where you go, would save trying to locate or carrying replacements.
I will be using either Heidenau K60 or MEFO MFE99 tyres as they are about as 50/50 as they come with good wear rates (8-10k).
I have used the Heidenau on a GS1200 and they wore well and were ok off road, did 5k on them and they were about 40% worn rear and 20% front.
If you can catch Chris Scott he's a very nice guy who I'm sure will give you advice.
Grab an oil temp filler plug if you are going to a hot location as it's very handy.
If you need extra fuel capacity I'm just evaluating a 20l flexible fuel container that I'm hoping to distribute so let me know.
I'm looking into carb settings at the moment as well as jet changes for altitude so I'll let you know what I find.
Just the usual bearing changes in wheels, head ect. A grease nipple in the headstock would be a good move.
I trimmed the OE seat foam and re did it with a 1" sheet of memory foam which widened and flattened it out a bit to make long distances a bit more bearable. I know corbin do an up graded seat but I've heard from a couple of folks that they are crap.
Anyway, If I find anything juicy out about the XRL I'll let you know.
I'll be at the 08 meet so may catch up there.
Cheers.
Dave.