On my DRZ I had soft bags and a big roll bag. A fair bit of weight but I was crossing Africa for 7 months. I don't know the exact weight but I had lots of tools and spares. I did the 3x3 power on my DRZ and had a sports exhaust and up-jetted for power. I still struggled to cruise at 65mph. I tried all sorts of gearing but the bike wasn't powerful enough for lower ratios 'with luggage'.. Kills were a pain. I was travelling with a guy on an old battered F650GS and he left me behind with ease.

The DRZ is a fine bike. It's simple, reliable, lightweight and has decent components. I would happily do another trip on one but only if it was an off-road based trip. I would pack MUCH lighter and stay away from highways.

The XRL is in the same category as the DRZ but with a bigger engine. They are just as reliable but obviously more powerful and a little more thirsty with it.

The XRL is also a very TALL bike. I'd say a little more vibey than the DRZ too. It's got a much weaker rear subframe but it's very simple to strengthen.

The XRL is hugely popular in the USA. There are sooooo many parts available. It's been going in it's current for for over 20 years. You can also get a Corbin seat for it too which it DEFINITELY needs. As does the DRZ.

If you're based in the UK or Europe then outfitted a DRZ is much easier. However, the XRL has a strong following. You can get almost everything you need for an XRL from Gab at Zen Overland. He did a RTW on his XR650L and swears it's the best bike for the job.

Tell me about your trip... Where are you going and what terrain are you covering ??

__________________
Did some trips.
Rode some bikes.
Fix them for a living.
Can't say anymore.

I ride a KTM 625Sxc now and have been strongly considering using that. RTWPaul is currently doing just that and I am following his travels with a very close eye. I am worried about spare parts with the SXC mostly.

I am slowly working out the where now. I want to stay off major highways of course and really want to get off the beaten path, but still retain the capability to see the popular sites. As for the terrain, whatever is in front of me. I do not want to be limited to what the bike can handle.

The first part will be Central/South America. I am starting with Baja California and finishing with Argentina. It's a toss up on if I will ride home or have the bike shipped back. If things work out, maybe head back north and catch Brazil and tour some of the Amazon before shipping the bike back from there.

Second part will be New Zealand/Australia.
Third part will be Southeast Asia and India.
Fourth Part will be Russia, Mongolia and a couple of the 'stans, still working on that one.
Fifth Part will be Africa south to north

Your KTM could work! ... and if you put in the amount of work modding your bike that RTW Paul has, then it may be reliable. .. or not. (I'm following Paul's report too ...followed him for a year when he was in South and Central America on his Tenere')

If you really learn your KTM, dissect it's many faults & foibles and work your way round them all ... then you've got a bike that is good! If you don't mind the Vibes on your KTM ... then all good. (owned two KTM 640's) If you're mechanically astute and have parts and tools ... then all good. Not a bike for amateurs.

I believe the KTM will require just about as much prep/mods as either
XR-L or DRZ400S. Parts? Just because a town in Honduras or Peru' has a Suzuki and Honda dealer DOES NOT mean that dealer will have parts on hand for your bike. They just won't! You will have to wait.

Same with KTM. Set up a deal with a good KTM dealer in USA ... one email and parts on their way to you. In the end, probably about the same or shorter wait as ordering from a local Honda or Suzuki dealer.

Can we assume you are US/Canadian citizen and starting in USA?

I'm not an XR-L fan. Bought one NEW in 1993. Sold it off in less than a year. The motor runs HOT. Sub frame bends/breaks. Battery box breaks off. All can be helped with good mods and aftermarket parts.

Like your KTM, the Honda is very tall ... but suspension needs help to be it's best, the rear shock is a POS. Ted says the XR-L is very popular in USA. I'd say "it used to be popular!" but not much now. I rarely see one anymore. Lots of Orange bikes here in California. Honda are OUT.

The DRZ has the off road advantage over the XR-L with a few key mods. If you can get a better seat and fit your luggage, it's not bad. I owned a DRZ400E ... only rode Baja on it with a small backpack. Never toured. But many DO tour on the DRZ-S. See Adam's Jedi reports on ADV Rider.

You say the XR-L and DRZ are "very similar bikes". Not at all similar. The XR-L is old school air cooled, radial valve head, NO oil cooler, CV carb. The DRZ is liquid cooled, much more modern chassis, stronger everywhere, better design overall. (stock vs. stock)

Both can be modified to be super good for travel, both will make it. Your idea of going light is very smart. 40 lbs. is perfect! I carry about 60 lbs. on my
DR650 and trying to cut that down some. (not so easy)

Best of luck. I'd take a few short-ish shake down rides locally to figure out what bike is best for you.

Molly, that is a killer point. I haven't really considered thinking along those lines.

Also, if you follow what RTW Paul and other KTM 640 experts do ... you'll find the main bugaboos on that bike, carry the needed spare parts with you. Pretty sure this is what Paul is doing.

There are a few common failures on the 640's (which are commonly known among users) and most of the parts can be easily stowed on your bike for travel: Water pump kit, Valve gear bearings and a few other things I can't recall.

Most long time 640 riders KNOW when problems are coming and replace key parts as preventative maintenance, so no slow down when on the road.

Also, now-a-days ... there are several KTM dealers in S. America. I believe
Colombia, Ecuador, Peru', Chile and Argentina ALL have a KTM dealer(s).
Will they have parts for a bike they no longer make? Who knows? KTM is now BIG in S. America because of the Dakar race. Now a household brand.

Good luck with your planning! (talk to RTW Paul about Cent. America ... he's a border crossing God!)

Yeah, Paul is the man. I got his border crossing book. I chose SA/CA as my first leg because it should be the easiest for me to do. I will be following him like a hawk to see how he does on the BAM. I am well versed in bike maintenance, so working on the SXC doesn't bother me, it's just the fear that I will be miles from anywhere when it decides to act up.

Sounds good! I'm thinking once you're out on the road for a while you'll tune in to your KTM, learn it's sounds and ways. Hopefully any changes would be noticed in time, do a repair, replace worn parts. The longer you go the better you'll be able to diagnose and analyze issues ... hopefully catching things before any serious problems arise.

Here is a magazine that have tested and compared both the Tenere and the Sertao....Bikes: BMW 650 Sertao VS Yamaha 660 Ténéré - Transmoto

__________________
In the end everything will be fine. If its not fine its not the end....

I am 5' 8'' and 120 lbs. I am also 74 and fit. The bike I'm looking for is the crf230l for the reasons stated.
I've rode scramblers mx and I now ride a Honda cbr500 and have since it's inception.
I live in the Kooteny Bc where the riding is unparalleled both on and off road. I lived and worked in the Baja and know what it's like to pick up a bike more than I would like.
I am heading to SA next fall knowing that the little Honda will get me anywhere.
What kind of hurry can I be in when my whole object is to live with other folks without fear of theft or strife.
I just happen to like the little roads

Ted i would get 88mph out of my total standard DRZ400S on motorways which was max speed, not comfy but i screwed it like that for hours sometimes, not sure why you struggled to get 65mph and you had mods

Several guys in my group have (or had) DRZ400S, all would pull past 80, more like 85 mph ... at which point I'd slip by (barely) on my DR650 ... which could struggle up to about 95 mph. Maybe Ted had super low gearing? :confused1:

Although must say ... even my old "E" model DRZ would top out at 80 mph.
It was not pleasant at that speed however. The S is better on highway for sure.
Stock for stock I'd agree. I've ridden with buddies riding DRZ's ... going for days at 80 mph, then off road. Never seen a problem with one. KTM? Not so much.

But still, a good mechanic who really knows the KTM and keeps up on the shorter maintenance intervals ... can have a pretty reliable bike.

KTM is the better bike for sure but does need alot more maintenance and second hand parts like of ebay are not so available so you will be paying out your ass

Basic if my DRZ was to sh@t itself anywhere in the world with in a 10 minute search on ebay i could have the part brought sent to my family home and then fedex out in days.

KTM????

and as Ted said regarding the XRL

"I prefer the xr650l .. However, parts have to be imported from the USA if you're in Europe"

Availability to source parts fast was another reason on choosing the right bike

I'd say "better performance bike off road", but "better" can have a variety of interpretations ... as a traveler's bike, reliability and easy maintenance has to trump pure performance, no? (does for me anyway!) Also things like comfort, vibes, packing ability et al ... all must be factored in, yea?

But preaching to the choir here ... And cheap is important too ... and KTM parts can be expensive. True, lots DRZ & XR-L used parts cheap online. KTM? Not as much, but stuff is out there ... if you have the time and help.

I did not know that.
I thought Honda sold the XR-L in UK/EU, no? In any case, having parts shipped from USA would probably be CHEAPER than shipping from EU ... and parts prices themselves would be a lot cheaper too sourced from USA.

The trick is having someone at the receiving end to expedite parts through local customs. Not so easy. Checking in with your local embassy can sometimes present a solution.