Why don't you just buy XT660Z Tenere in good shape, because swaping engine sounds little unreasonable to me.

I think you're worrying about nothing - I'd take the XT660R and not worry about the FI; if you are really worried about it fit a filter and take spare fuel pump and injectors which should be cheap enough from a scrappie. Even the pumps ain't a big deal to source in Africa, so I am led to believe by a thread on Advrider (F658GS)....
Or just buy an XT600 as others have suggested.
One thing I would not personally do is swap the engines....but you pays your money etc etc - good luck.

Engine may or may not swap easy, electrics could be another matter....

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Anything can happen in the next half hour

I vote for using an R80GS engine. Just as fun to mount in the frame, twice as many nice simple bits of rubber to swell up and cover your boots in petrol before you can just swap them out and you get to combine the two bikes with the best reputations so your head has to happy with it

Seriously, this is going to involve home made major parts. Three ideas:

1. Take the XT600E you know.
2. Learn about the FI.
3. Start learning enough Swahili/Urdu/French etc. to ask things like "Is there a fab shop that can straighten a gearbox output shaft and weld this engine mount".

Ooh, I know, how about a 1974 Triumph Twin motor? Worked for Ted Simon and you never have to change the oil if you get the right one, just keep pouring it in the top

Good Luck & Enjoy your trip whatever you choose. Personally I'd just take the XT660.

Andy

I think swapping the motors is probably a bad idea, considering what you are planning on doing with the bike afterwards. If your main concern is reliability, then I'd suggest an amatuer engine transplant is about the worst thing you could do. One slightly mis aligned engine mount, one slightly dodgy electrical connection. These things may be fine for thousands of miles, but if they fail in the wrong place then it is is going to be very inconvenient.

Also, fitting a second hand motor is a big gamble. Can you guarantee its been looked after? Wihout pulling it apart theres no way of knowing.I know they are tough as old boots, its still a big variable to chuck into the equation. If you were commuting on it thats one thing, but RTW in another matter all together.
Generally I work on the principle that if it can go wrong it probably will at some time, so take all necessary steps to prevent it. Take the 660, you've got it how you want it, learn how to fix the FI before you go, fit an inline filter, and take a spare, filter the fuel you put in it if you're worried.

Just my opinion. Whatever you decide, good luck and have a blast!!!!

Ive had 11 XT 660`s,, 5 R`s ab 6 X`s.. all in all id say they are powerful hardy engines,, the last xt a had i bought from a guy who done a RTW trip on it,, it had 8k miles when he bought it,,, an when i bought it from him..it didnt go anyt better than a new oine,, an ive had 6 new ones... oh an anearly forgot it had 47000miles on it... an ran liek a sweetie,,,well nearly , as the TPS was shot when i got it fae hime,, it still ran but ran wi all they hiccups that the FI`s in the xt range have,, but thisone was really bad. i sourced a second hand TPS,, throttle position sensor,, an the bike ran liek a sweetie........... great bikes. but too much COULD go wrong wi that fuelling an injection system.. if something went wrong miles fae nowhere, an nae coputer..yer up the swannee..as ye dont need a mechanic,, ye need a puter whiz kid. id go wi a carb version xt600..so much simplier.. am not mechy minded,, but ad have a good shot at strippin an rebuilding a carb....a wis around teh doors playin on all ma xts,, done serious miles wi them,, an wheelied them tae know end...........they are very HARDY,, but ad be in two minds about a RTW trip[ on them,, IMHP.. but thats jist MY thoughts..... once a went tae the North o Scotland on mine,, a did many times but this sime,, i did 55 all the way fur 150 miles,, then refilled. i returned 73 taerthe gallon.........lasty week a followed teh 6 days trial in an around fort willy... includin ma trip up there.. never went above 55/60..... i got 65 tae teh gallon on ma xt600.02 model,cant complain about that.........

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That's a HUGE undertaking you have set yourself (in terms of skills needed and the likely costs involved). Make sure the contraption you design is safe to ride (you are sticking your fingers up to Yamaha R&D department lol). First time I have ever heard of this being done (with a XT6E and XT660 that is).

I think you will be hard pressed finding ANYONE who will slag off either bike (XT600 or XT660). Although the newer XT660 isn't quite a RTW/Trans-Africa legend like the venerable XT600 is (alongside BMW Boxers), it's certainly proving to be a future contender for this highly sought after title.

Personally I prefer the simpler XT600E over a more modern XT660 but that's because I own two XT6's.

Not many bikes can boast the bulletproof reliablilty of XT's whatever version. It's a great pity the stop button was hit in 2003 by Yamaha manufacturing the XT600E. I'm sure the XT660 could be marketed alongside it sucessfully. It was that pointless and expensive E.U beast that proved it's undoing - the beauracrats in the European parliament decided the XT600E wasn't green enough for modern engines. Pity they didn't listen to us riders eh?

Getting back to the point of this thread - why not just buy a low milage mint low milage XT600 instead or perhaps a new(er) XT660? I can't see why you would want to mess with either bike to the extent you propose here. The changes you are proposing will cost more than buying a new bike! Add to that the fact you will be messing about with a tested and proven design.. lol

Whatever you decide I wish you well.

Bama3 - Love those XT6E pics. What lovely scenery too...

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Triumph Bonneville 800 (2004), Yamaha XT600E (1999), Honda XBR500 (1986).