Tenere prep
 

Make an alignment bar for the rear wheel, this is basicaly a peice of tubing that slides through the rear wheel and holds the wheel cush drive and spacers in alignment and together while you offer up the rear wheel to the calliper and swinging arm. As you push the Axel into the rear wheel it will push the tube out and into the opposite side of the swinging arm. This will save you 30 minutes of cursing and struggling while attempting to refit the rear wheel.

Thanks all, this is really helpful stuff.

I am waiting for funds to clear in South Africa before I collect the bike. I think I will add a stronger bash plate for piece of mind, will order a higher level mudguard if I can get my hands on one and will sort a full service. Sounds like wheel bearings and brake pads at least should be on this list, along with a new chain and sprockets.

I have today taken the K60s off my KLR and refitted the old tyres. Having only ever changed tyres with rim locks before it was actually pretty straight forward. I will fit these K60s (they only have 30kms on them) to the XT with my travel tools only to make sure I have the right kit and will review the tool kit and supplement it as required. I have 2 front tubes, 1 rear, a patch kit and a mini compressor.

In terms of my tinkering I have a Cobrra Nemo 2 chain oiler to fit and, if I have time, a set of Oxford Adventure heated grips (both fitted to the KLR last week and now liberated).

Lastly I need to resolve my pannier options. I had a set of SW Motech Dakar panniers fitted to the KLR. I think my XT has the Yamaha pannier rails (anyone confirm from the pics?) which these panniers directly won't fit to. I am exploring options with the supplier - hopefully get a set of Dakar specific rails or swap the panniers to the Dakar freedom panniers which I think just strap to the standard rails.

Stuff...
 

Geez... You have left It pretty late :-(

* Handguards
* Crash bars
* Definitely Change or take spare brake pads - You'll use the rear heaps more off road
* Rack on the rear / side panniers
* Lots of straps (Vibration is a killer and stuff falls off)
* If you don't want to change the tyres - you'll still need some tubes at least and the tools to change them
* #8,10,12,14 sockets / spanners / Screw Drivers
* GPS
* Chain oil
* Serviceable Air Filer (DNA or K&N)

Good Luck

It might be worth checking the cush drive rubbers. If you can wiggle the sprocket around then pack the rubbers out with an old inner tube as described in Kev's cush drive mod. I can vouch for the pad to stop the injector wire shorting as I took the tank off my 2012 built Tenere to do but Yamaha had already done it!!
All the best for your trip.

With apologies for the serious delay in coming back to say thanks, I thought I'd drop by to say my XT660z was great in Africa. Bit heavy for me in the sand but a great companion overall; I definitely bonded with this bike. I have kept it in RSA - we have a reunion trip booked in December in the Western Cape.

Should it be of interest, brief highlights of my trip are here.
https://youtu.be/2fvK2CkSfGQ

Cheers
Andy