>How do you prep for a decent-length trip out of the country?
I did it by reading The Adventure Motorcyclist's Handbook, Riding South, some other books, and talking to people on the KLR/Adventure-Rider sites. The following is just meant to supplement those sources. Here's some other-than obvious stuff we did & took

B4 GOING: clean out wallets, renew library bks, check H insurance coverage, authorize credit cards & cell phones to work in Mex, find best rate 4 pesos, write important dates & phone numbers, print this sheet w/ Mapquest addresses. Any friends on the way? (AdvRider & Horizon's Unlimited R invaluable). Print useful Spanish phrases. Go over what to do Worst Case Scenario.

TAKE: 2x copies of papers(insurance, registration, title & copy, copies of passports, books, rainpants/gloves/booties, spare bulbs, bungies, fannie pack, Sandles, freezer bags/gbg bags, extra batts, sewing kit, 1st aid, pack food, water bottles. 2nd set of papers/keys hidden on opposite bike. Lots of Trail Mix.

Motorcycle Camping Checklist
Created: 23-Aug-2006 Motorcycle stuff backpack Oil Rain gloves Bike cover Raingear Boots & socks Spare bulbs Bungee cords Spare fuses Cargo net Spare key(s) Earplugs Tankbag Gloves & spares Tire patch kit Helmets Toolkit Jackets Windshield cleaner Leatherman tool Lock/security stuff Personal Stuff Antihistamines Medications Brush Reading glasses Casual clothes (non-riding) Safe sex stuff Chapstick Shampoo Comb Shaving kit Contact lenses & stuff Soap Dental floss Sunglasses Deodorant Toothbrush & toothpaste Towel(s) Fanny pack or backpack Washcloth Hygiene kit Kotex/Tampons Clothing Cycling shorts Sweater(s) Hat/sunvisor Swim suit Jeans T-shirts Shirts Tennies/sandals Shorts Underwear Small backpack? Socks Information Book(s) Paper & pencil/pen CDs? Passport/ID Camera & accessories Phone List / Rosters Cellphone Registration papers Diary Spanish phrasebks Driver's License Tape/CD/MP3 player Insurance (proof of) Tickets/passes Maps Travel guide(s) Membership cards (AAA, etc.) Misc. Freezer bags (for packing) Bug repellent Ibuprophen/Tylenol Cable ties Rubber bands Cash and/or traveler's checks Sewing kit Credit card(s) Snake bite kit Duct tape Space blanket Extra batteries Sunscreen Extra bolts, tools, parts Superglue First aid kit Flashlight Camping stuff Air mattress Lantern Camp saw Matches/lighter Candles Sacks and/or bags Collapsible chair Sleeping bag Compass Sleeping pad Cord Stakes/rope Groundcloth Tent, poles, rainfly Hatchet Toilet paper Hunting knife Cooking stuff Camp stove & fuel Dishtowel Can opener Drinks Coffee making stuff Food Condiments Garbage/trash bags Cooking pots/pans Knife/fork/spoons Corkscrew Paper towels Cup(s) Water bottle(s) Dishsoap & pad Foodstuffs Coffee Sugar & creamer Salt & pepper
The tool that created this list can be found at: http://www.micapeak.com/checklists/

TOOLS: Wrenches, sockets & ratchets, extensions, spk plug socket, cresc wr, jump cables, Duct tape, zip ties, wd40, voltmeter, air press g, tire irons/spare tube/patch kits, tire inflator, mech wire, screwdr & phil#3 hds, lighters, Spare 14-tooth sprocket & tools to change, Loctite! Vice-Grips, JB Weld, Goop, fuses, bulbs. Spray all with WD40 to keep rust off.
Parts: Sp plug & socket, clutch & 1 throttle cable, misc bolts! Elec wire/bulbs/fuses, 2 qts oil(KLR's burn a LOT after 12 hrs on hwy)

Here's the list Greg Frazier put together to ride his KLR around the World:
Repair manual(s), air pump, Tire pres gauge, mixed cable ties, Misc nuts/bolts/washers for bike, safety wire, 6' electr wire, Duct tape, electr tape, JB Quick Weld, Goop household glue, Super glue, Misc hose clamps, Heat patch kit(for tubes), tire repair kit for tubleless tires, spare tubes(use 21 in back), Several extra pieces of inner tube(largest 6" diam), lightweight batt jumper cables(dumb to carry--just use the HD electr wire), master link for chain. Fuses, circuit tester, oil filter, clutch cable, any parts known to fail on this bike, many latex gloves(they also come in handy in the cold), small tube hand cleaner.

KLR-specific parts:
Carried coil, ign black box, charging syst components(Didn't need any of it)


Tools he carries:
3/8 dr socket set, 2-3 screwdrvrs, allen wr as needed, 2x extra-long irons/spoons, short-handled hammer, Vicegrips, large adj wr, set of box & open-ended wrs, hacksaw blade, misc necessary tools from orig toolkit, multi-tool, spare keys-not locked away but not easily found(We put the 2nd-set of keys & paperwork on the other guy's bike & ended up desperately needing them twice! Good call.)




Some resources:
http://www.klr650.net/forums/showthread.php?t=21813
http://www.cycoactive.com/mc/trail_tips/ctiw.html">xrdualsport.com/packlist.shtml
http://www.horizonsunlimited.com/tripplan/equipment/PackingList.php
http://www.xrdualsport.com/packlist.shtml
http://motorcycles.about.com/library/blpaklist.htm
http://www.micapeak.com/checklists/
http://www.bigcee.com/faq/tools.html

Since I wrote up this blog psting a year or so ago, some friends have pointed out that I did not go over how exactly we prepped our KLR's for such a long trip.

Sorry about that! & it WAS a year ago, so I probably won't write this up now, either. One thing we woulda definitely done differently is installing a Scottoiler or something similar, as both of our chainers were fried by the long ride down & back, tho we oiled them every night.

We tried to keep our rear trunks empty, so we could throw at least our helmets & gloves in them to walk around. A great suggestion I heard was to have grommets put into your leather boots(do it cheaply while in Mexico, por supuesta), so you can cable-lock them to the bike & wear flip-flops thru town.

SPANISH
Help! my friend is hurt. Where is the nearest hospital? Ayuda! mi amigo está lastimado. ¿Dónde está el hospital más cercano?

Can you replace or repair the alternator, front brake, rear brake, bearings, steering, bent forks, seat, lights, headlight, horn, broken frame, bent frame, non-functioning electrical system, flat tire, bent wheel, broken motor, broken transmission? Where can I buy motor oil or spare parts?

¿Puede usted substituir o reparar el alternador, freno delantero, freno posterior, cojinetes, manejo, bifurcaciones dobladas, asiento, luces, linterna, cuerno, marco roto, marco doblado, sistema eléctrico de no-funcionamiento, neumático plano, rueda doblada, motor roto, transmisión rota? ¿Dónde puedo comprar aceite del motor o piezas de repuesto?

Just writing down key words will save you a lot of time. My buddy didn't know oil was "aceite" & pantomimed pouring into his motor. For his trouble, he got a frosty cerveca, so it wasn't all bad.