Packing
Travel as light as possible, anything more than the bike is added weight that you're going to have to deal with. If you set yourself a goal weight that you're 'just not going over', what happens when you do? Which piece of 'vital' equipment are you going to ditch? Take as little as possible, but make sure that you can still enjoy a standard of living that you feel is acceptable. If you're always complaining about 'having to make do', it will reduce your enjoyment of the journey.
Allow as little as possible for packing space. It's a guaranteed fact that the more packing capacity you have, i.e.: tank bag, tank side pouches, panniers, top box, roll bag, etc., then the more 'stuff' you'll ending up packing because of the 'just in case' philosophy. If you have more than a tank bag, two panniers and a roll bag then reconsider. Every time you pack and unpack consider your reorganise your stuff so the most used items are easy to reach.
Use webbing straps cut to length for securing items on your bike. If you use 'bungee cords' (elasticated cord with hooks on the end) you might have to replace them every few months due to wear and tear. Webbing straps with buckles are much more hard wearing and allow to tie down kit much more firmly, vital if you're off-road or riding corrugations at speed, this is when you don't want anything to move or shift its weight
It's best to decant liquids into smaller screw top plastic containers which are more robust and easier to pack. Whether its shampoo or olive oil for cooking, the containers you buy them in are often to large to pack easily and are designed to look nice on the shelf of your local supermarket, not stand up to hour upon hour of bone shaking sandy corrugations of that desert piste you're hurtling down.
If you need to carry a number of medicinal drugs and generally cut up the plastic and foil strips they're supplied in then decant most into small plastic containers. Make sure you leave some still in the original packaging, should a border guard or official want to inspect. If he or she can't identify what you're carrying they're just as likely to confiscate the lot.
Space will always be at a premium, so use compression sacks to compress as much as you can, tent, sleeping bags, cloths, etc. Also apart from your riding gear, carry one pair of canvas type trousers (the kind that zip off at the knee to make shorts), two t-shirts, a few pairs of 'undies' and a fleece. To minimise the amount of space your clothes take up and to make for easier packing use 'compression sacks' which remove all the air from your packing and leave you with a solid block of clothing, which you can then slide into a pannier
Riding Gear
There is no 'best' gear, only what works for you. For long term over-landing, flip-face helmets are a good idea and is what works for us. A good flip-face helmet saves a lot of hassle at borders, checkpoints and routine stops. Before buying a new flip-face make sure that when the visor isn't in place, that you can still fit a pair of MX goggles.
Make sure you have a system for your keys. There should be just two places for the keys go. If you fit the bike keys with a mini karabiner, then you can clip them onto a cord around your neck as soon as you take them off the ignition.
Try using a kidney belt and a back protector. The belt also reminds you to keep you posture when tired.
If you travelling in a hot climate a jacket with loads of zipped vents will keep you cool. For colder climates a removable Gore-Tex liner will keep you 100% dry, even in the heaviest of downpours. If you invest in a jacket with a water pouch built into the back, then you can keep hydrated whilst on the move.
Don't ride in jeans or 'normal cloths', keep the few cloths you do carry for when we're off the bike, otherwise you'd simply look like 'shit' (scruffy) all the time.
Invest in a good quality MX boots. They might be hot and uncomfortable, but when they're protecting you feet and ankles from that 300+KG bike that's on top of you, you're glad you had them on. Once you break them in they should be pretty comfy.
Packing & Riding Gear
TIP: Get into a routine and stick with it. If you're travelling with one or more then try to organise who does what, it makes for less hassle and speeds up the process of loading or unloading so you can get on and enjoy your location.
TIP: You can pick up heavy duty webbing straps free from your 'friendly' bike dealer. They get them with each new bike they take delivery of as the strapping is used when the new bikes are crated and shipped to your dealer. Most have them lying around and will happily give them away if you ask nicely
TIP: The small cylindrical plastic, water and dust proof containers that your camera film comes in make a great and easy way for you to carry small cooking ingredients, i.e., crushed garlic, peppercorns, chili powder, spices, salt, etc. If you've gone digital ask your local photo lab for some 'empties'.
TIP: If you're travelling to or through a country that has a tough drug policy, get a Doctors letter describing what you're carrying and what it's for. Legitimising your everyday tablets can save you a world of hassle.
TIP: If you're away for more that a couple of weeks, consider using a silk sleeping bag liner. It's a whole lot easier to wash and dry a silk liner than your sleeping bag and adds a touch of luxury to your daily regime. They also pack down very small so take little extra space to carry.
TIP: Clean the hinges every 2-3 weeks of dust, sand and debris.
