Hey idf000.
Looks like some pretty well thought out mods you've got planned there. I've been looking at your list and can see no obvious flaws. Your use of logic and good research makes your trip half a success right from the start. Well done!
In the garage you've propably allready found out that the bike is a no-nonsense bike. Nothing more than common tools and a little bit of common sense is required to make the mods you plan.
Large tank or jerry cans: There simply is no "correct" answer to this question. Obviously, the more remote places you plan to travel, the more should you consider getting a larger tank. But if you only ocasionally plan to drive off the beaten track, a couple of jerry cans will suffice. But as someone else pointed out, this will cost space on your rack that could otherwise be used for other equipment. Let's face it, there's not a lot of room on a motorbike. Not to mention it is just easier to fill up the tank than to juggle three seperate containers around, while being hassled and pushed about by curious local bystanders and vendors.
And then there is also the peace of mind. You will have plenty of other things to worry about on your trip. Having a good fuelrange allows you to go where you want to. Not where you have to. Considering where you are going, fuel may not be as readily available as you are used to. Just because there is a town on your map, doesn't mean that it has petrol.
Having said all that (about now you are thinking if I am on commission from OTR) I have to agree that 900 Euroes is quite a chunk to take of the mod budget. And I agree, however reluctantly, that those money may be spent better elsewhere
.
For my own trip I considered the handlebars at great length, and ultimately decided against them based on an ill informed notion that "it's not worth the trouble". Raising the bar gives you a more upright riding position as opposed to the more road-style bars that are fitted. Sitting more upright will give you an advantage when driving in sand or other soft surfaces. When you lean in on the stock handlebars, as you tend to do on the stock bars, the front wheel is more likely to dig in to the surface when you hit an unforseen softspot (sanddune, loose gravel etc.). Sitting more upright distributes the weight away from the front wheel. Which is what you realy want in conditions like that. Also, it may prove to be more comfortable on those long days where you ride for hundreds of miles on tar-road. I'm thinking you've made a good decision about those bars.
I've dropped mine on more occasions than I care to count, but never did I worry that the handlebars might break. I don't think the sturdiness of the stock bars should be a reason to change them. Just make sure that your handguards are of excellent and strong quality (I've got the Acerbis ones like you. But without the Yamaha sticker). Handguards is actually not an acurate description, imo. They should be called "lever-guards". At one point I was traveling with a southafrican guy who was riding a Honda600XL. He had those flimsy plastic handguards that are in fact only supposed to protect your hands from wind, oncomming bugs, bushes and branches. We stopped for a break and we were just standing around talking when he leaned on his bike and it toppled over. Very undramatic. But the result was a broken clutch lever (he had an extra and we changed it on the spot). The point I am trying to make here is this: If you have positioned your handles in such a way that the protecters don't cover both you hands and you levers, and you have to choose between the two, then choose protecting the levers. You'll be wearing gloves anyway.
Sorry for the long post. I got carried away (again).
By the way, let us know how things turned out with the handlebar and risers. I've heard of some people having a spot of trouble getting the cables to stretch long enough. Would be great to hear if this is just a rumor or if not, how the problem is solved.
Oh and let me add: That trip is freakin' AWESOME!!!! I'm sorry to say that we all have to hate you now. Would love to see the eastern part of the world. India is definately at the very top of the list. Hope you take some good piccies for the rest of us to drool over. Remember, every time you think about posting a picture and then decide not to, God kills a kitten!
Best regards
Torsten