Why this motorcycle?
My first motorcycle for the round-the-world trip was a Suzuki DR-Z400, but unfortunately I had too many problems with it. My criteria for a motorcycle were: as light as possible, reliable, easy off-road, under £4,000, with good access to spares, close to stock, no problems and low mileage.
The CRF250 Rally was the best option I could find. I would have bought a CRF250L but I needed a bigger fuel tank and I preferred factory parts to aftermarket parts as there is less risk of problems such as leaking gaskets.
Modifications
Changes before leaving the UK
Progressive fork (added before I bought the bike)
Hagon rear shock (added before I bought the bike)
Heated grips
Protective hand guards
Gears reduced to 13/40 (with standard gears, sixth gear was for low power cruising only)
Speedometer heals to correct speed when I changed gears
2 x charging points
Rotopax 3.8 litre fuel tank
Rigid waterproof camera box
Special tool box (110 mm drain pipe)
Combination pushrods and skid plates
Modifications after leaving the UK
Reinforced clutch springs
Reinforced subframe
Honda toolbox removed
Fork sockets to protect seals
Luggage
Luggage setup is simple. I have a Kriega OS base with 2 18-liter bags, a 30-liter dry bag and a hard case for my camera.
Reliability
The CRF250 Rally was generally very reliable. I had only one problem - the headstock bearing. Other problems were due to me or common consumables.
The spindle head bearing broke after 8,000 miles. This is a known problem because there was too little lubrication at the factory, causing it to rust.
I broke the rear subframe because I had too much weight on my back, and then I drove offroad to India.
Service, maintenance and spare parts
The service intervals are really good! Rally needs a service check every 8,000 miles! The maintenance is also very easy to perform. As for spare parts, I can only comment on the wagon bearings and fork seals. I was able to get both when I needed them. The spindle rod bearing was purchased in Kathmandu, Nepal, and the fork seal was purchased in Bishkek, Kyrgyzstan.
Long distance comfort
There are certainly more comfortable bikes for long rides. I didn't struggle for comfort on the CRF, but I think a custom seat could have made a big difference. For longer days (600km through China) I used a "sweet cheeks" pannier with two water bottles to make the seat wider. (If you have limited space for water or fuel, this can be a big advantage too!)
But overall, no problems. It all depends on your riding style. If you like off-roading, the seat doesn't matter. And if you're not in a hurry, the seat doesn't matter either, because it gives you a reason to stop.
The good and the bad
The Honda CRF250 Rally is reliable, easy to maintain, has good off-road capabilities and is reasonably priced.
It's heavy for its power, and its off-road capabilities are limited. I wish it could lose 20 kg and have more torque!
Verdict
I wouldn't say it's perfect. I could name a lot of things I would change (power, weight, off-road capabilities), but if I had the option to choose again, I would probably choose the CRF250 Rally again.
I only tested one to rule it out, but here I am, 22,000 miles later, sitting on it in Thailand!
Travelling the world on a motorcycle is always a compromise. The roads and conditions change, but unfortunately your bike can't change with them. So choose something that allows you to enjoy your journey as much as possible. In my opinion, your mood is more important than the bike itself.
