You have the KTM now so just prep it well and use it for what it is intended for
I would say Rolling Hobo's KTM690 is the best set up i have seen as what he has done is all fit for purpose and not for looks & bling, some people will go out and buy the full rally fairing kit and other such "cool" items and not pay attention to the important modifications and the power to weight ratio is great out the box for the 690
The 690 is 143kg dry & 66 hp at the crank so if you drop 15% hp to bring it in line with rear wheel HP thats 57 rwhp
KTM 690 Enduro*R 2015 - Highlights
As for the DRZ they are great bikes but i would not take a standard one on another long trip as they are slightly under powered when loaded up as when offroading i felt i needed slightly more torque/HP.
DRZ400S 132 kg dry & 39.7 hp at the crank so again if you drop 15% hp to bring it in line with rear wheel HP thats 33.8 rwhp
Suzuki DR
So in standard form engine wise the KTM690 is 11kg heaver but with around 23 more rwhp which is a massive difference so if i was you i would stick with your 690 if prepared well
But if you do pick a DRZ i know this bike very well and if you require advice on preparing for a trip message me and i will advise how to prep it fit for purpose in a very cost effective way
But for me what i learnt was i needed a reliable bike just as the DRZ proved on my trip but also i needed more power.
My list for my next bike was based on the following
Must haves
1)Min 50hp at the rear wheel (standard DRZ is around 32-35)
2)Sub 150kg dry weight
3)Slightly longer fuel range as sometimes i was on my last 0.5l (i dont use a GPS so fuel stops are by chance when off main roads) i had 17L front & 5L rear tank
4)Better suspension set up (DRZ400s has great shocks out the box but require setting up right)
5) steel frame as stronger and easy to weld anywhere if it cracks
6) Min 3000 mile oil changes but longer would be better
7) Better throttle response (slight lag in Mikuni carb)
8) all ready available spare parts with not relying on dealership as this means high cost and can be long wait periods to obtain parts if not in stock, if i ever break down in the middle of nowhere i don't want to wait for dealer "help" i want to go on ebay now and buy the part today and have it shipped out to where i am
Nice to haves
1) Wider ratio gear box
2)better headlight
3)more ergonomic (bar raisers, wider foot pegs)
KTM690 was on the top of my list i even went to my local KTM dealer to consider buying one however i holded back as the CCM450 come out and now end of this year the AJP's PR7 660 is out. the CCM & PR7 on paper tick most my must haves straight out the box.
But i am abit like you willadams1 and to buy a new bike i would worry alittle with the same things you stated "risk damage, a lot of mileage, or worst case scenario, having to ditch the bike for whatever reason"
I like a older bike you can take a grinder to and know if i bodge it a replacement parts in on ebay 24/7 cheap
Also my nice to have list (not considering the PR7 as its not out now) has not been ticked
In the end i decided to go with what i know (also the DRZ was my first real bike that took me on an amazing first motorbike trip so i also have some sort of weird love affair with this model bike)and have slowly been modding a drz as per all items on my above wish list. with the help of friends and doing as much as i can all this finished would be around the same cost of a second hand but very good condition low mileage "standard" KTM690
Wide ratio gears, FCR MX carb, Hot cams, big bore, stroker crank, head & valve work.
Its more a hobby at the moment doing a little ever few months adapting and changing parts, buying the odd bit here and odd bit there. most parts i brought in new condition or used but in good condition on a DRZ400 super moto forum as the drz SM is a bike the kids buy after passing there test and mod the hell out of them, maybe compare it to a vauxhall nova but instead of body kits they are buying engine parts and then when older or they have spent there student loan fees on snake bite and mad dog 50/50 they sell cheap
These mods for the DRZ470 are standard in the various DRZ forums and many DRZ470's like what i am building have already done many thousands of miles with no issues(apart from a guy called uncle bob who also fitted a turbo charger to his and it blow up
on the way to the dyno test station straight after his built ) so its already proven
The bike finished i would say would go from the standard 132 kg dry to max +10kg (that's a over estimate in weight to be fair) with the extra fuel tanks and other fit for purpose items bringing it to around 142kg dry weight but with rear wheel horse power at around 57hp
There are many 100's pages on these 470 build on various forums but here is one link just for reference
57HP DRZ - graphs etc - Page 2 - ADVrider
So if comparing to a standard KTM 690 is goes like this
DRZ470: rear wheel horse power 57 & dry weight max 142 (also with wide ratio gears that the 690 lacks)
KTM 690 rear wheel horse power 57 & dry weight max 143
I am not trying to say the 470 would out preform a 690 as it will not but still the stats are very impressive if it is reliable however the 690 still has alot more torque per lb.-ft, its now all about horse power
I have a great bike mechanic engine builder who is kind of famous in my neck of the woods along with great friends who have inputted to this ongoing DRZ470 build
Now if the DRZ470 would keep its reliability considering i have been building this bike with reliability in mind and not just power like the following, big bore cylinder with a larger water jacket for greater cooling, fitting a oil cooler, radiators with 25% better cooling rate, new hose's all round, heavy duty stronger crank with new heaver duty bearings, stronger 1 piece valves rather than the 2 piece valves and so on.....................