Also spent the weekend installing:

• T-Rex upper & lower crash bars, skid plate, and center stand
  • https://www.t-rex-racing.com/Default.asp
  • Hint: Do the bars before the skid plate so you don't have to take it off to put on the bars
  • Assemble everything very loosely. Even at that I had to use a 4' long woodworkering clamp to pull the top bars front joint together
  • The center stand arm is *short* and doesn't provide much leverage. I'm about 170# and experienced with bikes and still need help getting it up on the stand
• PDM60 power distribution module
  • https://www.rowe-electronics.com/pdm60
  • can supply post-install photos if anyone's interested in my routing solution
  • Hint: save yourself a lot of hassle by getting a high-quality crimper
    • https://www.amazon.com/gp/product/B083L8QTCX
  • still not sure where to fasten it (the PDM60 box) under the rear cowling. Might just glue some foam padding to it and velcro it to the fender
• Trail Tech Vapor Tachometer
  • https://www.trailtech.net/en-us/shop/accessories/digital-gauges/vapor-tachometer/
  • Now I have a tach!!
  • I wrapped the tach sensor wire around the plug wire (5 coils, per instructions) just above the coil and secured it with two small, outdoor-rated cable ties
  • I didn't hook up the coolant temperature sensor since I wasn't in the mood to drain the radiator and cut the hose. Measure the hose diameter first, it says.
  • I didn't install the wheel-speed sensor since I would have needed to glue (JB Weld, I guess?) into the rotor, given that none of the bolts they shipped fit. This seems like a bad idea, and I already have a speedometer, so I'm probably going to just punt on this.
  • I was able to just force the holder/clamp over the bars without having to remove everything just to slide it on. It takes a bit of force, but I tried it several times and it seems none the worse for wear
• Double-take mirrors
  • my partner's bike has them and they're awesome
  • https://www.doubletakemirror.com/
• Oxford HotGrips - Adventure
  • https://www.oxfordproducts.com/motorcycle/brands/oxford/handlebar_accessories/hotgrips_premium_adventure/
  • This was a very, very easy install. No filing or cutting or fabrication. Just blew off the old grips (using a compressor and airgun), used a sanding sponge to remove the old glue remnants from the bars, completely covered the bars and inside of the grips in glue, and slid the new grips right on. Shockingly easy. I'm still waiting for something to go wrong.
  • Speaking of which, I did manage to slightly glue the throttle tube shut. Applied force. Now free.
  • Hint: put a sacrificial towel/tarp under the bars so that when you slide on the glued grips, the overflow doesn't land on the bike.
• Barkbusters hand guards (w/optional bar end weights)
  • https://www.revzilla.com/barkbusters
  • According to Revzilla customer support, there isn't a specific model for the 2022 KLR, so I got the universal set
  • Assembling black handguards with black screws at night while needing three hands is just as hard as it sounds.
  • They don't work with the stock bar-end weights but there are Barkbuster weights
    • https://www.revzilla.com/motorcycle/barkbusters-storm-vps-teardrop-bar-end-weights?sku_id=899177
    • which are not in stock just about everywhere
• RAM Mount for a GPS
  • I used the bar above the instrument panel. It's .55" and the only thing I could find that would fit it was:
    • https://www.amazon.com/dp/B00CU9BTKO
• About a gallon of blue Loctite

I got a factory service manual from eBay since the paper version is sold out everywhere. The one I got turned out to be a packaged PDF, hidden in an antique Flash app. Nice security there, guys. I was able to load it and print the entire thing to a PDF file so it could be read on a tablet. Absolutely critical to understanding where the damn hidden fasteners are.

Getting the tank off/on was not fun. I did that for routing wires after several fishing attempts failed. I do like the click-lock fuel-line disconnects. Unbolting the rear hold-down bolts and slipping a 2x4 under the rear of the tank helped make space to reach the fuel line. The service manual has a little diagram showing how to open the click-lock with a flat-bladed screwdriver. Will post a pic of the diagram.

Next up: learning to ride it (I'm from the sportbike/cafe world, so this is all quite new. It's weird being up so high.) I'm ODing on Bret Tkacs videos. Who else is good?