Welcome to the forum, Jack Straw.I just bought my first KLR, a 2008, stock but for footpegs and shifter. It's fairly low mileage at 8200. I just did the doohickey and torsion spring and replaced the dry-rotted tires with some Shinko 700s with new HD tubes. I'm a long-time wrench, former Honda mechanic at a busy dealer in Hollywood, California. I'm in Prescott, Arizona now and the surrounding countryside is laced with dozens of great dirt roads, fire roads, and jeep trails through beautiful territory. My road bike is a Suzuki SV 650 and it's a sweetheart but I fear it will be gathering dust now that I have the KLR.
Did you insert the EM "Deep Hole" bushing into the outer alternator cover, lower reduction gear bushing, along with installing the EM Doo-Hickey?
I read your credentials, but I will still ask if you have read this yet? https://www.klrforum.com/introductions/58921-dpelletiers-common-new-klr-owner-mistakes-avoid.html