You're so right about mechanics. So much of working on or assembling anything is touchy-feely and if it doesn't feel right or it feels too hard to break something loose it's best to step back for a minute and think on it before you break something unnecessarily. Don't rush repairs or assemblies! Thanks, Mike.
Pro mechanic 2cents. Impressed with ease of installation, a true bolt on. I recently installed Maier Woods Pro hand guards on a gen1. They required some bending on its inside radius for proper fitment and the polymer brush guards were not pre drilled. Are they worth the pain in the butt install, not for the average home modder. However I would say the Woods Pro guards are about 3 times as stout as the T Rex ones. Glad you found some that fit the KLR, I will recommend them based on your video.
My bar end bolt was cross threaded from the factory and broke off when screwing it out leaving half bolt in the handle bar. I am going to let my dealer drill it out and retap the threads so they can see it came from the factory like that.