Thank you very much for your notes. My comments inline:
1) The Progressive 465 shock is the same for the DL1000 or DL650. The OEM DL650 is about 4.5 mm shorter than the DL1000 OEM shock. The 465 shock's length splits the difference between the 2 bikes. So, the 465 will slightly raise the DL650 and will slightly lower the DL1000 (about 6mm, or 1/4 inch).
I suspected as much. I'm pleased to have it a smidge higher, so that's fine by me.
2) Usually the bushing is pressed into a spherical bearing, so there will be some variance in tolerance when assembled at the factory. If you find the top bushing to be a tight fit, you can try to carefully compress it in a vise or with a c-clamp. Remember though, it should be a pretty tight fit.
It is a spherical bearing, so your suggestion might have worked. The amount that I shaved off it was very minimal, though, and it still fits very snugly, so I'm ok with it.
3) The top preload collar ring can be tightened to place more preload on the spring. For example, if you have the hydraulic remote adjuster turned all the way in and you still have too much rider (laden) sag, you can turn the collar ring so that the total spring preload increases even more. I believe Progressive warns the user in their manual to only preload the spring so much from it's free length (you don't want to cause coil bind). If you are a heavier rider, you may very well find that you need to add more preload, since Progressive chose a pretty "light" spring IMO for this bike.
Curious. That would be great, except that the spring length as shipped is precisely the minimum length that they specify, making that not so useful.
I am 170 lbs, and I need at least a little preload when I have any luggage at all on the bike, so yeah, it seems like a fairly light spring. It does, however, manage to hold the right sag when fully loaded, which the stock spring could not. My on-the-fly metric for preload is the ground clearance of the kickstand: with the Touratech sidestand plate attached and with the bike vertical, it will just barely scrape the ground when preload is where I want it.
Very much so. Where did you get your detailed info about this unit?