Big difference between a KLR and a new Africa Twin.

IMO- the new AT is great fun, but not as bullet proof and simple as the old one. And it will be expensive, because you will need to do the suspension as well on the bike. Fuel range is also limiting, with very limited expansion options at the moment.

For a RTW, I'm of the opinion the old one is better. But I would also rather use a new AT as opposed to 800 beamer.

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Squily

you're absolutely right, the old Africa Twin and the new one are heavy, very heavy for an adventure bike IMO. CRF1000l is in addition expensive and quite complicated, not easily serviceable. Try to clean air filters when you have crash bars installed or get access to battery.... Additionally tank range is poor for adv riding. Don't get too sentimental, look for facts the new AT is not the old one with upgrades unfortunately...

Form what currently on the market I would look at klr 650, drz 650 or if you want to go more expensive route (meaning risky) see adventure models from ktm and bmw. Anyway choosing wet weight below 440lb is wise when riding alone IMO.

I feel the new Africa Twin would be a great travel bike, with some caveats, which I think you're already aware of. If you can stay mostly on paved roads then the Africa Twin would be a hoot. I've never ridden the bike but would love to ride one.

But ... it's no light weight at around 530 lbs. wet. Probably pretty close to your old AT? Add another 50 to 100 lbs for luggage, parts, racks, guards, whatever.

IMHO, you're on the right track leaning towards the KLR and bikes in that class.
Very low buy in compared to Africa Twin, F800GS or Tiger 800 or any KTM.

Options and alternatives to Africa Twin might be:
Honda XR650L, tall, runs bit hot, needs some mods but basically good
Suzuki DR650 (my personal bike and favorite) reliable, inexpensive, TONS of aftermarket support world wide. GREAT travel bike
KLR650 ... common RTW bike, lots of support like the DR650, can be made quite good with correct modification.
KTM 500EXC .. not ideal for travel but PERFECT for anything off road.
Suzuki DRZ400S ... cheap, cheerful, good with mods, good off road.

KTM 350, 690 Enduro or Husky 710. All expensive and exclusive and like the 500 KTM, very off road focused with the 690 Enduro having most potential to be a good travel bike ... good, but not GREAT, all need a lot of modification for ideal long range travel.

So what would be GREAT? That would be either a very well setup Suzuki DR650, KLR650, or Honda XR650L.

The big bikes would be more fun/comfortable on paved roads, but you may struggle off road, especially in DEEP Mud or Sand. You are not new at this ... so should not be too hard to pick a favorite. I owned 2 KLR's, Honda XR650L and have had 3 DR650's. The DR is by a wide margin, my favorite.

Smart to sell off down South and buy or rent something in Asia. A more low cost bike will be easier to re-sell in Argentina or wherever. A $15K bike may be harder to sell there, so you could take a big hit.