One thing that has been bugging me about KotFE is that logging into any alt for the first time since 4.0 feels like a considerable chore. I did sort of allude to having inventory problems in my first impressions post - sadly that hasn't remained a singular occurrence.
I think the biggest problem have been the heaps of companion gear that I received on every character. Players did ask, what with companion gear becoming purely cosmetic, if it would be possible to get back some of those original outfits that each companion comes with. Some of them look pretty good, but obviously a lot of players had discarded them in favour of something with higher stats over time - after all stats were what mattered for the past four years. It's nice of Bioware that they decided to fulfil this player request; I just wish that it had been optional somehow, or something we could deal with on our own time by pressing a button when we were ready.
As it stands, every single one of my characters had her inventory filled with companion gear, whether she wanted any of it or not. (Plus there was that problem with characters taking their trousers off and putting them in my bags for some reason - some even decided to get completely naked; don't ask me why!) So if I wanted my bag space back, I kind of had to prioritise figuring out my companions' outfits or at least whether I was interested in any of their old gear before doing anything else. I actually enjoy that kind of busywork sometimes, but not when it's forced on me while all I want to do is go do the new missions! It wasn't even done properly either, as I got some rather... odd mails in some cases, with gear for companions that I didn't even have as well as duplicates of other pieces.
It's not a big deal in the grand scheme of things and in a few weeks I'm sure we'll all have forgotten about it, but at the moment it's really rather annoying. Two weeks in and I still haven't sorted all my alts out. It's not hard for me to imagine a returning player taking one look at the mess in their bags and mailbox and going "screw this nonsense" before logging right off again.
Oh, and did I mention that all my characters who are crafters had to spend several hundred thousand credits on training a whole new set of level 1-65 schematics?
At least our specialisations didn't get reset for once - just the utility points, and those aren't too tough to re-assign quickly.