Okay, after yesterday's drama, went out this morning, stared at the thing....and then put it all together it about 5"...... ::025::
No binding. Throttle snaps right back.
As previously noted, I am a dumbass.... ::024::
What I didn't do was grease anything. ::010::
Assuming this is necessary, I'm going to make sure all works as expected, then pull it apart and juice the area up a bit.
Oh, and for anyone preparing to do this (Mark... ::024:
, when you get everything ready for re-assembly, set up your throttle cables 1st as others have noted then fiddle with the heater wire. I also found assembling it off the handlebar and then turning the bars all the way to the left (as if you were sitting on the bike) and sliding the assembled throttle tube on is the hot ticket. I think that was my biggest issue yesterday. (BTW, this method will NOT work if you retain the nub for positioning. Obviously others have done it without this method. Just my .02 cents)
Update: Pulled the thing apart and put a small amt of grease in the wire housing (not on the throttle assembly itself, Phil. I agree about the grunge build up). Again, it all went together easily OFF the handle bar. Didn't put the screws in but held it together and rotated the bars to the left (as noted above) and it all (again) popped right on. I DID grind off all nubs which allowed lateral movement of the throttle tube which allowed me to adjust it to the Kaoko. Also did this with all the switch gear which allowed me to position everything where I wanted it. Routing the wires is pretty fiddly but no big thing. There is a nice , unused metal wire loom under the R side of the bars. I ran the wires through this and then out the side. I presumed this is what it's for. If your going to use this, put the controller wire through 1st. The end pieces won't fit through if you already ran the grip wires. ::010::
One other tip that worked well. When you go to remove the L hand grip, peel it back a bit on the inboard side and spritz a bit of WD-40 in there. Wait a bit and it'll peel a little more. Spritz it again. In 10 minutes it slid off as if buttered. The added bonus was the glue retained of the bar came off pretty easily. Obviously be sure and degrease the area thoroughly afterwords.
Everything works as before and I now have heated grips... ::012::