ah, i don't have any of that (left and right movement)

 

You may be able to get some of the left/right movement out just by moving your switch housing a little. When you put the new grips on make sure the switch housing is as far left as it will go before you tighten it down. This should eliminate any slack in the grip.

 

ha!

that was rather easy.

 

I've got a little bit of left to right as well but that doesn't bother me as much. And you guys are definitely right about the cable throttle. I used to keep mine very tight with minimal slack. Especially with the 1/8 turn race throttles... man.... that thing was like a light switch and I loved it! Now I've got this fancy TBW and I've got more slop than a 30 year old metric cruiser! i guess I'll pull it apart and check the teeth as well as the tooth position and see if it gets any better. Anyone using Aluminum throttle tubes?

 

Maybe the grips are made with a larger inner diameter since they no longer just glue tight fitting grips on the bars. Made so they are easy to change out, which a lot of us do.

 

Can't remember where I found it, but I'm sure it was in the Service Manual. Loosen the switch housing and slide it in to adjust the inboard/outboard free play. Mine had quite a bit even after the 100 mile service they talked me into to "fix" these break in issues. Loosened the switch housing and slid it in to minimize slack without binding is what I believe the manual said.

 

So I took my controls apart today after doing major/minor clutch adjustment and found a few things... Should've taken pics, but my phone was dead. Anyways. I found 2 things, one I was able to correct the other needs parts.

1- I found that the piece of the TBW that fits into the noches on the bars was moving front to back. There was a bit of at there. It was a snug fit, just twisted front to back. So I cut a small piece of a rag and wedged it into either side. Slip there is now gone. Felt bitchin. I held the TBW tube and twisted the end gear forwards and back, and it was tight. No slop whatsoever.

2- I looked very carefully at the teeth on the end gear, and it appears that where the throttle tube actually meshes with the TBW, the teeth were worn down only 50% the width of the gear. This is what is causing my remaining "slop".

Need a new end gear, and throttle tube. I guess now is my excuse for new grips. Do I need these? No. But if I can eliminate my "slack" all together. I'm gonna do it. My throttle tube is kind of an OCD thing and now that I've isolated the issue, I can fix it and not worry.

I'd say putting in the little pieces of rag, helped the "slack" immensely. At least a 50% reduction. The remaining "slack" will be removed once I reace the worn end gear on the TBW and the throttle tube. I haven't looked yet, but is the end gear replaceable? And if so, I'd probably like to find one made out of metal instead. Maybe aftermarket TBW altogether if need be, or just wishful thinking.

 

I also moved the housing inward a bit to help with the side-to-side play. Much better now in the side to side aspect.

 

the end gear is not replaceable, and afaik, there is not an aftermarket tbw unit available. but, if you aren't using the wiring for the heated grips, you can get the se tbw unit that does not have that wiring, and it used to be cheaper than the stock unit. haven't checked in quite some time on the pricing.

 

I hope you wedged a piece of cardboard or something into the front brake lever before disassembling everything. Otherwise, you're gonna have another issue if that plunger popped out and shot into the unknown.