I just replaced my standard (small) handgrips with the largest size (1.6"). That was the easy part! Now, I want to make sure that the clutch is releasing properly since there is now less travel. Just for fun, I sat on the (cold) bike, put it in first gear, pulled in the clutch, and rolled the bike a bit. There is definitely some resistance, but I could still easily roll it around. The question is, *should* there be some resistance, or should it feel like I'm in neutral? I wish I had done this test for comparison before I replaced the grips!

And now for the worst part. Last time I lubed the right grip, I overtightened one of the switch housing screws - I didn't have a torque wrench that would fit back then, and the required torque is a lot less than you might think by "feel". So today when I was reassembling the right switch housing, my worst fear was realized - the threads are stripped in one of the bolt holes in the housing. Nice that the housing threads strip first to protect the screw. :( Any thoughts on what to do at this point? I could replace the housing, of course, but is there an acceptable way to repair this?

I just replaced my standard (small) handgrips with the largest size (1.6"). That was the easy part! Now, I want to make sure that the clutch is releasing properly since there is now less travel. Just for fun, I sat on the (cold) bike, put it in first gear, pulled in the clutch, and rolled the bike a bit. There is definitely some resistance, but I could still easily roll it around. The question is, *should* there be some resistance, or should it feel like I'm in neutral? I wish I had done this test for comparison before I replaced the grips!

And now for the worst part. Last time I lubed the right grip, I overtightened one of the switch housing screws - I didn't have a torque wrench that would fit back then, and the required torque is a lot less than you might think by "feel". So today when I was reassembling the right switch housing, my worst fear was realized - the threads are stripped in one of the bolt holes in the housing. Nice that the housing threads strip first to protect the screw. :( Any thoughts on what to do at this point? I could replace the housing, of course, but is there an acceptable way to repair this?

Adjust your clutch according to the manual if you have any doubts...its very clear about this...

As for the screw.....I had the VERY SAME THING HAPPEN....after many attempts to "engineer" a fix, I ended up replacing the housing....too much of a PITA to deal with it....

Hi Dave.
If it is a chrome one, then it would be worth the effort to save it. The way to do it is to get a Hellicoil kit of the size the screw is. Drill out the housing hole and retap it, then install the insert, and reassmble.
These kits are not cheap, as then will have 5 inserts, a tap and installer tool, and will cost about the same as if you were to get a black replacement part. The dealers ususaly have a box full of these used in the back....if you ask nicely, they will pull one out for you.

Yes, your clutch needs adjusting. When it's adjusted properly, there'll be no resistance like you felt.

As above, just follow the manual. If you haven't gotten one, this is a good time. I'm no mechanical genius, but it's very clear, and I'm glad to know how that part works. Now, on to the rest of it...

Can't help you on the stripped threads. Bummer.

Hi Dave.
If it is a chrome one, then it would be worth the effort to save it. The way to do it is to get a Hellicoil kit of the size the screw is. Drill out the housing hole and retap it, then install the insert, and reassmble.
These kits are not cheap, as then will have 5 inserts, a tap and installer tool, and will cost about the same as if you were to get a black replacement part. The dealers ususaly have a box full of these used in the back....if you ask nicely, they will pull one out for you.

That sounds like a GREAT idea...

I toyed with the idea of retapping it and finding a screw that matched, but I bought the chrome ones, instead! ;)

Yes, your clutch needs adjusting. When it's adjusted properly, there'll be no resistance like you felt.
I went the dealer and sat on a 2005 1200C, put it in 1st gear and tried to roll it. It felt exactly like mine - there was some resistance, so I think I got it right. The free play in my clutch lever was about 1/8" (spec is 1/16" - 1/8"), so I just adjusted it to 1/16" to make up for the larger diameter grip.
As above, just follow the manual. If you haven't gotten one, this is a good time.
First thing I bought a year ago. I was just trying to avoid jacking the bike up, removing the derby cover, not being able to re-install the quad ring (a *pain*) when all I did was install larger grips.
Can't help you on the stripped threads. Bummer.
As it turns out, you can buy just one half of the switch housing. It was only $21 to replace it, and my dealer had them in stock. The only difficult part was to reinstall the tiny screw that fastens the switches to the housing.

Sounds like a good, cheap fix.

I hope more come out that way.