sounds like you might have chipped a tooth off the plastic gear drive on the end of the throttle grip.

 

Well, if it were mine, I would loosen everything up and then properly re-align the throttle grip.
I think that's your issue.

See @12:00 into this video.

How to Change Grips,Levers,MC Covers & Mirrors Harley Davidson Touring - YouTube

 

Is there any end play in that grip? It might be sliding just enough to disengage the teeth on the actuator. Make sure it's pushed into the bars the whole way. The TGS should stop it from hanging up on the bar.

 

I would definitely be disassembling things and doing an inspection.

 

Took everything apart, thankfully nothing stripped or broken. If I had to guess, when I was goofing around tweaking the bars and controls, I wound up sliding the throttle out a bit so it was engaging the teeth but popped out today when pushed. I made sure I had pressure on it when snugging down the brake lever clamp and switch housing so it was fully seated. There's still a tiny bit of play but I'm guessing it's normal. Gotta wait until Tuesday to take a ride and test.

Thanks a ton for the advice everyone, you guys rock!!!

 

A little end play is normal. I had a similar situation when I put lighted switch housings on my bike. I didn't pay close attention to snugging the grip up as much as possible when I put it back and the throttle would pop out of the gear. Freaked me out a bit at first but was a 5 minute fix once I returned home.

 

Very cool....... everybody likes happy endings........hmmmmm I might could have worded that differently? NOT!!!