I rebuilt my Record shifters, and when I reinstalled the pivot pins that fix the brake levers in the body, there apparently was enough friction between the pin and the polymer body that driving the pin through the hole also pushed the sides of the body flanking the lever a touch too close together. Now the body apparently fits too snugly against the sides of the brake levers and they bind, preventing the levers' from auto-returning when released. So when I brake, I have to manually push the levers forward a bit to get them to return to the full-forward position. I've tested the brake levers removed from the handlebars and with the cables uninstalled, and I've tested the cable return with the brake levers not attached, and there obviously is some binding between the body and the lever. Throw in cable friction and it's more friction than the brake return spring can overcome.
Driving something narrow between the lever and body to create a touch of clearance seemed like the natural solution, but the fit is so tight, the only thing I possibly could get between them would be a knife blade. And I don't want to try that because I figure I'm almost certain to end up cutting into either the CF lever or the polymer body in the process. Not to mention the body is far more substantial than the lever, so all that would happen probably would be making the sides of the lever flex inwards, which I don't see helping my cause any.
Long story short, I figure to disassemble and reassemble them to try to fix that. Anybody have any suggestions how I can put them back together without reproducing the same "pinching" as I did the last time?