Well don't know if anyone is interested, but I seem to have resolved this issue. Bonzo kindly sent me his old actuator unit , which seemed to be even more fxxked than mine. The big gear attached to the cable operating shaft seems to distort and the magnet that triggers the hall effect chip does not stop the unit in the correct position reliably. This is not easily repairable (I tried). A brief search of the interweb showed that the actuator unit is a Ford part 3L3E-9G730-EA= 2004 F150 5.4L Intake Manifold Runner , available for about $40 US. It has not got the cable bellcrank, but has a beam type operating attachment . I have modified this (quite simple) and riveted on my existing cable bellcrank after removing it from the faulty unit. I went down this path after being quoted over$400 for a new Buell unit from HD.Thank you again Bonzo for your kind assistance, I will try to post photos if anyone is interested
Jim

I'm interested

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08 Specialized Langster

A 1000% hike in the cost of a replacement unit from Harley , yeah that seems about right.!!!