I have cleaned the throttle body out and noticed that at rest the butterfly doesnt sit perfectly. There is a 1mm gap top and bottom which only closes up when I manually turn the gear chain (inside). Is this gap ok or is the self returning spring too weak?
any suggestions?

 

Is your idle high? It sounds like you could have either a rough build up inside there that eluded your cleaning or possibly a small groove was etched into your throttle body housing from repeated use.