By chance did you ever put the slide on and then notice that the hump in the top rear of the trigger bar was sitting outside the frame? No, never.
Meant to say outside of the slide. When I did that to one of my P380's if I hadn't been looking I might not have noticed it until I tried to fire the gun, and I'm fairly certain I would have had a dead trigger. But I did notice it and pulled the slide off right away and righted it. It was used when I bought it so I'm not sure what caused it. I never did have any problems with it but then I don't think I put more than 25rds through it before trading it.
Is the cocking cam pivot pin seated correctly on both ends? Yes (At least I think so seems like you would notice that when the gun is field stripped?)
Not necessarily. Say for instance it is off by 1/16" on the left side. That could/would equate to a slightly larger amount on the right side. I'm not intimately familiar with the innards of that part of a Kahr, but if the triggerbar is riding on or against either the cocking cam or the right end of pivot pin, if the bar was out by as little as 1/16" it could put it in a bind against the cover plate, no?
About the trigger bar; As I said, I polished it, with special attention to a micro burr on the top of the disconnect lobe. While removed, I inspected it, but it is a series of steps and bends so it was difficult to tell, but it seemed straight. OF SPECIAL NOTE: When I was swapping side plates last evening, I had the slide off, and the plate off and I thought to press in on the rearmost portion of the trigger bar, and there was some very slight inward movement, which, when released, returned to it's normal position. When I say slight, I mean "SLIGHT", I thought to myself "well, that seems to be not extreme, it's probably going to have some slight movement" I don't think that's a contributing issue.
Oh, and here are the pics I took of the original (and still installed) trigger bar;
IMG_4706.jpgIMG_4708.jpgIMG_4710.jpg