disassembling half-twist throttle

kylerlaird

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Nov 13, 2020
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Location
Rensselaer, Indiana
Anyone have a favorite tool for disassembling half-twist throttles? My first version of a tool (attached) work but I really had to jam it in. Now that I have it apart, I see that my tool could have had much more chamfer. (I just realized that this picture doesn't show the chamfer. Oops.)

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I made myself little "spudgers" out of a vanilla bottle. The plastic was thick and wedges in over those edges.
 

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I used to just use a pair of flatblade screwdrivers stuck thru a sponge and another sponge between them so they wouldn't flop around when I wasn't holding them both.

I later made a split-pipe fixture with a chamfer round-filed on the ID, similar to those used for a number of other bicycle-repair / installation tasks.

But after too many attempts to fix throttles being too-often spoiled by the magnets being loose and falling out, then having to try over and over again to put them in the right way (not marked, little cubes that *each* fit in six possible ways on some, little rectangles that *each* fit in four possible ways on others), with each wrong assembly requiring disassembly of the throttle *again*, and then putting them back in, reassembling, retesting, getting wrong voltage range on hall output, rinse and repeat...and fixing that only to then have something go wrong with the cable or the sensor itself from all the faffing around....

I gave up fixing them and looked for something more durable--now I use a really cheap metal ATV thumb throttle that pulls a cable-operated throttle body, which is actually waterproof-sealed (unlike the typical throttle grip or thumb). For those that prefer grip throttles there's plenty of motorcycle/atv/etc grip types that pull single-cables.

After several years the cable wore enough to begin sticking just a bit (even with lube) so ti doesn't always return fully to zero, so I need to replace that, but the thumb control and the throttle unit still work fine. (thankfully the Cycle Analyst v3 I use to convert and filter my sensors and inputs to make a throttle signal for my 2WD controllers has settings for all the throttle voltages, to compensate for whatever a throttle actually puts out and transform that into what a controller needs...so I have not had to get around to replacing the cable yet).
 
Started with a set like this... remember to apply constant opening pressure.


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Then tried something spectacular...

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Ended up preferring something simple...

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Modified paint can openers! :p

If desired see the evolution thru my signature link...


Regards,
T.C.
 
How does the signal get to the controller with cable-operation. Would you post a link please and thank you.
Same way as any other throttle--the sensor unit is wired into it just like a regualr throttle. The only difference is that the sensor unit is not inside the handgrip or thumb unit, it is a little box that is operated by a cable pulled by the handggrip/etc.

See this thread for how I used one for a variable-regen brake lever (I don't have a link to the posts in the SB Cruiser thread about the actual throttle setup, but it's probably in the posts around 2018, if not then probably the same time range as this thread).
 
BY FAR the easiest twist throttle disassemble tool is a length of appropriately sized aluminum (or plastic) tubing. The one I accidently found to work was a 6" section I sawed off an old folding aluminum picnic chair, one of those ones with nylon woven webbing that were so common the H/W stores used to sell webbing repair kits. Slides right in and easily engages all the lock tabs at once and the pieces slide apart. Slick!

MDUG0506.jpg


If I can find it I will post the diameter ID and OD.
 
It seems that an ebike throttle is such an inexpensive part, why waste your time taking it apart.
Regardless, I once took one apart, and boy was I surprised! I expected to see some sort of potentiometer, but I only saw a little piece of metal and a bit with wires to it. As one who was bread and buttered in vacuum tube technology, this was just another of my technological humiliations.
 
It seems that an ebike throttle is such an inexpensive part, why waste your time taking it apart.
The only reason I would do it myself now is if it were some OEM unit that can't be replaced with generic for some reason, or one with some function or form that isn't available in any other unit, pretty much forcing a repair situation.


I expected to see some sort of potentiometer, but I only saw a little piece of metal and a bit with wires to it.
They do make those...Magura, Domino, and a few others, including some cable-pulled (cable operated, COT) throttle "boxes". Just not something you'll see on the average ebike--the pot throttles are either more expensive for the good ones, or poorly made for the cheap ones, in the latter case it's better to have a cheap hall throttle as it's less likely to fail simply from it's cheapness. ;)
 
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