E-bike Thumb Throttle replacement
Patricia Garcia
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Publicado:2025-12-02 22:04:56
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I broke 2 throttles in a month riding my sondors x fat ebike. i opened the casing and set to work reverse designing. it works as is, however, the magnet protrudes a little bit from the original which causes enough friction to stop the spring from returning to zero position freely. i actually don't mind as it creates a cruise control effect. Notethis is made to install on the left side of the handlebars, if your original doesn't look like the 'scooter throttle' picture, it probably won't work. Update* I added another file titled v2, the spring moves freely in this version to get the oem fit after some sanding of the interior and exterior rings. im still using v1 and actually prefer it, but i can see it being a bit of a hazard, so added v2. i also beefed up the connection a bit
Print Settings
Printer Brand:
Creality
Printer:
CR-10S
Rafts:
No
Supports:
Yes
Resolution:
.2
Infill:
50% octet in cura
Notes:
Print as is, with or without support based on your machine. i used 15% zigzag with a 100% concentric interface roof support and it came out pretty well. i used 50% octet infill from Cura. maybe overkill, but i wanted it to be resilient, but it's pla and a moving part, so i'll revisit if/ when it breaks.
Post-Printing
Step 1 Curved Magnet!
you will have to pry out the magnet from the original throttle body. you can insert the magnet into the new printed piece by press fitting. rest the magnet in the thin side slot first, and gently press the other end into the wide slot. it will all make sense when it's in your hand. i used super glue and pressed fairly hard for about a minute and it held nice and firm. don't skip the glue!
Step 2 Sanding
i had to sand the interior ring of the print, you may get lucky, but it only took about 10 minutes of sanding and fitting. i didn't have to sand anything else on the part
Step 3 Assembly
Place one leg of the spring in the small hole in the outer housing first, then the other leg into the printed piece, i got lucky and it caught the small hole on the second try, keep at it and slide the outer shells to match profiles and snap together, take care not to pinch the wires.
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