Sled in question: *'97 Formula III. *It has a single stage throttle lever and after riding a few miles my thumb is killing me. *Is there anything I can do to make this pull softer? *I have an entire '96 parts sled, which has the two stage throttle lever. *I don't know how I can swap it over without destroying the grips though. *Any suggestions?

take the springs out of the carbs and whack off 6-8 coils? Worked for me.

In 97...were the stock throttles single or two stage? I bought mine with a two stage...just curious as to what stock was?

Stock is the single stage on the '97. *Is is possible to remove the grip without damaging it or the warmer so I could swap the throttle with the two stage lever I have?

try using compressed air in the end of the bar and just pull and turn * should come right off * * * use a heat gun and try heating it up is that doesn't work * * * one other thing that will be better is to get your hands on a set of flatside from a 99 Mach * * * way easier throttle pull and better throttle response. should bolt right up too(with a little jetting)

My 99 HO came with the same single-stage thumb throttle. *
I switched the thumb throttle with my 97 583 two-stage.

All i did was use dish-soap and worked it into the grip to remove it. *Then I carfully slid *the old throttle off, sliding over the heat wires. *Then carefully silde the new one on. *Again i used dish soap to make it more lubricated. *It did this on the HO and 583 and did not mess up eigther heat wire. *both are working fine.

One more thing - *the two stage throttle does not travel the same distance to the bar. *So you will have less cable length pull. *I took a heat gun and heated up the two-stage throttle and bent it our futher. *Now it has more than enough cable pull. *Remember to re-sync your carb slides and cable adjustment when you are done.

good luck.

What is the problem with the single stage? Just that your thumb get's tired?

in my experience, *i find that using the single stage is great for holding it wide open for long amounts of time. * but when it comes to real tight and twisty trails and I am constantly on and off the gas, then the two-stage is ALLOT more comfortable with the round-body carbs.

Exactly, Rocketman.

I don't think I'd need to sync the carbs since I'd actually be using the throttle lever it was originally setup for but can you explain how this is done? *I remember reading something about holding the slide open with a drill bit but don't remember the rest.

Jet- I dont understand your last reply, *Originally, you asked if there is a way to remove the throttle with out damage?

After you answered how to remove the throttle, you suggested that I sync the carbs if I switch the throttle levers. *The carbs came off of the '96, from which I would be taking the 2 stage throttle. *Therefore, I wouldn't need to sync the carbs. *I asked how carb syncing is done because I figured if I have some time I'll do it anway.

Sorry for the confusion, I hope that cleared it up.

How do you get the dish-soap under the grip? *Just dip the end of the bar in a water/soap solution?

If I had your problem, I would ride more. *Your thumb just needs more strength and endurance. *Ride every day until your fat, lazy thumb looks like Arnold. *Ha!

Ok- gotcha, *i didn't know you were changing the carbs too...

As for the soap, I put it in a spray bottle and keep spraying it on the edge of the grip, while twisting the end of it. *Edventually it works loose and the water works its way down the grip. *I have also heard allot of people say compressed air works really good too. (like 1000imp mentioned)

the next 4 images are out of the 99 shop manual, *hope this helps...

one

two

three

four

here is a couple more that might help....

six

seven

Thanks for the info, doomaster.

I'm surprised there is no mention of using a manometer. *After doing a search I found this site:

http://www.off-road.com/snowmobile/info/howto/carbsync/carbsync.html

Seems like a much more involved process than what your manuals calls for.

jetrep,
*you have to use a two stage.
*i have heard from a couple people that air will work to take off the grip, but i tried with the bars off in hot water and ruined the heater. so the next time i cut the grip off, watch that you don't get the heater. the heater element will come off with heat {start the sled and flick on the bar warmers}, to put it back on i used contact cement. to put the grip back on i boiled it then sprayed something on the element as a lube to slide the grip, some guys use hair spray as a lube and i think that is best i forget what i used.