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How should OTK Throttle/Brake position sensors be mounted?
Hall magnet has to stay in front of the sensor through the whole pedal swing or you lose the signal. OTK pedals don't leave a decent face for that. Figure a short arm off the pedal so the magnet sweeps past a frame-mounted sensor. Anyone gone that way or put a rotary on the pivot instead? Brake travel is shorter so the same geometry probably won't copy over.
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The intended mount is the cable-sleeve stop on the frame, magnet on the inner cable. A typical OTK sleeve stop is a tab perpendicular to the cable axis; a short bent steel or aluminum piece bolted there puts the sensor parallel to the cable so the magnet stays in the sensing axis for the full stroke. Because the cable already moves in a straight line, throttle and brake share the layout, and the shorter brake travel simply produces a smaller linear displacement rather than a different arc.
AIM's installation notes specify a 5 to 40 mm magnet-to-sensor gap. Closer or farther and the Hall element may not register. Pedal-mounted geometry is different: magnet travel is the pedal angle in radians times radial distance from the pivot, so shifting the pair toward the pivot reduces throw and shifting it away increases throw until the motion stays inside that gap window. A rotary sensor on the pivot avoids gap tracking, but it is extra hardware once the cable path is used.
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You can have the prettiest mount in the world and still chase ghosts if the sensor and the pedal don't stay put relative to each other when the chassis is wracked over the bumps. I'd look at a stout spot on the frame first not the prettiest one, cause a little rock in that hall gap will draw a throttle trace that looks like you're stabbin it when you ain't.
If y'all ever film the foot, that and the TPS ought to tell the same story. When they don't, it usually ain't the driver, it's the mount walkin around.
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