I have a 2012 Polaris 850 and I bought it with a code 520 194 3 which is a code for throttle safety voltage. The code was putting my machine into limp mode. I removed the cover off the throttle and tried to adjust the throttle to specs but the code kept coming back. So I finally put a zip tie in between the two little contacts on the throttle safety switch and disconnected the battery which resets the machine and the code didn't come back. So I'm confused, are the contacts in the throttle not supposed to make contact with eachother at idle? I tried to adjust mine so they weren't and I couldn't get them to not touch at idle. Thanks.

 

Unless the specs have changed the contacts are closed at idle on the 850,at least on the 2009 manual I have. Adjust the throttle cable to where you have 2-3 mm between the throttle arm and throttle stop pin.If in doubt just get the cheap 5 buck manual for the 2012 model.2012 Polaris Sportsman XP 850 HO Service Manual PDF Download You'll need it for other repairs/service.

 

I guess if they are supposed to be closed that means something else could be acting up, tps might be at fault then. But I'll have to try adjusting it again. Thanks.

 

Unless you have the correct tps adjuster harness wouldn't touch the tps setting it as it's preset. D shape idle screw would have to be backed off and tps set back to original base setting then to the final idle adjustment with the idle screw.If you're having idle or throttle problems,check the wiring for any bare or soft feeling wires on the tps and tbap sensors.Sensors themselves weren't usually a problem area and don't think Polaris had any better connectors or wiring on the 2012 models than they did on earlier models.Otb makes better sensor harness repair kits than what Polaris offers and the 850 is included if needed.https://otbpowersports.com/products/

 

I finally figured it out, it was not the throttle free play causing the problem. On the side of the throttle housing/4wd switch housing there is a connection going into it. Mine was really dirty and the pins were very loose. When I wiggled the connection the code would appear and disappear every time I turned the key on and off. I took the connection off and cleaned both sides of the connection, I put some electrical grease in the connection and then used some hot glue on the back side of the tab to hold the pins tight in the connection. Code disappeared and I haven't seen it since.

 

Glad you were able to find the source of the problem. Same sort of thing that would happen on the connectors on the left control switch.

 

Yes i'm so glad I fixed this problem, but now I have a new code when I ride at high speeds and then let off sometimes . 520 194 7 is the new code i'm getting which is "stuck throttle cable" It doesnt come on everytime but every now and then it pops up and throws my machine into limp mode.

 

Cable connector may have been part of the problem but you may need a new throttle base also.Polaris 2009-2017 Sportsman 550 850 XP ATV Throttle Base Assy 2010359 New OEM