I recently broke the throttle on a late model sportsman. I have ordered part#2010359 which replaces the whole assembly. How difficult is the replacement.? The 4x4 switch and throttle cable are involved. Not sure if this can be done by me or do I need to have the dealer do it.. Thanks..

 

You can do it. Pull the connector,pop the top cap,pull the throttle cable until it reaches the cut out slot on the inner lever,pull up and out. Remove the cable assy from the old housing. Then just remove/replace the throttle housing,side the cable in,pull the cable until you can reach the cut out slot,drop the cable fitting in. If it doesn't want to idle when you crank it up,you may have to adjust the distance on the etc switch contact points with the cable adjuster down from the housing.Hopefully you wont have to. Your owners manual will show you this also. Distance is around 2 mm between the contact points. Plus it's similar to the older style setting on the thumb lever slack. Around 1/8" slack only at the thumb throttle. Plus here's a general video on this.

 

Very easy to replace, I did not have to remove the entire housing. The throttle has one phillips screw to hold it in place. Repair took 5 minutes.. Someone needs to make an aftermarket thumb throttle in billet aluminum..

 

You took the thumb lever shaft off the new housing and installed it in the old housing? They actually do make aluminum thumb levers,but if the stem is broken still have to get a new housing assy.Sucks I know.http://www.ebay.com/itm/Polaris-Throttle-Control-Lever-Aluminum-Repair-Part-/251897259515?hash=item3aa63f25fb&vxp=mtr

 

Yes exactly I took the shaft off the new assembly and used on the original. I don't see how the aluminum throttles you referenced would work as the shaft and thumb assembly is all one piece.

 

Does show that it fits these models.
2010250 Throttle Control-ASM, AWD
2010221-***-Throttle Control Diff.
2010204-ASM-Throttle Control Hobbs
2010205-Throttle Control ASM, AWD
http://www.ebay.com/itm/NEW-OEM-Polaris-Throttle-Assembly-2005-2007-Sportsman-450-500-700-800-/171721453661?pt=Motors_ATV_Parts_Accessories&hash=item27fb65705d&vxp=mtr As far as yours,cant remember if it has the screw recessed up in the lever or one piece. http://www.ebay.com/itm/POLARIS-SPORTSMAN-THUMB-THROTTLE-LEVER-BASE-4X4-4X2-SWITCH-NEW-OEM-PART-2010359-/131426374309?fits=Make%3APolaris&hash=item1e999f52a5&vxp=mtr

 

Mine uses the 2010359, screw in the top.. my machine is 1000 XP Sportsman..BTW I got the parts from your recommendation, dirt cheap yamaha polaris parts 47.99 plus shipping..

 

old polaris tech
I know this is an old post but seem to be having problem pulling the connector from the throttle assembly on an 850xp trying not to tear anything up. Anything special I need to do to get it off? Thanks in advance

 

If you're talking about the electrical connector it just has a plastic release part on the connector itself that has to be firmly pushed so you can remove the connector without any damage.

 

Hooked my knee getting off the thing to grab my dog, and am shocked at the need to replace an entire $365 module for that?

I am looking for less intense options and welcome any ideas from the forum.

2015 Sportsman 570 SP MODEL A15SHE57AM

I have read others mention a "scored" groove designed to snap. Mine shows the same. What's up with that?