2005 polaris 500 sportsman thumb mechanism for throttle assembly

Thunderdually · #1 (**permalink**) 01-04-2012, 05:35 AM

Any one have or know where i can get a used thumb throttle for a 06 Polaris sportsman 450. I just need the thumb lever it’s self. Seems Polaris either needs money or they are just money hungry not sure which. They won’t sell just the lever you have to buy the whole switch assembly for over $160.00 It’s a shame they have to screw the people who buy their products for $ 5 worth of plastic.

stmar · #2 (**permalink**) 01-04-2012, 06:40 AM

Look on Ebay, they have all kinds of options so you may be able to find something that will work. Would one of those aftermarket extenders work or the twist grip mod?

AKStew · #3 (**permalink**) 01-04-2012, 09:53 AM

We have an ATV salvage yard nearby where I am usually able to find what I need. You might check around your area to see if one exists there.

You might also try craigslist to see if somone might be parting out a machine that has the same throttle assembly as yours. I believe the only difference for several years was the type of 2x4/AWD switch that was in the assembly.

Sometimes a non-dealer repair shop will have old parts laying around. You might get lucky with one of them...and they might know where to get used parts as well.

stmar's thumb extender idea sounds pretty good too if you have enough of the old one left to attach it to.

Stew

**blueline15** · #4 (**permalink**) 01-04-2012, 11:25 AM

Its the stupid electronics that you dont need that cost this much. But you can do this.

You can buy from the dealer or online this OEM# 2010335. Its entire throttle assembly, from a 2x4 trail boss. But it should only be like $30 still. Then you just take the lever off of the new throttle assembly and put in on your current assembly housing. I think its like one philips screw is all, underneath the the lid of the housing.

Did it all the time for customers when I worked at the dealer. Worked great. It should work for everything 2005 and newer that is a "utility" line-up and not an XP. It may work for older machines, and XP's, just never tried it.

But it should work well for you, unless something has changed since I left the shop, but I doubt it has.

Thunderdually · #5 (**permalink**) 01-04-2012, 11:41 AM

Quote:

Originally Posted by AKStew

We have an ATV salvage yard nearby where I am usually able to find what I need. You might check around your area to see if one exists there.

You might also try craigslist to see if somone might be parting out a machine that has the same throttle assembly as yours. I believe the only difference for several years was the type of 2x4/AWD switch that was in the assembly.

Sometimes a non-dealer repair shop will have old parts laying around. You might get lucky with one of them...and they might know where to get used parts as well.

stmar's thumb extender idea sounds pretty good too if you have enough of the old one left to attach it to.

Stew

Thank you for your reply. We don't have an ATV scrap yard any where close But i will try some of the dealers and see if they have a used one.

I can't use any kind of extender because the thumb lever has a plastic shaft that broke off inside the switch box.

Quote:

Originally Posted by blueline15

Its the stupid electronics that you dont need that cost this much. But you can do this.

You can buy from the dealer or online this OEM# 2010335. Its entire throttle assembly, from a 2x4 trail boss. But it should only be like $30 still. Then you just take the lever off of the new throttle assembly and put in on your current assembly housing. I think its like one philips screw is all, underneath the the lid of the housing.

Did it all the time for customers when I worked at the dealer. Worked great. It should work for everything 2005 and newer that is a "utility" line-up and not an XP. It may work for older machines, and XP's, just never tried it.

But it should work well for you, unless something has changed since I left the shop, but I doubt it has.

Thank you for the information. $30 dollars is still a lot of money for a small plastic part but it's a lot better then $160 that's for sure. I'll check out that part.
I'm going to keep a spare with me just incase one breaks again. it's a bitch being stuck out in the woods.. LOL

Thunderdually · #6 (**permalink**) 01-06-2012, 08:55 AM

Well I fixed the problem traded it in on a new Can Am runs great now. J/K I Epoxied the stem back to the lever part with Plastic Weld then as the stem is hollow I filled it with quick steel putty epoxy to give it more strength so far it’s holding..

AKStew · #7 (**permalink**) 01-06-2012, 10:44 AM

Well, that's one way to fix it! I bet the epoxy works. That stuff is amazing if it can get a hold onto something.

Good luck,
Stew

shui5612 · #8 (**permalink**) 01-06-2012, 03:45 PM

i feel your pain...
on my seadoo theres a small TINY little propeller, with 4 blades and holds on a 1"long 1 mm thick metal "rod".
those blades break off eventually... either from getting on a trailer or from the speed....
seadoo only offers the entire speed sensor with the propellor... AKA 250$ for a 5$ prop... its JUST a piece of plastic....
luckily i have found some for sale on ebay...just the little prop but for 25-35$ plus shipping... major ripoff..

id look around ebay... maybe find a thumb throttle that someone makes for quads....

another thing would be... find a good neighboor with a quad like yours... sneak out at night (assuming the atv is outside, if its stored inside, flood their garage so they put the atv outside for the night and steal the thumb throttle and put your broken one back on his...
LMAO just kidding..

im not sure if these thumb throttles are used for other powersports other than the atv...
anyone have any ideas? like some snowmobile .. so that maybe the parts are for sale through them..

also, look for the part at atv dealers or people who repair quads they might have one laying around from an old quad...