02 500 6x6 thumb throttle - Polaris ATV Forum
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post #1 of 3 (permalink) Old 01-30-2018, 05:48 AM Thread Starter
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02 500 6x6 thumb throttle

I have an 02 500 6x6 and the thumb throttle broke off. they want me to replace the entire housing but I just need the thumb throttle itself. The ones I have found online don't match the part number though they look like they should work. has anyone tried using one of these?
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post #2 of 3 (permalink) Old 01-30-2018, 06:30 AM
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That throttle assembly was used on all these models:

Assemblies where 2010205 is used
2001 325 MAGNUM 4X4 HDS (A01CD32FB) - Controls Throttle Asm./Cable A01cd32aa
2001 500 MAGNUM 500 HDS (A01CD50FB) - Controls Throttle Asm./Cable A01cd50aa
2001 DIESEL (A10CH46CA) - Controls Throttle Assembly/Cable
2001 INT'L BIG BOSS 6X6 (A01CL50DA) - Controls Throttle Asm./Cable A01cl50aa
2001 MAGNUM 325 4X4 (A01CD32AA) - Controls Throttle Asm./Cable
2001 MAGNUM 325 4X4 MOSE (A01CD32AB) - Controls Throttle Asm./Cable A01cd32aa
2001 MAGNUM 500 (A01CD50AA) - Controls Throttle Asm./Cable
2001 SCRAMBLER 500 4X4 (A01BG50AA) - Controls Throttle Asm./Cable
2001 SCRAMBLER 500 4X4 (A01BG50AB) - Controls Throttle Asm./Cable A01bg50aa
2001 SPORTSMAN 400 (A01CH42AA) - Controls Throttle Asm./Cable
2001 SPORTSMAN 400 (A01CH42AB) - Controls Throttle Asm./Cable A01ch42aa
2001 SPORTSMAN 400 (A01CH42AC) - Controls Throttle Asm./Cable A01ch42aa
2001 SPORTSMAN 500 DUSE HO (A01CH50AF) - Controls Throttle Asm./Cable A01ch50aa
2001 SPORTSMAN 500 HO (A01CH50AA) - Controls Throttle Asm./Cable
2001 SPORTSMAN 500 HO (A01CH50AB) - Controls Throttle Asm./Cable A01ch50aa
2001 SPORTSMAN 500 HO (A01CH50AE) - Controls Throttle Asm./Cable A01ch50aa
2001 SPORTSMAN 500 HO (A01CH50AK) - Controls Throttle Asm./Cable A01ch50aa
2001 SPORTSMAN 500 RSE HO (A01CH50AJ) - Controls Throttle Asm./Cable A01ch50aa
2001 SPORTSMAN 6X6 (A01CL50AA) - Controls Throttle Asm./Cable
2001 WORKER 500 (A01CH50EB) - Controls Throttle Asm./Cable A01ch50aa
2001 XPEDITION 425 (A01CK42AA) - Controls Throttle Asm./Cable
2001 XPEDITION 425 (A01CK42AB) - Controls Throttle Asm./Cable A01ck42aa
2001 XPEDITION 425 (A01CK42CA) - Controls Throttle Asm./Cable A01ck42aa
2001 XPLORER (A01AG25CA) - Controls Throttle Asm./Cable
2001 XPLORER 400 (A01CG38CA) - Controls Throttle Asm./Cable
2002 325 MAGNUM 4X4 HDS (A02CD32FB) - Controls Throttle Asm/Cable A02cd32aa/Ab/Ac/Fb
2002 500 MAGNUM VL HDS (A02CD50FB) - Controls Throttle Asm. A02cd50aa/Ab/Fb
2002 INT'L BIG BOSS 6X6 (A02CL50DA) - Controls Throttle Asm/Cable A02cl50aa/Da
2002 LUH 6X6 PPS (C02CL50AB) - Controls Throttle Asm/Cable
2002 MAGNUM 325 4X4 (A02CD32AA) - Controls Throttle Asm/Cable /Ab/Ac/Fb
2002 MAGNUM 325 4X4 (A02CD32AB) - Controls Throttle Asm/Cable A02cd32aa/Ab/Ac/Fb
2002 MAGNUM 325 4X4 FREEDOM (A02CD32AC) - Controls Throttle Asm/Cable A02cd32aa/Ab/Ac/Fb
2002 MAGNUM 500 (A02CD50AA) - Controls Throttle Asm. /Ab/Fb
2002 MAGNUM 500 RMK (A02CD50AB) - Controls Throttle Asm. A02cd50aa/Ab/Fb
2002 SCRAMBLER 400 4X4 (A02BG38CA) - Controls Throttle Asm/Cable
2002 SCRAMBLER 500 4X4 (A02BG50AA) - Controls Throttle Asm/Cable /Ac
2002 SCRAMBLER 500 4X4 FREEDOM (A02BG50AC) - Controls Throttle Asm/Cable A02bg50aa/Ac
2002 SPORTSMAN 400 (A02CH42AA) - Controls Throttle Asm/Cable
2002 SPORTSMAN 400 (A02CH42AB) - Controls Throttle Asm/Cable A02ch42aa
2002 SPORTSMAN 400 (A02CH42AC) - Controls Throttle Asm/Cable A02ch42aa
2002 SPORTSMAN 500 ALL OPTIONS (A02CH50) - Controls Throttle Asm/Cable All Options
2002 SPORTSMAN 6X6 (A02CL50AA) - Controls Throttle Asm/Cable /Da
2002 SPORTSMAN 700 (A02CH68AA/AB/AC/CA/CB) - Controls Throttle Asm/Cable
2002 XPEDITION 325 (A02CK32AA) - Controls Throttle Asm/Cable
2002 XPEDITION 425 (A02CK42AA/AB) - Controls Throttle Asm/Cable
2002 XPLORER 400 (A02CG38CA) - Controls Throttle Asm/Cable
2002 XPLORER 4X4 (A02CG25CA) - Controls Throttle Asm/Cable
2003 MAGNUM 330 4X4 (A03CD32AA/AB/AC/FB) - Controlsthrottle Asm/Cable
2003 SCRAMBLER 500 4X4 (A03BG50AA) - Controlsthrottle Asm/Cable
2003 SPORTSMAN 400 (A03CH42AA/AB/AC) - Controlsthrottle Asm/Cable
2003 SPORTSMAN 500 HO (A03CH50AA/AB/AC/AD/AE/AH/AJ) - Controls/Throttle Asm/Cable
2003 SPORTSMAN 600 (A03CH59AA) - Controlsthrottle Asm/Cable /Af/Ag
2003 SPORTSMAN 6X6 (A03CL50AA) - Controlsthrottle Asm/Cable
2003 SPORTSMAN 700 (A03CH68AA/AC/AF/AH/AL) - Controlsthrottle Asm/Cable
2004 A04BG50AA SCRAMBLER 500 4X4 (A04BG50AA/FA) - Controlsthrottle Asm/Cable
2004 MAGNUM 330 4X4 (A04CD32AA) - Controlsthrottle Asm/Cable /Ab/Ac/Fb
2004 SPORTSMAN 6X6 (A04CL50AA) - Controlsthrottle Asm/Cable
SERIES 10 PTV 6X6 (C10CL50AA) - Controlsthrottle Asm./Cable

Try to get a used one on ebay and just change the lever part, or get a Honda TRX400EX or 450R throttle assembly and install it. As for the wires going to the Polaris throttle - just cut them off or follow them back to where they plug in and unplug them - there's a switch in the Polaris throttle that cuts the ignition when the switch closes. This happens when there is not enough slack in the throttle cable or the carb sticks open. If you eliminate the switch, you just have be prepared to hit the kill button if the throttle sticks open. I don't have any knowledge of a carb ever sticking open. It has never been reported to me that it happened.
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post #3 of 3 (permalink) Old 01-30-2018, 07:05 AM Thread Starter
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Great, thanks for your help!
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