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- เผยแพร่เมื่อ 21 พ.ย. 2024
- Here's a common issue with the Polaris ATV. Symptoms are, Intermediate stalling, no start, Back firing and ruff Idle. Also if the cable is adjusted to tight you can also end up with a check engine light on. This video covers how to adjust the throttle cable in order to set the switch properly, how to remove or by pass the switch and How to remove or replace the thumb throttle if needed.
Bypassing that killswitch is the best thing that ever happened to my 850. Thank you. The killswitch isn’t necessary. If (big if) it does break and the throttle sticks open, then simply turn off the key. It will accomplish the same thing!
I have Polaris 2001 425 xpedition that has been running rough since last winter. Replaced parts...new carb,new fuel pump,new fuel lines, checked for intake leaks, adjusted cam rockers and still ran like shit then I watched your video and took my throttle cover off and sure as shit little spring laying loose in there. Fixed it and son bitch runs great! Thanks so much for posting this video! Polaris service manual never mentioned to look at this possible problem.
My 06 500 was doing the same thing, looked at the cable switch and saw that the contacts were actually about 1/2 in apart. I could move the throttle in and out before the cable moved, and the switch was real loose. Adjusted the cable as you demonstrated in your video, and this helped tighten up the switch, and close the contacts. The 500 isn't shutting off when I drive it and let off the throttle any more, so I hope it stays this way. Thanks for the great video.
This zip tie trick does indeed fool the the ECU into thinking all is well with the safety system. However, according to the service manual the throttle switch is supposed to make contact at idle not be open all the time. In fact it's looking for a resistance of 2.15k ohm when closed and 6.76k ohm when its open. The 520194 7 code issue tends to be thrown because of an elevated idle with the throttle switch closed making the computer think the throttle is stuck open. This is caused by no free-play in the cable or the TPS is worn or damaged. Try loosening the the TPS and rotating it enough to achieve an idle of 1250 RPM. It solved my issue and didn't need to keep zip-tie in.
Al you are correct - the fix is in the manual - the contacts should touch at idle - the first step is to fix throttle as per section 2-10 much like this video with 2-3mm gap at the stop with contacts touching at idle - then the next fix is the as adjustment of the TPS reading on the throttle body as per section 3-24 to adjust the voltage to 0.700 as per service manual (for a 850 Sportsman - maybe different for other models) - i think thats the correct fix for the idle issue most people are having if the plugs ecu feul pump etc all work fine
Worked perfect brother.! Thanks for sharing.. I thought it was my fuel pump, but it tested fine. Then I came across your video. Thanks again!!
Just got myself a nearly new 2013 -same colour- 150 miles on it and it back fires sometimes and stalled just yesterday. I will check out my switch now!!
Cut 1 coil out of the spring. It will open the contact and still allow the switch to work if the cable breaks. Did mine yesterday. Good video by the way!
I struggled with this for months....goes into limp mode at the worst of times causing me to blip the throttle to kick it out.....It is a pain in the ass to find the "sweet' spot to make it work.....poor design to say the least...if and when it does it again....I'm going to use this fix...THANX!!!!!!!
Great video man , I heard that Polaris makes Dissolving Stoppers for the throttle body ! That way they can sell you more parts !
I adjusted mine this way...that small spring next to contacts where you placed zip ties..just turn counterclockwise to spread it a bit to prevent touching..thats it
We have a Sportsman 325 ETX with some engine cutting issue. This throttle release switch (TRS) observation is interesting, but I think it is not the primary fault. The TRS is supposed to e closed at idle. When it is closed it should not cut the engine. I should send a signal to the ECU (ECM in Polaris manual), and the ECU should make the engine idle. If the ECU has some malfunction or bad software/algorithm, then it may be cutting the engine. This fix will certainly bypass that. The TRS seems a bit unnecessary to me. There is a kill switch on the left handlebar switchgear. Thanks for the video, and we may end up with this fix.
thanks man helped me out alot with my 1000xp now its ideling good
Great job man ! I believe Polaris puts a self dissolving tablet between the contacts so you will take it back to Dealer to fix ! $$$$$ , love the Zip Tie trick , could one File the contacts ?
A 1000 xp backfireing must sound like a cannon
I have the 850 and sounds like crap 😢 like the pistons are loose. Hopefully is juat a simple fix 😮
Outstanding thanks so much for helping me fix my problem .
definitely going to try this! thank you for the video
You're a legend, this was very clever and simple. Thank you!
The service manual says the contacts should be closed in the idle position and open when the throttle is applied
Polaris. The Ford of the ATV world
TRUE LOL
Canned HAms are the Chryslers of the atv world.
Mine was doing this and when i took it apart i found that the wires that go to the contacts had broken with only a strand or two connecting them. Removed connectors and reattached wires, fixed the problem for now. Waiting on a new one to replace it for the spring.
I have a 2015 sportsman 570 it runs well I noticed tho when decelerating off the throttle it back fires just a bit but if I let off completely it doesn’t backfire at all will this fix the issue?
Buddy you sound just like the movie actor who’s the comedian shit I forgot his name but dude he’s awesome actor
this has been plaguing me for 2 days. i thought it was cable, harness, fuel pump, bad battery. all this shit right? come to find out, the back firing and cutting off was due to the neg batt terminal being a tad loose. when it was still, ran fine, but when it hits a certain rpm, that magic freqency actually levatated the screw off the battery terminal, and the motor and pod would turn off. i could stop, cut it off, and it would start right back up. but yeah, check to make sure what you already got, is tight. haha
wow. i think this has been my stalling issue and now its also back firing. I will check it out. thx
I got a stalling issue too does it was your problem??
Did you fix this?
I did this fix but it is still stopping the engine. Any thoughts on cause?
did you ever adjust the spring?? perhaps of you expand it a bit wit will keep the contacts from touching
You have to cut a coil out. I stretched mine first to no help. Then I cut a coil out and it allowed the contact to remain open
Needs a stiffer spring. Spring is old
Me too.
I tried this and seems to work on my 2012 850 sportsman xp eps
Great video. Thanks man!!!
I forgot about this damn thing lol I fixed it but after rain and son rips of patch in plastic cover allowing rain to make it in lol . I did it once this just reminded me completely forgot about that one other killswitch or safety feature is has
I figured it out. Its actually on where the gas flicker goes up and where the screw holds the assembly the 4star shape in the plastic acually has play in it. So its just plastic that has been squashed with hard push on the throttle over a long time. Its kinda simmular to the 10$ gear shifter spline lol. Polaris doesnt it break it just loosens up 😂
Saved my bacon in montana
Is this fuel injection machine ? How do you know the contacts aren’t supposed to touch ? I have a 2021 750 sportsman and they say they are supposed to touch . I don’t know which way they supposed to be. Do you ?
Thanks thats what my 2010 500 h.0. is doing cutting off for no reason while riding when I turn the wheels or sometimes just sitting idling and I have changed everything but I checked and there is alot of movement in there so I am pretty sure that is the problem
We use our 2021 Sportsman 850 on the farm every day; we’re really stuck without it and doing farm chores. Ours only has about 400 miles on it and we’re having an issue with it shutting off and not starting up until it sits for an hour or so. Does this sound like the same problem or something different?
(We went back and forth or whether to buy this machine or a Honda. Guess which one will be our next purchase?)
Did u ever fix the issue? Mine does the same
@@joeycarpeal th-cam.com/video/zGQ41W5l4H4/w-d-xo.html
Mine does the same also. 2017 with less than 200 miles on it. I’ve replaces the fuel pump twice. First time the machine would run and die, run and die, new fuel pump fixed it.
Second time it would not start, new fuel pump and it started right up
Now it runs for about 30 minutes, dies and sometimes backfires
Guess I’ll try this trick or at least see what the contacts are doing
Geez did I buy a lemon or what???
I’ll never have another polaris anything
I was warned not to buy a Polaris. People told me if I did, I’d need two because one will always be in the shop for repair. Got mine back from the Polaris dealer’s shop and, within a couple of days, indicator lights on recommending service. Next machine: Honda
Cable adjustment will give you the gap you need.you canceled the safety.
i dont speak english great, but this can make rev limit in polaris phoenix at full thortle ? i cant drive faster then 60km/h
It just looks like a very bad design, they could have found a better way to do this.
David Gardner That’s how Polaris does everything. Cheap, lazy and unreliable.
Fixed my 2001 scrambler! Thanks
A little bit of water in there would mess it up too right?
Your (throttle arm stop) is on the left side under assembly. Section 2.9 of shop manual I have. Mike S.
im not having any problems but my bike boggs out when i give it gas and i notice the two wires are cut and wonder do that have something to do with it
My 2004 Polaris 400 idles and starts fine but when I give it gas it stalls as if I turn the switch off any advice?
Northern Heaven250 carbureted? If it is than sounds like u need a carb job
CDI box cut the black wire n C if that makes any difference
Try stretching the spring. Maybe both springs.
could you just unhook one side of the switch?
Can you just buy. A new switch???
i have a 1998 polaris sportsman 500 it will run but it blows stuff out the carb and then it will backfire and blow the carb off the intake someone please help me out
Does it work for a 2020 570
Put the end of a zip tie in their to keep the contacts apart.
That works for me thanks man.....
My 850 xp won’t idle without trottle and when it does rpm at idle goes up and down. Also smell gas in oil. Can you comment back. Thanks
Did find out what the problem was? I'm having the exact same issues with mine
Has it ever tripped your check engine light? I'm getting a code of 520194,2 on my clusters diag code.
NO, not mine cause i adjusted the cable correctly.
Mine tripped it
That code is usually tripped by the four wires going into where the 4x4 switch is it. I could not firgure it out until I read to pull those 4 wires out which is like a 4pin plug and sure as shit it was very dirty and corroded. Cleaned them up put some dialectic grease and light hasn't came on
do you think it would work on a 2016 570 sportman?
probly. open it up and take a look.
Hello I have a Polaris sportsman 550 efi problem with start coming failed code 5201937 + oil in airbox please help
Did you ever find while the oil went in the airbox
I need help.
Duck tape conducts electricity it's for metal duck work. Keep it off wires! Use black electrical tape.
Ok I found the actor “TJ miller” you sound just
Like him man are you him buddy? lol narrator of emoji movie played in dead pool movie
Your cable is to tight and does not have enough play to make the gap at the switch, Mr bennett has the answer below.
Does this fix the tps code?
What code will it throw with that problem
Royce Kennedy 520194-7
I'm having the same issue with my 2013. But this didn't fix the issue. Idles fine. But when you get past half throttle it bogs down. 😩
Dirty Bird mine does the exact same thing. Did this, new cdi , new fuel pump and filter, so far nothing.
I heard it could be the gasket right before the head, right after the fuel injector, before gas flows into the head. This gasket may be out of position and stopping the flow of gas into the head. I have NOT tested this yet. I just heard it today and thought I would bring it up.
carb
any update?
It didnt work for me
Thanks.
Hi, I have a problem with my sportaman 400. It turns on correctly, everything is fine, but when accelerating and releasing the accelerator it makes explosions. please help.
im having same problem, did you ever figure it out, id love to know.
I have a 2014 rzr 900 xp and is backfiring after riding for about 5mins and loses power then works back on and does the same thing after stepping on gas does some one knows whats the issue?
yes mine did the exact same thing it turned out to be water in my gas drained the tank and it ran fine
Mine does the same thing
I’m working on one of these for another guy. I just absolutely hate polaris
Why do you hate Polaris?
I need help ASAP
Polaris piece junk
That's all I see in Colorado mountains, must not be too bad