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Discussion Starter #1
Okay guys.

It's time to find a throttle return spring that isn't so heavy, anybody find one?
 

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I have been thinking the same thing but have not yet started looking. I have a loop through my trails that takes about an hour to complete. At the end of an hour my old right leg is strained. I hope someone has found something.
 

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Discussion Starter #4
Really heavy boots!

Have you guys looked at the spring? Its way too thick for the job.
 

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OK, it is a pretty hefty spring.
I wouldn't know how to go about finding a replacement that has the right size and shape spurs on the ends to fit in there.
 

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Kind of a long shot, but if you can have a replacement in case it doesn't work, maybe you could take if off and try to stretch it out a bit?
 

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Does anyone have ability to measure the length and diameter of the coils, the wire diameter, and the distance between the hooks on the ends, I can check through a bunch of springs in our diesel fuel injection parts here at work to see if there is one with less tension. I will have to go home tonight and look at mine so I can compare it to what we have at work, and if I come it with something, I can let you know.
 

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When I install the EPS kit, I'm going to be taking a lot of plastic off in that area. I'll see if getting access to that spring becomes easy.
 

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Sounds good. When I get home this evening, I'll see if I can even see mine. We'll put our heads together and see if we can find a good candidate to lighten it up a bit! I can't wait to find out about the EPS kit. Sounds interesting!
 

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Discussion Starter #10
Yeah its easy to see, it's right on the pedal where it bolts to the frame.
 

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Throttle return springs

I took a look at the throttle return spring on the ACE, and did some measurements. The spring looks like the picture below. Dimensions of mine are as follows:
7 coils, 0.118" wire, OD of spring coils is 1.180", and this makes the ID of the coils roughly 1.062". OD of shaft it fits on is 0.897" Width of coils is 0.857". Length of hooked leg which goes around pedal from top of coils to bottom of hook is 2.278". Length of leg with 90 degree bend from top of coil to bottom of bend is 2.837". I did not measure the torsion of the spring since I did not remove it from the pedal. I believe that the ACE spring is a left hand wind spring.


View attachment 1079
According to ebay, there are loads of heavy duty throttle return springs for sale to fit the RZRs. Some folks on the forums write that the original spring is too light when on rough terrain, which would be the reason that there are a proliferation of these springs on the market.

Does this mean that the original RZR throttle return spring is lighter than the one we have on the ACE? Don't know. Would the original RZR spring fit on the ACE? Don't know that either. Maybe someone with both can compare the RZR spring to the ACE spring. If there is one already made for another machine that would fit perfectly but have less tension, that would be ideal.

Meanwhile, I will do some looking for other suitable springs in the aftermarket.:)
 

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I just measured (VERY clumsily, with a stick and a postal scale) the amount of force necessary to depress the gas pedal on my ACE and my RZR.
I found that it took roughly 10 lbs to push down the pedal in the ACE, and about 5 lbs for the RZR.
Keep in mind that I have had the RZR for 3.5 years, and 2600 miles - so its spring might not have as much sproing as it did when new.
The springs look roughly the same size and shape to my untrained eye.
So based on that, it seems worthwhile to try a 2010 RZR S spring.
 

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Awesome, Scoundrel! That's what I was hoping for when I was reading about the RZR return spring. I gather from reading the forums that the RZR owners were wanting a heavier duty spring to prevent their foot from pumping the throttle while traversing rough terrain. On the ACE, we want it a bit easier, but not too easy. Maybe that will be the answer!
 

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I have found that taking over a 1/2 in of free play out of the pedal made a big difference for me. It seemed getting full throttle a lot easier, or even part throttle for that matter. Cheers
 

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Discussion Starter #17
I knew y'all could figure this out! I'll try the free play thing first, then go for a lighter spring.
 

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Is this truly an issue of a hefty spring, or one of too much throttle free play? I posted about too much free play in mine earlier. I haven't spent all day in the seat like most of you experienced folks. What is the consensus of opinion about the spring?
 

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Discussion Starter #19
That's a good question. Im gonna put some miles on mine tomorrow after fixing the freeplay and see.
 

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Great! I look forward to your reply. Then if it is the spring issue, I'll contact a couple machinist friends so we can work on an answer. I don't want too light of a spring because I'm afraid of a bouncy accelerator over rough ground if it's too easy to press.
 
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