Motion Pro Revolver Push Pull Throttle Kit - Manual (Page 3)

Make sure the Revolver™ tube flange fits inside the
recess on the Revolver™ reel. Install the throttle tube
on the handlebar. Use some high quality grease on
the barrels of the Revolver™ cables and fit the push
and pull cables into the Revolver™ reel. The cable
wires will wrap around the reel and attach to the reel
on the opposite side from the cable elbows. The pull
cable barrel hole will fit very closely to the barrel, while
the return barrel hole in the reel is slightly oval. Use a
small amount of grease on the outside diameter of the
reel as well, where the cable wires ride. Install the two
halves of the throttle housing around the throttle tube,
reel and cable elbows. The housing halves should fit
snugly together and the throttle should operate
smoothly. If not, double-check to make sure the
elbows are aligned correctly and that the wires are
routed properly on the outside of the reel. Once
everything is fit correctly, install the two housing screws and tighten them evenly to clamp the
housing on the handlebar. Do not exceed 90 kg/cm torque (78 in/lbs or 6 ft/lbs) on the housing
screws. The setscrew can be used once the housing is tight to help maintain the location of the
throttle on the handlebar. Some bikes have handlebars with a dimple specifically designed to
accept the setscrew. At this time, the cables will still be slightly loose, but the throttle should
operate smoothly and snap back quickly to the closed position.
Step 4: Cable Adjustments
The aluminum inline adjusters on the cable housing near the throttle should be closed all way
before starting this step. Some motorcycles have threaded adjusters on the throttle body or carb
cable mounts. If so, this is where you will start. If there are only slip-on fittings at the carb or
throttle bodies, the adjustments will be made at the inline adjusters only. Start with the pull cable
and adjust the adjuster until there is approximately 1-2mm of free play in the cable. The throttle
should be able to rotate a few degrees before starting to open the carbs or throttle bodies. Once
this adjustment is complete, twist the throttle and let go several times. The throttle should snap
back closed very quickly. If it does not, double check all of your previous work to determine the
problem. DO NOT continue until the throttle snaps back quickly on its own once released. Once
the pull cable is adjusted, now adjust the return cable. The return cable should have 2-3mm of
free play. If you can reach the exposed wire of the return cable at the carbs or throttle bodies, you
should be able to deflect it from straight by a millimeter or so if it is adjusted properly. Open the
throttle and release again and it should snap back as quickly as before. If not, the return cable is
too tight. Adjust and operate the throttle again, until it snaps back quickly.
Step 5: Install the Grips
Use some good grip glue on the grips and install them. Make sure that the throttle side grip does
not contact the throttle housing, which will cause drag. Reinstall any bar ends that may have been
on the handlebars and test the throttle again to make sure the grip does not drag on the bar end
as well.
Step 6: Reassemble the Rest of the Bike
Reassemble the airbox, tank, seat and anything else that was removed when you started. Make
sure to make all the proper hose and electrical connections, while referring to the factory service
manual for details.
I01-2614 7/2010