Motion Pro 01-2529 User Manual

Page 2

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7. The type of twist grips varies, but all types will install and work similarly. Slide the throttle sleeve onto the
handlebar. Next, install the cable through the top half of the throttle housing and connect the cable end to the slot
in the throttle sleeve. Install the plastic cable guide or wheel into the upper throttle housing. Make sure the cable
fits into the groove of the guide or wheel. Note: Some throttle designs do not have plastic guides or wheels. Refer
to individual throttle instruction sheets. Assemble the upper and lower throttle housings while positioning the
throttle sleeve stop above the housing stop. Allow an 1/8 inch clearance between the grip and handlebar end. This
will prevent the grip from binding on the end of the handlebar. Position the throttle so that the throttle cable will exit
above the front brake lever assembly. Insert the throttle housing screws and tighten.

8. Throttle cable adjustment:

A

LL THROTTLE CABLE ADJUSTMENTS ARE DONE WITH THE ENGINE OFF

. Start by

synchronizing the carburetors. With the air cleaner box off, you can feel the backsides of the throttle slides with
your fingers. When you twist the throttle with your right hand you can feel the throttle slides move with your left
fingers. Adjust the carburetor top adjusters, so that both slides (from the fully closed position) begin to move
simultaneously when the throttle is opened. As a double check, open the throttle so that the backs of the slides are
even with the top of the throttle bore. Set the highest slide even and bring the other slide up to match. Reinstall the
air cleaner box. Adjust the top throttle cable adjuster so there is a slight amount of free play (1/16 to 1/8 inch).
Tighten all adjuster nuts. Reinstall all cable clamps and guides. Check that the throttle will snap back from the full
open position in all handlebar steering positions. Also, check that the cable has free play when the handlebars are
turned side to side. Note: Cable routing and throttle position affect the smoothness of throttle operation. Route the
cable to avoid sharp bends or kinks. Position the throttle so that it does not create sharp bends or kinks in the
cable.

9. Electrical Connections: This machine is equipped with a THROTTLE OVERRIDE SYSTEM. The purpose of
this system is to turn off the ignition if the carburetor slide sticks open in the throttle body. When the stock thumb
throttle and carburetor top/switch assembly are removed, this system is disabled. When working on 1988-2001
models, the ignition system will also be disabled. The control box, located inside the front left fender, must be
removed for the ignition system to work. When working on 2002 and later models it is not necessary to remove the
control box, just unplug the lower electrical connector from the stock thumb throttle and loop together the two pin
connecter where the stock thumb throttle attaches on the main wire harness or where the thumb throttle plugs into
the CDI box. Either way, you are connecting the plug back in where it was disconnected from (One way to loop the
connections is to use the last three inches of the thumb throttle lower connection attach the two wires together and
plug back into the main harness). Cover all exposed wires and connector's with electrical tape. Or, use Motion Pro
Switch Elimination Coupler Assembly part number 11-0040 and snap coupler directly into existing 2 pin connector
where the thumb throttle was plugged into the main harness. THE THROTTLE OVERRIDE SYSTEM IS NOW
DISABLED.

10. Install the fuel tank and seat. Start the engine to check throttle operation. Using throttle, raise engine speed
momentarily to 4000 RPM and release throttle. Engine speed should drop quickly to idle speed without hesitation.
Next, while turning the handlebars side to side, there should be no change in engine speed. Repeat step 8 if
throttle is not operating as described above.

11. It is suggested that you familiarize yourself with the operation of the twist grip throttle. Run the machine at
different speeds until you are completely familiar with how the throttle operates. If you have experience riding
motorcycles the twist throttle will be quite natural. If you have only used the thumb type throttle you should practice
until operation of throttle is done without second thought.

I01-0313

12/2009

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