Motion Pro 01-0339 - Manual

IMPORTANT - READ BEFORE INSTALLING
THIS KIT IS TO BE INSTALLED BY A TRAINED TECHNICIAN IN A PROPERLY EQUIPPED SHOP
FOR THROTTLE KIT P/N 01-0339 (YFS 200 BLASTER)
THESE INSTRUCTIONS ARE FOR USE WITH THE THROTTLE KIT LISTED ABOVE. THIS KIT IS DESIGNED
TO REPLACE THE ORIGINAL THUMB THROTTLE WITH A TWIST GRIP TYPE THROTTLE.
1. Remove the seat and fuel tank. Carefully observe how the stock throttle cable is routed from the thumb throttle
to the carburetor. This is how you will want to route the new cable.
2. Temporarily remove any clamps or guides used to retain the throttle cable. Remove the stock thumb throttle
assembly.
3. Before removing the carburetor top/switch assembly, clean the outside of the carburetor and switch assembly
thoroughly. On the outside of the carburetor you will find a gold colored carburetor top locking plate. Remove this
plate and unscrew the carburetor top. Remove the carburetor top/switch assembly. Do not allow any dirt or foreign
material to enter the opening left in carburetor. Placing a clean rag in the opening of the carburetor will help avoid
this problem.
A NY DIRT OR FOREIGN MATERIAL THAT ENTERS THE CARBURETOR CAN CAUSE THE THROTTLE SLIDE TO
STICK .
4. Remove the right hand side plate (5 screws) from the switch assembly. Again, be careful that dirt or foreign
material does not enter the switch assembly. Remove the old cable and replace with the new cable supplied in the
kit. Re-install the side plate making sure the gasket is in the correct position and tighten the screws.
5. Remove the rag in the carburetor opening. Again, be careful that dirt or foreign material does not enter the
carburetor. Install the carburetor top/switch assembly onto the carburetor. When installing the throttle slide into the
carburetor, make sure the guide pin slides into the groove on the slide (slide cutaway to rear). Tighten the
carburetor top and reinstall the locking plate. Pull on the top cable end to make sure the full travel (up and down) of
the slide is smooth, without bin ding.
6. Remove the right hand grip from the handlebar. With an Allen wrench, disassemble the new throttle assembly.
Using the throttle sleeve as a guide, mark the handlebar showing where the sleeve will fit. With fine sandpaper
remove any paint on the handlebar where the throttle sleeve will fit. I
T IS VERY IMPORTANT THAT THE HANDLEBAR BE
CLEAN AND SMOOTH . I F THE HANDLEBAR IS NOT CLEAN AND SMOOTH IT IS POSSIBLE FOR THE THROTTLE
TO STICK .
7. Slide the throttle sleeve onto the handlebar. 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. Install the throttle
cable adjuster and lock nut onto the cable. Insert the cable end into the threaded adjuster hole in the upper throttle
housing. Screw the throttle cable adjuster into the throttle housing and connect the cable end to the throttle sleeve.
Install the guide wheel so the cable fits in the groove of the wheel. Install the housing cover, insert the screw and
tighten.
-OVER-
I01-0339 12/2009