Motion Pro 01-0511 - Manual (Page 2)

7. 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 throttle housing. Make sure the cable fits into the groove of the guide or wheel. 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 . Adjust
the throttle cable 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.
I01-0337 12/2009