Motion Pro 01-0511 User 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 01-0337, P/N 01-0350, P/N 01-0500,

P/N 01-0511 (YFS 200 BLASTER)

NOTE: When this kit is used with stock carburetors it will be necessary to install an idle kit P/N 08-0045.

THESE INSTRUCTIONS ARE FOR USE WITH TWIST GRIP TYPE THROTTLE KITS. THESE KITS ARE

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 (original equipment carburetor). 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. ANY DIRT

OR FOREIGN MATERIAL THAT ENTERS THE CARBURETOR CAN CAUSE THE THROTTLE SLIDE TO STICK.

4. Pull the spring away from the slide and remove the retaining plate. Remove the slide and spring from
the carburetor top/switch assembly (original equipment carburetor). Install the adjuster, carburetor cap,
spring and slide onto the new cable. Make sure the needle is in the correct position and reinstall the
retaining plate.

5. Remove the rag in the carburetor opening. Again, be careful that dirt or foreign material does not
enter the carburetor. Install 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 cap. Pull on the top cable end to
make sure the full travel (up and down) of the slide is smooth, without binding.

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. IT IS VERY

IMPORTANT THAT THE HANDLEBAR BE CLEAN AND SMOOTH. IF THE HANDLEBAR IS NOT CLEAN AND SMOOTH IT
IS POSSIBLE FOR THE THROTTLE TO STICK.

-OVER-

I01-0337 12/2009

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: ALL 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