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CR PRO THROTTLE KIT P/N 01-2569
FOR BOMBARDIER AND CAN-AM OUTLANDER SERIES ATV 2004-2007. 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.
IMPORTANT - READ BEFORE INSTALLING
WE RECOMMEND THAT THIS KIT BE INSTALLED BY A QUALIFIED MECHANIC
IN A PROPERLY EQUIPPED SHOP.
1. Temporarily remove any clamps or guides used to retain the throttle cable. Remove the throttle case cap and disconnect the
stock throttle cable. Note: The thumb throttle/ 4X4 switch assembly is retained. Only the thumb throttle lever components will be
removed. Remove the throttle cable lever screw, throttle cable lever, spring and washer. The throttle cable lever screw that
holds the throttle cable lever has an application of blue thread lock on it. Apply heat to the throttle cable lever screw to loosen
the thread lock compound and then remove the throttle cable lever screw. The screw head will strip if you attempt to remove it
without first applying heat to loosen the thread lock. Please use caution when heating and working with hot parts. Improper
procedures for heating and handling hot parts will result in serious injury. We recommend you take
to a qualified technician for removal of the thumb throttle lever screw. Slide the throttle lever out the bottom of the thumb
throttle/ 4X4 switch assembly and replace the throttle case cap, gasket and tighten screws.
2. Remove the right hand grip from the handlebar. With the Allen wrench supplied, disassemble the new throttle assembly.
Using the throttle sleeve as a guide, mark the handlebar where the throttle sleeve will fit. With fine sandpaper remove any
paint on the handlebar where the throttle sleeve will fit.
HANDLEBAR IS NOT CLEAN AND SMOOTH IT I S POSSIBLE FOR THE THROTTLE TO STICK
IT IS VERY IM PORTANT THAT THE H ANDLEBAR BE CLEAN AND SMOOTH. IF THE
.
the thumb throttle assembly
Remove the original throttle cable from the carburetor or throttle body as specified in your Bombardier, Can-Am or Clymer
3.
service manual and install your new Motion Pro throttle cable supplied with your throttle kit. Cable routing should be the same
as the original throttle cable.
4. Remove the plastic cable guide from the throttle housing. Install the new throttle cable into the throttle housing. Thread the
throttle cable adjuster all the way in. Install the cable guide so the cable fits in the groove of the guide. Slide the throttle sleeve
onto the handlebar and connect the cable end. Assemble the upper and lower throttle housings while positioning the throttle
sleeve stop above the housing stop. Allow a 1/8 inch clearance between the grip and handlebar end. This will prevent the grip
from binding on the end of the handlebar. If possible, position the throttle so that the throttle cable will exit without interfering
with the thumb throttle/ 4X4 switch assembly. Insert the throttle housing screws and tighten
5. Throttle cable adjustment: ALL THROTTLE CABLE ADJUSTMENTS ARE D ONE 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.
6. 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 5 if throttle is not operating as described above.
7. 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.
I01-2569 10/2010
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