Motion Pro Revolver Push Pull Throttle Kit User Manual

Revolver™ Push Pull Throttle Kit

Thank you for purchasing the Revolver™ Throttle Kit. You have in your hands one of the most
advanced yet easy to use tunable throttles ever developed. This product will allow you to set the
amount of throttle twist to suit your style and riding conditions. This throttle kit is meant for off­road and closed course track use ONLY. This kit should only be installed by a professional
mechanic and must be installed and maintained in accordance to these instructions to work
properly. Warning: Incorrect installation or maintenance of this product could result in
great bodily injury or death. Always refer to a factory service manual in conjunction with these
instructions when installing or maintaining this throttle assembly.

Familiarizing yourself with the components of the kit

The kit contains:

1. Revolver™ throttle and its components

2. Throttle Cable

3. Revolver™ interchangeable reels

4. RoadControl™ grips (a.) for street or DirtControl™ grips (b.) for Off-Road applications

The throttle consists of the two piece throttle housing, the tube and four throttle reels in sizes
35mm, 40mm, 45mm and 50mm. The throttle housing incorporates a setscrew to fix the throttle to
the handlebar in applications that require a pin for mounting to a locating hole in the handlebar.
The throttle reels are designed so that they will only fit in one direction on the throttle tube and the
throttle tube has a locating ring to position it in the throttle. The throttle housing has a stop built
into the recess for the throttle tube locating ring. Always make sure the throttle is properly
assembled when installing it. If the components don’t fit easily together, something is in the wrong
position.

Never mix the components of this kit with any other throttles or cables. This kit is a stand­alone assembly and any other components from any other assembly can cause the throttle not to
operate or possibly stick or drag, resulting in possible injury or death. Replacement Revolver™
throttle parts and Revolver™ cables are available through your local dealer or Motion Pro.

Some motorcycles have the engine kill and starter switches built into the throttle housing.
If this is the case with your motorcycle, you will need to purchase the accessory handlebar switch
part # 11-0057 to replace the stock switch assembly. The replacement switch is not included in
this kit.

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4 b.

4 a.

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How the Revolver™ throttle works

The Revolver™ throttle has several different size reels that will change how much twist is
necessary for the throttle to completely open the carbs or throttle bodies on a motorcycle. The
larger the reel is, the shorter the twist will be. Each reel size will shorten the twist by about 9
degrees. If your stock throttle has a 40 mm reel and stock twist is 90 degrees (1/4 turn), the
45mm reel will reduce the twist to 81 degrees and the 50mm reel will reduce it to 72 degrees. The
35mm reel will increase the throttle twist to approximately 99 degrees. This is just an example;
every model of motorcycle is different.

Installing the Revolver™ Throttle Kit

Step 1: Removing the stock throttle and cables

Consult your factory service manual for disassembly procedures for your particular motorcycle.
On most bikes, it will be necessary to remove the seat, tank and airbox to access the throttle
cables on the carbs or the throttle bodies. Some bikes will require additional disassembly. Once
you are able to access the cables on the carbs or the throttle bodies, remove the bar end on the
throttle side (if there is one), disassemble the throttle housing on the handlebar and remove the
housing, the stock throttle tube and the cables. Keep the stock throttle tube handy for use later in
the installation. Make note of how the stock throttle cables are routed and then remove the stock
cables from the carbs or throttle bodies.

Step 2: Installing the Revolver™ Kit Cables

Before installing the new cables, use a cable luber
and high quality cable lube (Motion Pro Cable Lube
part # 15-0002 and Cable Luber part # 08-0182).
The cables are not lubed at the factory, so this is an
important step for best feel and cable life. Install the
Revolver™ cables using the same routing as stock
and connect them to the carbs or throttle bodies.
Make sure that the pull cable is attached to the pull
side of the throttle bodies or carbs and the return
cable to the return side. If you reverse them, the
throttle will operate backwards. Do not tighten the
adjusters all the way on the cable mounts at this
time.

Step 3: Installing the Revolver™ Throttle

Take the stock throttle tube and measure the
diameter of the stock reel. Refer to the illustration for
the proper method to measure the diameter of the
tube. With this measurement, if you want to have a
faster turning throttle, select the closest but larger
size Revolver™ throttle reel and install it on the
Revolver™ throttle tube.

WARNING: Always select the closest size first. NEVER install the largest reel right away. Making a
major change in how your throttle operates could result in loss of control of your bike and serious
injury or death. Always work one size at a time and ride the bike long enough to get used to how the
throttle operates before making another change.

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