Motion Pro 01-0362 - Manual

IMPORTANT – READ INSTRUCTIONS BEFORE INSTALLING
THIS KIT IS TO BE INSTALLED BY A TRAINED TECHNICIAN IN A PROPERLY EQUIPPED SHOP
FOR THROTTLE KITS P/N 01-0316 & P/N 01-0362
THESE INSTRUCTIONS ARE FOR USE WITH THE THROTTLE KITS LISTED ABOVE. THESE KITS
ARE DESIGNED TO BE USED WITH MIKUNI SMOOTHBORE CARBURETORS.
1. Remove the seat and fuel tank. Carefully observe how the stock throttle cables are routed from the throttle to
the carburetors. This is how you will want to route the new cables.
2. Temporarily remove any clamps or guides used to retain the throttle cables. Remove the existing throttle
cables and throttle assembly.
3. Install the Mikuni Smoothbore carburetors. Refer to Mikuni’s instruction sheet for carburetor installation.
4. Install the throttle cables onto the throttle cable bracket located on the carburetors. Screw the throttle cable
adjusters all the way down onto the cable bracket. Install the cable ends into the carburetor bell crank. Route the
cables to the area where the throttle assembly will be mounted.
5. Clean the area of the handlebar where the throttle is to be mounted.
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 . Refer to STEP 5a. For kit P/N 01-0316 or STEP 5b. for kit P/N 01-0362
5a. Kit P/N 01-0316 is supplied with a #01-0058 throttle (Honda-Type). With this type of throttle, mount the
lower throttle housing onto the pull cable. Then install the push cable onto the lower throttle housing. Next, slide
throttle sleeve onto the handlebar and connect the cable ends to the sleeve. Install the upper throttle housing 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. Insert the throttle housing
screws and tighten.
5b. Kit #01-0362 is supplied with a #01-0073 throttle (Yamaha-Type). With this type of throttle, there is a
locating pin cast inside the mating surface of the throttle. This pin prevents the throttle from rotating on the
handlebar. Position the throttle assembly on the handlebar allowing a 1/8 inch clearance between the grip and
handlebar end. This will prevent the grip from binding on the end of the handlebar. Mark the handlebar with a center
punch where the locating pinhole is to be drilled. At the center punch mark drill a 5/32 hole about 1/8 inch deep.
De-burr the edges of the hole and remove all metal chips from the handlebar. Slide the throttle sleeve onto the
handlebar and connect the cable ends to the sleeve. Assemble both upper and lower throttle housings while
positioning the throttle sleeve stop above the housing stop. Insert the throttle housing screws and tighten.
6. Throttle cable adjustment: A
LL THROTTLE CABLE ADJUSTMENTS ARE DONE WITH THE ENGINE OFF . Adjust the pull
cable so there is a slight amount of free play (1/16 to 1/8 inch). Adjust the push cable adjuster to the point where
the throttle does not snap back, then loosen the adjuster two turns. Tighten all adjuster lock nuts. Reinstall all
cable clamps and guides. Check that the throttle will snap back from the full open position in all handle bar
steering positions. Also, check that the cables have free play when the handlebars are turned side to side. Note:
Cable routing and throttle position affect the smoothness of throttle operation. Route cables to avoid sharp bends
or kinks. Position the throttle so that it does not create sharp bends or kinks in cables.
7. 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 6 if throttle is not operating as described above.
I01-0316 5/2009