got my new revelations set up nice, but when i press the bar mounted lever to lock out the forks, their is still about 25mm of travel there.
can i set them up so there is no travel.

It's not a total mechanical lockout, so will always move if you hit something big enough (It locks out oil flow but had a 'blow off' valve) You should be able to adjust the threshhold of the 'blow off' to firmer or softer with the 'Floodgate' which is the tiny knob or allen screw right in the centre of the right hand leg top cap…..

Unless they are cheaper ones and don't have the adjustment that is! 🙂

Is the poploc lever pulling the lockout adjuster far enough for 'full' lockout? Before tightening the grub screw that holds the cable to the lockout lever, take out the slack by twisting the lockout lever slightly first. This is what I had to do with my older Revs.

As said above, Floodgate adjustment or cable tension it does need to be quite tight to get all the slack out. And they will 'blow throught' the lock on 'hits' or if you lean on the bars for a while.
In addition if this continues it might be worth checking the oil level.