The former Cape star will join JJ Abrams and Eric Kripke's thriller, TVLine reports.
Lyons will reportedly take the role of a Marine called Bass, a character originally conceived with Billy Burke in mind.
The Twilight actor originally signed up for the role of Bass earlier this month, but will now appear as protagonist Miles.
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Lyons came to international attention playing troubled doctor Simon Brenner in the last two seasons of ensemble medical drama ER and has also appeared alongside Julia Roberts, Viola Davis and Javier Bardem in Eat Pray Love.
Revolution - which is set in a world where all forms of energy have mysteriously ceased to exist - will feature Giancarlo Esposito (Breaking Bad) as Captain Neville, a tough military man with a secret agenda.
The ensemble cast also includes Tracy Spiradakos (Being Human), Graham Rogers (Struck By Lightning), Anna Lise Phillips (Terra Nova), Ringer's Andrea Roth and Zak Orth (Fringe, 30 Rock).
Iron Man star Jon Favreau has been linked with the director's chair on Revolution.