You're assuming that the Jedi Council could have known that Revan had such memories. Carth says that the Force can "... wipe away your memories and destroy your very identity." Not that Carth is really the authority here or anything, but it seems perfectly plausible that when Revan's mind was destroyed by Malak and/or wiped by the Jedi Council, and then replaced, that there would not have been anything that the Jedi could identify. Indeed, I doubt that creating a new persona is something the Jedi would do without great need and deliberation, so it's not like you would expect them to have much experience and practical knowledge. Even if the memories were still there, I wouldn't expect them to find them, assuming that what they did to Revan even requires that they interact with the mind in such a way that would make that possible.
So your saying that somehow revans memories of the star forge survived when somthing as old and as cemented as where he came from and how he lived/was trained got wiped away? Methinks that he wouldn't forget where he came from and how he was trained. Besides they would have noticed if he didn't act like a total newbie to the force thing, after a while I would think that using your weapon would become physical memory that is very hard to supress. and he wouldn't want to forget those skills now would he?
Sith naming conventions aren't exactly rock solid evidence, it's just something I noticed, a difference that got me thinking. You could very well be right, but my idea fits so nicely with the theory of Revan being Sith from the beggining that I have grown a little attached to it. It hints at conspiracies and deeper meanings, and Darth Revan just makes so much sense as a Sith title.
I was wondering what the heck Sion was supposed to stand for too. I suppose it could be a creative spelling of scion, but why change just one letter, especialy for such a weird title as "scion"? Something related to pain or his "broken" body would be cool, but I don't speak Latin, and nothing in English comes to mind. Weird.
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Sion could just be his name you know. I mean it's not like everybody has to have a different name. If you notice one of the reasons why they change their name is so that they are not recognized by the populance as Count Dukoo or Emperor Palpitine. Sion couldn't exactly hide who he was because of Physical Deformity. Having a seperate name implies that you are hiding. After all if you didn't everone would know exactly who you were and where you lived and you would be facing 4 or 5 assination attempts per week.