Join Date: Apr 2005
Location: Guilford, CT, USA
Hey, James. You probably already know this, but just in case . . . The TSB to which Bigbear provided a link came out in 2003, and references the first of two cable upgrades. The '03 upgraded cables used a flat wire for the sheath and a thicker Teflon coating. They were a straight retrofit into the plastic housing at the throttle. In '05 (I think it was) BMW came out with another upgrade, which went on all '05+ bikes. I don't know how they changed the cables themselves, but the '05+ cables had new routing at the handlebars to decrease a 90 degree bend and eliminate the 90 degree metal tube that guided the cable, and a new fitting at the throttle. At least one person who wanted to upgrade his pre-'03 cables requested the "upgraded cables" from his parts department, and got the '03 upgrade. If you want the '05+ cables, make sure that you specify the '05 and later version, and get the retrofit kit with the new plastic fitting for the throttle. The '05+ bikes have a different lower right handlebar cover than previous years so that the cables come out from beneath the cover several inches away from the throttle grip, diminishing the radius of the curve of the cable as it approaches the fitting. Most people who have retrofit the '05 cables to a pre-'05 bike have cut a slot or hole in their pre-'05 lower handlebar cover to achieve the same effect. The TSB does not mention any of this because it only references the earlier cable upgrade. However, I found that it was useful reading for general purposes in retrofitting the '05+ cables. There is a ton of info on the site and at least one detailed post about installing and adjusting the '05+ retrofit. It can be a PITA to do, but almost everyone has found that it is well worth the time and effort. Good luck.
'99 Canyon Red K1200 LT - Buddah Bike