Throttle cable replacement

RBMann · 02-15-2006, 12:47 AM

I hope this can save others some trouble.

On the advice of an ex-BMW mechanic friend, I replaced all the related throttle cables(4) and the Bowden cable distributor box. It took five trips to the dealer and two parts being critical ordered with overnight delivery.

The cables were for a 2000 S with high bars. Make sure the parts person knows which bars you have on the bike. The other big issue is the cable from the right hand grip(throttle) to the Bowden box. The original cable was part #3273-1-342-814 superseded to #3273-7-659-680 and now superseded to #3273-7-692-488. I don't know when these changes happened but the catch is #488 has a curved metal pipe on the end compared to a staight end like the original #814. So when you get #488 it looks wrong. The dealer had to call BMW to figure out that you now need Repair Kit #3272-7-691-990(accelerator cable deflection and cover) to make the new style cable work with your right side throttle grip housing.

Everything works smoothly now and the TB sync seemed easier.

RB

New #488 on the left and the old #814 on the right.

foobeemer · 02-15-2006, 05:16 AM

I took read advice and did both mine when I had a problem with the right one and was faced with having to replace it. Well worth the effort, indeed, but a biotch nonetheless...and they're expensive buggers!!

wswartzwel · 02-15-2006, 05:21 AM

How many miles are on your bike? Were the cables frayed and needed replacement, or was it just preventive maintenance?

repoe3 · 02-15-2006, 05:34 AM

speak up, i cant hear you.

repoe3

foobeemer · 08:16 AM

If you're asking me, the right side had a thread problem at the set screw ass'y--I managed to end up with some strippage...not sure if I caused it or just helped it, before I pulled it I could not get the TB to hold the balancing adjustment point. Initially I thought I could steal some threads up at the handlebars....then I was introduced to Mr. Bowden and he educated me about HIS world.....

ps I only replaced the output cables from the BB to the TB's. I reused the other 3. Bike had 14,000 mi on it at the time.

wswartzwel · 02-15-2006, 08:22 AM

I was asking RB...(but thanks or your response). and anyone else who has replaced throttle parts. I have heard rumors that the throttle cable system was a weak point. I was hoping to get more information to determine if the rumors were indeed fact. If so I may pull mine apart with 30K and inspect it.

repoe3 · 02-15-2006, 08:51 AM

yeah, what he said.

repoe3

JonyRR · 02-15-2006, 09:18 AM

WHEN it's my turn I'm going to reengineer that cluster-bleep with the %$%^^^&& bowden box. perhaps two distinct cables or somesuch.
since I don't need the enrichener cable, that's going in file13 also.
there's got to be a better way than OEM in this regard....

wswartzwel · 02-15-2006, 09:30 AM

I have seen some nice machined aluminum cable splitters made for multi cylinder 2 stroke race applications.... kinda what I had in mind 2 Jony..... "IF" there is a history of failures......

RBMann · 02-15-2006, 10:13 AM

Sorry I had to get some sleep. The bike has 55 K on it. There wasn't any major wear on the cables that I could see. However I could not go between tune ups without syncing the TB. The shop my friend worked at, would replace the fuel filters at every 6 K and the cables at 20 K. Really unnecessary I think. Although it helped generate shop $ I am sure. If mine were normal they could have gone 100 K from a wear point of view.

However the feel is much better and smoother. The sync was easier than normal. It is wear in the bowden box that causes trouble syncing the TB and I was finding it impossible to match things up accross the full range. As someone with the surge issue I might be a little too sensitive to the TB sync.

Finally, what a hassle. If your are happy and don't have a problem then leave it alone. Ask me again in 5 K if it was worth it.

wswartzwel · 02-15-2006, 10:17 AM

55K... I got time...

Thanks so much!

JonyRR · 02-15-2006, 10:32 AM

RB; when I first saw that bowden box charlie-fox I was appalled. No-wonder these things don't stay synched thru a full range-of-movement.
Bill, can you recall where you saw those aftermarket splitters...I'm looking for something like that as barnett can make me any cable I want. I DO want to file13 that whole bowden nightmare. the fast-idle cable is stupid-useless (I just run mine at 2K for 30 seconds at cold starft and it idles like a diesel afterwards)

wswartzwel · 02-15-2006, 11:13 AM

Jony, I gave one away the other day to a fellow, Think it came with a Racing carb conversion for a Banshee ATV... Might look in a Sudco Catalog.... I will look around and see what I can locate.

ErricZ · 02-15-2006, 11:42 AM

Bout time they added that curved section ... only took 15-20 years?

wswartzwel · 12:04 PM

Jony, here is an image I found of something similar.... looks like they are being used by ultralight builders too.... The red anodized splitter is what I was talking about..

Here's another...

emccarty · 02-15-2006, 07:48 PM

My throttle cable just broke at 49,000 miles. I just pulled out to pass a car when it happened.

JonyRR · 02-15-2006, 08:10 PM

this might be a legitimate area tha's un or underexplored. Smooth, progressive thorttle slide/valve/plate opening is critical for power and control. I think the bowen box goat-fornication-thingie can be vastly improved upon.
Bill; the setup illustrated above is a bolt-on setup for an ultralite or somesuch?
Is there just a cable assembly available..
yeah, I know, go search sudco myself *sigh*

02-15-2006, 08:14 PM

Mine broke as I was overtaking a wheelstanding GSXR 1000!
And I did wonder what the consequences would have been if I had of been overtaking a car or shooting for a small gap??
As I was a very long way from home, I was able to adjust the throttle screws so the bike idled at 5,000 rpm and ride home at around 100kmh. Some extra boost could be obtained by holding up the cold start lever and you need to declutch and turn off the ignition on long windy down hill sections (note I ride a non power assisted brake version of the S).

Cheers,

Frank

wswartzwel · 02-15-2006, 08:34 PM

Jony,
It just has a pipe clamp holding it down to an aluminum angle bracket... look at the lower picture to see the internals....

hmmm may throw a roll of dental floss in the tool pack, for a roadside mcgyver throttle cable fix

wswartzwel · 02-15-2006, 08:42 PM

here you go... $6.95 each!!!
http://www.greenskyadventures.com/throttle_cable/throttlecable.htm