The later model caps were extended (longer) to increase the tension on the chains AND provide more effective stroke of the tensioners. EDIT: The fiche seems to not reflect this.... not sure if this is 100% accurate. I have a 06 ADV on the rack right now that I can measure the caps on to compare to your 04.
If the new style caps get you within service limits again, then I would run them!
It does not take much change in chain length or surface wear on the guides to make the early tensioning system go "out of spec". What I have seen comparing a new chain set to a old set is something to the tune of 1mm maybe 1.5mm difference in length is all.
Head2Wind screwed with this post 01-06-2013 at 08:35 PM