Aftermarket clutch cables

[Randy98199]

Does anyone know if there are better quality aftermarket clutch cables out there for the S1000XR? The cable on my 2019 with 16K miles broke on me today, pulled right out of the crimped on end at the lever. A friend has a 2016 and his failed in the same way around 20K. I have a new one ordered but have to wonder if it's a manufacturing issue.   

[Antares]

Pretty sure Venhill makes some decent ones.

[SimonUK]

40,000 miles on my 2016 XR and 42,000 miles on my S1000R, both going strong and both still have the original clutch cables! (there I go, just jinxed myself)

[bennymx]

Originally Posted by SimonUK

40,000 miles on my 2016 XR and 42,000 miles on my S1000R, both going strong and both still have the original clutch cables! (there I go, just jinxed myself)

Yep never replaced mine on multiple bikes at over 60,000km. Hardly ever adjusted them either.

[af1-windy]

There have been a few cases of them fraying and even snapping at relatively low miles. 

I was worried about this so bought an nice red one for back up. In the end, I swapped it out and gave my 10k miles cable to Antares, cos his had started to fray..

Pretty sure it was this one.. https://www.venhill.co.uk/bmw-featherlight-clutch-cable-b03-3-118.html

  windy

[Mareng1]

Someone (on here?) hypothesised that many failures were down to aftermarket levers some of which may prevent the end-crimp from rotating in the lever bush.  That led to work-hardening of the strands , leading to failure.

I think for the sake of a few quid - if you have the tank off for any reason, fit a spare cable - ready to fit in emergency.  I'm not sure if you can carry one and fit it externally to at least get you home, or to somewhere under cover?

[Antares]

I had stock levers all life of my clutch cable and actually the cable I got from windy also popped 1 strand not long after fitting (probably my fault) but just replacing the old cable it was significantly freer moving etc.

[Randy98199]

Originally Posted by Mareng1

Someone (on here?) hypothesised that many failures were down to aftermarket levers some of which may prevent the end-crimp from rotating in the lever bush.  That led to work-hardening of the strands , leading to failure.

I think for the sake of a few quid - if you have the tank off for any reason, fit a spare cable - ready to fit in emergency.  I'm not sure if you can carry one and fit it externally to at least get you home, or to somewhere under cover?

Interesting, I do have Rizoma levers. When I replace the cable I'll pull out the original stock lever and see if there is any difference in how that end crimp can rotate. Some lithium grease in there wouldn't be a bad idea too, and inspect/grease yearly.

[SimonUK]

Originally Posted by SimonUK

40,000 miles on my 2016 XR and 42,000 miles on my S1000R, both going strong and both still have the original clutch cables! (there I go, just jinxed myself)

To add to this, I have had after market levers on pretty much the entire mileage on both bikes

[Randy98199]

I'm pretty sure I figured out how this failed. The barrel at the end of the cable that goes into the slot on the lever has a plastic bushing around it. When I took mine out, that plastic was broken and jammed into the rest of it. This caused the barrel to not be able to rotate and allowed the cable to bend a little back and forth each time the lever was pulled and released. The slot in my Rizoma levers is exactly the same as stock and the slot for the cable to move in is actually longer, so can't see any way the lever is to blame. The slot that the barrel/bushing goes in has no burrs or defects. I can only think that plastic bushing just failed.