Author Topic: Gear cable breakage  (Read 2471 times)

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Offline avrin

Gear cable breakage
« on: June 10, 2025, 10:06:11 am »
My 2020 Trek 520 suffers from repeated gear cable breakage. The cables break mostly on the right brifter (rear derailleur cable), but I've had the left side (front derailleur cable) break as well. The breakage is at the typical spot, in the brifter, the cable head breaks off. It is not unusual for me to bust a cable after 1500 miles. Reliability is key for me as I'm looking forward to some longer and more rugged tours.  The bike has Shimano Sora 3/9 brifters. If I switched to Ultegra Flight Deck ST-6510's, will that alleviate the problem? I think that's what I had on my old bike, a Cannondale T1, and I did not have an issue.   Any other suggestions? Thanks. 

Offline John Nettles

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Re: Gear cable breakage
« Reply #1 on: June 10, 2025, 01:01:08 pm »
Not sure but you might get an more educated answer over at the BikeForums.net > Bicycle Mechanics forum since the equipment is very specific. 
Hope you find a solution. 
Tailwinds, John

Offline DonKahn1

Re: Gear cable breakage
« Reply #2 on: June 10, 2025, 05:30:24 pm »
I am not a big fan of these type of shifters on touring bikes.  I have broken my right side shifter cable two times on my gravel bike.  Luckily I have bar end shifters on my touring bike, and have never had any problems, with over 15,000 miles on the original shfter cables.  On my old gravel bike I converted my stock shifters to bar ends.  I think the companies are making a big mistake going away from bar end shifters on touring specific bikes.  Another plus of the bar end shifters is that you can change to friction mode if your rear deraileur gets out of adjustment mid tour

Online ray b

Re: Gear cable breakage
« Reply #3 on: June 19, 2025, 11:48:47 pm »
Though I'm strictly a flat bar single speed or Rohloff kind of guy, I like the Shimano Soras - they've been around a long time. That said, they are entry level.  I would take a very careful look at the the shifters to make sure they haven't worn in a way to increase drag or have picked up some rough edges, and that surfaces - especially the outer cable guide and joint - contacted by the cable are smooth. (I'm always reminded that the less expensive the parts, the better mechanic one has to be.)

Though the original cables on the 520 should have been stainless steel, if one's not careful, replacement cables can be prone to corrosion and failure at the points of contact. Sometimes, just moving to a more expensive system like Jagwire's pre-stretched, slick, polished stainless steel cables can result in longer life (and often, surprisingly smoother shifting). (I use Jagwire for all my braking needs and have never seen the appeal of hydraulics - especially on long tours.)

On the other hand, if you want something nice to replace the Soras (and you probably do), you could try the familiar 6510s, but you're going to get used equipment and older engineering. Cruising Ebay might give you some ideas. 

Personally, I would take a hard look at the Shimano-compatible Microshift R9s... This is a link to their drop bar shifters, but they also have bar end shifters and other options.  https://www.microshift.com/models/sb-r493/  I see there's a few pairs of the R9s on sale at Jenson.

Make sure you have fun.
« Last Edit: June 19, 2025, 11:50:34 pm by ray b »
“A good man always knows his limitations.”

Offline avrin

Re: Gear cable breakage
« Reply #4 on: June 20, 2025, 09:13:41 am »
Ray,
Thank you for your thoughts. I have looked into the Microshifts, but not extensively. A mechanic at my lbs said he tried to build a bike with Microshift brifters and the advertised compatibility with Shimano components did not work in his case. I think the word he used was "nightmare."   As for other line Shimano brifters , another good idea you float, there are apparently (the lbs tells me) compatibility issues with my Deore rear deraileur, which was not stock on the bike but was an emergency replacement.   

Offline jamawani

Re: Gear cable breakage
« Reply #5 on: June 20, 2025, 09:14:21 am »
Oh, for the days of downtube shifters and exterior cables.
Not only did they rarely break, but they were easy to fix if they did.