Barnett Cable Mod
I'm sure most every ones' cables are breaking similarly, right at the swag. I have had two break here! If you look carefully at the areas of the barrel, directly above and below the exit for the swagged cable, you will see that there is wear from the control handle -looks like a little darker path on the barrels metal then the rest of the finish.
I was only able to retrieve one of the barrels from my bike, so my thoughts on the matter are narrowed, but supported by the cable guy I talked to at Barnetts. He was familiar with the tell tale signs on the barrel.
In my experience as a aircraft mechanic this wear is caused by a galling condition between the barrel and the control handle. The metals difference between the barrel and the control handle causes friction, not allowing the barrel to swivel inside the control handle which otherwise allows the inner cable to remained aligned with the outer cable jacket.
The number of miles you have on your bike will make little difference because it's the constant use of the shift control handle that eventually work hardens the cable when the barrel will not swivel inside the handle. In other words a non-stop trip of 6000m. I will only use my shift control handle about 12 times, where if your starting, slowing stopping more frequently, your going to use it more often; say 1200 times in a season back and forth to work and play.
Barnett's cable mod uses a hard plastic sleeve that slips over the barrel before the cable is swagged. The sleeve acts as a bearing which allows the barrel to move more freely in the handle there by keep the inner cable aligned with the outer. The assembly looks identical to the old installation except for a dark gray outer sleeve.
Theoretically if this works as a better bearing surface, then all the problems are solved for Barnett and us. I received the cable after repair in quick time, and the people at Barnett were pleasant enough; of course I'm already out almost half the cost in a new cable in shipping costs.
I'm giving them credit for taking it serious and finding a fix for this cable breaking. But I swear if it happens again I will be beyond pissed. This cable I just installed is the third one, so I guess you could say, I've had two out of three break so far.
So far so good. I'll let ya know.
