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Keep 'em lubed and they will usually last the life of the bike - mine always have. But there is such a thing as "factory defect" that can rear it's ugly head at any time.
Funny you should ask. My buddy and I were riding to Sturgis, he was nodding off (not good on the bike) so we pulled off at an exit and stopped at a closed for the night BP station. While we were there I walked up and turned his throttle a couple of times. He had the iso grips on so I was looking at those, after a couple of turns on the throttle I heard a snap..so did he. He looked at me and I said "it only sounded bad" nope it was his cable. So there we were in the middle of nowhere Alabama . I asked him if he got HOG like I told him to and we could get towed, he didn't. I asked him if he got roadside assistance through Geico, again no. So I had to call my mother (no kidding, my mommy) Her and my step dad came with a trailer 2 hours to get us. The next day we call the local dealer in Northern Georgia and told them we were on a trip and needed to get it replaced, they aid they could squeeze us in, in a couple of days. I reminded them we were on a trip, they didn't care. We ended up calling an independent shop and he had the bike running with in 2 hours and charged us $80 for parts and labor. I think the bike was an 04 electra glide with 30k miles on it.
I'm guessing between 250,000-300,000, on bikes, and I've had it happen once. On I-95 south out of DC during rush hour. 1987 FXLR Willie G Anniversary LowRider. Once is enough! Nearly bought it on that one. I still thank God I was on the outside lane and able to get OFF that killer freeway! Not a pleasant memory for me....This is something I will never forget. It's seared in my memory... Kind of like the assassination thing....
They don't all break but it is not uncommon. Keep them lubed. Also bad routing can decrease the life of cables.
There is usually visible wear or rust before they break, also if the cable doesn't move freely expect problems.
Day one, Saturday, of a RT66 trip. 3 blocks from the start and my buddy starts to yell "pull over" I stop and he says he has no throttle. We pull apart the grip and sure enough the cable has snapped. He says go ahead and I'll catch up in St.Louis. Call him when we get there, he waited 5 hours for roadside to pick him up and the dealer doesn't have the correct cable because of the ape hangers. Can't get it till Tuesday! Needless to say, I went on with the group and he spent the week looking at new bikes to make sure this will never happen again. Now he rides an 08 with DBW. I will check mine before any trip just to make sure!
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