Short answer: the AS3 upgrades that pay for themselves fastest are the parts that break first in a crash: forged brake and gear pedals, flexi levers, radiator guards and a skid plate. After that come wide footpegs, CNC-machined covers and oil filler caps, and smooth Venhill cables for more feel at the handlebar.
In this buying guide we list the product groups from the AS3 Performance collection, explain when forged is better than CNC and help you choose for your make and model.
Which AS3 Performance parts are there?
AS3 Performance is a British company making parts mainly for off-road, enduro and adventure bikes. These groups appear in the catalogue:
- Brake and gear pedals – cold-forged aluminium, individually or as a set, plus the Factory Series version with CNC-machined titanium-coloured tips.
- Brake and clutch levers – forged replacements for the stock levers and flexi levers that fold away on impact.
- Footpegs – titanium, Factory Series and Racing Series (CNC-machined from 6061 aluminium) and cast stainless steel footpegs.
- Covers and caps – Factory Series clutch and ignition covers, oil filler caps, brake and clutch reservoir covers, starter motor and power valve covers.
- Protection – radiator guards, aluminium and DTC plastic skid plates, crash bars, brake disc and master cylinder guards.
- Venhill cables and lines – Featherlight throttle, clutch and hot start cables and braided brake and clutch lines.
- Maintenance – including seal kits, gasket kits, stainless steel hose clamps and 7075 aluminium rear sprockets.
Forged or CNC-machined: what is the difference?
AS3 deliberately uses both techniques for different parts.
- Cold forging is used for pedals and levers. According to AS3, forged aluminium is slightly softer than cast or CNC-machined material. As a result, a pedal or lever tends to bend on impact rather than snap. You can often bend a bent pedal back and keep riding; a snapped pedal means the end of your ride.
- CNC-machined from billet is used where an exact fit and a clean finish matter: clutch and ignition covers, oil filler caps, footpegs and pedal tips.
- Combinations also exist. The flexi levers are forged and CNC-machined, and the Factory Series pedals have a forged body with CNC-machined tips.
Which materials does AS3 use, and what for?
| Material | Used in | Why |
|---|---|---|
| 6061 aluminium (billet) | Clutch and ignition covers, oil filler caps, Racing and Factory Series footpegs | Machines well and can be hard-anodised against wear |
| 7075-T6 aluminium | Rear sprockets, some of the oil filler caps, footpeg reinforcement | Higher strength at low weight |
| Cold-forged aluminium | Brake and gear pedals, brake and clutch levers | Bends on impact instead of breaking |
| Stainless steel | Pedal teeth, footpeg plates and teeth, hose clamps, radiator grilles, inner cables | Wear-resistant and corrosion-resistant |
| Titanium | Wide titanium footpegs | According to AS3, the strongest and lightest footpegs in the range |
| DTC plastic | Skid plates (with or without linkage protection) | One-piece, less vibration |
Pedals and levers: what should you look for?
The forged AS3 pedals have a spring-loaded tip that gives way on impact. The brake pedal has 9 replaceable stainless steel teeth for grip, the gear pedal has serrated grooves. A steel brake snake is included to stop the brake pedal catching in deep ruts or behind rocks and bending.
The Factory Series pedals are bead-blasted and matt anodised for an OEM-style look. Here the brake pedal has a fixed tip with several adjustment positions, and the gear pedal a spring-loaded tip.
For levers you can choose between forged replacements, which fit straight in place of the stock levers and bend in a crash, and flexi levers, which fold away and have adjustable reach. If you ride a lot in woods or rocks, flexi is the safest choice. If you have a hydraulic clutch, many riders opt for the shorter 3-finger clutch lever.
Protection: radiators, engine and footpegs
- Radiator guards for motocross and enduro bikes have a 3.5 mm wraparound frame with 5 mm reinforcing strips, designed not to restrict airflow. For adventure bikes there are 1.5 mm 304 stainless steel grilles with a laser-cut honeycomb pattern.
- Skid plates are available in 4 mm aluminium with double welded seams, and in one-piece 6 mm DTC plastic. Some DTC versions also protect the rear suspension linkage.
- Wide footpegs give more support and grip than most stock pegs. The Racing Series has 34 replaceable stainless steel teeth, the Factory Series stainless steel plates and an anti-vibration pad, the titanium version 48 teeth, and the stainless steel footpegs are cast in one piece without welds.
Covers, oil filler caps and Venhill cables
The Factory Series clutch and ignition covers are CNC-machined from 6061 aluminium and hard-anodised, so they stand up better to boots and dirt rubbing along the outside. You fit them with the original bolts and gasket. The oil filler caps in 6061 or 7075 aluminium replace the stock plastic cap and have pre-drilled holes for lock wire.
Venhill Featherlight cables have a low-friction PTFE liner and a marine-grade stainless steel inner cable, for lighter and more precise operation. The braided Venhill brake and clutch lines expand less than rubber, which improves the feel at the lever and pedal; according to the manufacturer they are tested to 1500 psi.
How to choose in 3 steps
- Start with what breaks most often. Pedals, levers and radiators are the classic casualties of a crash. Upgrade those first.
- Match the material to your use. Forged for parts that take impacts, CNC for covers and caps, plastic or aluminium skid plates depending on enduro or adventure.
- Select by make, model and year. AS3 parts are model-specific. Browse by make, for example AS3 for KTM, AS3 for Honda or AS3 for Yamaha, and check the model years in the title. Besides these makes, the catalogue also covers Husqvarna, GasGas, Kawasaki, Suzuki, Beta, Sherco, Triumph and Sur-Ron, among others.
Frequently asked questions
Is forged aluminium better than CNC-machined for a brake pedal?
For a brake or gear pedal on an enduro or motocross bike, forged is usually the smartest choice. AS3 states that cold-forged aluminium is slightly softer than cast or CNC-machined material, so a pedal tends to bend on impact rather than snap. AS3 mainly uses CNC machining for the tips and for parts where precise dimensions matter more than flexibility.
What is the difference between 6061 and 7075 aluminium?
Both are widely used aluminium alloys in motorsport. 7075 (often in T6 temper) is harder and stronger and is used by AS3 for parts such as rear sprockets and some of the oil filler caps. 6061 machines and anodises well and is found in covers, footpegs and most oil filler caps.
What exactly do flexi levers do?
Flexi levers have a hinged section that folds away in a crash or impact instead of breaking off. AS3 makes them from forged and CNC-machined aluminium, with adjustable reach so you can set the lever to the size of your hand. Separate short 3-finger clutch levers fit the regular AS3 flexi levers, but not the Factory Series flexi levers.
Should I choose an aluminium or a plastic skid plate?
A 4 mm aluminium skid plate with double welded seams is stiff and suits adventure and touring bikes well. The 6 mm DTC plastic skid plates are made in one piece; according to the manufacturer they are 40% lighter than aluminium, vibrate less and are more impact-resistant. That makes plastic the logical choice for enduro in many cases.
Do AS3 parts fit every bike?
No, almost all AS3 parts are specific to make, model and year. Always check the model designation in the product title. Skid plates have been developed on a bike in stock condition; a centre stand or crash bars from another brand can affect the fit.
Why should I choose Venhill Featherlight cables?
Venhill Featherlight throttle, clutch and hot start cables have a very low-friction PTFE liner and a marine-grade stainless steel inner cable. That gives smoother, more precise operation, which you notice especially when riding slow technical sections. They are a direct replacement for the original cable on your specific model.
Need help choosing?
View the full range in the AS3 Performance collection; all parts are shipped from the Netherlands. Not sure which pedal, lever or guard fits your bike? Send us a message with the make, model and year, and we will look it up for you.