I make sure to clean all points of contact then use a new 'O' ring. Its worked so far. My complaint with the other Brands like Magnum and Barnett are the quality and longevity leaves much to be desired.

 

It pissed me off also that the Diamondback clutch cable is only braided down to the adjuster. Live and learn. Still, I have had good luck with it also.

 

I have a co worker who had the same problem with his stock clutch cable. He found that his transmission wasn't venting properly to due mud dabblers trying to nest in his vent, pressure has to go somewhere so tranny vented through clutch cable.

 

Just out of curiosity, are you by chance running a heavy duty spring in your clutch?

 

I am using a heavier spring, but not the SE spring. The spring is a factory spring for the police bikes. A heavier spring should only effect the cable itself, not the housing and if it did, it should show signs of pulling out of the fitting, which the 2 leaking cables did not. The first cable showed the stainless braiding, under the clear plastic coating, to be turning dark all the way to the adjuster which means oil had leached through the braiding of the housing and forced past the fitting.

I have also checked the vent and it is completely clear.

I have replaced the clutch cable (3rd cable now) with the Magnum cable which has a rubber seal inside the fitting where the housing fits into it so it is not supposed to leak oil into the housing and out around the fitting. Time will tell I guess but I cannot believe this is a common problem because I have not heard of it before. I also had to lube the cable twice with spray silicone which helped make the clutch pull much smoother. The Magnum cable has a plastic covering over the cable itself which fits within a plastic liner in the housing. There is a seal inside at the transmission end and a seal at the lever end. It definitely appears to be a well made cable.

 

If you still have the 2 old cables, check to see if the inner seal that the cable actually slides through has been destroyed. That's what happened to mine when using the heavy spring and it allowed oil to leak inside the cable and leaked at the swivel on the outside of the cable.

 

I checked both cables and neither showed any signs of wear to the inner liner of the cable at the transmission end. In fact the cables look like new (which they should with only a few thousand miles of use each) with the exception of them leaking out of the fitting. Thanks for the idea.

 

Another vote for Barnett. I've used they're stealth cables, black cable with black fittings, on my last 2 bikes when swapping the bars, and zero issues.

 

I used the Drag Specialties cables on my RGC with apes. They have worked very well to date. I also think the box was marked "made in the USA", which made me feel good.