Wire Routing Tips
Wire breakage inside the cable can be one of the most difficult and frustrating problems to find. Almost all wire breakage problems can be traced to two common installation mistakes:

1. Crushing the wire
Nylon tie wraps are very useful in giving the wiring harness a neat and finished appearance, but applying them too tightly can crush the wire insulation and pinch the wires. When the cable is pinched, it doesn't allow the wire to slide inside the cable jacket and creates a stress point (See Figure 1).

2. Forcing the wire to flex at one point
If the wire from the control handle is routed down the joystick shaft with little slack, the wire will tend to flex over a small area. Eventually the repeated flexing will cause the wire strands to break. The solution is to provide enough slack in the cable so that the flexing motion is distributed over a longer section of wire.

Ideally, a loop should be left around the mounting stud to spread the flexing point over a larger area. The loop can be created either inside or outside the rubber boot.