Have 1994 300 4x4. My question is about the pair of fine gauge wires that run down to hub on each side in front. I have one side that is broke in half about half way down. The other side is still functioning, but clearly very hard and presumably brittle.

I understand this is a common issue with polaris atv's. I assume quick fix is to just reconnect broken wires. But as long as I'm going to be in there working on it, I'm wondering what improvements might I be able to do to prevent further issues. Thicker gauge wires? Provide a little extra length inside the plastic loom so as too allow for more flex? Any ideas?

 

We didn't have many problems with the wires becoming brittle,just if not protected well were easily snagged/broken. I'd splice in a new wire,don't go too big on the wiring and protect it better with a longer wire loom if you have to and zip tie it up and away from getting snagged.The small wires should be running inside the brake line loom already.Just add to it if needed. 22 to 24 gauge wiring should be fine.