MoKitDora 14"-16" Handlebar Cable Kit Instruction Manual

1. Introduction

This manual provides essential information for the installation, operation, and maintenance of your MoKitDora 14"-16" Handlebar Cable Kit. This kit includes extended hydraulic clutch and brake lines designed for specific Harley Touring models. Please read these instructions thoroughly before beginning installation.

1.1 Included Components

• 1 Extended Hydraulic Clutch Cable
• 3 Extended Brake Lines (1 upper, 2 lower)
• OEM ABS fittings with UV protection
• Banjos with Copper Crush Washers

Figure 1.1: Overview of the MoKitDora 14"-16" Handlebar Cable Kit components, including the hydraulic clutch cable, three brake lines, and associated fittings and washers.

2. Compatibility

This cable kit is specifically designed for 14"-16" handlebars on the following 2017-2020 Harley Touring models with ABS:

• Road King
• Road Glide
• CVO Street Glide
• Electra Glide Ultra Limited
• Freewheeler Trike FLRT models

Ensure your motorcycle model and year match the specifications to guarantee proper fitment and function.

Figure 2.1: Example of a Harley Touring motorcycle, illustrating the type of bike this cable kit is designed for.

3. Safety Information

Warning: Installation of brake and clutch components requires specialized knowledge and tools. Improper installation can lead to serious injury or death. If you are not confident in your ability to perform this installation correctly, seek assistance from a qualified motorcycle technician.

• Always wear appropriate personal protective equipment (PPE) during installation.
• Ensure the motorcycle is stable and secure before beginning any work.
• Refer to your motorcycle's service manual for specific torque specifications and procedures.
• Brake fluid is corrosive. Avoid contact with skin and painted surfaces.
• Properly bleed the brake and clutch systems after installation to remove all air.
• Test the brake and clutch systems thoroughly in a safe environment before riding.

4. Installation Guide

While specific step-by-step instructions are not included with this kit, the following general guidelines apply to the installation of handlebar cable kits on Harley Touring models. Always consult your motorcycle's official service manual for detailed, model-specific procedures.

4.1 Preparation

1. Park the motorcycle on a level surface and secure it.
2. Gather all necessary tools, including wrenches, brake fluid, and a bleeding kit.
3. Carefully remove existing brake lines and clutch cable, noting their routing.

4.2 Installing Brake Lines

1. Connect the new upper brake line to the master cylinder and the ABS module.
2. Connect the two lower brake lines from the ABS module to the calipers.
3. Ensure all banjo fittings are properly seated with new copper crush washers and tightened to the manufacturer's torque specifications.
4. Route the brake lines carefully to avoid kinking, rubbing, or interference with moving parts. The transparent armor coat protects the braided stainless steel and components from abrasion.

Figure 4.1: The upgraded combined joint is screw-locked, allowing for multi-angle adjustment during installation for optimal routing and fit.

4.3 Installing Hydraulic Clutch Cable

1. Connect the new hydraulic clutch cable to the clutch master cylinder and the slave cylinder.
2. Ensure all connections are secure and tightened to specifications.
3. Route the clutch cable to prevent kinking or interference.

4.4 Bleeding the Systems

After installing the brake lines and clutch cable, it is critical to properly bleed both systems to remove any air. Air in the system can lead to a spongy feel and reduced braking/clutch performance.

• Follow your motorcycle's service manual for the correct bleeding procedure for ABS brake systems and hydraulic clutches.
• Ensure the brake fluid reservoir is kept full during the bleeding process.
• A soft brake lever or clutch lever after bleeding indicates air is still present in the system. Repeat the bleeding process until a firm lever feel is achieved.

5. Post-Installation Checks and Operation

After installation and bleeding, perform the following checks before operating the motorcycle:

• Brake Lever/Pedal Feel: Ensure both the front brake lever and rear brake pedal feel firm and responsive. There should be no sponginess.
• Clutch Lever Feel: Verify the clutch lever engages and disengages smoothly and completely.
• Fluid Levels: Check brake fluid and clutch fluid reservoirs to ensure they are at the correct levels.
• Leak Inspection: Inspect all connections for any signs of fluid leaks. Tighten any leaking fittings carefully, but do not overtighten.
• Cable Routing: Confirm that all cables and lines are routed correctly, without kinks, sharp bends, or contact with hot engine parts or moving components. Ensure full steering lock is possible without tensioning the cables.
• Test Ride: Perform a low-speed test ride in a safe, open area to verify proper brake and clutch function before riding at higher speeds or in traffic.

6. Maintenance

Regular inspection and maintenance will ensure the longevity and safe operation of your MoKitDora cable kit.

• Routine Inspection: Periodically inspect all brake lines and the clutch cable for signs of wear, fraying, cracks, or damage to the outer coating.
• Fluid Checks: Regularly check brake and clutch fluid levels and replace fluid according to your motorcycle manufacturer's recommendations.
• Connection Integrity: Verify that all banjo bolts and fittings remain tight and free of leaks.
• Cleaning: Clean the cables and lines with a mild soap and water solution. Avoid harsh chemicals that could damage the PVC coating.
• UV Protection: The lines feature a UV-protected armor coat to reduce fading and protect against abrasion. Keep them clean to maintain this protection.

Figure 6.1: The brake lines feature a transparent armor coat over braided stainless steel, designed for UV protection and abrasion resistance.

7. Troubleshooting

If you encounter issues after installation, consider the following common problems and solutions:

7.1 Soft or Spongy Brake/Clutch Lever

• Cause: Air trapped in the hydraulic system.
• Solution: Re-bleed the brake and/or clutch system thoroughly. Ensure no air bubbles are present in the fluid. For ABS systems, specific bleeding procedures may be required (e.g., cycling the ABS pump with diagnostic tools).
• Cause: Insufficient fluid level.
• Solution: Check and top up the fluid reservoir.

7.2 Fluid Leaks

• Cause: Loose banjo bolts or fittings, damaged crush washers, or improper sealing.
• Solution: Inspect all connections. Ensure banjo bolts are tightened to the correct torque with new copper crush washers. If leaks persist, professional inspection is recommended.

7.3 Cables Rubbing or Kinking

• Cause: Incorrect routing during installation.
• Solution: Re-route cables and lines to ensure they have adequate clearance from moving parts, sharp edges, and hot components. Verify full steering lock does not create excessive tension.

If troubleshooting steps do not resolve the issue, consult a certified motorcycle mechanic.

8. Specifications

Figure 8.1: Detail of the durable construction of the MoKitDora cables, featuring stainless steel braiding and PVC coating.

9. Warranty and Customer Support

MoKitDora stands behind the quality of its products. This cable kit is tested for reliable and consistent performance that meets industry standards.

For any questions, concerns, or support needs regarding your MoKitDora cable kit, please contact our customer service team. Refer to your purchase documentation or the MoKitDora brand store on Amazon for contact information.

We recommend retaining your proof of purchase for warranty purposes.