MoKitDora Prewired Handlebar Instruction Manual

1. Product Overview

The MoKitDora Prewired Handlebar is designed to enhance the riding experience and aesthetics of compatible Harley-Davidson motorcycles. This handlebar features a pre-wired design for simplified installation, maintaining the factory look while offering improved comfort and durability.

Key Features:

• Fitment: Specifically designed for 2008-2013 Harley Miter Cut Electra Glide, Street Glide, and Ultra Limited models, compatible with stock cables and controls.
• Pre-wired Design: Includes pre-installed CAN-Bus kit and TBW (Throttle By Wire) wiring for a quicker installation process. Note: Some soldering work is required for full integration.
• Meathook Design: Helps maintain the original factory appearance of your motorcycle.
• Enhanced Comfort: Engineered for a natural, relaxed grip and optimal pull-back distance to reduce fatigue during long rides.
• Durable Construction: Made from high-tensile strength carbon steel with a chrome-plated finish for longevity and resistance to scratches. Features diamond-knurled areas for stable installation and reduced vibration.

Figure 1.1: MoKitDora Prewired Handlebar, showcasing the chrome finish and integrated wiring for CAN-Bus and TBW systems.

2. Safety Information

WARNING: Installation of handlebars involves critical motorcycle components. Improper installation can lead to loss of control, serious injury, or death. If you are not confident in your mechanical abilities, it is strongly recommended to seek professional installation from a certified motorcycle technician.

• Always disconnect the motorcycle's battery before beginning any electrical work.
• Ensure all wiring connections are secure and properly insulated to prevent short circuits.
• Verify proper function of all controls (throttle, brakes, clutch, turn signals, horn, etc.) after installation and before riding.
• Check for adequate cable and wire clearance throughout the full range of steering motion.
• Wear appropriate personal protective equipment (PPE) during installation, including safety glasses and gloves.

3. Product Components

The MoKitDora Prewired Handlebar package includes the following components:

• One (1) Bagger Bar (Prewired Handlebar)
• One (1) TBW (Throttle By Wire) Cable
• One (1) CAN-Bus Switch Control Wire

Figure 3.1: Detailed view of the pre-wired CAN-Bus kit and TBW wire, designed for simplified integration.

4. Setup and Installation

This section provides general guidance for installing your MoKitDora Prewired Handlebar. Due to the complexity of motorcycle wiring and controls, professional installation is highly recommended.

4.1. Compatibility Check

Ensure your motorcycle is a 2008-2013 Harley Miter Cut Electra Glide, Street Glide, or Ultra Limited model. This handlebar is designed to be compatible with your stock cables and controls for these specific models.

Figure 4.1: Visual confirmation of handlebar fitment for specific Harley-Davidson models (2008-2013).

4.2. Pre-wiring Advantage

The handlebar comes with the CAN-Bus kit and TBW wire pre-installed to streamline the process. However, it is not fully plug-and-play, and some soldering work will be required to connect the handlebar's pre-wired components to your motorcycle's existing wiring harness.

4.3. TBW Application

Our product engineers have pre-plumbed the internal wiring and pre-cut the bar end specifically for TBW applications. If your stock TBW throttle wires are excessively long, you may need to trim the redundant portion before soldering them together for a clean and secure connection.

Figure 4.2: Detail of the handlebar end, illustrating the design for TBW (Throttle By Wire) applications and the distinctive meathook shape.

4.4. Connecting CAN-Bus Kit (Soldering Required)

Follow these general steps for connecting the CAN-Bus kit. This process requires careful attention and proper soldering techniques:

1. Prepare Wires: Strip the insulation from the ends of the wires until enough copper is exposed for connection.
2. Apply Solder Sleeve: Slide a heat-shrink solder sleeve onto one of the wires.
3. Intermingle and Twist: Carefully intermingle the strands of the pre-wired bar's wires with your bike's corresponding wires, then twist them together securely.
4. Heat Solder Sleeve: Slide the solder sleeve over the twisted connection to cover it completely. Apply heat evenly to the sleeve until the solder melts and flows, creating a secure and insulated connection.
5. Verify Connection: After cooling, gently tug on the wires to ensure the connection is fixed and robust.

Figure 4.3: Visual guide for connecting CAN-Bus wires using heat-shrink solder sleeves, illustrating the five key steps.

Repeat this process for all necessary electrical connections. Once all wiring is complete, carefully route and secure all cables and wires to prevent pinching or abrasion. Reinstall controls and test all functions before riding.

5. Operating the Handlebar

The MoKitDora handlebar is designed to integrate seamlessly with your motorcycle's existing controls, providing a comfortable and ergonomic riding position. Once properly installed, the handlebar functions as the primary interface for steering, throttle, braking, and other control inputs.

5.1. Ergonomics and Comfort

The carefully calculated pullback distance and natural grip angle are intended to reduce rider fatigue, especially during extended periods of riding. This design aims to provide a comfortable posture, minimizing strain on the shoulders and back.

Figure 5.1: The ergonomic design of the handlebar contributes to a comfortable riding experience, reducing fatigue.

6. Maintenance

Proper maintenance will ensure the longevity and appearance of your MoKitDora handlebar.

• Cleaning: Clean the chrome-plated finish regularly with a soft cloth and a non-abrasive, chrome-safe cleaner. Avoid harsh chemicals or abrasive materials that could scratch the surface.
• Inspection: Periodically inspect all mounting bolts and fasteners to ensure they are tight and secure. Check the wiring for any signs of wear, fraying, or damage.
• Corrosion Prevention: While the chrome finish is designed to resist scratches, regular cleaning and occasional application of a chrome polish can help protect against environmental elements and maintain its luster.

Figure 6.1: The chrome-plated finish and diamond-knurled areas are designed for durability and stable grip, requiring minimal maintenance.

7. Troubleshooting

If you encounter issues after installation, consider the following troubleshooting steps:

• Controls Not Functioning:
  • Verify all electrical connections (especially soldered joints) are secure and properly insulated.
  • Check for any pinched or damaged wires within the handlebar or along the routing path.
  • Ensure the correct wires are connected to their corresponding functions (e.g., CAN-Bus, TBW).
• Loose Handlebar:
  • Re-check the tightness of the handlebar clamp bolts. Refer to your motorcycle's service manual for proper torque specifications.
  • Ensure the diamond-knurled areas are properly seated within the clamps.
• Excessive Vibration:
  • While the design aims to reduce vibration, ensure all components are securely mounted.
  • Check for any loose accessories or fairing components that might be contributing to vibration.

If issues persist after basic troubleshooting, it is recommended to consult a professional motorcycle technician or contact MoKitDora customer support.

8. Specifications

Figure 8.1: Illustrative diagram of handlebar measurements, including overall width, rise, and clamp area diameter.

9. Warranty and Support

MoKitDora is committed to customer satisfaction. Your product is backed by:

• 60-Day Return Policy: For details on returns, please refer to your purchase documentation.
• 24/7 Customer Service: If you have any questions, require assistance with installation, or encounter any issues, please message MoKitDora customer service for a prompt solution.

For more information about MoKitDora products and support, please visit the official MoKitDora Store on Amazon.