Grommets in each of the wiring holes in the handlebar
must remain in position after routing the wiring through
the handlebar. Operation without the grommets in place
can damage wires, causing a short circuit which could
result in death or serious injury. (00416d)
5. If necessary, replace grommets on handlebars wire
openings.
6. Lubricate wire conduits with glass cleaner.
7. See Figure 2-105. Thread the wire leaders through the
handlebar grommets and to the center hole.
8. Pull wire bundles through to the handlebar center hole.
9. Loosely install left and right switch housings.
10. Pull slack from wire harnesses and remove the tape and
mechanics wire.
Figure 2-105.Wire Leader in Handlebars (Handlebars
Removed from Motorcycle)
11. See Figure 2-104. If lower handlebar clamps (4) were
removed, install lockwashers (9) on lower handlebar clamp
fasteners (10). Install ground cable (12) and ground cable
washer (11) on right-side fastener.
12. If removed, install cup washers (5), bushings (6) and
spacers (7) in upper fork bracket (8).
13. Slide lower handlebar clamp fasteners (10) through upper
fork bracket.
14. Loosely install lower handlebar clamps (4) to upper fork
bracket using lower handlebar clamp fasteners.
15. Place handlebars (3) on lower handlebar clamps. Install
upper handlebar clamps (2). Install but do not tighten
clamp fasteners (1).
16. Insert wires into proper locations in wire connector hous-
ings. See B.2 WIRING DIAGRAMS, 2008 Dyna Wiring
Diagrams.
17. Connect left and right hand control connectors [22, 24].
18. Connect turn signal connector [31].
19. Install clutch control and front master cylinder. Align
housings and tighten fasteners. See 2.24 CLUTCH CON-
TROL or 2.12 FRONT BRAKE MASTER CYLINDER.
20. Slide fuel tank into position and install fuel tank fasteners.
Connect vent hose and fuel supply fitting. See 4.5 FUEL
TANK.
21. Connect fuel gauge connector [117].
22. Install instrument console. See 8.17 INSTRUMENTS:
FXDWG/FXDC/FXDF.
23. Using knurled areas of handlebar as a guide, center
handlebars between lower handlebar clamps.
NOTE
On some models, knurled areas of handlebar will be completely
hidden by upper handlebar clamp when handlebar is centered
properly.
24. Raise handlebars to normal riding position and hold in
position.
NOTE
Gap between upper and lower clamps should be equal front
and rear.
25. Tighten front and rear fasteners to 12-16 ft-lbs (16.3-21.7
Nm).
26. See Figure 2-104. Remove one lower handlebar clamp
fastener (10). Apply LOCTITE HIGH STRENGTH
THREADLOCKER 271 (red) to fastener threads.
27. Install fastener and tighten to 30-40 ft-lbs (40.7-54.2 Nm).
Repeat for other fastener.
28. Connect negative battery cable to battery.
Be sure that all lights and switches operate properly before
operating motorcycle. Low visibility of rider can result in
death or serious injury. (00316a)
29. Test front brake lever for pressure and operation.
30. Test throttle for correct operation. Adjust as required. See
1.14 THROTTLE CABLES.
31. Turn the Ignition/Light Key Switch to IGNITION and test
switches for proper operation.
2008 Dyna Service: Chassis 2-73
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