The Sportster and Buell Motorcycle Forum - The XLFORUM®

The Sportster and Buell Motorcycle Forum - The XLFORUM® (http://xlforum.net/forums/index.php)
-   EFI Sportster Motorcycle Talk (2007 and up) (http://xlforum.net/forums/forumdisplay.php?f=263)
-   -   Battery cover popping open while riding?? (http://xlforum.net/forums/showthread.php?t=538118)

Cosmo Kramer 24th June 2009 02:13

Battery cover popping open while riding??
 
Well last year when I was riding if I hit a bad hole or bump (Nightster suspension) my battery cover would pop open. Well now I have crammed more junk under it so it pops open all the time. First I was going to use velcro on the inside but after thinking about it for a while I realized that it could still open up. I decided to do this....someone else may have done this before but I already took the pics so might as well do a write-up.

Here is the front clip that keeps letting my cover fly open. I took a small drill bit (less than 1/8" dia.) and made a series of holes and then used the drill to make all the holes one big slot:
http://i32.photobucket.com/albums/d2...p/100_1032.jpg

http://i32.photobucket.com/albums/d2...p/100_1029.jpg

http://i32.photobucket.com/albums/d2...p/100_1030.jpg

I was originally going to use a plastic covered piece of metal to slide in the slot but the slot wasn't wide enough, so my other thought was to use a clipped piece of zip-tie. I left the clipped end about 2-3" long so that I could slide it in and not worry about it working its way back out of the clip:
http://i32.photobucket.com/albums/d2...p/100_1034.jpg

Here you can see how the slot in the clip coordinates with the slot in the battery cover:
http://i32.photobucket.com/albums/d2...p/100_1036.jpg

Here is the cover installed and the zip-tie inserted:
http://i32.photobucket.com/albums/d2...p/100_1038.jpg

Here is a final pic with the stock seat installed:
http://i32.photobucket.com/albums/d2...p/100_1040.jpg

I have not taken it for a ride, but I can not pull the cover open with my hands without the bike wanting to tip! :tour

Phaedrus 24th June 2009 02:56

Good idea, I've used the same one for a couple of years with no further problems

ridinfool 24th June 2009 03:12

Yep...mine does the same thing...goin down the freeway at 75 and go over the bridge seams....it pops open everytime....Great pics and descripton Cosmo...thanks a trilli....:clap






:pgrflag:

Pork Chop 24th June 2009 03:29

excellent...i do something similar but this is a pretty smart idea

Cosmo Kramer 24th June 2009 03:47

Quote:

Originally Posted by Pork Chop (Post 2007845)
excellent...i do something similar but this is a pretty smart idea

Thanks guys & Pork Chop. I know some people zip-tie the cover directly to the frame and even leave the clip off and go hole to hole with a zip-tie. Problem is, if you want to open the battery cover you have to cut the zip-tie and install a new one. By doing what I did, you just pull the zip-tie out, open the cover, close the cover and insert the zip-tie.

All I know is that is going to be nice to finally ride without tapping my hand behind my leg to make sure the cover is still in place after hitting a bump in the road.

Donfunnici 24th June 2009 06:11

paint
 
For those of you that have had their battery cover pop off and hit the pavement i can repaint one cover or both oil tank and bat cover for a good price.Turnaround would be about 7 to 10 days depending on how bad they are messed up.PM me if you have a need for this service.Jason

Bob F 24th June 2009 13:22

I drilled a hole in the top of my cover and use a zip tie around the frame.

Cosmo Kramer 24th June 2009 15:27

Quote:

Originally Posted by Bob F (Post 2008933)
I drilled a hole in the top of my cover and use a zip tie around the frame.

Bob F...you would be the one I was referring to. I remember someone did that but couldn't remember who. That was going to be my next step if this didn't work out.

Tike71 24th June 2009 16:21

I knew about this trick but couldn't picture how it looked like. Thanks for the photos!

Red Red Kroovy 24th June 2009 16:34

Cosmo, that's a nice solution you've worked out I had the same problem a couple of weeks ago and haven't had time to sort through it. Thanks for thinking this up and sharing. I'll use it.


All times are GMT +1. The time now is 20:55.

Powered by vBulletin® Version 3.8.11
Copyright ©2000 - 2019, vBulletin Solutions Inc.
XL Forum® - Linson Media LLC