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24th June 2009
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Senior Master Custom Bike Builder
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Join Date: Sep 2008
Location: Anytown USA
Posts: 5,209 Sportster/Buell Model: 1200N Sportster/Buell Year: 2007
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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:
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:
Here you can see how the slot in the clip coordinates with the slot in the battery cover:
Here is the cover installed and the zip-tie inserted:
Here is a final pic with the stock seat installed:
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! 
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Cosmo
If you don't stand behind our troops, please, feel free to stand in front of them!
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24th June 2009
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Senior Master Custom Bike Builder
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Join Date: Sep 2006
Location: South Western Ontario
Posts: 4,590 Sportster/Buell Model: XL 1200 R Sportster/Buell Year: 2007 Sportster/Buell Model #2: Buell Uly (sold) Sportster/Buell Year #2: 2009 Other Motorcycle Model: 2010 Ural Patrol(sold)
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Good idea, I've used the same one for a couple of years with no further problems
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24th June 2009
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XL FORUM TEAM MEMBER
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Join Date: Jun 2008
Location: sky's the limit
Posts: 378 Sportster/Buell Model: 1200c Sportster/Buell Year: 2007
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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....

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"Four wheels move the body....Two wheels move the soul"
If you feel right about something, than go for it...if you go for it, then you feel right
Eat...Poop...Play.....Sleep....Repeat....
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24th June 2009
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Senior Chief Master Mechanic 1st Class
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Join Date: Mar 2009
Location: In the Georgia Swamp
Posts: 1,221 Sportster/Buell Model: XL883L chopped & dropped Sportster/Buell Year: 2007 Other Motorcycle Model: 1600 cc Volcan Classic Other Motorcycle Year: 05
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excellent...i do something similar but this is a pretty smart idea
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Ride Safe Eli !
Bought and paid for!
Chop, Drop, and Roll
Tankslapper of the Heavy Horses MC
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24th June 2009
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Senior Master Custom Bike Builder
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Join Date: Sep 2008
Location: Anytown USA
Posts: 5,209 Sportster/Buell Model: 1200N Sportster/Buell Year: 2007
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Quote:
Originally Posted by Pork Chop
excellent...i do something similar but this is a pretty smart idea
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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.
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24th June 2009
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Biker
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Join Date: Mar 2009
Posts: 35 Sportster/Buell Model: 1200c Sportster/Buell Year: 2008
Reputation: 10

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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
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24th June 2009
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XLF LIFEMEMBER Im retired
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Join Date: Feb 2007
Location: Pittsburgh, PA
Posts: 14,324 Sportster/Buell Model: XL50 0596 Black Sportster/Buell Year: 2007 Other Motorcycle Model: E-Glide Other Motorcycle Year: 2003
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I drilled a hole in the top of my cover and use a zip tie around the frame.
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Bob, a glutton and a winebibber, a friend of bartenders and sinners!
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24th June 2009
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Senior Master Custom Bike Builder
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Join Date: Sep 2008
Location: Anytown USA
Posts: 5,209 Sportster/Buell Model: 1200N Sportster/Buell Year: 2007
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Quote:
Originally Posted by Bob F
I drilled a hole in the top of my cover and use a zip tie around the frame.
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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.
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24th June 2009
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Know It All
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Join Date: Apr 2009
Posts: 191 Sportster/Buell Model: 883 Iron Sportster/Buell Year: 2009
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I knew about this trick but couldn't picture how it looked like. Thanks for the photos!
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24th June 2009
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Flat Track Champion
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Join Date: Sep 2008
Posts: 645 Sportster/Buell Model: 1200XLC Sportster/Buell Year: 2009
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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.
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