Ive got 2K on 08 - 1200 Sportster. The battery cover keeps opening up on anything longer than 10 minute runs. It looks like one of the harnesses is keeping the (Rather Cheap Looking) plastic clips from holding. I have it Taped up to keep it on the bike for commute. Anyone one else run into this problem?

LOL
Harley says this isnt a problem !
Even when you have the cover fall all the way off !

mine was kinda loose....took it off put the cheap plastic bracket on right then put the cover back on..works fine now...those brackets are a pain...do you have it pushed all the way in the hole..its hard to snap them in

Yeah, cause Ive crammed too much stuff under it. I drilled it and put a rubber grommet then made a hook from a hanger that clips to the frame.

The local service center said they would replace the clips, but it wouldn't fix the problem? I asked if they would replace the cover when it fell off on the freeway? They said it would not be covered under warranty. Jeezzzzzz

The clips are in place. I popped off the seat to make sure the cover was fully latched. The harness that has a filtered hose seems to eventualy force the front clip to let go.

There are a couple ideas in this (http://xlforum.net/vbportal/forums/showthread.php?t=460750) thread
for keeping them from falling off.

Most people that have that problem just end up zip tying it to the frame.

Put a zip tie through these two holes. I believe these are only existent on 07-09. Others have drilled small holes on older bikes. Cheap insurance.

http://i115.photobucket.com/albums/n306/exgratiaiii/MysticalExtraHole.jpg

The local service center said they would replace the clips, but it wouldn't fix the problem? I asked if they would replace the cover when it fell off on the freeway? They said it would not be covered under warranty. Jeezzzzzz

My cover on my 2006 was replaced under warranty, and I did not have the old cover to give back to them.

Mine did the same thing and I took it back to the dealer and havent had any issues since(about six moths and 2000 miles later).They said they couldnt find anything wrong with it ha ha so they put new clips on anyway they said(how nice of them lol).

I drilled and ran a small screw in from the top. No more problems

The older covers ('06 and earlier?) had, I think, just two slotted holes in the top that aligned with the two plastic clips. Newer ones have a third hole half way between the other holes. Through this hole I passed a length of 10mm wide Velco One Wrap tape then around the frame tube and sealed the tape to itself. Better than a zip tie because you can get it off without tools and it can be reused.

Fox

Put a zip tie through these two holes. I believe these are only existent on 07-09. Others have drilled small holes on older bikes. Cheap insurance.

http://i115.photobucket.com/albums/n306/exgratiaiii/MysticalExtraHole.jpg

I have the same holes on my 06, and yes that's where the zip tie is.
I keep a few spare zip ties in my tool bag, and a pack at home in case I use them.
Zip ties are cheap and I only open that cover once a year to hook up a battery tender.

Most people that have that problem just end up zip tying it to the frame.

Part of my job duties is I'm a Controls Electrician. I've spent a lot of effort making sure nothing was pushing the cover open but it still kept popping open. I drilled a hole in it and zip tied it to the frame. 106 years later and Harley still does some very poor engineering.

I thought about mounting a stud off of the battery bracket and using a wingnut like the old car air cleaner covers.
I still may do that sometime.