I haven't had this problem....yet. knock on wood. I have custom paint on mine and don't want to have to replace it. It is even more likely now due to the ECM relocation I did.


Anyway what I am going to do now is place a zip tie around the plastic tab that the cover hooks on at the bottom. If you slide the cover over the tab then get a zip tie around it, this will at least hold it on the bike if the top comes un clipped. Could save from having to buy another.....Just some thoughts.

 

The cover already has a slot manufactured into it. I created an oval hole in the clip to pass a zip tie through. The end of the tie prevents the tie from falling out while you're riding. No need to loop the zip tie. I use the same zip tie again and again. With a small amount of patience, I can remove/replace the zip tie without removing the seat.
Props to OFG.
These are the original POS, first-run 2004 clips:

 

I posted this in another side panel falling off post. I took my bike right back to the dealer when mine unhooked 8 blocks away from pulling out of the parking lot...the mechanic wire tied it...free of charge! first thing I ever got from them for free...lol you cant see the tie, & it hasn't fallen off since

 

Reminds me to secure mine I also have custom paint...jeez.

 

Zip strips, wish i had thought of that!

 

I have an issue with my side cover, too. It hasn't popped off while riding yet but the cover won't reach the clip on the left side in order to lock in. It's close, maybe within a few millimeters, but it seems as if something is pushing it back. I checked behind the cover and everything seems fine. I'm sure something is up, though.

 

I'm new to the forums and Harley. Just bought an 09 Nightster. Knew about the side cover problem from this forum. These people ROCK! Happened to me the other day. Only thing that held it on was the passenger peg. After that. Zip ties for a quick road side fix. Haven't figured out a more permanent fix yet. I'm now onto replacing leaky cracked oil lines. The fun never stops!

 

if it's not fitting right then it's not sitting on the hook on the bottom side correctly,


these things popping off is a huge problem, do yourself a favor & cable tie it or something before it flys off..


some clever person though to drill a small hole though the clip & slide a nail though in there to lock the panel in place

the battery side is the problem , the oil tank side is fine.

and don't put your registration/ insurance card behind there. would hate to lose that.

 

Sorry to hear that .. i had the same problem ...how i solved it after finally getting a new one at 137 bucks ..ouch ..get some smallish not the smallest nylon ties ...you can fit them thru the holes on the cover , get black ones ..looks better better ...
run them thru the holes on the cover and around the chassis ...yes i know if you need to get to the battery cover you have to cut them ...but they are cheap ..a bag of fifty doesn't cost more than a few bucks..
i always ride with some nylon ties in my bag ...