Left Side Cover Fell Off

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Left Side Cover Fell Off

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Left Side Cover Fell Off - 6/16/2007 8:55:57 PM

ravenron

Posts: 6
Joined: 5/7/2007
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Hey guys...new to this board and impressed by the amount of knowledge here. \\; Recently purchased an 05 Sportster XL883 Custom \\;for my son and have had trouble keeping the left side cover on. \\; I thought I had finally gotten it attached firmly but hit an unexpected bump amidst some road construction on Thursday...Damn...it was pretty violent (thought I might have bent the rims). \\; In any case, after regaining control of the bike, I noticed the side cover bouncing off into traffic...

Long story slightly longer...side cover trashed, new one ordered, $107 poorer. \\; Is there any better way to attach this cover to prevent similar issues in the future? \\; I''ve ordered new clips hoping that will help. \\; You''d think the old one''s would still be good after only 4500 miles. \\; Has anyone else had this happen? \\;

Thanks in advance and ride safe...

RR

< Message edited by schumacher -- 6/9/2008 10:23:23 AM >

Post #: 1

RE: Left Side Cover Fell Off - 6/16/2007 9:10:15 PM

Booey420

Posts: 1094
Joined: 2/24/2007
From: Fairview Park,Ohio
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I have seen many threads on here about this happening.I am always amazed when it happens cause all the side covers on my 03 883r are bolted on.Not with clips but with screws and bolts.I don't know why Harley decided to go with clips but it seems to not be a very good idea.

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Post #: 2

RE: Left Side Cover Fell Off - 6/16/2007 9:22:17 PM

Dallastx

Posts: 5126
Joined: 11/15/2006
From: Dallas, Texas
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Never had that problem. I'm sure the retaining clips loose their tensile strength over a period of time.

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Post #: 3

RE: Left Side Cover Fell Off - 6/16/2007 9:33:16 PM

outdoorgirl57

Posts: 785
Joined: 6/16/2006
From: Alamogordo, NM
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Mine did the same thing the other day. Fortunately, my suitcase sized saddlebag kept it from totally dislodging and falling off and I was able to pull over. Now I tug on it really hard to make sure it is firmly clipped in there.

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Post #: 4

RE: Left Side Cover Fell Off - 6/16/2007 9:34:37 PM

aceospades

Posts: 1136
Joined: 4/3/2006
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quote:

ORIGINAL: ravenron

Hey guys...new to this board and impressed by the amount of knowledge here. Recently purchased an 05 Sportster XL883 Custom for my son and have had trouble keeping the left side cover on. I thought I had finally gotten it attached firmly but hit an unexpected bump amidst some road construction on Thursday...Damn...it was pretty violent (thought I might have bent the rims). In any case, after regaining control of the bike, I noticed the side cover bouncing off into traffic...

Long story slightly longer...side cover trashed, new one ordered, $107 poorer. Is there any better way to attach this cover to prevent similar issues in the future? I've ordered new clips hoping that will help. You'd think the old one's would still be good after only 4500 miles. Has anyone else had this happen?

Thanks in advance and ride safe...

RR

join the club..mine has fallen off twice now..107 bucks? you could have got the chrome cover cheeper than that!!

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Post #: 5

RE: Left Side Cover Fell Off - 6/16/2007 9:45:16 PM

ravenron

Posts: 6
Joined: 5/7/2007
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Yeah, you're probably right about getting chrome cheaper but then I'd have to buy two of them

and anyway, I was so pissed at the time I just wanted it replaced.

Impulse is rarely a good reaction but that was reflective of my state of mind at the time...

I appreciate the comments...sorry to hear that others are similarly afflicted. Maybe Harley or the aftermarket will come up with a better solution.

Be good.

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Post #: 6

RE: Left Side Cover Fell Off - 6/16/2007 9:48:55 PM

Dallastx

Posts: 5126
Joined: 11/15/2006
From: Dallas, Texas
Status: offline

Thye chrome cover is pretty cheap.

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Post #: 7

RE: Left Side Cover Fell Off - 6/16/2007 9:52:34 PM

ravenron

Posts: 6
Joined: 5/7/2007
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Can you recommend a website for the Thye covers?

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Post #: 8

RE: Left Side Cover Fell Off - 6/16/2007 10:02:02 PM

celtlion

Posts: 4511
Joined: 7/27/2006
From: Greensboro, NC
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There's a real problem with the battery cover if you don't get it locked down exactly right.

I lost mine on the interstate and even though I went back and got it..looked like crap on a stick..

I posted a wanted ad here and was fortunate enough to have good dudes like Flatlander and Grassman both offer to sell me theirs...they had upgraded to the chrome covers.

I kept one and the other went to PigInaBlanket who needed one also.

You should post in the wanted area for a cover. Even if you order one new it will probably take a long time to get it..I'm still waiting on a vivid black air cleaner cover I ordered 3 months ago..

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Post #: 9

RE: Left Side Cover Fell Off - 6/16/2007 10:23:49 PM

128auto

Posts: 2657
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From: Vancouver B.C. Canada
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I heard bad stories but never happened to me, I am too lazy to do the mod, maybe I will do it when I learn a lesson one day lol.

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Post #: 10

RE: Left Side Cover Fell Off - 6/16/2007 10:32:10 PM

anubisss

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From: Los Angeles, CA
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How much is a chrome one. The wife would love that...

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Post #: 11

RE: Left Side Cover Fell Off - 6/16/2007 10:39:22 PM

SportyPig

Posts: 3599
Joined: 7/20/2006
From: Nashville, TN
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This is a known defect. Especially with the 04 - 06 years. I had the stupid clips replaced 4 different times, then I completely lost the battery cover. And yes, there have been PLENTY of discussions here about this problem.

The best way to deal with this is the method that either Old Fender Guy, or raylow, hold the patten to. Drill a hole through the clip, and then stick a small zip tie through the hole. That will hold the cover in place when the clips fail, and if you need to remove the cover you just have to pull the zip tie out. So, there is no need to carry extra zip ties, knives etc on the bike, just to deal with this problem.

Next time something like that happens, check on e-bay. When mine was finally completely lost, I found one on ebay, from a guy that had bought either chrome or painted covers. I think it cost me about $30. Of course that was for a set...so if anybody happens to need a stock oil tank cover, just let me know. You can have it for the cost of shipping.

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Post #: 12

RE: Left Side Cover Fell Off - 6/16/2007 10:39:56 PM

CaptEvo

Posts: 14
Joined: 4/29/2006
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This is what was suggested to me on my '06. Took off my seat, at the top of the battery cover there are little holes right where the cover inserts into the plastic clips. I drilled a hole down that hole and through the plastic clip with the battery cover in its proper seated position. Then you just drop a zip tie down through the hole.....no more cover popping open. Just drop the zip tie down, don't zip it, that way you can just pull it out if you need to get to the battery without taking the seat off. The left side hole is really all you need, the right side doesnt have alot of clearance so I had to shorten it quite a bit to get it to drop....just an extra precaution.

Edit: And as usual......as soon as I post somebody beat me to it.

< Message edited by CaptEvo -- 6/16/2007 11:42:23 PM >

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Post #: 13

RE: Left Side Cover Fell Off - 6/16/2007 10:57:20 PM

128auto

Posts: 2657
Joined: 9/22/2006
From: Vancouver B.C. Canada
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The chrome battery cover costs around $120, you need a chrome one for the oil tank side too, so $240 right there. If you don't fix the original one, you will lose the chrome instead of the factory one lol, even worse.

quote:

ORIGINAL: anubisss

How much is a chrome one. The wife would love that...

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Post #: 14

RE: Left Side Cover Fell Off - 6/17/2007 10:25:54 PM

ravenron

Posts: 6
Joined: 5/7/2007
Status: offline

Thanks much for all the great advice! I will definitely do this mod when I get the new cover. Seems like a pretty simple fix but extremely effective. You guys are great. It's things like this that make this board so awesome. Hopefully I won't have to wait too long for the new cover. I shoulda looked here first for a replacement but, like I said, wasn't in the best frame of mind right after the "accident"

. I contacted the construction company and they're pretty agreeable to covering my loss. They thought $107 was pretty reasonable and just seemed glad there were no injuries. I'm really glad my 17 y.o. son wasn't on the bike...he's doing good but the experience isn't quite there yet. It is pretty awesome to have a riding buddy around all the time.

You guys ride safe...

RR

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Post #: 15

RE: Left Side Cover Fell Off - 6/17/2007 10:51:05 PM

OldFenderGuy

Multiple Time Contributor
Posts: 5346
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From: Ozark Country
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quote:

ORIGINAL: 128auto

The chrome battery cover costs around $120, you need a chrome one for the oil tank side too, so $240 right there. If you don't fix the original one, you will lose the chrome instead of the factory one lol, even worse.

quote:

ORIGINAL: anubisss

How much is a chrome one. The wife would love that...

Well, HD is 'proud' of their parts, but the chrome covers aren't quite that expensive (PN 66261-04 and 66262-04).

They have a 'suggested retail price' of $99 each, but there are a number of discount dealers where you can get 20% off, bringing the price to around $160 for the set.

(I forgot you were in Canada, but the $99 price is USD).

< Message edited by OldFenderGuy -- 6/17/2007 11:52:27 PM >

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Post #: 16

RE: Left Side Cover Fell Off - 7/1/2007 3:15:13 PM

ravenron

Posts: 6
Joined: 5/7/2007
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Well guys...got the new sidecover and performed the mod outlined on this site. Works like a charm! Anyone with a late model Sporty should take care of this before they start losing body parts. Thanks again!

RR

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Post #: 17

RE: Left Side Cover Fell Off - 7/1/2007 3:21:58 PM

russellabjr

Posts: 136
Joined: 5/26/2007
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take the clips off the frame and use black zip ties... it looks cleaner than the grey clips. its what i did.

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Post #: 18

RE: Left Side Cover Fell Off - 5/12/2008 11:32:46 AM

5k1ttl3

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Post #: 19

RE: Left Side Cover Fell Off - 5/12/2008 12:02:49 PM

flibuoy

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Ditto on either wire tie fix

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Post #: 20

RE: Left Side Cover Fell Off - 5/12/2008 12:12:01 PM

Gnight

Posts: 116
Joined: 2/19/2008
From: Boise, ID
Status: offline

Did the same thing as russellabjr, zip ties are awesome. Sad that I have to zip tie stuff on a brand new bike cause Harley takes the easy way out and uses plastic clips..wtf?

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Post #: 21

RE: Left Side Cover Fell Off - 5/12/2008 12:49:48 PM

Morloka

Posts: 55
Joined: 5/12/2008
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I lost mine, but was 2 up at the time so her leg held it in place, the clip broke when I was trying to put it back on, replaced the clip and havent had the problem again

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Post #: 22

RE: Left Side Cover Fell Off - 5/12/2008 1:02:29 PM

07HDnightster

Posts: 528
Joined: 11/19/2007
From: Conroe, Tx
Status: offline

quote:

ORIGINAL: CaptEvo

This is what was suggested to me on my '06. Took off my seat, at the top of the battery cover there are little holes right where the cover inserts into the plastic clips. I drilled a hole down that hole and through the plastic clip with the battery cover in its proper seated position. Then you just drop a zip tie down through the hole.....no more cover popping open. Just drop the zip tie down, don't zip it, that way you can just pull it out if you need to get to the battery without taking the seat off. The left side hole is really all you need, the right side doesnt have alot of clearance so I had to shorten it quite a bit to get it to drop....just an extra precaution.

Edit: And as usual......as soon as I post somebody beat me to it.

Same here....Works like a champ

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Post #: 23

RE: Left Side Cover Fell Off - 5/12/2008 1:03:03 PM

schumacher

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Posts: 5140
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From: Springfield, Ohio
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I'm gonna sticky this one so people don't have to go digging to find the fix.

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Post #: 24

RE: Left Side Cover Fell Off - 5/12/2008 6:40:43 PM

jsand5

Posts: 29
Joined: 5/3/2008
Status: offline

trusty old zip ties. My 2007 cover came off one week after I bought it. I didn't lose it though. My buddy just bought 08 1200 and it has the same junk clips and when I looked closer it was being held by one clip only. I let him know, I may have saved him a cover LOL. Them clips are junk!

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Post #: 25

RE: Left Side Cover Fell Off - 5/13/2008 12:18:01 PM

plevine1

Posts: 11
Joined: 5/23/2007
Status: offline

This is a huge problem. When I lost mine on my 06 it was covered under the warranty. After almost losing it again, I drilled a small hole towards the top of the cover then used a wire tie to secure it to the frame. Yes I do need to cut the tie every time I take the cover off but ties are dirt cheap and a non-warranty cover is not.

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Post #: 26

RE: Left Side Cover Fell Off - 5/13/2008 2:53:30 PM

Somber Goat

Posts: 91
Joined: 5/24/2006
From: Franklin, TN
Status: offline

this is happening way too often!

Months ago my battery cover came off as well, upon returning to the scene of the crime I found it road rashed beyond belief, who knows how far it skidded down the slap. Still surprised I found it later even though it was useless.

I replaced it with the HD chrome one and on my way to work last week i had glanced down to find it hanging down like it was an open door to my batter/fuse area. One thing after further investigation I noticed was the on the chrome cover where the front of the cover is supposed to come close to the frame there is a a gap that I could fit my finger through, which i'm guessing is how so much air gets behind these things to push them off, along with the sh!t clips they use. Anybody else ever notice that gap?

I did manage to pull off the highway before it totally got loose. Took a 10 minute pitstop under an over pass and was back on the road.

Moral to this story: Alway bring zip ties while riding, you'll never know when you'll need them.

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Post #: 27

RE: Left Side Cover Fell Off - 5/14/2008 1:52:00 PM

rookie003

Posts: 18
Joined: 3/29/2008
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Drilled the holes and used the zip ties last nite.Only took a few minutes and it was an easy task for a Rookie like me.

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Post #: 28

RE: Left Side Cover Fell Off - 5/15/2008 8:26:02 AM

trama

Posts: 115
Joined: 5/30/2007
Status: offline

this happening to the 07 sporty too? or did they fix it with the 06 models?

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Post #: 29

RE: Left Side Cover Fell Off - 5/16/2008 6:52:58 PM

Chief40al

Posts: 204
Joined: 6/27/2007
Status: offline

It came loose on my daughters 07 883 L
fixed with wire tie, as discribed on this post.
Thanks

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Post #: 30

RE: Left Side Cover Fell Off - 5/17/2008 10:38:47 AM

SpursDarkrider

Posts: 894
Joined: 2/16/2008
From: Houston, Texas
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The 07's are affected as well. the problem on mine was the left side clip, or the one towards the front, wants to pop off the frame when you try pushing the cover into the clip. I just took a piece of cardboard and wedged it between the ears of the clip where its secured to the frame so it wouldnt pop off when i pushed the sidecover on. Hasnt budged yet.

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Post #: 31

RE: Left Side Cover Fell Off - 5/17/2008 5:16:37 PM

Supercub

Posts: 2
Joined: 5/17/2008
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Yeah, my 2007 883C is only 5 months old and the battery cover popped open today. When I stopped at a light I noticed it hanging open. You have to get those top clips aligned just right and ensure they hold. Even then, it appears they will still release fairly easiliy. First time on the site. Thanks for the great tips!

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Post #: 32

RE: Left Side Cover Fell Off - 5/19/2008 2:10:19 PM

Somber Goat

Posts: 91
Joined: 5/24/2006
From: Franklin, TN
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@supercub, your right about lining them up just right but still if you notice them out of place later I'd advise not trusting them. Keep an eye on them and welcome to the forum.

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