Use to have a problem with the cover opening up a lot. Then I noticed that they weren't lining up properly when I was closing it. Even though at a quick glance they looked like they were clipped properly they weren't. As a matter of fact, that is one of the reasons they changed the design from the ones I have, which are the old stock ones. Because the old ones were not lining up properly all the time, it would eventually cause them to break. You have to really get down close and make sure the cover is between the two halves of the clip and then they work fine. I don't like the new design at all (my son's bike has them).

 

i did the same used cable tie works a treet

 

I used zip ties and also drilled a hole in each of the plastic clips. I put a screw thru the battery cover and the clips and its been holding nice and tight. I just keep it zip tied as a precaution so I dont end up losing the cover.

 

Or, look at post #32 in this thread.

 

My point was that there is more than one fix, therefore there is a choice. I was aware of your post and the solution you used is a good one, but not the only one, nor the one I used.

 

I have finally drilled the zip tie slip holes. i had the clips replaced back in 2013 and all was fine. they recently started failing on every ride and had me riding around looking like i was holding in a poo.

i'd finally had enough and just did it. i removed the clips drilled through the middle of the front one and slightly toward the rear of the rear clip. added an extra hole to the cover. no problems since. cost... 10 minutes of my life. i already had all that crap in my garage for other projects.


Thanks for the photos.

 

Funny how this keeps popping up. I almost lost mine today after almost a year free of problems. Turns out when I had it off this weekend, I routed the battery cable over the main fuse cable instead of under it which prevented it from seating properly. It's too fine a line between good and bad on that thing if you ask me.