Battery Cover "Side Covers"

[slowrower]

Mine broke and after getting a new set, I added some Kevlar to the tabs to reinforce them. The Kevlar is dam hard to cut but will last.

Is your thinking that the Kevlar will stop the tabs from breaking or just holding it together IF they break? I assumed you used fiberglass epoxy stuff?

Hi BigRon .. The Kevlar will prevent the tabs from breaking. I use it to reinforce high-stress areas in racing shells. It will flex, take vibrations and heat is no problem. As for Epoxy yup, I use West Systems and add fibers to reinforce it.

 

[tommyboy]

I have had 2 sets replaced the last set got the new rubber mount pins with no problems so far.

 

[PitBull43]

I have an 06 Pitbull (rigid) and one of my sidecovers cracked at the tab where the bolt goes through. While it was at the shop getting the new heads etc done for the lous ticking they had BD send them a kit that is used to fix the problem. The tech said it is a pain in the ass for them, to do but it is supposed to fix the problem. Apparently it is a shell that goes on the inside of the cover that is almost identical. We shall see when i pick the bike up later this week.

 

[Fibersnake]

I never had an issue on my 05 Mastiff, however the last time I had it in the shop to have fork seals and bushing replaced, my dealers indicated that there was a SB for the covers and that they would take car of it. When I got it back, the top bolts had been replaced with big ass pins that go through big rubber bushing. We will see if the hold up like the originals or not.

 

[Wildthing]

(07 Mastiff - 5.5K miles)
Replaced one set and the second set seems loose

 

[Big Ron]

I never had an issue on my 05 Mastiff, however the last time I had it in the shop to have fork seals and bushing replaced, my dealers indicated that there was a SB for the covers and that they would take car of it. When I got it back, the top bolts had been replaced with big ass pins that go through big rubber bushing. We will see if the hold up like the originals or not.

Fibersnake, talked to the dealer today and they are ordering my new side covers and they already have the new "push pin" kit that is supposed to fix this ongoing problem. Hopefully this will be the end of this.

 

[BigDogBro1]

I have loosened the four bolts that hold the covers onto the frame under the seat. They are snug enough to just stay in place. I'm hoping this will relieve some stress on the cover mount tabs. Low mileage yet though! 400mi.

 

[LamboV12]

After several sets of covers, the last fix that worked for me was the bracket and expoxy. Like BigDogBro said, about finger tight (10 ft/lb) on the bolts is VERY important - even tech's over tighten them. The last fix worked so well I was confident enough to do this: