After purchasing my Sportster I experienced the battery cover coming loose while riding and subsequently losing my registration papers. I found the following issue that caused this.
1. The fwd clip was being forced loose just by the action of trying to seat the edge of the cover over the lip and onto the pip. The clip would pop off and fall into the frame. I fixed this by installing a self tapping sheet metal screw in between the tangs forcing them to stay tight against the slot in the frame.
2. Next I noticed that the fuel tank vent check valve was lodging between the cover and the frame preventing the cover from fully seating in the fwd latch. The cover was contacting at the spot marked by the L/H arrow.
3. I slid the valve out of it's holder and positioned it below the clip and rerouted the drain line down in the frame to give the cover more clearance as in the picture below.
4. Now install the cover and you will notice that the front tang now engages tightly into the slot and is very secure.
You can now see that the cover is no longer hitting the drain valve and fits much better that before.
I hope this is some benefit to my fellow forum members.
AMA # 990571
2008 XL1200L in dark blue pearl
"Imagination is more important than knowledge" Albert Einstein
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