Our 2006 XL1200 had the same problem. My wife darn near got killed because it pinned her left leg to the bike and she could not put both feet on the ground. Dealer replaced with the grey clips, has not come off since the change.

 

It happened to me on the way home from buying my new bike...fixed under warranty, fell off AGAIN...this time, I put the plastic clamps on that hold it the cover on. I believe the problem is the clamps often do not actually "click" into place. They are REALLY difficult to get on right.

 

I've opened mine a few times to put the tender on. The next thing I know, the damn thing is hangin off DURING A RIDE and almost caused me to go down at a light. Then at home tryna fix it, one of those sh1tty clips fell out altogether.

 

same thing happened to me. I've since got an accessory hook up that mounts permanently to the battery and plugs into the tender. How do you get the clips back in, do you have to take the battery out to get under there. How do you zip tie the cover in place?

 

Before giving up and using tie wraps, I took the seat off and put the clip back in .... its always the clip closest to the handle bars. The problem is that when one tries to push the cover into the clip, the cover pushes the clip back, through the hole in the frame. Extremely poor design. As I mentioned before, one dealer said its not covered because its a wear and tear item.

 

I didn't have a problem with the dealer warranty issue. There is a FINAL version of those clips out now. I haven't had a problem with this since they installed those clips. That's been about 4,000 miles ago.

 

Ill ask about them next time Im in.