My son wanted a bike for his wife and got a deal on an 09 1200. He also rides it back and forth to work rather than his Ultra. Anyhow, we were out for a short ride today and the battery cover kept coming open. Got home, took the seat off and found two really cheap plastic clips that barely hold the cover closed. Anybody else find this to be a problem and is there a fix?

 

Yes, this has been a common problem for Sportster battery covers. A few guys have come up with different ways to mod the covers and then run a zip tie through them to ensure it doesn't come off. The dealer fix is usually a set of new clips which run about $40, but if the bike is under warranty still it should be covered. In '10 they actually have a slot near the top where you can run a zip tie straight through it and onto the frame. Search in the Sportster forums for "battery cover fell off" and you'll find a slew of pics from guys who have lost and later recovered theirs on the highways with a little road rash...along with their suggestions and fixes. Glad you caught it now!
https://www.hdforums.com/forum/sport...-fell-off.html

 

Thanks 09. Fix seems relatively simple. I'm surprised that Harley would put something this cheap on a bike and continue to use it after it's a proven problem.

 

I actually bought some of the new clips, didn't like them and couldn't run the zip tie through it. Went back to the old number and couldn't be happier. Drill a hole through the clip drop the zip tie through and voila.

MH

 

I don't even have clips.I just zip tied mine on.You don't need to open the cover unless you need a battery or to install a pig tail for a battery tender.If the battery needs charged you can do that at the battery cable on the starter and any metal part of the bike.

 

Since 04, Battery covers have been flying down the road ...

 

Same happened to my 2008 1200 Custom - the first year - I now use tie raps too but because of relay issues with the Sporty (water getting in the fuse area) I now carry a box cutter and spare tie raps in my tool pouch in case of a break down on the road - and yes, I carry a spare relay too!!!!

 

I put a screw in the front tab to keep it from being pushed through the frame and dropping down in front of the battery (already happened) and a 14" zip tie with lots of slack, so i can still open the cover without cutting the tie.

 

I'm guessing that the moco has recognized it's an issue since on my '10 there is a pre-drilled open slot in the top left of the tank cover, which fits perfectly for a zip tie.

 

I'm assuming you mean the battery cover not the tank cover correct?

The slot is nothing new. My 06 has it. Not sure how far back it goes.

MH