Topic: #$%!% Battery Cover (Read 3114 times)

Midnight Rider · « **on:** March 06, 2012, 11:13:55 AM »

Is it just me, or is the battery cover on the touring bikes a bitch to get off? I must not be holding my mouth right, or am overlooking the obvious, but I had a hell of a time getting to the battery posts yesterday evening. I've done it once before, but for the life of me, could not figure out how to get the cover to release from that silver L shaped, movable hold down in front of the battery. Got the ECM off, other stuff out of the way, two rear bolts removed, but could NOT get the friggin' thing to come off. Cussing didn't help...hitting it didn't help...being nice to it didn't help. In the end, I managed to gain access to the positive terminal without removing the thing entirely.

I'm sure I'm overlooking something simple, or that I'm stoopid (sometimes the simplest things confound me). The service manual was no help. Is there a "trick" to this?

Got the work done, but just wondering for the next time.

BTW...if the battery is down to 12.31 Volts, the starter won't engage...

Installing several LED's in place of "regular" stuff, Load Equalizer, and tailight flash module...doing all that, testing, and leaving the ignition on for a while when trying to keep the alarm from going off runs the battery down faster than I thought possible, and I keep it on a battery tender all the time. Thought maybe I'd left a connection on the battery loose, but knew better, so measured the voltage at the pigtail...12.3V Just clicks. Left tender on all night...fired right up this AM.

ultrafxr · « **Reply #1 on:** March 06, 2012, 11:56:32 AM »

No Terry, it is not just you. I've had the same problem getting that dang cover off.
It has been a while but I think there is a tab that engages a slot in the cover (on the front side) that causes the problem. For something so simple they sure can make it complicated.

Midnight Rider · « **Reply #2 on:** March 06, 2012, 12:05:04 PM »

Quote from: ultrafxr on March 06, 2012, 11:56:32 AM

No Terry, it is not just you. I've had the same problem getting that dang cover off.
It has been a while but I think there is a tab that engages a slot in the cover (on the front side) that causes the problem. For something so simple they sure can make it complicated.

Yea, Jerry...it's that stupid tab that I could not figure out how to release. Aggravating POS. And it doesn't look like it's really necessary, particularly since the bolts hold it down securely.

Trying to work in that general area is like trying to build a ship in a bottle in the first place!

spada84 · « **Reply #3 on:** March 06, 2012, 12:20:07 PM »

Yep! I fiddled with it for some time, and suddenly, it came off easily. Never figured out the trick to make it repeatable.

Deep Blue Dives · « **Reply #4 on:** March 06, 2012, 01:05:24 PM »

Amen to this discussion - when adding my heated gear cables, I couldn't believe the stuff sitting on top, attached to, and that damn bracket up front expected to hold the cover in place. Once I saw there was a curved bracket up there, I figured how to massage it off, and back on.

Plain simply a bitch! I can think of a few other things to fix before any re-engineering resources are spent on making an easier battery mount to get off/on.

lvngd · « **Reply #5 on:** March 06, 2012, 03:03:02 PM »

Had the same problem with mine but got it down now. I just push down on the top cover front and it seems to hop off. Then a little angling towards the front of the bike to get it back on. But yes, sure is allot of chit to move just to get to the leads!!

bikerboy53 · « **Reply #6 on:** March 06, 2012, 03:15:42 PM »

It's been awhile, but I do remember that it's hard to get that cover off. I think I trimmed some of the plastic off of the tab area the last time I was in there, but I don't remember exactly what I did. It's still not easy peasy tho! Not sure why they made it so hard to get off...

Wait a minute, now I think I remember -they want us to take the bike to the dealer!

DESERTBEAR54 · « **Reply #7 on:** March 06, 2012, 03:36:56 PM »

This is a funny thread because I have had the same issue and then all of a sudden it comes off and I think to myself "self" how did I do that and the process starts all over again the next time I go into the battery!! Getting older sucks!!

Midnight Rider · « **Reply #8 on:** March 06, 2012, 04:18:22 PM »

Yea, I had it off a year ago when I put the Legend Shocks on there and wired up the handlebar switch. I recalled last evening that it was a PITA to get off, but I did get it off last time. But, that was a year ago...I should take notes, but then I'd forget where I put the damn notes.

timo482 · « **Reply #9 on:** March 06, 2012, 04:50:05 PM »

supposedly the electrical system on the softails uses a LOT less wire and takes up less space

i wonder why that is not on the touring bikes

hmmm

to

Fired00d · « **Reply #10 on:** March 06, 2012, 06:36:00 PM »

What cover???

Just wanted to say how much I love my '04

.

Ride Safe,
Fired00d

grc · « **Reply #11 on:** March 06, 2012, 07:24:53 PM »

Quote from: timo482 on March 06, 2012, 04:50:05 PM

supposedly the electrical system on the softails uses a LOT less wire and takes up less space

i wonder why that is not on the touring bikes

hmmm

to

It will be in the near future. Harley doesn't put the new stuff on all models at the same time, probably because they realize they do such a lousy job introducing new technology and they don't want to have to fix every bike they build for the next two years. For the HDLAN (CAN-Bus) system, they chose the Softail model line. For the initial year of the new primary and Cruise Drive trans, they chose the Dyna models. For Electronic Throttle Control they chose the Touring models. Eventually all those things have or will become standard on the other models.

Actually the Touring models will be the ones to benefit most from HDLAN, once they get it debugged. Lots more electrical and electronic stuff, so the cost savings to H-D will be greater. If they eventually become sophisticated enough, they could offer the ability to alter the operation of various components with just a tweak with a scan tool, similar to what the auto folks have been doing for many years now. For instance, in the old days if you needed to add daytime runnng lights to a Ford, you had to buy a separate module and wire it into your vehicle's lighting circuits. These days, you just hook up the scan tool and navigate to module programming, find the setting for DRL, and toggle it on. Done.

Jerry

tazmun · « **Reply #12 on:** March 06, 2012, 08:02:13 PM »

Hey TC, what you should have done before you got upset was let that BH, look it over!
I've learned that years ago, explain it to her, show her what you've done, then wait
for the real simple answer! Then proceed to smack your head on the nearest wall!

Just saying!

Taz

Barmats · « **Reply #13 on:** March 19, 2012, 10:21:04 PM »

I've done it twice and it wasn't any easier the second time.

kravnut · « **Reply #14 on:** March 20, 2012, 07:37:29 AM »

I couldn't agree more with the battery cover being a PITA! I screamed, yelled, cursed and threw things when I was trying to get to the terminals to hook up the battery tender and heated gear leads. Finally had to call the dealer and talk to one of the techs, since the service manual was of no use at all.

Midnight Rider · « **Reply #15 on:** March 20, 2012, 09:39:48 AM »

Quote from: kravnut on March 20, 2012, 07:37:29 AM

I couldn't agree more with the battery cover being a PITA! I screamed, yelled, cursed and threw things when I was trying to get to the terminals to hook up the battery tender and heated gear leads. Finally had to call the dealer and talk to one of the techs, since the service manual was of no use at all.

Care to share any tips or tricks the tech gave you?

Deep Blue Dives · « **Reply #16 on:** March 20, 2012, 11:19:00 AM »

Quote from: Midnight Rider on March 20, 2012, 09:39:48 AM

Care to share any tips or tricks the tech gave you?

After having the battery cover off a couple of times in the last week, it has become much easier. What I have found works the easiest is after removing the two bolts from the back of the battery cover, slide the cover forward - towards the front of the bike, you can then slip your finger below the plastic tab and push the bracket towards the battery to release the plastic battery cover totally. Everything will lift easily up then. Work the same way in reverse, watching to make sure no harnesses (or added accessory lines) slip below the battery cover and interfere with it being snapped back into place. Hopefully I have described this well enough.

HogBreath · « **Reply #17 on:** March 20, 2012, 11:59:01 AM »

I had all three of my batteries off this weekend. All I can say is, if you think the touring bikes are a bitch, try a V-Rod. Finally changed the battery on the 06 V-Rod this past Saturday. Raise the seat. Remove the thing that looks like a gas tank. Remove the air filter cover. Remove the air filter. Remove 6 bolts and remove the velocity stacks. Remove the innerlower air box cover be careful to unplug appropiate wires, hoses and hard to reach clamps. . Remove the leads. Attach clamp and a come-along to the battery. Attach other end of come-along to a 4 WD pickup. Carefully winch battery out of designated slot.

To install reverse above, except a sledge hammer and a 4x4 block of wood to drive the battery into the designated area is required.

The bagger is a breeze!

Midnight Rider · « **Reply #18 on:** March 20, 2012, 04:37:16 PM »

Quote from: HogBreath on March 20, 2012, 11:59:01 AM

I had all three of my batteries off this weekend. All I can say is, if you think the touring bikes are a bitch, try a V-Rod. Finally changed the battery on the 06 V-Rod this past Saturday. Raise the seat. Remove the thing that looks like a gas tank. Remove the air filter cover. Remove the air filter. Remove 6 bolts and remove the velocity stacks. Remove the innerlower air box cover be careful to unplug appropiate wires, hoses and hard to reach clamps. . Remove the leads. Attach clamp and a come-along to the battery. Attach other end of come-along to a 4 WD pickup. Carefully winch battery out of designated slot.

To install reverse above, except a sledge hammer and a 4x4 block of wood to drive the battery into the designated area is required.

The bagger is a breeze!

Never even took a gander at what it would take to remove the battery from the Vrod....sounds like a bitch though. Is the bike still running good?

Harley Guy · « **Reply #19 on:** March 20, 2012, 07:00:19 PM »

I replaced the battery last fall - the cover made me feel stupid, dumbfounded and pi$$ed off. What a PITA.
.
.

HogBreath · « **Reply #20 on:** March 20, 2012, 07:09:25 PM »

Quote from: Midnight Rider on March 20, 2012, 04:37:16 PM

Never even took a gander at what it would take to remove the battery from the Vrod....sounds like a bitch though. Is the bike still running good?

Still runs good. 11,000 miles I think. None of my bikes have very many miles. My first thought is..I don't ride as much as I thought. Then I count up how many bikes I've had the last few years..LOL

kravnut · « **Reply #21 on:** March 20, 2012, 08:40:08 PM »

Quote from: Midnight Rider on March 20, 2012, 09:39:48 AM

Care to share any tips or tricks the tech gave you?

He basically said to lift up on the back of the cover and push down on the front of the cover at the same time and push forward at the same time. Even with this information it was a PITA, still thought I was going to snap the cover, but it did come off.

Sledge · « **Reply #22 on:** April 07, 2012, 05:38:09 PM »

Crap, my turn!! Just installed the tp quick disconnect hardware. Learned to never read the stupid instructions, just study the exploded diagram on the main install sheet.

Go to install my batt tender pigtail and there it is, the seemingly unremovable batt cover.

On my way back out to the garage to see if I can get it off. (after a short pause for a bit of refreshment)

I'll edit the post to let y'all know how it goes for me. Hey I got an unused takeoff 09 sg seat for 80 bux at the dealership. Looks pretty good.

UPDATE. Piece of cake! The description above is right on. The tab to the front of the bike holds it there and you got to spread and move around some cables to get enough room to push the cover forward, stick your finger down next to the metal tab in front and work it off, props to you guys again.

Sledge

CVODON · « **Reply #23 on:** April 07, 2012, 07:54:03 PM »

I read this link awhile back and thought, that must be a real pain. Then during Bikeweek I left the lights on in my wifes car and ran her battery down. It was 10:30 and I didn't want to wait for road service. Took bike seat off, took out the two rear bolts on battery cover and slide cover forward and off, no effort, no problem. Not sure what the problem was for others. Jumped the car, got it running and slipped battery cover on and off a couple times, just no effort.
Maybe it was because I was soaking wet with sweat in my eyes and couldn't see a problem if it existed?

Skillet · « **Reply #24 on:** April 07, 2012, 08:41:53 PM »

Can be a pain first time doing it.

Fired00d · « **Reply #25 on:** April 07, 2012, 08:44:36 PM »

Quote from: COR on April 07, 2012, 07:54:03 PM

I read this link awhile back and thought, that must be a real pain. Then during Bikeweek I left the lights on in my wifes car and ran her battery down. It was 10:30 and I didn't want to wait for road service. Took bike seat off, took out the two rear bolts on battery cover and slide cover forward and off, no effort, no problem. Not sure what the problem was for others. Jumped the car, got it running and slipped battery cover on and off a couple times, just no effort.
Maybe it was because I was soaking wet with sweat in my eyes and couldn't see a problem if it existed?

Wife might have been an incentive/reason you didn't have a problem getting it off too... just sayin'.

Ride Safe,
Fired00d

Sledge · « **Reply #26 on:** April 08, 2012, 03:21:37 PM »

Don't know about the folks that didn't have a problem but it might be they don't have the extra bundles of cables we bagger riders have, especially with all the latest gizmos and gadgets like amplifier leads and extra power to lights, etc.

I couldn't even see the bracket holding the front side of the batt cover until I moved quite a few cables out of the way. Once I unhooked a few and moved them it was easier, but still barely enough room. One of those things you have to do once before it becomes obvious I guess.

Sledge

Author Topic: #$%!% Battery Cover (Read 3114 times)