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General Category >> Rubber Side Down! >> Losing the ToolBox/Batter cover
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Message started by youzguyz on 09/28/10 at 11:10:48

Title: Losing the ToolBox/Batter cover
Post by youzguyz on 09/28/10 at 11:10:48

How it happens:

The cover (the prongs) is metal. The battery box (the holes) is plastic.
Vibration will cause the metal prongs to eat away at the plastic holes, enlarging the holes, and eventually cracking the plastic.
Goodbye cover.

I caught mine before it departed, now I need to figure out a cure.

Best guess is to use some of the epoxy putty and fill the plastic holes back to the original size and shape.

I sure use a lot of that putty stuff! ;D

Title: Re: Losing the ToolBox/Batter cover
Post by verslagen1 on 09/28/10 at 11:38:26

similar problem different cause...
I forgot to put the battery top cover back on when I worked on the carb. Didn't need it cause I also left the tool box where I could always find it too.
So I was going on a trip and decided a pack of lousey tools is better than no tools... oh sh!t, no cover. Scrounge for a bit and found a metal plate with a slot right where I needed it. Bracket off of something. No wife to complain about some niknak being hung on a wall so don't remember where it came from. ;D That and a flat head screw. Been on there a month or two, suppose I should check it. :-?

Oh and I bent down those stupid tabs on the box so they were tighter on the battery box lid.

Title: Re: Losing the ToolBox/Batter cover
Post by spacepirates on 09/28/10 at 12:19:00

I lost mine on the day I bought my bike. At first I took some sheet metal and bent it to fit, then after that ripped off on the highway I bought a replacement cover, but decided it was better left off anyways.

Got a cheap fork bag, stuck my tools in there. eventually I ripped out my airbox and found that those metal tabs make a wonderful home for the CDI.

in my mind, if your bike is still running after something falls off, leave it off!

Title: Re: Losing the ToolBox/Batter cover
Post by CalisOsin on 09/28/10 at 15:01:16

424150525441584350455442310 wrote:

in my mind, if your bike is still running after something falls off, leave it off!

Haha, very true!

Title: Re: Losing the ToolBox/Batter cover
Post by youzguyz on 09/28/10 at 15:40:21

7F6C7B7A65686E6C6738090 wrote:

Scrounge for a bit and found a metal plate with a slot right where I needed it. Bracket off of something. No wife to complain about some niknak being hung on a wall so don't remember where it came from. ;D

Ahhh.. thanks for the idea! Couldn't find a niknak bracket, and I do have a wife that would be noisy about such. Cut a piece of sheet metal so the edge would line up with where the slots used to be prior to enlargement and drilled a hole for the screw. Put it between the batt box plastic and batt holder cover. Screwed it down with the regular screw.. works fine!

Thanks dude! :D

Title: Re: Losing the ToolBox/Batter cover
Post by justin_o_guy2 on 09/28/10 at 18:44:41

I think the lesson here is
Its better to be the one with the harder prong.

Title: Re: Losing the ToolBox/Batter cover
Post by Digger on 10/21/10 at 21:12:39

Yet another thing to attend to in my quest to make my Savage last as long as I will be riding (only about another 27 years or so).....sigh.

I hope this is the piece y'all are talking about:

http://i235.photobucket.com/albums/ee201/Digger109/LS650/ToolBagCoverHolderE.jpg

Although I could see very little wear, I decided to apply the same fix I do to lots of things that are wearing from vibratory rubbing....and that is to apply UHMW polyethylene tape (http://www.mcmaster.com/#uhmw-polyethylene-tape/=9dp4r8) (I suggest the stuff with the "Super-Bond Adhesive") to the problem area:

http://i235.photobucket.com/albums/ee201/Digger109/LS650/ToolBagCoverHolder-UHMWTapeE.jpg

Although you really can't see it in the photo, I looped the tape all the way through the rectangular holes and to the underside of the chromed plastic bracket.

Well, tape in hand, I looked for other trouble spots. Found one on the tool bag:

http://i235.photobucket.com/albums/ee201/Digger109/LS650/ToolBagE.jpg

In particular, the metal snap on the plastic tool bag had been rubbing on something (not sure what, though).

A little of the magic tape, a (admittedly ragged and sloppy) trim job, and I'm back in business:

http://i235.photobucket.com/albums/ee201/Digger109/LS650/ToolBagSnap-UHMWTapeE.jpg

End of problem, real or imagined.

Thanks for the heads-up, youz!