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General Category >> Rubber Side Down! >> Simplest, Cheapest Battery Box Solution??
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Message started by BadaBing on 06/17/15 at 12:08:53

Title: Simplest, Cheapest Battery Box Solution??
Post by BadaBing on 06/17/15 at 12:08:53

Hello fellow riders,

I purchased my savage used with the airbox already removed. The previous owner just shoved an old big crank battery between the frame, so i don't have a battery box.

Its about time for a new battery, so I'd like to replace with an OEM sized battery.

My question: What's a clean, reasonably priced solution for a battery box? Anyone know of an aftermarket solution that replaces the OEM box?

I'd love an OEM box with those chrome side covers, but its tough to find one in good shape for a good price.

Also, I'm not sold on the mini battery install. I'd like to stay full sized.

Thanks everyone!

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by Steve H on 06/17/15 at 14:59:40

The battery box isn't generally hard to find. It's the chrome locking cover that is so hard.

The battery can be retained inside its box without the fancy chrome cover. You can get it later.

Here's one for $20 and no shipping.

http://www.ebay.com/itm/99-00-01-02-03-04-Suzuki-Savage-LS650-LS-650-S40-Battery-Box-Tray-Cover-/191593421798?hash=item2c9bdb9be6&vxp=mtr

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by BadaBing on 06/17/15 at 16:27:31

Thanks for the link.

This is sort of my last resort option. I'd love to bolt on something clean-looking and be done, but I guess that option doesn't exist?

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by Cronyschism on 06/17/15 at 17:31:47

17343134173C3B32550 wrote:

Thanks for the link.

This is sort of my last resort option. I'd love to bolt on something clean-looking and be done, but I guess that option doesn't exist?

When I pulled the carburetor to give it a thorough cleaning, the factory battery box had to come out ...not really any way around that. Well, I noticed the battery box was experiencing surface rust and was overall dirty. Using full strength Simple Green and a brush, I was able to give it a good cleaning followed by hosing it off and drying with compressed air. Afterwards, I gave it several coats of Ace Hardware house brand black gloss paint....looks great now! Sure, the chrome aspect is gone now, but at least it looks clean :D

My 2 cents

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by verslagen1 on 06/17/15 at 18:42:23

63524F4E5953434849534D200 wrote:

When I pulled the carburetor to give it a thorough cleaning, the factory battery box had to come out ...not really any way around that.

Well, yes there is. And it really helps when you drop the bowl too. Take a ratchet strap hook one end on the top shock mount then around the bat box and then to the axle or thereabouts. Tighten the strap till the bowl clears
Viola

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by Cronyschism on 06/17/15 at 20:13:53

Ah that's good to know, thanks for the tip!

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by BadaBing on 06/18/15 at 05:49:09

Thanks guys. Sounds like the stock box is the easy (read: only good) option.

If I get creative, I'll drop a link here...

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by MisterChris on 10/15/19 at 09:08:02

I bought another Suzuki 650, this time a 2008 s40 with 780 miles and a gummed up carb. I pulled the carb, cleaned it, changed jets, reinstalled it, and the bike started right up. Hurray. Now I have to get that battery box back on the bike or replace it. Any suggestions? I bought a lithium battery so it's smaller and lighter. Any small tips about how to do this will be much appreciated.

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by Tacopimp on 10/15/19 at 15:58:15

Shoot me a PM I have a battery box I can sell you.

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by MisterChris on 10/15/19 at 19:22:37

I have a OEM battery box in excellent condition. It getting something that is smaller that the deal.

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by ohiomoto on 10/16/19 at 05:28:38

Many small batteries ship with foam spacers that will shim the battery towards the top of the box and take up space on the sides. You can get some foam insulation or padding and cut it up to do the same. You might need to extend the battery cables as well.

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by MisterChris on 10/16/19 at 09:29:35

Thanks for the suggestions. I have a perfectly good OEM battery box so my question was if someone knew of a suitable substitute that is smaller. s

My other questions is this: I managed to get the battery box back in (sort-of). I was able to align one bolt, but am having trouble getting the other three to line up. Any thoughts on how to make that happen? I've tried using various pry tools to move it around, but no luck.

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by MisterChris on 10/16/19 at 10:25:13

I'd mention that on the some of the previous Savages I have owned, the battery box and the cover that holds he tool kit were often rusted, some quite badly. So on the one I just bought, I have clear-coated the inside of both the battery box and the cover. I figure it can't hurt.

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by verslagen1 on 10/16/19 at 10:42:59

The simplest solution is the stock box, maybe cheapest too as used ones are easy to get.

Especially if you want to use the stock tool box.

Next, electronic project boxes can be had in many sizes, but not simple.

Yeah, I had trouble getting it back in too. Check the wire routing, pry harder, put a ratchet strap around it, curse if necessary. 8-)

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by MisterChris on 10/16/19 at 10:52:01

Thanks. I'll try to figure out the ratchet strap idea. It's chilly here today so I won't try until tomorrow.

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by ohiomoto on 10/16/19 at 11:11:44

Don't tighten any bolts until you have them all started.

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by MisterChris on 10/16/19 at 12:30:53

Thanks. A helpful reminder. I actually knew about that, but now I have to check if I remembered to do that. Ah, the absent minded professor!

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by BrokeAss on 10/16/19 at 20:51:03

The factory starter wire and ground wire reach and work perfectly in this box (managed to fit the starter solenoid in the box beside the battery):

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by MisterChris on 10/17/19 at 09:07:39

Thanks for the suggestion. I'm still wrestling with the OEM battery box. Maybe I'll figure it out.

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by Ed L. on 10/17/19 at 19:20:14

There's a little protrusion on the back side of float bowl that doesn't seem to do anything except get stuck on the battery box when trying to drop the bowl. In a fit of What The Fu*k is that there for I filed most of it off, really helps getting the bowl off without screwing around with the battery box. Just something that makes working on the carb easier.
Just remembered about filing it off when reading about needing to ratchet strap the battery out of the way to work on the carb.

Title: Re: Simplest, Cheapest Battery Box Solution??
Post by MisterChris on 10/18/19 at 12:05:05

I got everything back together yesterday after several efforts to get that battery box back on the bike. Somehow I did it. I'll post a picture at some point. Thanks to everyone who took the trouble to make suggestions and share tips. Much appreciated!