SuzukiSavage.com - Losing the ToolBox/Batter cover

youzguyz

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Losing the ToolBox/Batter cover
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! Grin

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2002 - Silver (Thumper)
2000 - Green (Mad Hamish)
Most motorcycle problems are caused by the nut between the seat and the handlebars. Make sure yours isn't too tight or too loose.

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verslagen1

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Re: Losing the ToolBox/Batter cover
Reply #1 - 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. Grin

That and a flat head screw. Been on there a month or two, suppose I should check it. Huh

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

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spacepirates

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Re: Losing the ToolBox/Batter cover
Reply #2 - 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!

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CalisOsin Senior Member Offline Rather die, than live down on my knees. Posts: 297 Orange County, Ca Gender:	Re: Losing the ToolBox/Batter cover Reply #3 - 09/28/10 at 15:01:16 spacepirates wrote on 09/28/10 at 12:19:00: in my mind, if your bike is still running after something falls off, leave it off! Haha, very true!
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youzguyz

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Re: Losing the ToolBox/Batter cover
Reply #4 - 09/28/10 at 15:40:21

verslagen1 wrote on 09/28/10 at 11:38:26:

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. Grin

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! Cheesy

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2002 - Silver (Thumper)
2000 - Green (Mad Hamish)
Most motorcycle problems are caused by the nut between the seat and the handlebars. Make sure yours isn't too tight or too loose.

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justin_o_guy2 Serious Thumper Offline What happened? Posts: 55279 East Texas, 1/2 dallas/la.	Re: Losing the ToolBox/Batter cover Reply #5 - 09/28/10 at 18:44:41 I think the lesson here is Its better to be the one with the harder prong.
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Digger

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Re: Losing the ToolBox/Batter cover
Reply #6 - 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:

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 (I suggest the stuff with the "Super-Bond Adhesive") to the problem area:

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:

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:

End of problem, real or imagined.

Thanks for the heads-up, youz!

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Digger
2001, Metallic Glacial Blue, Raptor Petcock, Verslavy (first hole) (otherwise, mechanically, the bike is stock), 13,xxx miles
I don't own a cage.
www.astronautbiker.com

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