skeebo wrote on 05/27/12 at 11:35:24:

The pictured one isn't mine; it's one from a '95.   Mine's a 2009, but has the same chamfer shape at the bottom.  I looked at pictures of boxes dating back to '87, which indicates the shape has been around forever.  This is why it seems to me that the problem should be more outspoken.   What I mean is, either I bought the ONE battery that won't fit the stock box, or everyone else is modifying their boxes to fit the squared off batteries, or a bunch of folks are returning batteries to the vendors?  If it's the latter case, then that's a whole lot of wasted money in shipping (batteries are heavy).

I spent all day yesterday searching for batteries online, and didn't see a single one that appeared to have a chamfer like the stock battery, at least not from the pictures.   This is why it is not making sense to me?   Normally, a universal problem like this will reach critical mass, and the vendors will change something.

BTW, I know I could hack something to solve the problem, as others have done or suggested, but I'd prefer to keep the bike stock if possible.   Note, this fiasco would be a non-issue if Suzuki had simply designed a square box, but instead they made this weird shape that doesn't fit the majority of the batteries out there.

FYI, the size of both my stock and new AGM battery is...

6 5/8  =  6.625  =  168mm    (H)
3 1/2  =  3.5    =   89mm      (W)
5 1/4  =  5.25   =  133mm    (L)

This is verified both by me physically measuring and the recommended Savage/S40 size from battery mfrs.

I did find one battery that has the same specs, except that it is slightly shorter in height (6.4in), which might be just enough to squeeze in.   I am tempted to order and cross my fingers...

http://www.batteryweb.com/motorcycle-batteries-detail.cfm?model=PTX14AHL-BS

It's frustrating, but thanks for your insight and suggestions.   It's nice having a supportive resource like this with its depth of experience.

I bought a agm magnapower battery from autozone 4 years ago and it fits like a glove. And the battery still is as good as the day I bought it. Never a single issue. 4 years is a great age for a motorcycle battery. If this one ever bites the dust, I'll get the same one again.

http://www.batterymart.com/c-big-crank-batteries.html

I just went through the same problem replacing the stock battery with a Chinese "Power Source" sealed battery # WP14L-2, guaranteed to fit, at least according to the dealer's aftermarket parts catalog.  

Well, the new battery slid in 3/4 way before bottoming out on those protruding top brackets at the ground terminal side of the battery box.  I removed said box, trimmed foam, cussed some, and reworked said box profile scientifically with a hammer by pounding out the bottom chamfer and brackets till the new battery just squeezed in.  It is now an interference fit.

Just ran into this in April.
My new battery didn't fit as well as the previous.
I made it fit, but it took manipulating. I thought it was just me.


--Steve

The Magnapower battery has rounded off edges so that is probably why it fit anyways. The measurements usually are from flat side to flat side. Things like radius edges are not mentioned in the description. Mine is a tight fit as well, however I didn't have to work around it. It slid in just fine.  If my battery had full sharp edges, it would not have fit either.
I paid $92 for my Magnapower back in the day, but I don't remember the specs like cranking amps or AH, it just worked flawless the whole time. I will gladly buy it again when the time comes.