Side Cover

BAR1 · Jun 26th, 2009, 11:53 AM

I have the Iron 883, and after the first month or so of riding it, my side cover fell off. It appears that I only have 2 clips holding it in place, when some of the other sportsters show 3 clips. Well, long story short, I took into my dealership, and they supposedly fixed it. I went riding this past weekend for a couple of hours, and what do ya know...it fell off again! Is anyone else having this same problem? If so, how many clips do you have? I'm taking my bike in again tomorrow to have them "fix" it, but I want to make sure what they're doing is correct.

jloomis19 · Jun 27th, 2009, 12:06 AM

I had that problem with mine too. I had to take it in 3 times before they actually got it right....But Im pretty sure it only has 3 clips...But I may be wrong, its been like 3 years since it happend, lol.

Hobbit · Jun 27th, 2009, 12:07 AM

the correct way is a Zip tie, the clips are more or less a waste of space and have been since they changed to the new rubber mounted motor in 06 so its not a new problem.
open the cover and remove the seat and towards the base of the tank you will see a hole in the frame, there is a cooresponding hole in the top of the cover, just whip a zip tie between the 2 and job done.
the FI sporties seem to suffer more than the carbed ones, and they are a fortune to replace if it actually comes right off and bounces down the road.
there should be 2 push clips on the top to hold it up

NEWHD74FAN · Jun 27th, 2009, 11:15 AM

Kinda sad that zip tie is required on a $10K bike...just to be able to "say" that it was "tooless" entry to get at those fuses and such. Don't forget to carry extra zip ties in case you are doing some "road-side" service.

cedarbrook63 · Jun 27th, 2009, 11:48 AM

Like Hobbit and NHDF74 said. My 09 Sporty has 2 clips and the side cover fell open a couple of times when I was first riding it. When Hobbit and I staged 1ed it last month - he put a Zip tie into the hole in the cover at the front end. It is a pain having to do that on a new bike but that's the way it is and I carry a knife and a few spare ties with me always in case I should need to open/close it. I've had to do this a couple of times since as I was tweaking the Pots on the TFi to get it singing just right.
With the TFi in place under there - there's no way it was closing shut securely. Before fitting that it wasn't too loose - but that's just not dependable enough. Zip tie dependant now.....

supertone · Jun 27th, 2009, 10:19 PM

It has happened on my Nightster too (even on the test ride bike I looked down and found it resting on my left leg!) - I think it is quite common, you either don't push it into the clip enough, or push the clip off the frame rail. There are two clips, I just take extra care when putting the side panel back on that it is alligned properly with the slot in the clip, then push it fully home.

NEWHD74FAN · Jun 28th, 2009, 03:09 AM

Do the zip tie thing to be sure...those clips lose tension after a while, just easy and inexpensive insurance!

BAR1 · Jun 29th, 2009, 11:08 AM

Zip tie it is then! It's just frustrating when you spend money on a brand new bike, and you have to constantly take it in to get fixed. Oh well....thanks for the advice guys!

Jun 26th, 2009, 11:53 AM	#1
BAR1 Start The Engine Ride: 2009 Iron 883 Join Date: Jun 15th, 2009 Location: Milwaukee, WI Posts: 20 My Mood:	Side Cover I have the Iron 883, and after the first month or so of riding it, my side cover fell off. It appears that I only have 2 clips holding it in place, when some of the other sportsters show 3 clips. Well, long story short, I took into my dealership, and they supposedly fixed it. I went riding this past weekend for a couple of hours, and what do ya know...it fell off again! Is anyone else having this same problem? If so, how many clips do you have? I'm taking my bike in again tomorrow to have them "fix" it, but I want to make sure what they're doing is correct.

Jun 27th, 2009, 12:06 AM	#2
jloomis19 Warming The Wheels Ride: 2006 Sportster XL883C Join Date: Mar 28th, 2009 Location: Zanesville, Oh Posts: 99 My Mood:	Re: Side Cover I had that problem with mine too. I had to take it in 3 times before they actually got it right....But Im pretty sure it only has 3 clips...But I may be wrong, its been like 3 years since it happend, lol. __________________ H-D = Hundreds of Dollars

Jun 27th, 2009, 12:07 AM	#3
Hobbit Moderators Ride: 2009 FAST 103 Street Bob Join Date: May 18th, 2007 Location: The Shires UK Posts: 7,470 My Mood:	Re: Side Cover the correct way is a Zip tie, the clips are more or less a waste of space and have been since they changed to the new rubber mounted motor in 06 so its not a new problem. open the cover and remove the seat and towards the base of the tank you will see a hole in the frame, there is a cooresponding hole in the top of the cover, just whip a zip tie between the 2 and job done. the FI sporties seem to suffer more than the carbed ones, and they are a fortune to replace if it actually comes right off and bounces down the road. there should be 2 push clips on the top to hold it up __________________ Please stop by the "self help section" for maintenance tips, diagnostic codes and much more. >>Self Help Information and Tips<< click me!

Jun 27th, 2009, 11:15 AM	#4
NEWHD74FAN Moderators Ride: 2004 Sportster XL1200RS Join Date: Aug 24th, 2008 Location: Camarillo, CA Posts: 3,556 My Mood:	Re: Side Cover Kinda sad that zip tie is required on a $10K bike...just to be able to "say" that it was "tooless" entry to get at those fuses and such. Don't forget to carry extra zip ties in case you are doing some "road-side" service. __________________ Please stop by the "Self Help section" for maintenance tips, diagnostic codes and much more. >>Self Help Information and Tips<<

Jun 27th, 2009, 11:48 AM	#5
cedarbrook63 Contributor$ Ride: 2008 XL883 Sportster SE Stage 1 Join Date: Dec 29th, 2008 Location: Gloucestershire, England Posts: 429 My Mood:	Re: Side Cover Like Hobbit and NHDF74 said. My 09 Sporty has 2 clips and the side cover fell open a couple of times when I was first riding it. When Hobbit and I staged 1ed it last month - he put a Zip tie into the hole in the cover at the front end. It is a pain having to do that on a new bike but that's the way it is and I carry a knife and a few spare ties with me always in case I should need to open/close it. I've had to do this a couple of times since as I was tweaking the Pots on the TFi to get it singing just right. With the TFi in place under there - there's no way it was closing shut securely. Before fitting that it wasn't too loose - but that's just not dependable enough. Zip tie dependant now.....

Jun 27th, 2009, 10:19 PM	#6
supertone Start The Engine Ride: '08 Nightster Join Date: Jun 27th, 2009 Location: London SW14 Posts: 24	Re: Side Cover It has happened on my Nightster too (even on the test ride bike I looked down and found it resting on my left leg!) - I think it is quite common, you either don't push it into the clip enough, or push the clip off the frame rail. There are two clips, I just take extra care when putting the side panel back on that it is alligned properly with the slot in the clip, then push it fully home. Last edited by supertone; Jun 27th, 2009 at 10:21 PM.

Jun 28th, 2009, 03:09 AM	#7
NEWHD74FAN Moderators Ride: 2004 Sportster XL1200RS Join Date: Aug 24th, 2008 Location: Camarillo, CA Posts: 3,556 My Mood:	Re: Side Cover Do the zip tie thing to be sure...those clips lose tension after a while, just easy and inexpensive insurance! __________________ Please stop by the "Self Help section" for maintenance tips, diagnostic codes and much more. >>Self Help Information and Tips<<

Jun 29th, 2009, 11:08 AM	#8
BAR1 Start The Engine Ride: 2009 Iron 883 Join Date: Jun 15th, 2009 Location: Milwaukee, WI Posts: 20 My Mood:	Re: Side Cover Zip tie it is then! It's just frustrating when you spend money on a brand new bike, and you have to constantly take it in to get fixed. Oh well....thanks for the advice guys!

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