Missing battery cover -- what's it made of, what's its purpose? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

 
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post #1 of 4 Old 07-13-2016, 02:55 PM Thread Starter
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Join Date: Jul 2016
Location: East GTA
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Missing battery cover -- what's it made of, what's its purpose?

My KLR's a bit of a rat bike, so it's missing bits here and there. One of those bits is called a 'battery cover' in the fiche, and is just that -- part number is 14024-1375.

Before I even knew this thing existed, I bought a new battery, and paid no attention to where the terminals were (facing forward or backward with the positive on the inside) and it turns out the terminals are on the wrong side; facing forward, rather than backward. Thus, while it works perfectly fine, I can't use the battery cover (which is cheap from a dealer) if it's metal, not that I'd want to, as it'll cover the terminals, making jumpstarting a bit of a pain.

Second question, is it really necessary? This is an AGM battery, so checking the battery level with the little marks I see on the OEM piece is unnecessary. Does it provide any meaningful armour? Could I just cut a piece of plastic/metal and run it up the side of the battery to do the same?

Next time I replace the battery I'll get the cover from the dealer, but that's not for a couple years at least.

I don't suppose it's advisable to turn the battery around eh? I'd have the positive terminal facing out near the frame, and though it'd be covered, I'd be a little worried about grounding it out.
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post #2 of 4 Old 07-13-2016, 05:41 PM
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It is made of plastic like the air box/battery box.

It does engage the top 'lip' around the perimeter of the battery box and keeps the batteries from shaking Vertically as well as Horizontally with-in the battery box. A loose battery really can be shaken to Death! Shock Damaged, but not electrically speaking though.

The short metal end cap by its self allows quite a bit of movement.

pdwestman
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post #3 of 4 Old 07-13-2016, 05:54 PM Thread Starter
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Join Date: Jul 2016
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Quote:
Originally Posted by pdwestman View Post
It is made of plastic like the air box/battery box.

It does engage the top 'lip' around the perimeter of the battery box and keeps the batteries from shaking Vertically as well as Horizontally with-in the battery box. A loose battery really can be shaken to Death! Shock Damaged, but not electrically speaking though.

The short metal end cap by its self allows quite a bit of movement.
I can shim away vibration easy enough -- I've already bent the end cap to compensate and hold it in well. Like I said, I didn't even know this existed, and I just did things as if it was supposed to be like it is.

I do like the perch for the plug on top though -- right now it just sort of hangs around on top of the battery.

So maybe I'll put some 'armour' in place to protect the relatively exposed battery, and some shims to quell the vibrations. Lesson learned, I'll get the right one next time.
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post #4 of 4 Old 07-14-2016, 05:25 PM
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I shim the battery and throw that cover away. IMO, it's a PITA which keeps from connecting jumper cables and high rate chargers to the battery positive.
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