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Discussion Starter #1
OK...I just got back from the east coast (maybe I was trying to outrun Irma)...getting GAS WAS A BITCH.

But I digress. Here's my issue. My last three or four trips...my LEFT side cover pops off. I have tried several things to keep it on...but mostly wrapping the NIPPLES on the cover with 3M double sided tape to make them STICK to the rubber grommet. I also cleaned the grommets with alcohol to try and get rid of the slippery dust and stuff.

But even after CAREFULLY adding this double sided tape...AGAIN after 1500 miles I felt the side cover pop off....

Does anyone else have this issue...and how the heck did you fix it. I guess I could replace the grommets...but I would like to NOT have to worry about grabbing the cover when I'm doing 85mph and holding into place while I find a place to pull over.

Thanks.
 

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I noticed the other day that one of my left side rear rubber grommet was missing. Going to order some extra grommets. But so far have not had trouble with the covers coming loose.
 
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Apply heat shrink to the male prongs. If one layer doesn't do the trick, add another and another until it does. Maybe new grommets might be in order too. If so, take one out and go to your local Ace hardware and match it.
 

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Discussion Starter #5
Apply heat shrink to the male prongs. If one layer doesn't do the trick, add another and another until it does. Maybe new grommets might be in order too. If so, take one out and go to your local Ace hardware and match it.
By george...I think you have something there Ricz!!! Thank you sir.
 

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Once in a while I have a lucid moment. :)
 

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Sadly, none of these will fix the problem. There are several cables behind that cover. There is a large connector for the trunk at the rear which must be carefully routed. There is also a bunch of them near the front. Once you get these right, the covers work great.
 

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Also, if you have the small sanding drum or similar for a Dremel rotary tool, that's great news. As noted, there are a lot of wire harnesses on the left side. If, like me, you've also added things like a PCV, the keyless ignition and now the Extreme Audio System, you have even more wire harnesses to deal with.

What works great is to first, ensure you have the harnesses routed and secured as best as possible. Then, you'll very likely still have an issue. With the bike secure on the side stand, sit down on the left side and simply carefully look at what the left side cover top edge is coming in contact with. If you can't move the wire harness, you'll simply have to remove a bit of the material on the side cover itself. Pay particular attention to the top edge as that very likely is what's keeping the left side cover from staying in place. Draw a couple of contact reference marks on the side cover and determine how much material you need to remove. Go slow, move steady and when you're done, you likely won't be able to tell it wasn't contoured like that from the factory.

Best of all, your expensive side cover will now stay firmly in place. Of course first ensure the rubber grommets are there.
 

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For the last two years I owned my XCT, I had just the upper-front barb on each side covered in heat shrink tubing:



(Just the upper-front one on each side, 3/8" shrink tubing, aim the heat gun away from the cover when shrinking.) This was a concept that someone posted in maybe 2014, here or on the other forum. This worked fine, even with a PC-V under the left cover. Incidentally, I never removed the topcase or disconnected the wire loom to it, so however the stock loom was positioned didn't seem to interfere with anything.

Also, maybe the year before, I replaced some grommets. One was actually missing on the right side, and some others were pretty shabby.

Of course, you have to make sure the covers are seated properly, if you do remove them, when putting them back on. I used to line up the rear barb, push in the bottom and then the front, push in the rear, and then -- after all three were presumably pushed in -- push in the center of the cover ... as a final check, because at that point there should really be no movement.

Last, if you connect some stuff through the side covers, you have another line of defense, should something go amiss.

Through the left, I added a Powerlet outlet, for charging and heated gear: see Victory Powerlet in Side Cover . This is not as dumb as it may look; @LILMAGS500 followed those instructions, and it looked even better on his XC.

Through the right, I added a Schrader valve: see Adding an External Schrader Valve for the Air Shock on a Victory Cross Country Motorcycle . I believe @JPokerwinski is in the process of doing this mod.
 

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I did do what Bill said.. AND i put heat shrink on the pegs AND i got new grommets. I found that if you take the covers on and off a lot and with the heat of the road they stretch and lose their effectiveness. Engineers who designed this felt it was strong enough because in the lab they tried it ONCE.
 
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Discussion Starter #11
I actually just purchased some new grommets. One particular note that may help someone else wanting to replace those grommets.
There are TWO different grommet catalog numbers and descriptions.
This is the one I ordered a long time ago (never used)
Grommet Side Cover -rectangle oval (but it also says cheese wedge): 5433833 (DO NOT USE).
Grommet Side Cover - round (according to exploded view part): 5413055 (USE THIS ONE).

Once I get the grommets in...I will change them out.
 

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Trick I saw that helped out a guy here that had a issue with the cover popping out was get the round grommets off a 1800 Goldwing, better rubber and thicker all around, he tried them and pretty sure still has them on the bike and has not had any issues with it and this was back in 2014?15? Cant remember when I found out about those.

Did the same thing for a gent that was passing though to New york and he almost lost his cover on the turnpike, he stopped in and I sold him the GL ones and put them on in the parking lot, two days later he called me and told me how they worked and said that the cover had never fitted that good even since day one and it was a ton more secure.

53504-GEO-000 is for the round ones

83551-GE2-000 is for the oval ones.
 

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I did do what Bill said.. AND i put heat shrink on the pegs AND i got new grommets. I found that if you take the covers on and off a lot and with the heat of the road they stretch and lose their effectiveness. Engineers who designed this felt it was strong enough because in the lab they tried it ONCE.
Back when I had my day job -- I was a database administrator, instructor, etc., i.e., all-around geek -- we got a new version of GroupWise, a LAN-based email system. You know in the PC world, when a letter is underlined you can use an Alt-[That Letter] combination to invoke it, as opposed to clicking on a menu item, that sort of thing?

In any case, out comes that new release, and on one of the program's screens, I press Alt-A or something, to invoke an underlined-letter menu choice. And nothing happens. As I told my brother, another geek, "They couldn't have tested this even once!"

But I digress ...
 
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My XR does not have all that wiring and stuff behind the side covers, yet they had lost their grip early in my ownership of the bike. It was still under warranty then and the dealer gave me a new set of six. No problems since. Go figure.
Adding a rear shock hose extension relieves having to pull the right cover every time you want to change the pressure.
 

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Discussion Starter #15
Trick I saw that helped out a guy here that had a issue with the cover popping out was get the round grommets off a 1800 Goldwing, better rubber and thicker all around, he tried them and pretty sure still has them on the bike and has not had any issues with it and this was back in 2014?15? Cant remember when I found out about those.

Did the same thing for a gent that was passing though to New york and he almost lost his cover on the turnpike, he stopped in and I sold him the GL ones and put them on in the parking lot, two days later he called me and told me how they worked and said that the cover had never fitted that good even since day one and it was a ton more secure.

53504-GEO-000 is for the round ones

83551-GE2-000 is for the oval ones.
What do ya'll charge for shipping for 3
of the round ones?
 

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