G'day, took my battery tray and oil tank off the troubleshoot a leak on my sportster and it seems that it hasn't gone back on the way it came off. The battery now barely slides into its tray and what it does basically touches the motor. I loosened bolts and tried to push it over but it doesn't help. Has anyone encountered this?

 

 

.cheers

Pics would help people trouble shoot.

what yr model 

1990, I'll organise some pics tomorrow I've been on the ipad cheers

1990 is the last year of the 4 spd gearbox  , these early evo sporties had a problem with the oil tank cracking behind bottom front oil tank mount , cracking behind mount meant that to weld or braise  bottom mount all over as you can not get behind it , keep a cold wet rag on the  out side paint work , done heaps of them thats were they leak oil from, there is only one way to route the battery lines or the battery won't fit proper , esp up behind & inbetween the oil tank & battery tray 

1990 is the last year of the 4 spd gearbox  , these early evo sporties had a problem with the oil tank cracking behind bottom front oil tank mount , cracking behind mount meant that to weld or braise  bottom mount all over as you can not get behind it , keep a cold wet rag on the  out side paint work , done heaps of them thats were they leak oil from, there is only one way to route the battery lines or the battery won't fit proper , esp up behind & inbetween the oil tank & battery tray 

It must have cracked because I fixed the hose up and it still leaks. I'll have to pull it off again and maybe fix the battery. Yes it goes on one way but it's still out of alignment

after welding the oil tank , clean out inside proper  even if you have to put in 50 nuts in there & shake it around with some kero

What about some plasti weld putty, i wonder if that would do the trick. I know we used to use it at work to seal barrels that had been pierced by the fork lifts.





They are the pics, better late than never huh? But in all seriousness i probably cant be helped until i actually pull it apart myself. I just thought maybe this was a common obstacle with re installing the above.

, on the oil tank inner  mount's should be the 3 factory rubber isolater mount's that screws onto the frame & tank these are 19m.m. or long 3/4 " also the 1 under the battery mount bracket,make 4 ,  you could always space the battery box out a little with big dia 1/4 " washers each side of the rubber vibe mounts, check the right part # for the battery size etc & thickess of rubber mat , if think that model had a bit of rubber strip on the inner wall on the battery box to keep the battery out a bit 

I was thinking the same as Daddyracer56, just not as detailed. BUT that's if the tray can't be angled away from the motor coz it don't look in line with everything (seems to be sloping towards the front of the bike), though it's hard to tell from the pics. I'd remove the battery and check out the tray to see how it's mounted to see if it can't be moved or angled better.

Yeah some good points. I had a better look today and reminded myself the battery, is not touching, it is the chrome cover. However this cover never fouled on the motor. Also, the battery now is almost impossible to get out by hand and needs a screwdriver to pop it out. So definitely something wrong. Ill pull it all apart and pay more attention to spacing and what not.

Managed to get the battery tray lower by levering it and then fastening the bolts. Battery sits nice but still needs a screw driver to pop it out once its mounted. The top chrome cover still hits the motor. Im thinking maybe it needs to be spaced outwards now that it sits lower, ill try that.

just cut the top cover & clean it up the original cover nevr went that deep i have done that before plenty of times no worries you dont want the cover near the battery post 

If it was ok b4 you pulled it apart,then ya just fucked up puttin it back together!!!
Pull it apart n start again,slowly,with a factory manual,and a friend.
No need to cut and butcher things.

Yeah now im not too sure it was ever ok as those gouges in the rocker cover were not from me. Anyhow im happy than i can at least pop the barrery in easily enough. I might just cut the corner off the chrome cover as suggested. But to be honest i might stuff it off completely i dont like it. Ill just retain the strap.

To be honest though its only three bolts, cant really stuff it up. Probably a matter of stuffing around with some washers and what not to get it sitting out.