I've had this problem ever since I first took apart the radio console in order to work on the air filter and install the rear speakers. The ignition cover wasn't laying flat again when I put everything back together. I double checked the cables to make sure none of them were lying underneath the radio, pushing it up and causing the problem. Another minor thing is that the two black wing inserts underneath the handlebars also aren't fitting back in the way they did previously. I'm not sure if the two things are related.
When I had the console off yet again during some other work I was doing, I once again, double, triple and quadruple checked to make sure all the cables, hoses, etc are going where they're supposed to. The radio cables are sitting in the slot designed for them and they're coming out the back straight and not bending underneath the radio. The rubber cover is fully flat and not bunching up or doing anything funny. Everything is back exactly the way it was when I took it apart, but the damn cover still refuses to sit flat like it's supposed to. Something is still causing it to rest skewed. I'm VERY open to suggestions at this point. I know it's not a massively big deal, but I'm a bit of a perfectionist and it's something that's staring at me all the time I'm riding the bike. See pictures included.
If you are positive that no wiring or cabling is misrouted between air box and/or frame and shelter.
Did you have air cleaner box removed? The box has tabs where bolts hold down the rear in correct position. It is possible to have air box drain tubes get scrunched up or misrouted underneath not allowing it to rest further down where it is supposed to be.
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Nothing leaves my shop till its' perfect
This is what I do
The end where the gap is is the first end to set into place. Set it in place with the upper end a little up into the instrument panel, maybe a half inch, and then pull it back until it matches the radio panel. Then press the forward end down into place around the ignition lock.
Russell
Those who say it cannot be done should try not to interrupt those who are doing it.
Those who say it cannot be done should try not to interrupt those who are doing it.
I'm guessing that the two grommets were dislocated when you first pulled that ignition panel off.
Seat those grommets back properly, but put a small amount of all-purpose grease on them first. And quick swipe of the round part of each of the "bosses" that fit into those grommets won't hurt either.
The 2nd time I removed the console, I actually lost one of the grommets when it went flying. So I replaced both of them with new ones. They're SUPER tight but even when I remove the grommets entirely and just let the cover 'sit' in the slots, it's still off-kilter.
What was the part # of the grommets that you got?, , I would bet they are "thicker" than the ones that originally were there, thus they make the panel sit "higher" . You might have to "shave" the grommets 1/16"-1/8" off the top/bottom to get the panel to sit flush.
The part # for the rubber grommet on the Centershelter of a '99 Aspencade is , , 83156-MNS-000 and is just a couple bucks from most of the parts warehouses. Other grommets have different part numbers which possibly indicates they have different dimensions and even though they fit, the result might not be the same.
With the grommets removed, the only thing holding the panel in place is the front "tabs" and they're sometimes strong enough to keep the back-end from sitting flat on the shelf of the centershelter. The holes where the grommets fit into is bigger than the two "bosses" so they do nothing to hold it down flat on the shelf.
Last edited by bluthundr31 on Thu Apr 23, 2020 9:57 pm, edited 1 time in total.
Removing the grommets means there is nothing to make the panel sit flat on the shelf of the centershelter. The holes in the "fingers" of the centershelter are bigger than the bosses but the tabs in the front of the panel could be strong enough to keep the back raised up slightly, , , makes sense if you think 'bout it.
There is a clip/hook on the front of the radio that needs to go over the lip of the front of the radio shelter. The best way to install the radio back into the radio shelter is to lay the shelter upside down,hold the radio also upside down at a downward angle facing forward. Make sure that clip/hook is over the front lip of the shelter and tip the back of the radio down. Then replace the mounting screws for the radio. It might not sound right but when you do it, you will see what I mean.
I would imagine most of the folks suffering from this had taken the radio out from the shelter for one reason or another. Whether the radio needed to be sent in for service or modded for an Aux input, etc. Most who have had this problem, myself included, the first time didn't really pay close attention to how the radio was in there. It looks like you just take out the 4 screws and you are done. The radio then pops off pretty easy. It kind of just falls out of the shelter. That clip is partially hidden by the big black rubber boot for the radio harness so you don't really pay attention to it or might miss it. At first glance, it appears to be more of a retainer for the big rubber boot than a mount for the radio. Then when you go to reinstall the radio, like I did, you just kind of pop the radio back into position and put the screws back in. This then puts the clip underneath the shelter pushing up a bit. The radio needs to be tilted in ensuring that clip goes around the lip. Real easy mistake to do.
bellboy40 wrote: ↑Thu Apr 23, 2020 10:53 pm
There is a clip/hook on the front of the radio that needs to go over the lip of the front of the radio shelter. The best way to install the radio back into the radio shelter is to lay the shelter upside down,hold the radio also upside down at a downward angle facing forward. Make sure that clip/hook is over the front lip of the shelter and tip the back of the radio down. Then replace the mounting screws for the radio. It might not sound right but when you do it, you will see what I mean.
I would imagine most of the folks suffering from this had taken the radio out from the shelter for one reason or another. Whether the radio needed to be sent in for service or modded for an Aux input, etc. Most who have had this problem, myself included, the first time didn't really pay close attention to how the radio was in there. It looks like you just take out the 4 screws and you are done. The radio then pops off pretty easy. It kind of just falls out of the shelter. That clip is partially hidden by the big black rubber boot for the radio harness so you don't really pay attention to it or might miss it. At first glance, it appears to be more of a retainer for the big rubber boot than a mount for the radio. Then when you go to reinstall the radio, like I did, you just kind of pop the radio back into position and put the screws back in. This then puts the clip underneath the shelter pushing up a bit. The radio needs to be tilted in ensuring that clip goes around the lip. Real easy mistake to do.
Thank you. I'll have to take a look at that this weekend. I never actually took the radio completely out of the shelter, but I did remove all 4 screws when I first took it all apart, because I wasn't sure yet what needed to come apart and what didn't. It might have gotten dislodged. I'll take a look at my service manual and carefully re-read your instructions this weekend after I take the radio off again. The last time I had it off, I had noticed that previously, one of the cables that attaches to the back was wrapping under the radio and pushing it up that way, so I was sure when I resolved that problem, that it would sit properly again. Looks like I'll have to take the whole radio console out of the shelter completely and re-seat it very carefully. Maybe once it's sitting right, the other two side pieces will sit properly again as well.
bellboy40 wrote: ↑Thu Apr 23, 2020 10:53 pm
There is a clip/hook on the front of the radio that needs to go over the lip of the front of the radio shelter. The best way to install the radio back into the radio shelter is to lay the shelter upside down,hold the radio also upside down at a downward angle facing forward. Make sure that clip/hook is over the front lip of the shelter and tip the back of the radio down. Then replace the mounting screws for the radio. It might not sound right but when you do it, you will see what I mean.
I would imagine most of the folks suffering from this had taken the radio out from the shelter for one reason or another. Whether the radio needed to be sent in for service or modded for an Aux input, etc. Most who have had this problem, myself included, the first time didn't really pay close attention to how the radio was in there. It looks like you just take out the 4 screws and you are done. The radio then pops off pretty easy. It kind of just falls out of the shelter. That clip is partially hidden by the big black rubber boot for the radio harness so you don't really pay attention to it or might miss it. At first glance, it appears to be more of a retainer for the big rubber boot than a mount for the radio. Then when you go to reinstall the radio, like I did, you just kind of pop the radio back into position and put the screws back in. This then puts the clip underneath the shelter pushing up a bit. The radio needs to be tilted in ensuring that clip goes around the lip. Real easy mistake to do.
100% this is the problem. I've encountered this before. You can put the radio in place, without hooking that clip into place properly. It looks like it is set in there properly, but the ignition key cover won't seat properly, as you are experiencing.
Remove the ignition key cover, the acorn bolts holding the bottom of the radio panel, and undo the radio panel clips in the fuel area. Remove that radio panel, and then reinstall it, ensuring the clip is properly slotted in.
Mark,
My beast doesn't have the metal hook under the shelter like the others are describing. My '91 Interstate didn't have the cassette stereo like most other GL1500's. I used what I knew about my beast to try to diagnose your problem, , ,sorry if it wasn't the solution to your situation.
It is always appreciated when someone that has had a problem and then gets it sorted out comes back and lets everyone know what the issue was. We all learn from the trials and tribulations of others, on motorcycles and real life.
This is exactly how I just fixed mine. This is why forums are the best place for information. User experiences are shared and absorbed. Thanks for the this encyclopedia of knowledge!
If all else fails an indispensable tool to have for our TIGHT Wings, a borescope. One with its own screen. So far the 2 meter cable is working fine for me. The real cheap one's clarity is really poor.
Decent one's are now around $40.
The more I use mine the more places around the garage, house, throat & ears it's used.
