I've got a 16 ultra limited. The gas cap is difficult to unscrew and screw back in. Anyone else have that problem? It seems that I have to get it just right for it not to be hard. Just doesn't seem right... The lid... anyone ever thought that it'd be better flipped around? I think it'd be better opening towards the handlebars as opposed to away from them. What do y'all think?

 

I was reading another thread about this problem. One guy actually removed a lip at the end of the threads which made it easier to install and remove. It wasn't much but he said it worked.

 

Common problem. Several threads on it. 2 min fix. Search gas cap

 

Had the same issue, dealer replaced mine about 9 months ago under warranty, no issues since.

 

Go buy a Slant gas cap at autozone for $7 and be done with it.

 

sTant part number 10834

OP - check out my post here for a photo comparison of the stock & Stant caps

https://www.hdforums.com/forum/new-r...l#post15338192

 

Dealer just replaced mine for the second time. Same problem. The bike is a 2016 FLHTCU, purchased in January 2016. The first cap was replaced this mid-summer, it was so bad it really could no longer be used. That new gas cap lasted until late November, when it got real tight. I had already tried filing the end of the cap, as others here have done, but it didn't really help long-term. It would be easier for awhile and then get hard again. I hope they gave me a re-designed cap on this second visit. It is a real ridiculous problem that I've never seen or heard of on any other motorcycle in 55 years of riding all brands.

Yes, my first impression was that the pop lid for the gas tank should have been oriented the opposite to how they did it. However, I did get used to it over time, and now no longer consider it to be an issue. As long as I can get my gas cap on and off without a crowbar, I'm not going to worry too much about the pop lid.

 

My friend has a machine shop,and he measured the difference between the thread depth and the end of the cap.

It is .060 difference which would explain the caps getting harder to remove and install.

It definitely seems like it is related to the ethanol in the fuel, and also due to the superior Chinese quality control.

The replacement caps from Harley work great at first, but get progressively tighter as it swells up.

Instead of filing the end of the cap he chucked it up in his lathe and removed .060. The cap looks better than original and fits great now.

 

The redesigned Harley fuel cap should have a painted dot on the inside of the cap. If it doesn't, you got an old cap and it will warp again.

 

I've got an older model Willie G skull gas cap that was on my '11 Heritage that I use to replace the stocker on my '14 RK. It's all good...