Yeah, mine's crap too.

 

My son in law had the same problem with his 2016, last time he had to use channel locks to get it off and it would not go back on . Dealer replaced his filler neck and cap.Ebert

 

My 2016 has this issue and it seems to be heat related. It will screw on and off pretty easily in the cool garage, but go out riding and let this cap warm up and expand the plastic and it's real tough to get off the tank

 

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.

 

Thanks to the forum, even though my dealer offered to replace it for free, I bought a Stant 10834 and it's perfect. Well worth the $4.97

 

I noticed the same issue on my 2016 TG. I was concerned that it would totally fail while I was on the road, so I ordered a Stant 10834 from Amazon. It came yesterday and I tried it out. Seems much better than the original. Well worth the $5.00 for the piece of mind.

 

A number of touring bikes in the last two years had that problem. I looked at my cap an noticed the threads extended out further than past models.

Got a flat file and 10 minutes later it fits fine. That was a year ago.

It was a manufacturing defect. Alcohol does not impact plastic.

 

I tried to warranty mine and they never had one after I filed on it never had another problem I haven't tried to warranty it again it's been working good

 

just cut off up to 1st thread, file rough edge then blow out with compressor then completely clean ... goes on like butter

 

Any 17 with this?