I was a batch of bad gas caps for the 16's. Dealers no I walked in and had mine replaced no questions asked. They knew about it.

 

Even though the service bulletin only mentions the 2016 model year, many 2014-2015's were also affected.

 

sorry to dredge this back up but wanted to add that my bike is brand new
with 140 miles on the odometer.. went to top it off for first time as they were calling for snow and the cap was HARD coming off and just as hard going back on..


going to hit that lip with some emery cloth as soon as it warms back up here


BUT on that stant cap, haven't been able to find the answer I need so hoping someone can tell me for sure..


is it a correct swap out for our caps or did someone just find a cap with the right threads and depth and just go with it??

 

On the 2d trip to dealer shop for the binding gas cap, I got the new, improved version. It has a green paint dot on the inside. It works great. The first time I went in, they gave me a standard cap, and it only lasted three months. Look for that green dot.

 

two laps with a file around the very tip of the cap right before where the threads start will cure the problem forever.

 

Any dealer that still has the old fuel caps in stock obviously doesn't pay attention to updates Harley sends them. Many months ago, Harley sent a notice to send back all their old stock of fuel caps. Which were replaced by the updated fuel caps. Makes you wonder what else they don't pay attention to.

 

Took mine in for the 1000 mile service back in September and complained about this problem.

They laughed and went to the parts department and got a new cap. Said there was a recall.

In an effort to keep the Rushmore's affordable they went with Chinese caps that swell when they contact gasoline. It looked good on paper!!!!

They replaced mine with one from Mexico that is great but came with a warning: Do not let this cap come in contact with refried beans.

I did however have to promise not to ever set my cap on top of a gas pump while refueling!

 

Yes!!!

 

I did this on my first binding cap. I didn't use a file, though, I used some fine grit sandpaper. I worked it quite a bit, several times, taking off a small dusting of plastic, and this kind of made it easier, but not a total solution. It got tighter again in a short time. I managed it better by indexing the threads backwards when screwing it back in, until I felt it drop in. Light downward pressure as I turned, and it would go in easier, but still a struggle, especially when removing the cap. Sometimes it would just stick solid and have to be bumped out.

Yours may be a different problem. Filing or sanding may not help much, and it tightens up again.