My gas cap on my new bike rattles too. It's really loud and annoying. This is the 10th HD I've owned and none of the others had this problem. I'm going to ask them to replace it when I go in for the first service.

 

Just took my Sport Glide in for 1k service. Had them replace my gas cap. New one lasted about 25 miles. I think this one is even worse.

 

This has started happening on my Breakout. Going to pop to the dealer next week and see if i can get it replaced. Might see if i can go with the locking fuel cap.

 

Hi Guys

I m quite new in the forum . I have had the same issue and more

 

I have the same problem with my Heritage. My dealer here in the UK would not swap it under warranty because "the new one would be just the same".
He did suggest buying a pair of caps from the accessories catalogue, that would have cost about £100.
Things like that will put me off buying a Harley when I come to change bikes. I typically change bike every 18 months, and of course I suffer all the depreciation and the dealer makes all the money.
Their loss.

 

The solution is quite simple actually. Just take a piece of an o-ring, about 1 cm and push it in per the image below.


gas cap rattle

 

That sucks. I'm in the UK and my dealer offered to replace the one on my Breakout. Decided not to bother as i'd planned to switch it out for a black one. Ended up buying the Diamond Black Cap. Looks much better on my bike and no more rattle.

 

The outer piece of the cap, (black, gray, chrome whatever) is simple a cover to the actual cap. Turn the cap over on a padded surface and stake the cap along the edge that is already crimped, tightening the crimp up some. super easy to do, and has been the solution for years.......

 

Mine rattled after I put the first tank of gas in it. Took it to the dealer and this is what they did. Hasn't rattled since.

 

For what it's worth, the crimping or other solutions to fix it yourself seems to be the way to go. I've had mine replaced once so far and it just rattles anyway. Replacing the gas cap with another OEM gas cap doesn't resolve the issue for long before it starts to rattle as well so it's just a waste of time for everyone.