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Oil tank cap fix .

 
  #1  
Old 05-27-2019, 04:31 AM
Midpegs
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Default Oil tank cap fix .

I've been having the usual issues with my 2004 XL1200 oil filler cap . It wouldn't turn the last 20 degrees unless I fitted a slightly smaller O ring but when I did this it leaked . So I went down to my HD dealership and bought a genuine O ring. I tried to fit the cap but I still couldn't get it to turn those last 20 degrees . What I then did was make a little sanding block and used it to slightly round off the angle on the spiral groove just where it transitions to the lock position. Result , turns all the way and doesn't leak !
 
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Old 05-27-2019, 05:52 AM
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Thanks for sharing your solution.
 
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Old 05-28-2019, 05:55 AM
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I'm going to try that, thanks
 
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Old 05-28-2019, 07:42 AM
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Thanks for sharing.

Perhaps this is a tolerance problem as the two bikes I have here do not suffer like yours does.
 
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Old 05-28-2019, 08:22 AM
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Originally Posted by Andy from Sandy View Post
Thanks for sharing.

Perhaps this is a tolerance problem as the two bikes I have here do not suffer like yours does.
It's not just mine , there are numerous references to this issue on this forum . I do agree though . I was in a Harley dealership the other day and every new bike that I tried had a cap that popped in and out without any bother. New ones do have ridges on though .
 
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Old 05-30-2019, 04:17 PM
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Default Another update.

I am delighted to report that after a 40 mile run there is not the slightest trace of oil dribbling from around the filler cap . So , rather than mess around with under sized O rings , if your filler cap gets too tight , just get a new genuine Harley Davidson O ring . The little modification I did just helps the tabs in the tank neck make the transition from spiral groove to horizontal groove . Works for me .
 
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Old 05-31-2019, 12:06 AM
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Thats exactly what I had to do to mine. I have osteo-arthritis in my hands and I don't have the strength I used to have, so it was getting impossible to open. I could just barely do it when I got the bike, but not at all now. So 2 days afo, I did the same thing, except with a small file. There is still a bit of effort required but easily doable by me now.

Had not looked it up on the forum, but good to know I was on the right track.

Thanks for posting.

Forgot to add, mine has the temp sensor cap on it.
 
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Old 05-31-2019, 04:13 AM
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Originally Posted by Midpegs View Post
I've been having the usual issues with my 2004 XL1200 oil filler cap . It wouldn't turn the last 20 degrees unless I fitted a slightly smaller O ring but when I did this it leaked . So I went down to my HD dealership and bought a genuine O ring. I tried to fit the cap but I still couldn't get it to turn those last 20 degrees . What I then did was make a little sanding block and used it to slightly round off the angle on the spiral groove just where it transitions to the lock position. Result , turns all the way and doesn't leak !
Did you sand on the top, bottom or both?
 
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Old 05-31-2019, 04:25 AM
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Just the bottom where the clean spot is.
It the plastic deformed that much you should keep a new one as a spare in your bag just in case.
 
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Old 05-31-2019, 10:57 AM
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Yea just the bottom. Do it a little at a time. Don't want it too loose.
 
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