o-rings worked for me. nice tight seal, but still vents. no more rattle.

 

Weird, never had a problem with mine rattling.

 

Rubber "O" Ring.

 

I've done this a couple of times. I only do enuf to stop the rattle. The cap is still functional after over 100k miles.

 

Thanks guys. Can't believe I've let this rattle drive me nuts for almost two years now and it was such a simple fix. I even ask a dealer mech to look for a rattle one time and he came back with a note on the service slip, "couldn't stop the gas cap rattle".

A pointed punch tapped with a screw driver handle just a few times around the underside of the rim and WALA! This thing even FEELS newer with out that ANNOYING noise every time the engine connects with the gas caps.

 

Guys, I hate to revive a necro thread here, but..... one burning question just screams out in this thread: where are you guys getting these rubber o-rings?

I found this thread through a regular Google search. I did the crimping trick with a hammer and punch. It definitely helps, but I still get a chatter. Maybe a combination of the crimp and the o-ring might work? At least the o-ring should prevent any metal-to-metal chatter.

 

Update: I went to Walmart and got some large hair ties. These are the perfect size to go around the outside of the rubber gasket without stretching. If it doesn't work, I'll try some smaller ones that require a little stretching to stay on.

 

It's a Sportster... it's gonna rattle.

Buy another cap with a gasket or try to replace your gasket.

 

Ace Hardware, and it's a crap idea. I ran that for a year or so. Wish I'd never tried it. Go to JP Cycle and just get a replacement OEM seal. That's all you need to stop the rattle.

I've been through replacement o ring, replace the whole cap, now I've replaced THE OLD cap back on with the NEW seal off the new cap and it fixed every complaint I had with the original stock cap. They are about $3.

 

This thread is pretty ancient, but I resolved the problem. What I do is just leave the caps between clicks. I'll turn them until they click a couple of times, then again and stop before the next click.

It works.