gas cap rattle
Road Master
Joined: Dec 2007
Posts: 1,125
Likes: 22
From: Phoenix, AZ
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.
Cruiser
Joined: Jul 2013
Posts: 232
Likes: 54
From: Bedford Indiana
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.
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.
Grand HDF Member
Joined: Jul 2017
Posts: 4,698
Likes: 5,297
From: Behind you, making faces
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.
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.
Grand HDF Member
Joined: Jul 2017
Posts: 4,698
Likes: 5,297
From: Behind you, making faces
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.
Buy another cap with a gasket or try to replace your gasket.
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Cruiser
Joined: Jul 2013
Posts: 232
Likes: 54
From: Bedford Indiana
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.
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.
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.
Grand HDF Member
Joined: Jul 2017
Posts: 4,698
Likes: 5,297
From: Behind you, making faces
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.
It works.