Help with Gas Cap
- Thread starter EODMB
- Start date
big dog jr
New Member
If your in a pinch what I and a few friends have done is take the cap and use a thread file on the threads and file them down. If you don't have a thread file a regular metal file works you just need to hold it at a angel in the thread grooves. Also file the outside diameter of the threads and the smooth cylinder at the bottom of the cap. I did mine a few years ago and it still spins on freely.
C00lHandLuke
Active Member
This is what I did with mine.
First I removed the insert (lucky yours came out easily).
Second, because I had some very small paint blemishes around the edge of the bung, I purchased a paint saver ring. This ring is rubber and chrome and goes around the very outside edge of the bung. You can find them at most major retailer like J&P Cycles (I think I bought mine from ebay). This ring covers any blemishes, prevents getting gas on the tank during fill up, and doesn't interfere with any after market gas cap.
Third, I purchased an aftermarket "custom looking" gas cap. The cap looks better, I don't get gas on my tank, and my cap is much easier to get off.
In my opinion removing the insert was one of the best decisions concerning my BDM I have made so far. You will find people who disagree with me, and in the end you have to make your own decision but I don't regret it one bit.
First I removed the insert (lucky yours came out easily).
Second, because I had some very small paint blemishes around the edge of the bung, I purchased a paint saver ring. This ring is rubber and chrome and goes around the very outside edge of the bung. You can find them at most major retailer like J&P Cycles (I think I bought mine from ebay). This ring covers any blemishes, prevents getting gas on the tank during fill up, and doesn't interfere with any after market gas cap.
Third, I purchased an aftermarket "custom looking" gas cap. The cap looks better, I don't get gas on my tank, and my cap is much easier to get off.
In my opinion removing the insert was one of the best decisions concerning my BDM I have made so far. You will find people who disagree with me, and in the end you have to make your own decision but I don't regret it one bit.
Last edited:
C00lHandLuke
Active Member
I thought the gas caps were nothing but a hassle, the best think I ever did to my Big Dog was removing the stock cap and insert.
they are a PITA but just replacing the cap is the simplest fix for the problem. if you have the time and the extra $, completely replacing is the way to go, make it a little more custom and to your own taste.
besides, if you keep the plain jane cap, not too many people will steal it.
besides, if you keep the plain jane cap, not too many people will steal it.
Roaddawg
Well-Known Member
I simply took a razor knife and cut the threads back some. I trimmed the thread edges, top, bottom and overall circumference. Then a little sand paper to smooth it all out. I sprayed it with WD-40, wiped it down and screwed it in a few times. Since then (about 3 years ago), I have never had a problem getting it off and on and it doesn't leak.
