My FXSB Softail Breakout needed its first refuel so off I go to the petrol station and I could not get the petrol cap off. I though it was just me so I tried again and again but not success. I rang frasers and they said it was a simple turn off type. I kept trying with no luck. I took the bike to frasers, feeling like an idiot, and Michael got it off but with a lot of effort and later said he had a sore hand. To cut a long story short a heap of people tried getting if off and some could and others couldn't . They have ordered me a new cap. I got a call from them a few days later as HD Oz asked what type of fuel I was using. As Frasers fuelled it the one and only time only they knew. Apparently it was Caltex 98. 

Today I finds out that the other FXSB delivered at the same time as mine had the same problem only this time they had to use brute force and tools to get it off. HD are saying its the fuel we use that causing the o ring seal to expand or swell which causes it to stick. Apparently Newcastle and Perth are the only ones so far to experience the problems. 

I'll see what the new cap does. I was thinking of putting a pop up cap on it.

The o ring should be resistant to fuel, a bit of octane either way shouldn't affect it. Hope they sort it for you promptly, new bike, weather getting better soon, your gonna wanna be riding it!

Type of fuel? That's ludicrous.

Doesn't ethanol affect rubber?

Hey DAve, I had a similar problem with my pop up types on the fatty when i had it. (lucky i have popeye arms ha) anyway, i have some rubber grease that doesn't make it swell as some lubricants can do. A bit of a smear now and again on the o ring worked a treat. I know we shouldn't have too, but thats what we put up with sometimes hey. Hutch

 Yeah your right Hutch but honestly it's a joke. I refuelled today and the cap is still a shit to get off. No word from Frasers yet about the replacement.

Hey mate. Just got a 2015 breakout and had the exact same problem. Has the new gas cap fixed the problem? Mine doesn't sit flush to the tank very well either. Thinking of going for a flush mount gas cap and see how that goes.

Hey guys,

Same problem here, picked up my 2015 Breakout 1 month ago...got home and couldnt for the life of me remove the cap.

Finally got it off. I just purchased the flush mount cap. What a difference, easy to use and undo and looks great!!

Get a tube of rubber grease and put a small smear on the "o" ring every time you wash the bike. You will thank me one day..............

Hi Guys, bought a Breakout new in March 2014 and got a pop up type put on by M&W, never had a problem with it...

Got my BO from M&W in June,was shown how to remove the gas cap, "using your palm press down and rotate". On trying to remove the cap the first time sat at the servo for close on 40min trying in vein to get the cap off....finally engaged and I was able to remove it. But the chrome gas cap trim scratched the tank - I bought a pop-up cap that came with a trim ring so I could cover the scratch - needless to say I was (and still am) sweriously pissed off.

$30k for a new bike and they put a $2 dollar piece of sh!t cap -WTF!!!!

Cheers

My breakout had the same issue. Makes you look like a real badass when you can't get your fuel cap off !! I carry a little rubber square that my mrs had in the kitchen for opening jars. Works a treat. I think it's from over tightening when it's new, and also when my hands are cold it tends to happen more.

As Hutch said, bit of rubber grease on the 'o'ring should fix it.

I have a 2015 Low Rider and I am starting to have the same problem which is getting worse plus the cap is now starting to buzz and vibrate as if there is someting loose inside when twisting the throtle at any speed.

I haven't been back to Frasers yet.

Luckily, I had a spare cap from a Sportster I had and the problem has gone but put the original back in and it starts all over again.