See Safety First → Safe Operating Rules and review the following safety alerts.
WARNING
Avoid spills. Slowly open fuel filler cap. Do not fill above bottom of filler neck insert, leaving air space for fuel expansion. Secure filler cap after refueling. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00028b)
WARNING
Use care when refueling. Pressurized air in fuel tank can force gasoline to escape through filler tube. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00029a)
WARNING
Do not store motorcycle with gasoline in tank within the home or garage where open flames, pilot lights, sparks or electric motors are present. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. (00003a)
WARNING
Do not use aftermarket fuel caps. Aftermarket fuel caps may fit improperly and leak, which could lead to death or serious injury. See a Harley-Davidson dealer for approved fuel caps. (00034a)
NOTICE
Do not spill fuel onto the motorcycle while refueling. Immediately wipe up fuel spills on your motorcycle. Fuel can cause damage to cosmetic surfaces. (00147b)
NOTICE
Use only unleaded fuel in catalytic converter-equipped motorcycles. Using leaded fuel will damage the emission control system. (00150c)
Modern service station pumps dispense a high flow of gasoline into a motorcycle fuel tank. This can cause air entrapment and pressurization.
FUEL FILLER CAP
Removal
See Figure 1. Turn fuel filler cap (1) counterclockwise to remove. The cap turns approximately three-quarters of a turn before it begins to loosen.
1Fuel filler cap
Figure 1. Fuel Tank
Filling
See Figure 2. Do not overfill the fuel tank. Insert the pump nozzle into the filler hole. Do not fill the tank beyond the bottom of the filler neck. A warm engine, the sun or extreme temperatures can cause the fuel to expand. Fuel can spill out of the tank and damage the finish. See Safety First → Safe Operating Rules.
Figure 2. Fuel Level below Filler Neck
Installation
Turn fuel filler cap clockwise until it clicks to install. The ratchet action of the cap prevents over-tightening.
LOCKING FUEL FILLER CAP
Replacement Keys
Find the four-digit key number stamped on the back of the key opposite the H-D logo. Write the key number in the space provided at the front of this manual. With that number, your Harley-Davidson dealer can order a replacement.
Removal
  1. See Figure 3. Rotate the lock cover to access the key lock.
  2. Insert the key.
  3. Hold the fuel filler cap in place. Turn the key counterclockwise until it stops.
  4. Turn key back to its original position. Remove the key.
  5. Turn cap counterclockwise until resistance is felt. Continue to turn cap counterclockwise to remove cap.
Figure 3. Locking Fuel Filler Cap
Installation
  1. Insert the key into the lock.
  2. To make sure that the cap is unlocked, firmly, hold the cap. Turn the key counterclockwise until it stops.
  3. Allow the key to return to a neutral position. Remove the key.
    4. NOTE
    When installing the fuel cap, rotate the cap one full turn past the audible click.
  4. Turn the cap clockwise to install the fuel cap.
  5. Close the lock cover.