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The fuel gauges are notorious for being inaccurate. Many including myself use the tripmeter. Around 190 to 200 miles be looking to fill up and reset tripmeter at each fillup and you should be fine. This will give you about a gallon of reserve. Keep track of your mpg and adjust fillups accordingly.
Got you beat - had mine in like five times - finally gave up - as said, Harley gas guages are not very accurate. Mine takes 60 miles to move off full, 120 miles on 1/2 full, and low light comes on at 160. But, mine is a 5 gal tank.
Best you can probably get them to do is get it close at say 1/2 or when the low light comes on - then ignore the rest.
Ignore the gas gauge. They suck, and have for years. Use the fuel remaining calculation on your '09 coupled with reseting your B trip meter when you top off your tank. You should get the low fuel light around one gallon remaining. If your getting 38 mpg then you should see it around "r 38". Once the remaining milage gets to 10 it will jump to "lo". Ask me how I know. I've put over 6.1 gallons in my '08. I've gotten up to 260 miles on a tank. I try to look for gas after 200 miles on a top off.
With the 6 gallon tanks you really have to "pack" the fuel in to top it off. You have to really nurse it in slowly stopping often to let the fuel settle. I rock the bike a tad to burp the air bubbles out of the top of the tank when topping off. They are really hard to fill to the brim.
There's no "calibration" of the fuel quantity system. It's very accurate using the fuel remaining feature once you learn how to use it. I never look at the gauge. I've thought about taking it out completely.
I don't pay attention to the gas gauge.. use the odometer only, I know when i ride fast and heavy I need fuel around 170 miles... light and easy I can go 200 - 220 miles.
Mine is fuggin useless. I have had it come on and put 3.5 gal in, and I have had it come on and run out of fuel in 10 miles. Literally 10 miles. I have run out of fuel twice now thanks to the dang gauge.
I heard the fuel gauge is the main reason HD started Harley Assist.
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