6 gallon tank?
Road Captain
Joined: Oct 2009
Posts: 666
Likes: 5
From: Bay Area, CA
I have an 09 RK Police with a 103" motor and time and again, when I get to 50 miles remaining, the bike lets me know it ain't happy.
It may be a 6 gallon tank but the fuel pump likes that last gallon or so all for itself.
It may be a 6 gallon tank but the fuel pump likes that last gallon or so all for itself.
6th Gear
Joined: Sep 2010
Posts: 13
Likes: 0
From: Woodstock
The low fuel warning light on my Street Bob
The fuel gauges & low fuel warning lights on Street Bobs & Ultra's may be as different as the bikes. My low fuel light has come on when the gauge was at 2/3 full. My mechanic said one day "fuel gauges are as dependable as SCUD missiles". He also thinks they work better when there's a full moon.
Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,898
From: Bedford UK
I am in the process of adapting a 2009 6 gallon tank to fit my old Evo and have it in pieces as I write. The photos show the plastic 'top plate' that lives under the filler flap on touring bikes. The left photo shows the top plate viewed from above, in the right it is upside down. The EFI pump, a filter and the fuel gauge device are normally under it, but I don't have them for my carb bike.
So this is my suggestion! Drill say three 3/16" holes into the lower filler neck, underneath the plate, as seen in the right photo, and as close to the plate as practical. That should help fill the top inch of the tank and may improve capacity.
Outstanding HDF Member
Joined: Jun 2008
Posts: 2,134
Likes: 4
From: Third Coast, South Texas
I was having the same issues... now I know it isn't a good idea to run an EFI bike dry, but I had to know. No one could give me an answer. So I had a Qt gallon gas can. I put that in the tour Pak. I filled up the 6 gallons and headed out for a freeway ride which took me from San Diego to Yuma. I got 244.8 miles before I got a sputter. I pulled over right away and then put the qt gallon I had in the can and then found a gas station about three miles down the road. I filled up and then headed home. Silly experiment maybe, but my gauge was on empty at 194, the reserve with 54 miles came on and the low fuel light was also on until I hit the 244.8 mark. I was cruising 80 to 85mph cruise control the entre way.
I go by the miles, not the gauge. The gauge gives me an idea, but the miles are what I go by if I'm riding long distances.
I go by the miles, not the gauge. The gauge gives me an idea, but the miles are what I go by if I'm riding long distances.
Ultimate HDF Member
Joined: Jun 2009
Posts: 6,932
Likes: 4
From: 46th State, USA
I've gotten as high as 242 miles before having to fill up. It took 5.4 gallons to top-off the 6 gallon tank. What I was surprised about was, after removing the almost 40 pound tour pak, the fuel mileage got a little better.
Last edited by shortride; Sep 10, 2010 at 07:23 AM.
Tourer
Joined: Aug 2009
Posts: 491
Likes: 1
From: Northern VT
Totally agree....I've yet to put in more the 5 gallons and I've been down to single digits on the clock. I'm not complaining mind you....but I've found I usually get around 225 before I have to fill up...I know for sure I can get another gallons worth of mileage..but why push it.
Road Captain
Joined: Dec 2007
Posts: 660
Likes: 0
From: Grayson, GA
The problem is the fuel gauges are not accurate at all. I have calibrated mine and two others to where it shows completely empty there is approximately .5 of a gallon left.
The gauge and the "Low Fuel" light are driven by the float in the tank, it is all part of the fuel pump, filter and regulator assembly. The float is on a wire arm that is about the same gauge as a wire coat hanger. If you follow the steps to replace your fuel filter, the entire assembly comes out of the tank. While holding the wire as close to the pivot point, you need to gently (very gently) bend the wire arm up a little at a time making sure to hold it tight at the pivot point. I found it most accurate if you completely drain the tank, measure exactly 3 gallons if you have a 6 gal tank or 2.5 gal if you have a 5 gal tank, put measured gas in tank and replace the pump/filter/float assembly with 2 or 3 screws, turn on ignition and check gauge, if not exactly at 1/2 tank (be sure bike is level and not on side stand), repeat previous steps until gauge is calibrated to 1/2 tank. When you are satisfied reassemble. That is as close to accurate as you can get with the gauges.
I recommend for the next few tanks of gas that you confirm accuracy with your trip meter.
The gauge and the "Low Fuel" light are driven by the float in the tank, it is all part of the fuel pump, filter and regulator assembly. The float is on a wire arm that is about the same gauge as a wire coat hanger. If you follow the steps to replace your fuel filter, the entire assembly comes out of the tank. While holding the wire as close to the pivot point, you need to gently (very gently) bend the wire arm up a little at a time making sure to hold it tight at the pivot point. I found it most accurate if you completely drain the tank, measure exactly 3 gallons if you have a 6 gal tank or 2.5 gal if you have a 5 gal tank, put measured gas in tank and replace the pump/filter/float assembly with 2 or 3 screws, turn on ignition and check gauge, if not exactly at 1/2 tank (be sure bike is level and not on side stand), repeat previous steps until gauge is calibrated to 1/2 tank. When you are satisfied reassemble. That is as close to accurate as you can get with the gauges.
I recommend for the next few tanks of gas that you confirm accuracy with your trip meter.
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Club Member
Joined: Jun 2007
Posts: 45,429
Likes: 2,898
From: Bedford UK
That's a great tip from 02Ultra for calibrating the fuel gauge. On recent bikes the float is part of the top plate assembly.
Club Member
Joined: Dec 2007
Posts: 23,178
Likes: 19
From: elsewhere
The most gas I have put in my '08 has been 5.4 gallons. The countdown was at 2 miles left. My pal, with a 5 gallon tank but who gets better mpg than me, had just sputtered to a halt. I usually just fill up by 150 miles, as I probably need a break anyway. Besides, HDs are not fun to push!
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