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Buell Forum » Knowledge Vault (tech, parts, apparel, & accessories topics) » Troubleshooting (Poor Starting/Running/Handling/Ride Issues) » Archive through August 08, 2007 » Fuel light turns on prematurely - @ 26 mi!!! 1st time. « Previous Next »

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Rasmonis
Posted on Tuesday, July 17, 2007 - 08:15 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

On the way to work, filled up at a gas station, 26 miles later, fuel light comes on and stays on for a few minutes. Turns off for a few, then comes back on.

What?!!!?
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Blake
Posted on Tuesday, July 17, 2007 - 12:04 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Could be a malfunctioning meter. When the level drops to about a quarter tank, after around 100 miles, try sloshing the fuel back and forth to dislodge a possibly dirty and/or sticking meter.

The fuel gage in our Ford Exploder pooped out years ago, so it always shows the tank empty. We just use the trip-meter. Every once in a while the gage will decide to start working again, but only for a short while.
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Sparky
Posted on Tuesday, July 17, 2007 - 01:40 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Or it could be a defective fuel level sensor on the fuel pump assembly or the wiring connections to the sensor. The sensor itself is, I believe, a thermistor that changes resistance when the fuel level drops and it becomes exposed to air inside the tank.
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Rasmonis
Posted on Tuesday, July 17, 2007 - 06:36 pm:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Sparky,

How difficult is it to find the fuel pump assembly/wiring to the sensor?

I'll try Blake's solution first. The light came on right after I filled up on the way home @ 1.1 miles. ????

Thanks guys.
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Sparky
Posted on Wednesday, July 18, 2007 - 01:27 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

Do you have the service manual for your bike? If not, I have one for an 03 XB9R so, if the wiring is the same wrt the fuel sensor wiring, the low fuel sensor is a part of the fuel pump assembly which is in the bottom left of the chassis/ tank area.

The yel/red wire of the connector out of the fuel pump is the fuel sensor wire. That wire goes on its way to the instrument cluster. That's about all there is to the circuit, but the wiring involved in the circuit may be suspect.

What you can do, if you don't want to take the bike to the dealer, is inspect that wiring every inch of the way from the fuel pump to the instruments, hoping to find some kind of defect like a loose contact or an exposed wire at a wear spot in the insulation that might be causing the problem.
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Rasmonis
Posted on Thursday, July 19, 2007 - 09:15 am:   Edit Post Delete Post View Post/Check IP Print Post    Move Post (Custodian/Admin Only) Ban Poster IP (Custodian/Admin only)

I tried the simple shake n' stir, weaving, layin' it real low on the curves etc, at various levels of fuel without success. I filled it up, and the light and fuel odo came on almost right away.

I'll check the wiring next. Thanks Sparky.
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