Fuel light no worky

**SwitchThrottle** · 03-06-2009

My "your almost outta fuel idiot" light stopped working on my '08 SM450R. I barely got the bike fired up and to the gas station on the way home today. This is the 2nd time this has happened. Last year I was lucky and ran out right next to a gas station. I know the pump is getting all the tank has to offer cause this afternoon I put 1.96 gallons in it.

Has anyone had this issue and were able to fix it? If so, please enlighten me.

**ClintMD** · 03-07-2009

Same issue here on my '08 610. A friend of mine has an '08 510 and his is out also.

Hopefully someone can fill us in on an easy fix.......

**Fast1** · 03-07-2009

I've had two issues with my fuel pump and the low fuel light.

1st was caused by the pump sliding up in the housing and not being able to utililize all the fuel in the tank.

2nd was caused by a faulty low fuel sensor on the fuel pump assembly and was replaced under warranty.

**SwitchThrottle** · 03-07-2009

Originally Posted by Fast1

I've had two issues with my fuel pump and the low fuel light.

1st was caused by the pump sliding up in the housing and not being able to utililize all the fuel in the tank.

2nd was caused by a faulty low fuel sensor on the fuel pump assembly and was replaced under warranty.

I know it's not #1 cause I can run the tank bone dry, so I guess it may be a sensor issue. I am thinking about strapping an MSR bottle on the bike so I don't have to push it if it runs out.

**Fast1** · 03-07-2009

I'd check and determine if your dealer will get it covered under warranty. If not you may want to remove it yourself and ensure you don't have a problem with the leads that run to the sensor. This was reported by one individual with the same type of issue last summer on another forum.

You can also test the sensor per the shop manual instructions. That is how the service manager identified the problem I had for Husky warranty coverage. That type of sensor is common/similar to most FI type bikes.

**beavisblack** · 03-07-2009

reserve?

**lammyracer** · 03-07-2009

Mine went out two weeks ago, and the dealer is replacing it under warr. They just called me to say that they got a new pump in, but I haven't been able to take the bike in yet, so i've just been re-setting and watching the trip odo.

**r6addict** · 03-09-2009

Similar issue-- 08 510 SMR

Mine went out yesterday on the way to church and I coasted it into the parking lot. No light and there was still a little gas in the bike. I loaded it in my buddies pickup and pumped 1.5 gallons into the tank. Gonna need a canteen or two full of VP strapped to the front forks.

How can I determine if the problem is a faulty sensor or the fuel pump sliding up in the housing? I'm guessing the pump has moved in the housing, as there was still a little gas in the tank that was not being consumed. Looks like my nearest dealer is 100 miles away. What should I do?

**Fast1** · 03-09-2009

Originally Posted by r6addict

Similar issue-- 08 510 SMR

Mine went out yesterday on the way to church and I coasted it into the parking lot. No light and there was still a little gas in the bike. I loaded it in my buddies pickup and pumped 1.5 gallons into the tank. Gonna need a canteen or two full of VP strapped to the front forks.

How can I determine if the problem is a faulty sensor or the fuel pump sliding up in the housing? I'm guessing the pump has moved in the housing, as there was still a little gas in the tank that was not being consumed. Looks like my nearest dealer is 100 miles away. What should I do?

Having additional fuel in the tank indicates that the pump has slid up in the housing.

**r6addict** · 03-09-2009

pumped 1.5 gallons before she would fire. What does the tank hold? 2 gallons? trying to figure out how much I had left before the light kicked in post fuel starvation

**Fast1** · 03-09-2009

that will change depending on how much the fuel pump pick up slides up in the housing every time you ride it.

**Roma** · 03-10-2009

have the same issue on 610... when it just stopped working I run out of fuel out of the city ,it was 3-00 at night)

**r6addict** · 03-10-2009

So apart from zip tying the pickup in the housing, is there a permanant fix from the factory? Is Husqvarna aware that this is a known issue with their road bikes and is a serious safety factor for riders? I was traveling at highway speed in 6th gear and was nearly steamrolled by a semi when my bike cut out. Seems like the Husqvarna service network should be made aware of this to resolve the issue for affected 08 FI models. I know a few people in the industry who work for BMW Motorsport and will be looking into this and will post my findings on the forum soon. Are any other years/models affected?? Please speak up if other years/models are affected.

**mmulisha1022** · 03-11-2009

Originally Posted by SwitchThrottle

My "your almost outta fuel idiot" light stopped working on my '08 SM450R. I barely got the bike fired up and to the gas station on the way home today. This is the 2nd time this has happened. Last year I was lucky and ran out right next to a gas station. I know the pump is getting all the tank has to offer cause this afternoon I put 1.96 gallons in it.

Has anyone had this issue and were able to fix it? If so, please enlighten me.

Yeah mine ran out on Saturday and i didnt have Cr150f with me to give me some fuel.... I barely made it to the gas station. It stalled right before i pulled in and had to run it across the street to the pump. I still have to try #1.

**SwitchThrottle** · 03-11-2009

You still haven't fixed that?

Funny thing is that when I ride the Honda, the guys are referring to it as the XR Valdez because of the 3.8 gal tank on it.

**r6addict** · 03-25-2009

I'm getting between 40-49 miles on a full tank before the bike shuts off. I'm able to slosh the tank around and restart it, but upon deceleration, the bike simply dies and I'm hunting a gas station. I'm pumping anywhere between 1.2 and 1.4 gallons. Just doesnt seem right. I'm riding 50% urban stop and go and 50% highway cruising. Short shifting, etc to keep the revs low.

Time to order a new pump. Warrantee covers this, right?

**mmulisha1022** · 03-25-2009

I took my fuel pump out last night and indeed it did slip up. So i pushed it back down and zip tied it. I havent ridden it but the light went on!! So i think im good to go. Really easy fix...

**jlk_250** · 03-26-2009

Originally Posted by r6addict

I'm getting between 40-49 miles on a full tank before the bike shuts off. I'm able to slosh the tank around and restart it, but upon deceleration, the bike simply dies and I'm hunting a gas station. I'm pumping anywhere between 1.2 and 1.4 gallons. Just doesnt seem right. I'm riding 50% urban stop and go and 50% highway cruising. Short shifting, etc to keep the revs low.

Time to order a new pump. Warrantee covers this, right?

You almost certainly have the "fuel pump sliding up, need to slide it back down and zip tie it tighter" issue. The tank really does hold 1.9 gallons so you still have lots left when it runs out of gas. The dealer should fix it under warranty or you can do it yourself with the information people have already posted on here. Fast1 even posted pictures of the solution.

**SwitchThrottle** · 04-03-2009

Pulled the fuel pump last night while doing oil and valve checks. Both wires were separated from the sensor. In the pic below, orange and black sleeved green wire. Looks like the solder just broke.

I was gonna just fix it, but may just get a new one under warrenty. Decided to do it another day. Nice day on Sunday, and wanna ride.

**Yellowsierra** · 04-20-2009

Im glade I found this thread!!!

I guess my pump has slide up... The first day i rode it my low fuel light came on so i went to the gas station. Now the bike runs out of gas before the light comes on and it only takes 1.4 gallons to fill it up. I guess Im going to pull the pump. oh and i drove from gainesville ga to murphy NC on 1.45 gallons. It was a 80 mile trip so that means i got about 55MPG hehe... Not bad!

**mmulisha1022** · 04-20-2009

Originally Posted by Yellowsierra

Im glade I found this thread!!!

I guess my pump has slide up... The first day i rode it my low fuel light came on so i went to the gas station. Now the bike runs out of gas before the light comes on and it only takes 1.4 gallons to fill it up. I guess Im going to pull the pump. oh and i drove from gainesville ga to murphy NC on 1.45 gallons. It was a 80 mile trip so that means i got about 55MPG hehe... Not bad!

Yupp def. slide up on ya... easy fix took me 20 min to fix.

**dreadhead13** · 04-20-2009

glad i found this post too! i was only getting 55-60 miles before mine would start popping and stalling on decel. only taking .9-1.2 gal at a atime too. gonna take a look at the pump when i have the tank off during valve time this week! good info.

**mmulisha1022** · 04-20-2009

I throw 2 more zip ties on and it seems to be working great.

**foxinredsox** · 04-20-2009

Check the red an d the blue cable, we also had some probs with that. It looks like the cable is OK, but when you look at it from near you will see that it doesnt fit anymore. I think it doesn't like the fuel

**dreadhead13** · 04-20-2009

where exactly are you guys putting the zip ties? will it be obvious as soon as i get the pump out? cuz i haven't seen the guts of my tank on this bike yet.

**mmulisha1022** · 04-21-2009

The shitty clip that is suppose to hold the pressure pump down doesn't do a damn thing. The pump will rise up and not let you be able to run the tank dry. And if it moves up too far then it won't even pick up any fuel under the sensor (giving you no warning on running out of fuel). So push the pressure pump down so that the shitty clip is clipped over the shinny metal part on the pressure pump. Then what i did was added two more zip-ties next to the exsiting zip tie.

**dreadhead13** · 04-21-2009

ah i see now! excellent work man. forums come in handy eh?

**neptyr** · 04-23-2009

Just ran out of fuel yesterday, funnyfunny..

But i noticed there is Two wires running to the "fuelcock", the "off On off" switch on the tank, and one of the wires have come lose, could this affect the light?

I'm considering riding with a 1,5liter bottle of fuel in the bag now, just to be on the safe side..

**wilmar13** · 11-21-2009

Bump for a useful thread... I did more than 300 miles on my new (to me) 510 and ran out of gas twice with only about 65 miles and yet couldn't get more than 1.4 gallons in... I figured the tank was smaller than claimed, but this makes sense... will pull the pump and fix it tomorrow when I check valve lash. Good to know

**High-Side** · 11-21-2009

My fuel light came on at 98 miles and I pumped in 2.4 gallons of gas. I went from fifty plus miles per gallon to around forty just by going with the power-up kit. Is there another view of where I need to zip-tie the pressure pump?

**lammyracer** · 11-21-2009

Originally Posted by High-Side

My fuel light came on at 98 miles and I pumped in 2.4 gallons of gas. I went from fifty plus miles per gallon to around forty just by going with the power-up kit. Is there another view of where I need to zip-tie the pressure pump?

With the power up kit, I get about 45 mpg commuting. I usually reset my trip odometer when I fill up and will re-fill at 100-110 miles rather than wait for the light (mine failed once already and left me stranded...).

**High-Side** · 11-21-2009

Originally Posted by lammyracer

With the power up kit, I get about 45 mpg commuting. I usually reset my trip odometer when I fill up and will re-fill at 100-110 miles rather than wait for the light (mine failed once already and left me stranded...).

Mine never came on before....
I live in the shadow of Mount Tamalpais and that is my ride of choice - which is probably why I get such crappy mileage.

See picture below:

**mmulisha1022** · 11-23-2009

Haha. Damn i would love to have roads like that around me...
I put (2) more zip ties in the same spot just over and under the existing factory zip tie. When you pull the pump assy. out you will figure it out its not to bad. Only took me 20 min or so. I put the extra leaders in that photo that you "quoted" because i got confused on the original fix description. After the ties i have not had a problem, but i havent ridden it much this year. Between work (which i refuse to commute down the highway with her) and mx training on the weekend i havent had the time and/or have a sever case of monkey ass. hope thats the problem. good luck man.
Chris

**jlk_250** · 11-23-2009

I added only one additional cable tie and it was 100% secure, but the problem returned because cable ties swell up in gas. Then I used stainless steel safety wire and no more problems. Same thing for another guy on cafehusky.

**High-Side** · 11-24-2009

Originally Posted by mmulisha1022

Haha. Damn i would love to have roads like that around me...
Chris

The road is like that almost all the way up and back. At a good pace it's an hour and a half of fun.

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