Bike shuts down on reserve

[alanncote]

I have an 04 FLHTPI with two very annoying quirks that no one, not even the dealer can explain...1) when my fuel reserve light comes on and I come to a stop, the bike shuts off! completely shuts down and you cannot keep it running...this is especially bad when like the other day I was on the interstate in bumper to bumper traffic...the light came on and the second I pulled in the clutch and slowed to under 25, the bike would stop. I re-starts without a problem but trying to get to an exit ramp where there was a gas station took me several miles and about 30 re-starts! 2) the bike will not start in any gear or neutral unless the clutch is fully engaged. the dealer says it is not a factory thing and suggested it may be a kill switch installed by the PD but I cannot find it anywhere.....any thoughts!

[garyad]

Did you check the fill cap for proper venting? I would not let the fuel get that low and not worry about it. I know thats not much help with your problem but that is what I would do.

[02flhpi]

FLHPI "wheels" need the clutch lever fully engaged for the "wheel" to start. This saftey feature comes from the factory on all police modles.

[route66paul]

You have FI and the suction tube to the pump has a hole in it. It is fine as long as gasoline is covering it, but when it starts sucking air, it doesn't deliver enough fuel. When you cut down the Rs, the suction created by the engine is not strong enough to keep the fuel flowing.

[cycopostie]

Originally Posted by route66paul

You have FI and the suction tube to the pump has a hole in it. It is fine as long as gasoline is covering it, but when it starts sucking air, it doesn't deliver enough fuel. When you cut down the Rs, the suction created by the engine is not strong enough to keep the fuel flowing.

I think you may have nailed it Rte66paul.
I wouldn't trust the "reserve light" or the fuel guage, I keep track of my fuel by resetting my trip meter on fill-ups and at around 150 miles start lookin for a gas station.
I like the idea of not being able to start the bike without pulling the clutch lever in.

[toybox99615]

Originally Posted by cycopostie

I think you may have nailed it Rte66paul.
I wouldn't trust the "reserve light" or the fuel guage, I keep track of my fuel by resetting my trip meter on fill-ups and at around 150 miles start lookin for a gas station.
I like the idea of not being able to start the bike without pulling the clutch lever in.

There are numerous problems with Harley fuel guages. They rely on a float in the tank to determine the fuel level. The manual says the light comes on with 1 gallon left in the tank. But in my experience that is a wild guess at best. One of my bikes (1999 FLHTPI) turns the light on with less than 1/4 of a gallon left in the tank. Another (2003 FLHTPI) shows low fuel light on at 1 1/2 gallons left. Meanwhile my other 1999 glide never had the light come on; even when the tank was bone dry and the bike stopped running. So you could just be having float issues with your fuel gauge causing your problems. Should the fuel level be low enough the bike would run out of fuel and the guage just sensing the low fuel level at the same time.

I would suggest you test the fuel guage by allowing the bike to run out of fuel till the light comes on. Then filling the tank and determing how much was actualy left in the tank. Do the test while you have a known amount of gas in another container of gas with you so you can add it when the light comes on and the bike stops running. Then fill the tank and determine how low got before the light came on.

[cod]

I have a 2003 and did not know that there was a fuel light on it.
My fuel guage is never correct ,I just use the trip and go from that.

[yamahonkawazuki]

Originally Posted by garyad

Did you check the fill cap for proper venting? I would not let the fuel get that low and not worry about it. I know thats not much help with your problem but that is what I would do.

yup, perhaps try it on prime, ( if equipped) and see if problem still happens