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Discussion Starter #1
I have an 08 electra glide. Only stage 1 mods. Problem is bike starts to run out of fuel at 1/2 tank. I can visually see fuel on the fuel pump side so I know it is not empty. So far I have replaced fuel pump, fuel filter, pressure regulator and check valve/fuel supply line. None of these have helped the problem. If I run it down to 1/2 tank and it starts to miss and sputter, I can pull into a gas station, fill it up and it runs fine again until it gets down to 1/2 tank again. Thanks in advance for any ideas on possible solutions.
 

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Could be a cracked fuel line from pump to filter allowing air into the line? Have you checked fuel pressure? Those internal fuel lines are famous for cracking, pin holes...

Also, the regulator housing has been known to crack...

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Discussion Starter #3
Thank you NORM9278. The fuel line from pump to the filter was replaced when I replaced the fuel pump. Yes I have heard that the plastic regulator housing has been known to crack. However, the regulator housing is above the fuel level after about a gallon of fuel has been run out and my issue only occurs after I have run just over 3 gallons out of the tank. Assuming that a submerged leak wouldn't cause a fuel starvation issue. I am at a loss and considering replacing the plastic housing for the filter/regulator just because it is just about the only thing left in the tank that hasn't been replaced.
 

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As you know, those pump / sending units are a bit+&# to get in and out of the tank. Possible that it got damaged on reassembly? No way to verify the problem without a fuel pressure test.
You have one of the fittings needed to Fab a test rig if you replaced the check valve.

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Discussion Starter #5
I am not an expert by any means but if it is running at fulltank then it would have pressure. Then at half tank it wouldn't have pressure based on what my bike is doing. Also, since the regulator is above the fuel level after only a gallon has been run out then why would the bike not have problems until it ran down to half a tank. I also noticed a few minutes ago that after I had ridden it earlier today and limped home (I purposely didn't refuel so I can try and figure this thing out), after it was leaned over on it's jiffy stand, more gas had transferred to the pump side and I took it for a short(2 miles) drive. Definitely has something to do with fuel level needing to be just above pump height. The plastic housing for the pump even if it had a crack shouldn't impact the pump should it?
 

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Are you sure your crossover line in the front of the tank is clear?

No, I don't think is likely the regulator housing.

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Discussion Starter #7
Hi Norm. If you mean the siphon line that runs from the right side of the tank to the pump side of the tank, yes it is. I blew through it when I had it apart yesterday replacing the checkvalve/ supply line. I had that thought also. I took the pump out because I wanted to recheck all the hoses connected to the pump before I put the new checkvalve in. Unless the new hose I put in that runs from the pump to the filter had a crack in it down near where it connects to the fuel pump, I am stumped. That assumes that the pressure of gas being above the crack would be enough to keep it from leaking. Ideas?
 

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I'm gonna say you are gonna have to Fab up a fuel pressure test rig. All you need is the male fitting that plugs into the "check valve" that you already have, a tee and a pressure gauge. Or you can buy one already factory made. Without knowing what the pressure is and when we're just guessing.
But, you said it ran after setting it on the side stand? That tells me the crossover may be plugged up....dunno?

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Maybe drain all but a gallon and run the pump and try to see if fuel is squirting out inside the tank. Might be able to see, or hear something.

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Discussion Starter #10
I don't already have the male connector. I replaced the check valve only because the hose that runs from the regulator to it can't be purchased separately. I can probably rig something up when I get a chance. I was just hoping that someone on this forum already had this issue before. Thanks for your help Norm. Ride Safe!
 

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Discussion Starter #11
Norm. Yes, I am going to have to take the console off again and run the pump to see if/where it is leaking. There has to be a leak somewhere just below the half tank fuel level. Thanks again Norm!
 

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it's in the tank,,,, I had an 08 softail come in with a similar problem,,, history was,,, the dealer replaced the pump and regulator,, it never ran right.

loosen and lift the console,, lift the access plate,,, turn the ignition on,,, listen and look for the leak...
 

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I had an outboard would run for awhile and then stop. Wait a little time and away we go until it crapped out again. The lining inside the fuel line had collapsed from the tank to the motor from use of ethanol gas. I could get some gas, but not enough. Cut the line open and it looked like the lining was folded. A new line from tank to tank helps peace of mind.

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Discussion Starter #14
Thanks tall terry. Yes, that is my next step. I'll let you guys know what I find when I get a chance to check it. Thanks again all and ride safe!
 

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Almost sounds like a tank venting issue, but that shouldn't be the problem as you get a 1/2 tank used before it happens.
 

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I have the check valve and the male fitting that I got off of eBay when I was having issues. I can loan them to you if you need them. Just shoot me a PM.

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Discussion Starter #17
I have the check valve and the male fitting that I got off of eBay when I was having issues. I can loan them to you if you need them. Just shoot me a PM.

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Hi Norm. Just pulled the filler neck out which has the filter/regulator assembly attached. There is a hole on top of the regulator housing (definitely factory hole) that sprays fuel out when pump is turned on. Is the hole some sort of bypass? Thanks for the loan offer, I may have to take you up on that if This current attempt at locating the problem is not successful.
 

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I have an 08 electra glide. Only stage 1 mods. Problem is bike starts to run out of fuel at 1/2 tank. I can visually see fuel on the fuel pump side so I know it is not empty. So far I have replaced fuel pump, fuel filter, pressure regulator and check valve/fuel supply line. None of these have helped the problem. If I run it down to 1/2 tank and it starts to miss and sputter, I can pull into a gas station, fill it up and it runs fine again until it gets down to 1/2 tank again. Thanks in advance for any ideas on possible solutions.
Do you maybe have a lift on the tank? I would expect that to make a difference, due to where the fuel picks up normally, and where the fuel would mostly sit on a lifted tank.
 

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@motorbikeman

The pressure regulator has to provide a constant fuel pressure of 55 psi to the fuel rail of the throttlebody and if the output of the pump exceeds these 55 psi the regulator dumps the excessive fuel back into the tank, maybe through the whole you described. You said that you blew air through the outside crossover line, did you also try to clean kneeformed tubes at the tank that accept the crossover line with a thin brush?

Armin.
 

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Discussion Starter #20
@motorbikeman

The pressure regulator has to provide a constant fuel pressure of 55 psi to the fuel rail of the throttlebody and if the output of the pump exceeds these 55 psi the regulator dumps the excessive fuel back into the tank, maybe through the whole you described. You said that you blew air through the outside crossover line, did you also try to clean kneeformed tubes at the tank that accept the crossover line with a thin brush?

Armin.
Do you maybe have a lift on the tank? I would expect that to make a difference, due to where the fuel picks up normally, and where the fuel would mostly sit on a lifted tank.
Do you maybe have a lift on the tank? I would expect that to make a difference, due to where the fuel picks up normally, and where the fuel would mostly sit on a lifted tank.
No, there is no lift on the tank. Just a standard bike.
 
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