I've been riding my 2013 1200 Custom (4.5 gallon tank) for almost two months and I've been trying to stretch out how far I can go before a fuel stop. The low fuel light comes on at about 105-110 miles and at that point it will only take a little less than three gallons. I stretched it out to about 150 miles and it took about 3.5 gallons. On my last tank it started to sputter and cut out while accelerating after 160 miles. I stopped to fill up and it only took 3.7 gallons. Is it normal to have that much gas left in the tank and have fuel pickup problems? It wasn't fun to be taking off from a light and then feel like you're going over the front end because the motor pretty much shut off.

 

Do not know why it is not picking up the fuel. I do know you are going to kill your fuel pump if you keep trying to find the limits. FYI the pump is lubricated and cooled by gasoline.

 

Yep. Most common reason for failure in fuel pumps is running tank too low. I always fill bike around 120 miles or so. Mine did the same as yours the one time I tried to go 30 extra miles. Will never go that far again before refill.

 

doesn't seem too normal...I have and 04 883 with the 1200 kit with a 4.5 gal tank and sheesh, I'm not turning on my reserve until like 175 miles, and could probably squeeze 200 out of a full tank if I ride like I have some sense...But then again I'm not sure how the EFI bikes work, I think a carbed bike is more accurate...the most i've gotten out of a tank was like 190 miles and I think i end up putting about 4 gal in it

 

But then again, I don't want to know how far I can get...I soon as i hit reserve, i go get gas at the closest place...like those guys are saying...it will kill your fuel pump

 

My low fuel light on my 2011 1200 custom comes on about exactly the same as yours OP. I stretched it out a few days ago to about 160 miles. No problems but like you I only put about 3.2 gallons of fuel in.

 

I have an 07 sportster and I have ran it up to 210 miles before filling it up. i only did that once. but like you was trying to see how far I could go, and it only held 4.2 gallons.

 

When you get to the last gallon and a few tenths or so , heavy turns, stops, sudden acceleration will cause the fuel to slosh around in the tank enough to starve the pump and cause the cutout.

 

I have 4,5 and the most I have gone without a fill-up was about 160 miles but I did not experience any issues. I think it was about 3.8 gals to fill up when I did that. Normally I'll be looking for gas at around 140. But its nice to know I could probably go another 30 miles or so if I needed to. I don't think I'd want to try and run it out of fuel for obvious reasons.

 

my 2013 1200C does the same as yours....low fuel light at about 110 miles