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Discussion Starter #1
So like the title says, after about 900 miles, I'm reporting my first issue. I'm not sure if I should bother taking it to the dealer though.


I have the SE muffler, intake, and stage 1 download, and whenever the tank is a little low (the light is JUST beginning to fade on/off), the engine cuts out when I take off a little hard from a stop.


I'm sure its due to one of a couple reasons, either a lack of proper baffles in the fuel tank, causing a lack of fuel pressure to the injectors under heavy acceleration, or there's an issue in the fuel/ignition map.


Anyone having a similar problem? I doubt the dealer would own up to it... saying that they couldn't replicate the problem, or some other nonsense. When it happens, its a little scary actually - kinda like someone slamming on the front brake for a split second.
 

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I know the problem you are speaking of. My 750 did the exact same thing. I took it to the dealer and had them test ride it. Also the fuel light NEVER came on at all.
On the test ride the machine acted just as I told the technician it would. The fuel pick-up is at the front of the tank so when it is low on fuel and you take off rather quickly all the fuel is sent to the back of the tank, hence the jerk and cut-out you get when you first accelerate. The light not coming on was something different, they ordered a complete fuel injection system ( pump I guess). It will be installed Friday the 29th.
Run your machine until it is low on fuel and take it to your dealership and tell them to test ride it. This problem was reported to Harley by the technician that test rode mine and they are now aware of it.
 

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Discussion Starter #3
Thanks, that helps me a ton to know I'm not the only one. That was a dumb move... Not exactly the first bike these guys have made.
 

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Yes, with the fuel pick-up in the front of the tank this will happen when low on fuel but it's probably with less than 1/2 gallon of fuel in the tank. I've had mine down to 1/2 gallon and didn't experience the problem.

My low fuel light also had a problem (light always on) and the pump assembly was replaced. My problem now is that it doesn't come on until I'm down to 1/2 gallon so it needs to be calibrated by the dealer. That will be taken care of next week. We need it to come on with about 1 gallon left in the tank and I believe that's what the service manual calls for.

I suggest never running it down to less than 1/2 gallon if you can avoid it. It's not like it costs a lot to fill it up.
 

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Thank goodness I'm not the only one with this problem. It has happened a few times and I thought it was simply my shifting!
 

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Discussion Starter #6
Not the point. It's a design flaw and needs to be fixed. My fill up today was 2.1 gallons, and that was topped off, so the tank had plenty of fuel (of course only in my opinion).

Something like this is worthy of a safety recall. This is an easy fix... Unless the tank outlet is just a welded on bung. I haven't pulled it apart, and I'm really not interested enough to. That's saying a lot.
 

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Not the point. It's a design flaw and needs to be fixed. My fill up today was 2.1 gallons, and that was topped off, so the tank had plenty of fuel (of course only in my opinion).

Something like this is worthy of a safety recall. This is an easy fix... Unless the tank outlet is just a welded on bung. I haven't pulled it apart, and I'm really not interested enough to. That's saying a lot.


You had 1.4 gallons in the tank if it took 2.1 gallons and this problem should NOT be happening. I'd take it to the dealer and they will report it to Harley. Something is wrong with your fuel pick-up.
 

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Discussion Starter #12
Initial update... As I expected, the dealer is attempting to blame the absence of baffles on the screamin eagle muffler... That won't hold water with me though.
 

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Discussion Starter #13
So, the dealer stated that they were able to replicate the issue, but there are no TSBs out to fix it. They are saying it's a lack of fuel pressure.

Unfortunately, they're blaming what I stated above. The theory right now is that the engine is leaning out. OF COURSE IT IS... IT HAS NO FUEL PRESSURE! They think the lean condition is being caused by the exhaust being too free, and the lean spot killing power to the fuel pump.

I offered to reinstall the baffle plates, and I did... They will continue working it tomorrow. I don't suspect it will solve the issue though.
 

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Initial update... As I expected, the dealer is attempting to blame the absence of baffles on the screamin eagle muffler... That won't hold water with me though.
Okay, two people claim they had the same problems , yet only one uses the screaming Eagle muffler.:nerd:

It sounds like your dealer is grasping at straws, with a mechanic that doesn't know his a$& from a hole in the ground. It really makes me wonder if some of these mechanics are certified mechanics and actually went to school and have training. If a mechanic would've said something that stupid to me I would ask him to see his diploma.
 

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Discussion Starter #15
My first statement to him was "before you try to pull the wool over my eyes, I'm an EFI tuner, and a practicing engineer."

That's when I offered to go get the plates, just to prove my point.
 

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The problem is that you are low on gas, simple as that. And he is correct,...there are no TSB's out concerning this. Just keep the tank fueled at a level that prevents the pick-up from being above the fuel line. I agree that it is a bad design. The pick-up should be at the rear of the tank so you can get over the next hill.
 

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Discussion Starter #17 (Edited)
If they turn me away because they can't do anything about it, I'm submitting the issue to the NHTSA for a safety recall. I'd suggest others that have experienced the same issue to do the same. They need to fix it the right way before someone gets hurt.
 

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why do Harley keep trying to do things differently, why not just have it on the rear like everybody else ???? I don't understand why they need to keep doing weird things , just build a normal bike like everyone else , simple .
 

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It really is a safety issue since it will usually take a second or two before it picks up the fuel and gets back to normal. This could cause an accident. I also don't have a screamin eagle exhaust.
 
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