2008 TE-510 Low Fuel Light not working

I have about 800 miles on my 2008 TE-510. The low fuel light has been working flawlessly until today when I ran out of gas. Luckily, I only had to push the bike about 1/2 mile to the gas station where I put in 1.95 gallons. Does anyonne have a fix for the low fuel light problem? I have a new IMS 3 gallon tank, but it is not installed. I'd like to fix the low fuel light problem when I install the new IMS tank. Pictures or detailed instuctions would be appreciated.

Thanks

Mine only comes on for a few minutes.....if i am not looking for it, i will miss it. once it goes out it never comes back on....strange!!! I don't rely on it, just calculate my mileage in my head....I have the new IMS tank and I plan my range on 80 miles between stops!

Here are a couple pics from TT that show the guts pretty well..

The fuel level sender unit is circled in RED. The actual fuel pump assembly is circled in BLUE. Make sure the zip-ty is holding the pump securely seated and check the wires on the fuel level sender.




Be careful when installing the pump into the IMS, it's easy for a couple of these wires and/or the lower mesh looking inlet filter bag to get stuck between the mounting flange and the new tank if you're not watching closely.
HTH

You guys are a blessing. I bought my TE450 08 used with 20 hrs on her and I've never seen the light come on. In fact, I just ran out of gas and never saw a light. So, all this spurred me to mount the 3gal IMS tank and while R&R the fuel unit, and the fuel pump slide foward, so pushed it back and added another zip tye. Checked all the wires and even measured 12.5vdc at the fuel sensor connector. The fuel sensor reads 2 ohms and varies slightly (1.9 to 2.1 ohms in and out of gas. Is it possible the fuel light is burned out? Anyone take similar measurements at their fuel sensor?

I'll just comment that if you got 1.95 gal. out of the tank you did a lot better than average, which would be around 1.75 gal. I've got the see-through IMS tank. I've run it out and put a mark where it ran out. That and knowing the general range in miles will probably be more reliable than the warning light. IIRC I only went 5 miles or so after the light. I was carrying 2 liter bottles of fuel for the occasion.

IMS seemed to run out at 2.75. You might be able to slosh a little more gas around and get more.

Anyone opened the instrument speedo unit to see if the bulbs can be checked/replaced. Perhaps the low fuel light got the swine virus and died.

If you got 1.95 gl in the tank you most likely have a bad low fuel sensor and not the problem of the fuel pump sliding up in the sleeve. The sensor can be tested, which I had done with the same problem, and then had the entire fuel pump assembly replaced under warranty. BTW, the power up kit was installed the day I purchased the TE510 and had no impact on warranty coverage with my dealer.

On my bike, the bracket that holds the low light sensor broke (I assume from vibration) that would cause the sensor to drop down into a lower position and would probably cause it not to come on. Ken

Check the continuity of the orange & black wires coming from the sender, the orange wire broke, inside the insulation, causing my low fuel light to not work.

Mine did that. Both wires broke off. Dealer was worthless for getting warrenty work.

about how far does a injected te 450 go once it is on reserve?dan

I never pushed it, but I would say no more than 15 miles. I can say that because I had the light come on when leaving work, and got gas on the way home, and that was about 10 miles, and the bike still had about a quart or so left in it.

I've ran out in 11 miles on my TE510 (dirt riding) after the light came on. It somewhat depends on your terrain and right hand.

This forum is the best!
Yep, the none working fuel light was due to the broken wire at the sensor. Re-soldered the wire, and she works. Great. But, Husky wins a "prize" for using the least amount of copper allowed by "law." Husky could easily improve their reliability by looking at a Honda for connector, wires and connector strain relief. Since so many people have fuel light problems, I reinforced the two wires at the low-fuel sensor by tie-wraping a 2" piece of tie-wrap to the wires and sensor. My thought is the fuel washing action on those wires causes the wires to flex back and forth until they brake. I have photos if interested (have not read how to attach them to a post yet).

Does anyone know were i can buy a new sensor?

Ya i need to buy a new sensor as well mines junk the tests i ran on it failed where can i buy just the sensor?

Ouch. That nipples the first thing I saw.