I did a few tests on mine and cannot get it to 'go stupid' by turning the ignition off and back on no matter how low the fuel level. I am starting to wonder if your fuel gauge might not be off a little bit and could use calibrating (read: bend the float arm until it screams 'Uncle' and behaves properly). At this point, I would ask that you note where your fuel gauge bars change regarding mileage and we can compare them. The first bar lasts a long time, far more than 'one bar's worth' of fuel; the fuel gauge is very non- linear and not calibrated to the fuel tank in any way. All of this, coupled with you running out of fuel early leads me to believe that your fuel gauge is off or your fuel pump sock is partially clogged, forcing the fuel pump to draw fuel from higher than it normally does.
I ran my bike until the calculated range was 22 miles then shut it down overnight. After starting off again, the range reading did start off in the high 30's range but quickly (less than a mile) settled down to 24 miles, which is more than repeatable assuming there was 1/2 gallon or so left in the tank. I filled the tank about 3/8" above the splash plate and the bike took just under 5.5 gallons, again leading me to believe that the 22 to 24 mile range was very close to correct. I will continue to test this as I am curious but so at this point it does appear that the ECU and / or the dash readout stores and re-reads the last estimated fuel level when the bike is turned off and back on.
Otherwise I am out of ideas. ??
Brian
I installed Brian's low fuel warning eliminator last week. I can actually use the range function now when it is actually needed (thank you Brian!). It's a great concept. Anyway I decided to test it this weekend in a controlled setting. Unfortunately the bike ran out of gas when it said I still had 24 miles range. Disappointing but good to know. I was on ECO fuel map and taking it easy to stretch the range. It was also good to find out the bike doesn't just die. The engine starts missing and surging for a few minutes before total loss of power. I got it to the top of a hill, put it in neutral and coasted down the hill to a gas station. By the time I got to the gas station the engine was not running. It took 5.75 gallons in up to the bottom of the filler neck with the bike on the side stand.