2009 TE310 - Fuel Pump Problems

Just bought a used 310 w/ about 1,300 miles. First time out I filled the tank and went out for a ride. After about 35 miles the bike died like it had run out of gas. The Warning light did not come on. I rocked the bike back and forth a few times (could hear gas slushing around). It started, and ran for a mile or so, then quit again. I did this several more times to get back home. Then I took the tank off and drained the remain fuel - there was still about 1/2 gallon of fuel left. Then took the fuel pump off and I noticed 2 things: the orange wire wasn't connected to anything, and, the fuel pump canister was loose - in other words the clips at the end were not holding it down in place. I believe the orange wire is supposed to be connected to the end of what I think is the low fuel sensor - is that right? Also, the zip ties around the fuel pump canister were loose - I assume they should be tight so the fuel canister stays snapped in place. Do you think correcting these 2 issues will correct the problem I'm having with fuel left in the tank? It's runs great until it gets low on fuel so I don't think there are any issue with the fuel filters - unless there's is something specific to the "reserve" part of the tank. Thanks!

Obviously you need to get the pump to stay in place, there are several ways: more zip ties, zip tie from top to bottom. safety wire it, etc.

The low fuel wires, in my opinion, are not worth the effort to reattach, the gizmo is just not worth the effort, mine broke off in the tank long ago, I have always used the tripometer as my fuel gauge anyway, its your call on that.

A 2009 Husky that might have been manufactured in Sep of 2008, had gas in the tank since then and has 1300 miles, the pump may have some varnishing inside of it, and when it gets hot, it can seize up. You are not going to know this until you get low on fuel (but not out of fuel), get the bike in some singletrack, and when the bike dies, you listen for the pump to prime when you turn the key off and then back on. A labored sound or no sound at all means time for a new pump.

Wiring diagram should be in the shop manual, located here:
https://docs.google.com/folder/d/0B...edit?pli=1&docId=0B87JGKEoBQdzMlBJdmN3Z2pRQUE

Thanks OlderHusky - snapped the fuel canister back in and tightened the zip-ties - soldered the orange wire to the side of the low fuel sensor. Well, that took care of my low fuel issue. I guess if that canister is loose, when the fuel level gets to a certain point it must start sucking air rather than fuel. Once that's pushed down tight, it pulls fuel from the bottom of the tank. My warning light didn't come on yet - but maybe the fuel level isn't low enough for the light to switch on. Time will tell.

Yes, I am having the same exact issue. Just picked up my bike a month ago and this has happened on two of my rides. Low Fuel Light doesn't come on, and tank still has some fuel in it, but it is low. I had to add fuel unless it would continue to stall. Not only is this frustrating but it also plays mental issues when you know you still have fuel in your tank.

Bump ..... more info.
Went to change the fuel filter and there is an orange wire flapping around ... I cant see what is would solder to ??
Any one have a pic or 3 they would care to share... The manual and FSM us well useless. Ebay has some good pics but not of the side of the assembly needed.

Thank you in advance .

Stolen from someones photobucket .... is this the correct location for the orange wire ???

As it turns out I put a tiny ring connector on the wire and just put it under one of the self tappers holding up the sensor. Works for me!

The next time you take your tank off, put some of that reflective insulation tape/sheets on the bottom of the tank. You can buy it in sheets at most automotive shops and many moto shops. It will bring the fuel temp down a bit in the tank near the fuel pump.

Just used this cable tie method to solve my dislodged fuel pump! Runs like a dream