Since my 06' FST was new this Feb, I've gone through a couple of tanks of gas and experienced the low fuel light come on around the 45-50 mp range. I have read all the concerns and the instructions how to bend the probe, but haven't touched it yet. On my last 2 rides, I noticed the fuel gauge doesn't change even though it shoud. The first time I noticed I had traveled 103 miles on a full tank before it even droped 1 bar. I ended up filling up 7 gallons worth of gas and the gauge went back to full. Since then, my sled received it's first dealer service and the the battery was checked as being 12.7 volts fully charged. The battery gauge on the MFD read full and with a full tank of gas, so did the fuel guage. After riding all day on Sunday, I noticed the fuel gauge didn't move once even though I had to top off with 6 gallons late in the day, however, the battery guage did read half. Has anyone experienced such a thing? Could the battery guage in the MFD actually be reading the fuel consumption and the fuel gauge be reading the battery status?

Sounds like the float is caught on a fuel line and not dropping down.

I've noticed occasionally my voltmeter drops down to half or less bars, even getting so low at times that the voltmeter flashes just like the fuel gage does when your tank is nearly empty. This usually happens at idle when my hand/thumb warmers are on high, and my electric faceshield is plugged in. If I give the sled a little throttle and pick up the RPM's, the voltmeter climbs right back up again. Of course I don't have a battery like you do, but you might want to see if raising the RPM's has any effect on your voltmeter. I think this would be the easiest way to determine if the MFD is wired correctly or not.

A FST alternator can handle lights, warmers and elec shield at idle. The voltage should nt drop.

I looked in the gas tank through the filler neck to see if I could see the float caught up in any of the fuel lines and I couldn't. I didn't take anything apart and brought the sled to the dealer yesterday afternoon. I haven't heard a response yet, but as soon as I do, I'll post it.

On my 08 it seems to work OK, at 100 miles the flashing started and I put in 7 gallons. The little bars on the gauge come down slowly, sorry.
Does anyone know if you had a shorter filler neck inside the tank would it hold alot more fuel>

Dealer called this afternoon and said there is a fuel pump sender unit inside the tank that is faulty. They drained the remaining fuel making the tank empty and the fuel gauge still read full. Said they did a test on the sending unit and there was no resistance therefore, ordered a new one. Have to wait a few days to get the sled back...

Picked up my sled this morning. The dealer installed a new fuel pump/sender assembly. The part was $420. covered under warranty. The gauge reads correctly now and the dealer said the problem should be solved. Heading north in a few days to see for myself.

I had a similiar problem. Last Friday in Pitts during that windy mid-winter type conditions, I lost it off a drift and came off the sled. The sled didn't tip over, but landed sideways. Anyway, my fuel gauge flashed "F" and was only showing one bar. We rode about 20 more miles and fueled up. The gauge stayed on empty for about 5 miles after fueling then went to full. It has been fine since. Maybe same thing, float wrapped by the hoses?