My bike's warranty was out when I purchased the bike few weeks ago. Nevertheless, the dealer (600 miles from my home and over the phone) said that (as described in several threads) the issue is not the gauge but the sonic-based sensor inside fueltank.
They said that although the cost for the unit is about 130 € (about $165) and there is no recalls on that (thank you Harley for switching the part numbers!), they'll buy it and ship to my home FOC if I'm able to do the assembly or buy the work at local authorized shop.
Two weeks passed and bingo! Package arrived with the strangest looking fuel sensor I've ever seen... With great enthusiasm and no service manual at hand I rushed to bike and started to change the unit. It seemed pretty simple, plug and play installation as there were no threads or boltholes. Little did I know that there was a effin' circlips holding it inside the fueltank.
After almost destroying the old unit with coule of big monkey wrenches I realized that the old sayings "when everything fails, grab a bigger hammer" and "real men don't read manuals" have proven somewhat wrong and forced myself to push the cave-man-frenzy aside and bringing back my civilized engineering self back in place. Ahem. Disassembly of the complete fueltank top including the fuelpump wiring and fuel lines was necessary.
After disassembling everything on top and removing the top, I was able to easily remove the circlip, faulty fuelsensor and replace the newer version that looked exactly the same.
After another about 30 minutes wrestling of getting the fueltank-top-plate-sealing-o-ring (at that moment I had far more descriptive and colorful phrases that I used) in place and everything sealed off I was able to hook back all the disconnected lines. Presto! Everything in place without any immident fuel leaks.
Test drive showed that everything should be okay. I'm gonna go for a 1500-mile rally during the next few days so I'll be able to verify whether the new sensor fixed the issue....
The moral of the story? Being trained and worked as mechanical engineer I'm quite familiar of the concepts called Design for Manufacturing and Design for Assembly. Fueltank design on v-rod is clearly lacking at least DfA part. Otherwise the bike is great and I love to drive it.
Keep the faith!
tigg3r from Finland