I fill mine just until the fuel reaches the little holes in the overflow, with the bike on the jiffy stand. So far, no problem with overflowing after a fill-up. By the way, I have put as much as 5.2 gallons in mine using the above method, so it obviously holds more than that. As for the gauge, it is just as big a joke as the rest of the gauges. Mine pegs on the full side for the first 50 miles, drops to 3/4 at 90 miles, 1/2 at 140 miles, 1/4 at 160 miles, and about 3/16 to 1/8 at 180 miles (4.8 gallons to fill). I have never had the nerve to let the gauge actually touch empty, since this sucker outweighs me by about 640 lbs. and I'd rather not push it to the next gas station. I plan to make a little modification to the gauge in the near future, and in the meantime I just use the trip odometer and ignore the gauge.