Fuel Smell in Cabin

[AXE]

Recently I started smelling fuel in the cabin of the H2 after driving just a short distance. No leaks detected. I've seen some recent posts about the same issue and it seems as though its a pinched vent line, plugged line or bad rollover check valve. Also rollover valve might not be installed correctly.

I ran mine a few miles with the gas cap loosely installed. This seemed to help, but maybe not 100% cause the gas cap vents into the cabin too.

So I decided to pull the seat and center console to check the line and valve. Had to remove the seat and console (see pictures). Line seemed fine no kinks and I pushed some short blips of air through it from the tank end of the hose and could hear it venting.

I haven't pulled the check valve yet, but noticed after another blip of air it did not seem to vent much. Maybe I caused the valve to stick or damaged it even though I was only using <20 psi of air. Anybody know what direction the valve should point (see picture)? I sort of feel like its the right direction, but might be faulty. Might get an aftermarket valve and see what happens.

 

[AXE]

Looks like there is a T in the line before the check valve. It exits via a line under the driver seat, but not sure where it terminates. The line after the check valve follows the shift linkage out the back and comes up the fender well and terminates in a hole in the roll cage frame.

Not sure if the valve is functioning correctly. It is really hard to flow in the direction from the tank vent line to though the check valve, but easy to flow air from the check valve back to the tank. Maybe that's correct, so fuel doesn’t spill upside down and its just letting fresh ait into the tank. If so, then I assume the line before the check valve is letting the tank vent fumes when it's pressured up.

Might have to dig up the service manual or parts diagrams.

 

[olliechristopher]

What about getting rid of the in line check valve altogether and just use a simple roll over vent where it terminates? Way way back in the day that's what we used in our Baja Bug aux tanks. Summit racing sells them as well as any aux fuel tank supplier.

 

[AXE]

According to the parts diagram, the second line ciming off the T before the check valve goes to the other side of the fuel tank. So there are two fuel breather lines off the front corners of the tank.

At this point, all lines seem to be clear and can easily pass air, so I believe this valve is faulty. I cannot push air through it with my lungs. I have to use higher pressure to get it to pass air.

Not sure where the fumes are coming off the tank as all the fittings were very tight. Maybe pushing out the fuel line fitting or pump/filter seal, possibly the gas cap, but it seemed very tight when I unscrewed it.

 

[AXE]

I set my compressor down to 10 psi or so lowest my guage read. I could get a small amount of air to pass through the valve. So it must have operating parameters around that pressure +/-. I know at 20 psi, it moves a lot of air.

So I think one of the steel ball style valves from the KRX aftermarket would be best, but has to be mounted vertically with ball in the down position. That will require realignment of some of the hoses in the OEM location. Or like Ollie said, mount it off the end of the hose where it enters the frame in the vertical position.

Amazon.com: BIGLKNM Fuel Tank Roller Valve, 304 Stainless Steel Breather Rollover Vent Valve with Steel Ball For KRX 1000 : Automotive

Buy BIGLKNM Fuel Tank Roller Valve, 304 Stainless Steel Breather Rollover Vent Valve with Steel Ball For KRX 1000: Valve Parts - Amazon.com ✓ FREE DELIVERY possible on eligible purchases

a.co

 

[KawiH2]

RCOR sells a roll over valve. Its a two way valve. It allows air in and out. I dont think the H2 has a way to vent, so this fixes the high pressure problem. It stops fuel in a roll over. Krx has same issue.

 

[AXE]

It's the same as the one I posted from Amazon. I ended up buying mine from ebay for $12.

For 2020 2021 Kawasaki KRX 1000 Oil Fuel Tank Vent, Breather, Rollover Valve US | eBay

For Kawasaki KRX 1000. Rollover Fuel Tank Roll over vent valve. 1PC Rollover Valve. The valve will stop fuel from dumping out. We have professional team to care about every piece of fairing sale from us.

ebay.us

The problem with the H2 is that the lines are configured differently and it will require modification of the hoses to get that valve mounted vertically. The vent line enters the frame above the drivers side rear wheel well. There is some slack in that line as it comes up from the center of the floor. That might be the best location without hacking up the lines coming into the OEM valve.

In this case, you can remove the OEM valve by the e-brake by discarding the smaller two inch hose and connecting the remaining lines via the t splice that is there. I just bypassed mine for now and well do some testing while my new valve arrives.

 

[AXE]

RCOR sells a roll over valve. Its a two way valve. It allows air in and out. I dont think the H2 has a way to vent, so this fixes the high pressure problem. It stops fuel in a roll over. Krx has same issue.

I've pulled the OEM valve. Like the KRX valve, it it intended to let air into the tank, but keep gas from flowing through it in a rollover. It will allow air to pass out of the tank, but requires a lot more pressure to exit. I believe it's too much pressure to exit easily (especially if faulty) and then the fumes are escaping into the cabin. Not sure why it just started after 700 miles, but it may be that some of them just fail prematurely too.

A other reason theres so much pressure in the tank is that the coolant lines run right below the tank, so your getting a lot of additional heat on the bottom of the tank from 180-200+F coolant flowing back and forth. Gasoline hydrocarbons starts to boil at 100F +/- and continue up to 200F. I think that's partially why I'm seeing this occur as ambient temps have risen as well.

 

[AXE]

Since removing the OEM rollover check valve, I am not getting as much fuel smell in the cab. However, it did not eliminate the smell. I still get a whiff of it once in a while cruising the neighborhood. Might pull that discharge line out of the frame and leave it hang in the open and see what happens.

 

[Sand Shark]

I am guessing when you re-route the vent line the smell will go away.

 

[25sanpete]

Do you have a pic of where you put the roll over valve?

 

[AXE]

Do you have a pic of where you put the roll over valve?

I haven’t installed it yet. I just got it delivered today. I'm leaning towards putting it in the line vertically along the rear fender well. Either where it comes up along that electrical panel cover or pulling some of the slack and making a vertical section before it enters the frame. I don't think you can do it easily in the stock location as they're isn't enough room or line to mint vertically.

 

[AXE]

Got the new rollover valve installed today. Put it in the section of vent line located vertically behind the wire loom cover plate with rectifer attached to it.

You have to remove two 10mm bolts and a screw to remove the plate and let it hang downward. Mark the spot on the vent line about 1.25 -1.5 inches below the clip. Then pull the vent line from the plastic clips and from the frame. Pull the vent line out far enough to cut it squarely at the mark. Then push the barbed ends valve into the vent line. Then put the vent line and clips back in place making sure the valve has the large end up, so it's vertical. Then put the cover back on and snug fasteners.

I took a 5-6 mile ride and the wind was swirling some. I still got a couple whiffs of fuel when I was going slowly, but I would say it was noticeably less and most of the time I did not smell it.

So removing the OEM valve made a pretty big difference in intensity of smell and this new valve almost eliminated it. To be honest, I'm am not sure why this valve would stop fumes, as air will flow relatively easy both directions same as with out a valve at all.

I tested the valve upside down with water some water from.a syringe. It would let a little water pass through, but mostly sealed. The slightest amount of jiggling of the ball inside the valve would drain water easily. So I think if you're upside down, it'll mostly stop flow if the ball seals properly. But if you were crawling out of the car or jostling the car at all, I think some fuel will leak. Probably not a big deal, so long as the line is inside the frame. I was considering bringing the line up the frame further and putting a filter on the end.

Gonna have to test it some more. Gas cap did not have much pressure, just a little. But I didn't have much of an issue with that before either.

 

[Beasy]

Got the new rollover valve installed today. Put it in the section of vent line located vertically behind the wire loom cover plate with rectifer attached to it.

You have to remove two 10mm bolts and a screw to remove the plate and let it hang downward. Mark the spot on the vent line about 1.25 -1.5 inches below the clip. Then pull the vent line from the plastic clips and from the frame. Pull the vent line out far enough to cut it squarely at the mark. Then push the barbed ends valve into the vent line. Then put the vent line and clips back in place making sure the valve has the large end up, so it's vertical. Then put the cover back on and snug fasteners.

I took a 5-6 mile ride and the wind was swirling some. I still got a couple whiffs of fuel when I was going slowly, but I would say it was noticeably less and most of the time I did not smell it.

So removing the OEM valve made a pretty big difference in intensity of smell and this new valve almost eliminated it. To be honest, I'm am not sure why this valve would stop fumes, as air will flow relatively easy both directions same as with out a valve at all.

I tested the valve upside down with water some water from.a syringe. It would let a little water pass through, but mostly sealed. The slightest amount of jiggling of the ball inside the valve would drain water easily. So I think if you're upside down, it'll mostly stop flow if the ball seals properly. But if you were crawling out of the car or jostling the car at all, I think some fuel will leak. Probably not a big deal, so long as the line is inside the frame. I was considering bringing the line up the frame further and putting a filter on the end.

Gonna have to test it some more. Gas cap did not have much pressure, just a little. But I didn't have much of an issue with that before either.

Hey AXE . I put the rollover valve in and I'm starting to think it's not the problem completely, something is telling me it's the overflow valve vent line, I believe fuel is easily being push out and running down the frame , especially on a full tank. Experienced this yesterday, it was bad !! But got way better when tank was half full. I'm no expert, but riding trails and sloshing it around may push the fuel out . I noticed when I go up a trail pretty quick bouncing off rocks, when I get to the top it's rough on fuel smell. Then after a bit it kinda goes away, thinking fuel leaks out strong smell , then evaporates from it's location on the frame area and gets better, and just repeats . Idk need to figure this out, nearly killed 3 of my passengers yesterday , I told them not to light a cigarette

 

[AXE]

Hey AXE . I put the rollover valve in and I'm starting to think it's not the problem completely, something is telling me it's the overflow valve vent line, I believe fuel is easily being push out and running down the frame , especially on a full tank. Experienced this yesterday, it was bad !! But got way better when tank was half full. I'm no expert, but riding trails and sloshing it around may push the fuel out . I noticed when I go up a trail pretty quick bouncing off rocks, when I get to the top it's rough on fuel smell. Then after a bit it kinda goes away, thinking fuel leaks out strong smell , then evaporates from it's location on the frame area and gets better, and just repeats . Idk need to figure this out, nearly killed 3 of my passengers yesterday , I told them not to light a cigarette

LOL.......I think your right in some respects. Before I messed with the lines and valves it definitely smelled like raw fuel and was getting pretty strong in the last 100 miles, especially since ambient temps are over 90+F. Didn't start until I had 600 miles or so on clock.

Mine seems to be random in occurrence. But one of the most consistent things I've noticed is that when I run around my neighbood the smell is the worst in the first 300-1000 feet after leaving my driveway. Always hits after I make my first left turn. Doesn’t smell at all in the garage when off or idling to warm up. I stood behind it the other day and doesn't seem to be from the exhaust. I might pull my driver's seat and verify that line is good. It seemed.to pass air through lines into the tank, so not sure it has anything to do with it. But previously I had only pulled the passenger seat base.

I definitely think that pulling the line from frame and running it up behind into the cargo space with a filter on the end might be the next thing I try.

 

[Beasy]

Got the new rollover valve installed today. Put it in the section of vent line located vertically behind the wire loom cover plate with rectifer attached to it.

You have to remove two 10mm bolts and a screw to remove the plate and let it hang downward. Mark the spot on the vent line about 1.25 -1.5 inches below the clip. Then pull the vent line from the plastic clips and from the frame. Pull the vent line out far enough to cut it squarely at the mark. Then push the barbed ends valve into the vent line. Then put the vent line and clips back in place making sure the valve has the large end up, so it's vertical. Then put the cover back on and snug fasteners.

I took a 5-6 mile ride and the wind was swirling some. I still got a couple whiffs of fuel when I was going slowly, but I would say it was noticeably less and most of the time I did not smell it.

So removing the OEM valve made a pretty big difference in intensity of smell and this new valve almost eliminated it. To be honest, I'm am not sure why this valve would stop fumes, as air will flow relatively easy both directions same as with out a valve at all.

I tested the valve upside down with water some water from.a syringe. It would let a little water pass through, but mostly sealed. The slightest amount of jiggling of the ball inside the valve would drain water easily. So I think if you're upside down, it'll mostly stop flow if the ball seals properly. But if you were crawling out of the car or jostling the car at all, I think some fuel will leak. Probably not a big deal, so long as the line is inside the frame. I was considering bringing the line up the frame further and putting a filter on the end.

Gonna have to test it some more. Gas cap did not have much pressure, just a little. But I didn't have much of an issue with that before either.

Hey AXE . I put the rollover valve in and I'm starting to think it's not the problem completely, something is telling me it's the overflow valve vent line, I believe fuel is easily being push out and running down the frame , especially on a full tank. Experienced this yesterday, it was bad !! But got way better when tank was half full. I'm no expert, but riding trails and sloshing it around may push the fuel out . I noticed when I go up a trail pretty quick bouncing off rocks, when I get to the top it's rough on fuel smell. Then after a bit it kinda goes away, thinking fuel leaks out strong smell , then evaporates from it's location on the frame area and gets better, and just repeats . Idk need to figure this out, nearly killed 3 of my passengers yesterday , I told them not to light a cigarette

LOL.......I think your right in some respects. Before I messed with the lines and valves it definitely smelled like raw fuel and was getting pretty strong in the last 100
Ikez especiallysince ambienttemps are over 90+F.. Didn't start until I had 600 miles or so on clock.

Mine seems to be random in occurrence. But one of the most consistent things I've noticed is that when I run around my neighbood the smell is the worst in the first 300-1000 feet after leaving my driveway. Always hits after i make my firts left turn. Doesn’t smell at all in the garage when off or idling to warm up. I stood behind it the other day and doesn't seem to be from the exhaust. I might pull my driver's seat and verify that line is good. It seemed.to pass air through lines into the tank, so not sure it has anything to do with it. But previously I had only pulled the passenger seat base.

I definitely think that pulling the line from frame and running it up behind into the cargo space with a filter on the end might be the next thing I try.

I plan on removing everything around the fuel tank , make sure nothing is pinched or cut etc . Tighten down fuel pump bolts possibly bad sealing. Literally just walked over to the passenger side door and opened it up and smelled fumes, it's been sitting overnight not running on the trailer here at campground, so something is definitely going on .I'll keep you posted!!

 

[AXE]

Hey AXE . I put the rollover valve in and I'm starting to think it's not the problem completely, something is telling me it's the overflow valve vent line, I believe fuel is easily being push out and running down the frame , especially on a full tank. Experienced this yesterday, it was bad !! But got way better when tank was half full. I'm no expert, but riding trails and sloshing it around may push the fuel out . I noticed when I go up a trail pretty quick bouncing off rocks, when I get to the top it's rough on fuel smell. Then after a bit it kinda goes away, thinking fuel leaks out strong smell , then evaporates from it's location on the frame area and gets better, and just repeats . Idk need to figure this out, nearly killed 3 of my passengers yesterday , I told them not to light a cigarette

I plan on removing everything around the fuel tank , make sure nothing is pinched or cut etc . Tighten down fuel pump bolts possibly bad sealing. Literally just walked over to the passenger side door and opened it up and smelled fumes, it's been sitting overnight not running on the trailer here at campground, so something is definitely going on .I'll keep you posted!!

Yes, I think the fuel in the tank heats up and may be boiling and pushes the vapors out the vent line, where it turns back into condensation in the vent line and then may be discharged into the frame like you said. I agree, there may be a leak around the fuel pump housing or perhaps somewhere else in the tank.

Still not sure why mine just started doing it recently. I did run in some warmer weather last fall when I got it early September, so don't think it is just the ambient temps being higher.

 

[Beasy]

Yes, I think the fuel in the tank heats up and may be boiling and pushes the vapors out the vent line, where it turns back into condensation in the vent line and then may be discharged into the frame like you said. I agree, there may be a leak around the fuel pump housing or perhaps somewhere else in the tank.

Still not sure why mine just started doing it recently. I did run in some warmer weather last fall when I got it early September, so don't think it is just the ambient temps being higher.

Definitely wild on why now ! Only thing I done differently is just added different tires on and rollover valve. With a little over 1,1,00 miles on it . Weather could possibly change the elements of all what's going on , just having the right conditions. But I still think it's something that we will find physically and be able to repair

 

[AXE]

Definitely wild on why now ! Only thing I done differently is just added different tires on and rollover valve. With a little over 1,1,00 miles on it . Weather could possibly change the elements of all what's going on , just having the right conditions. But I still think it's something that we will find physically and be able to repair

You running a windshield? Coincidentally, mine started smelling after I installed a windshield even with the vents open. Took it off for a while and it didn't seem to make a difference. Its back on now, but might take it off for summer.