Fuel Smell in Cabin

[AXE]

Yes, and a full enclosure. And rear windshield. I went on many rides with fully enclosed and never smelled fuel . Something is definitely leaking, no way it went from no fuel smell to fuel smell without a leak from a cut line or loose fitting or fuel pump . I'm ok with those options, it's the unknown if those aren't the case!!

Yep, I think we'll get to the bottom of the issue. But in our cases, it started after ru ning a while.

I know others have been dealing with pressure build up in the tank, vapor lock, no start/run due to low fuel flow, and gas burping out the tank. I've never seen those issues, just the smell.

 

[Beasy]

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.

Running front and rear windshield and full cab enclosure. I'm not sure what the torque specs are on the fuel pump cover, but I turned all bolts down probably a good full turn , they definitely wasn't tight at all. I put the vent valve back on as well , air pushes through it with air compressor, so I know it at least works. Imagine I'll build up pressure again in tank . Plus I have the rollover valve inline as well. Guess will find out what happens!!! BTW I didn't notice any vent hose cut or pinched. I found where the vent line goes into on the frame, passenger side right behind the door latch into the tubing.

 

[AXE]

I didn't try to tighten my fuel pump bolts, but didn't see evidence of leaking or fuel smell. I also pushed air through the tank with opposite corner lines removed and cap off. The lines definitely moved air easily.

I did a ride this morning to take my dog for a run and it was completely calm and cooler out. Very little fumes today.

 

[AXE]

I didn't try to tighten my fuel pump bolts, but didn't see evidence of leaking or fuel smell. I also pushed air through the tank with opposite corner lines removed and cap off. The lines definitely moved air easily.

I did a ride this morning to take my dog for a run and it was completely calm and cooler out. Very little fumes today.

I'm starting to think that the vent line might be undersized for the pressure. I think both tank corners are pushing fumes and it should have had a larger line after the junction of the two tank lines.

I was also thinking about venting my cap and running a line off it. Like the dirt bike gas caps.

Seen a guy on Facebook say he relocated his vent line from the frame behind the seat to the back of car and it worked by just adding some more line to get it away from cabin

 

[Beasy]

I'm starting to think that the vent line might be undersized for the pressure. I think both tank corners are pushing fumes and it should have had a larger line after the junction of the two tank lines.

I was also thinking about venting my cap and running a line off it. Like the dirt bike gas caps.

Seen a guy on Facebook say he relocated his vent line from the frame behind the seat to the back of car and it worked by just adding some more line to get it away from cabin

Definitely a good possibility on vent line size !! I'm not really sure on doing the vented gas cap , your passenger will get hit first with the fumes! Then you will most likely have too much venting in the cab . Unless you plan on running a line through you skid plate and let it hang towards the ground, I'd be afraid of going through water and it running up into the fuel tank or even getting clogged by mud etc . Running it to the back isn't a bad idea, thinking run it all the way to the tail lights and make a shield or something that keeps water and debri from getting to it .

 

[AXE]

Definitely a good possibility on vent line size !! I'm not really sure on doing the vented gas cap , your passenger will get hit first with the fumes! Then you will most likely have too much venting in the cab . Unless you plan on running a line through you skid plate and let it hang towards the ground, I'd be afraid of going through water and it running up into the fuel tank or even getting clogged by mud etc . Running it to the back isn't a bad idea, thinking run it all the way to the tail lights and make a shield or something that keeps water and debri from getting to it .

If I vented the cap, I would run the line to the back. I feel like the space behind air intake and cvt intake is a nice spot for relocating the vent lines. There is a little covered space and that would protect the line and I'd put a filter on the end.

 

[AXE]

I had some 1/4 inch clear poky line in my garage, so I extended the vent line and ran it up to the cage, behind the CVT air inlet, and back down the cage and just let it hang off my tool box at the very back of the sxs. For the most part, this resolved the fuel smell in my cabin. But need to test for some longer runs to be sure. Also ambient temps were only low 70s, so not the same as previous rums.

I think I will get some actual fuel line and a small breather filter and locate it along the upper subframe and tie it off where the rear cage comes out the bed of the sxs.

So my final conclusion is that this tank builds a lot of pressure quickly and the OEM vent valve isn't functioning well enough to let fumes escape under light pressure. So it pushes hard enough to get past the valve and then spits out the vent line into the frame where it's condensed as it cools to raw fuel and you get the heavy gas smell.

The aftermarket rollover valve works better to allow gas tank pressure to vent easier (both directions) and solves majority of the issues. Relocating the vent line away from the cabin and people seems to address the residual fumes that can accumulate when the tank heats up during normal operation and pushes some fumes through the vent line.

It may be worth doing the extension and reroute of rhe vent line out the back before you remove the OEM valve. It's much easier to access and you valve may be working normally. You may not need the replacement rollover valve.

 

[Beasy]

I had some 1/4 inch clear poky line in my garage, so I extended the vent line and ran it up to the cage, behind the CVT air inlet, anf back down the cage and just let it hang off my tool box at the very back of the sxs. For the most part, this resolved the fuel smell in my cabin. But need to fo some longer runs to be sure. Also ambient temps were only low 70s, so nonthe same as previous rums.

I think I will get some actual fuel line and a small breather filter and locate it along the upper subframe and tie it off where the rear cage comes out the bed of rhe sxs.

So my final conclusion is that this tank builds a lot of pressure quickly and the OEM vent valve isn't functioning well enough to let fumes escape under light pressure. Sonit pushes hard enough tonget past the frame and then splits out the vent line into you frame where it condensed to raw fuel and you get the heavy gas smell.

The aftermarket rollover valve works better to allow gas tank.pressure to vent easier and solves majority of the issues. Relocating the vent line away from the cabin and people seems to address the residual fumes that can accumulate when the tank heats up during normal operation and pushes more fumes through the vent line.

It may be worth doing the extension and reroute of rhe vent line out the back before you remove the OEM valve. It's much easier to access and you valve may be working normally.

A lot good information . Ok gotcha on running a line off of fuel cap and run to the back. My only issue with the factory pressure release valve is that it makes the fuel cap a bitch to get off lol. I'm definitely going to do like you did on running the vent line to the rear. I agree on the condensed to raw fuel and getting hit with all those heavy fumes.

 

[AXE]

After some more testing, I've decided that running a new fuel line from the outlet end of the new rollover valve up to the frame and out by the rearmost mount for the cage (need about 3.5 feet of line). Then I put a small breather filter on the end of the fuel line and tucked it out of the way under the cage to give it a little protection from heavy mud and water.

This fix seems to work about 95% and it should be relatively safe from fuel leakage. I am still getting some fumes that occur within the first 300-1500 feet of travel and then they seem to disappear. Never get any fumes at start up or idle, maybe just a hint of fumes occasionally when running harder.

My theory is that the vapors coming from the tank are heavy after some run time. When you shut off the car, they continue to flow until the fuel cools down. The vapors condense and are then trapped in the line. When the fuel warms again, pressure builds quickly, and all that residual in the lines pushes out heavily. Then the system normalizes and you don't get many fumes when running.

Also, l left my OEM line in the cage and behind that cover. That way if Kawasaki ends up with some better fix, I can covert it back quickly with just a new 1/4 inch barb.

 

[Sand Shark]

Hopefully that works.

 

[Beasy]

After some more testing, I've decided that running a new fuel line from the outlet end of the new rollover valve up to the frame and out by the rearmost mount for the cage (need about 3.5 feet of line). Then I put a small breather filter on the end of the fuel line and tucked it out of the way under the cage to give it a little protection from heavy mud and water.

This fix seems to work about 95% and it should be relatively safe from fuel leakage. I am still getting some fumes that occur within the first 300-1500 feet of travel and then they seem to disappear. Never get any fumes at start up or idle, maybe just a hint of fumes occasionally when running harder.

My theory is that the vapors coming from the tank are heavy after some run time. When you shut off the car, they continue to flow until the fuel cools down. The vapors condense and are then trapped in the line. When the fuel warms again, pressure builds quickly, and all that residual in the lines pushes out heavily. Then the system normalizes and you don't get many fumes when running.

Also, l left my OEM line in the cage and behind that cover. That way if Kawasaki ends up with some better fix, I can covert it back quickly with just a new 1/4 inch barb.

I'm going to try this , works on vehicles!

 

[AXE]

I'm going to try this , works on vehicles!

You can get those Chinesium K&N filters on Amazon for $7.

 

[Beasy]

You can get those Chinesium K&N filters on Amazon for $7.

Thanks for heads-up, I haven't ordered anything yet, just trying to figure out which setup I'm going to try. I did find a cheaper vapor canister on Amazon earlier today at work.

 

[AXE]

Lately I've had no fuel smell at all. Just another observation after running the last few rides with less than 1/2 tank of fuel. Temps have been pretty warm between 90-100F. I'm probably around 1/3 tank today based upon mileage. So if you're experiencing heavy fuel smell and can operate with less than 1/2 tank, it might be worth trying until there's a reliable warranty fix.

 

[Sand Shark]

Lately I've had no fuel smell at all. Just another observation after running the last few rides with less than 1/2 tank of fuel. Temps have been pretty warm between 90-100F. I'm probably around 1/3 tank today based upon mileage. So if you're experiencing heavy fuel smell and can operate with less than 1/2 tank, it might be worth trying until there's a reliable warranty fix.

I was out in Barstow this weekend and it was in the upper 80s and low 90s. I never had any fuel smell in the cab. I had passengers in my car at different times and no one said they smelt fuel. Also noticed this time when I removed the gas cap it did not release any pressure like it has in the past in the dunes.

 

[Beasy]

I removed factory pressure valve and installed the rollover valve, went on a couple big rides including windrock. Ran vent line to the rear. I took a pretty sturdy fuel tank and added a connector to it so I can run vent line to it . I keep the vent off the fuel tank barely cracked open. It's not the permanent fix I want , but it did great !! No fuel issues or pressure problems.