[Odey1979]

Ok so I’ve been trying to track down this fuel smell for awhile now. First noticed it when I was working in the garage with the door open. Had to rule out many possible sources. Gas cans, snowblower, my truck ect...  unloading my zforce last night I caught it again a little bit. Seemed strongest in the right front corner. No sign of a leak yet and can’t seem to track it down yet. Is there a vent hiding in that area somewhere that I haven’t seen yet?  Is this somewhat normal as it’s not very strong and no one else in the house seems to notice it?  It’s driving me nuts and I must look like a moron moving all my stuff around the yard then walking to each thing sniffing away lol.

[NMKawierider]

Ok so I’ve been trying to track down this fuel smell for awhile now. First noticed it when I was working in the garage with the door open. Had to rule out many possible sources. Gas cans, snowblower, my truck ect...  unloading my zforce last night I caught it again a little bit. Seemed strongest in the right front corner. No sign of a leak yet and can’t seem to track it down yet. Is there a vent hiding in that area somewhere that I haven’t seen yet?  Is this somewhat normal as it’s not very strong and no one else in the house seems to notice it?  It’s driving me nuts and I must look like a moron moving all my stuff around the yard then walking to each thing sniffing away lol.

Two places it usually happens on a Z. The first and most often is the retainer ring for the fuel pump on top of the gas tank is loose. over 60% of them from the factory are loose or not tight enough. Pull the passenger seat and you will see it. With a blunt object and hammer tap the ring tight...yes.."righty-tighty". Be aware its plastic so don't over do it. The next thing that happens is...and not often but it did on mine...was from over filling and getting the tank check valve wet a lot, the disk warps and won't seal any more. This lets gas shoot up the vent tube and they have it sticking in a hole in the frame...so it fills the frame tube with gas and stinks for a long time. I have a how-to on installing a secondary check valve on that line to fix that issue.

Anyway after taking the seat out you will see this. Its that large ring you want to tap-tight. Go easy. Yours won't have that cut-out piece like mine. I did that so I could remove the fuel pump without removing all that plastic sections.

[Odey1979]

Sounds like a good place to start thanks. I will get into it this weekend and see what I come up with.

[Odey1979]

Well I looked into it and since its under warranty I asked the dealer about it too. They confirmed it was a common thing for the fuel pump ring to be to loose. I was in there getting a service manual which they were nice enough to hook me up with. I did find a little bit of residue around that ring and was able to tighten it by hand so I'd say thats obviously to loose. Tightened it ever so gently with a massive hammer lol. No but really just just tapped it tight with a small hammer and brass punch. Being plastic I went easy and I'll keep an eye on it for awhile now. Thanks again. may not have caught that one as easy unless I happen to pull the seat while it was still wet.

[2themax]

Hello,

I've had my Z800 for a little over a month and on the last few rides, when I fill the tank, we notice a fuel smell in the cabin. It seems to go away when the tank is Half and below.
I have removed the seat many times to look for fuel, but never see any... It also sits in my basement when not being used and have not seen any fuel on the floor as described by other riders.

Where is the overflow vent you mention located so I can check out this issue ?

Thanks

[NMKawierider]

Hello,

I've had my Z800 for a little over a month and on the last few rides, when I fill the tank, we notice a fuel smell in the cabin. It seems to go away when the tank is Half and below.
I have removed the seat many times to look for fuel, but never see any... It also sits in my basement when not being used and have not seen any fuel on the floor as described by other riders.

Where is the overflow vent you mention located so I can check out this issue ?

Thanks

99.9% of the time the retainer ring that holds the pump assembly in is loose. Hundreds of Zs have had this. Just take the passenger seat out and you can see it on top of the tank. With a blunt object and hammer tap the ears on either side and tighten." Righty-Tighty". Remember it is plastic so make it good and tight..just not enough to break it. The only other thing is the tank vent check valve. If you ever loosen the gas cap after a hot ride and there is NO pressure, then the check valve is stuck open and if so, it will send fuel up the vent tube and into a hole in the frame where they terminate it. It will fill a part of the frame with gas and smell..a lot. Mine did that. I added a secondary check valve on mine to fix that. There is a how to in the how too section for that. Good luck.

[2themax]

Just had my first service, and you would think the dealership would check this if it is a common problem. A friend of mine bought the same machine 2 weeks after me and his doesn't have the same issue.
I will check on these 2 areas,

[aganarr]

My zForce 800 I just got was leaking fuel from the ring after a fill up.  I, too, noticed the retaining ring was a bit loose.  A good snug hand tightening is all it took.

[MIcftrail]

Noticed the same gas smell and I was able to confirm it's coming from around the ring that secures the gas sender unit. I tried tightening it by hand and it was not really loose but when turning the ring, the entire cap is turning. I didn't want to break any of the little plastic barbs that the hoses are hooked to and decided to gain better access to the area, plus I'm not sure if the gas leaks there or maybe somewhere else around that spot. I started pulling plastic grommets and screws and wow, that's a lot to take apart! Two questions: Anyone has a service manual to share for a "22 without the wet clutch? Where can I get some of those pesky plastic grommets cause I broke a few already. Is there a tool for easier removal? Thanks in advance!

[NMKawierider]

Those push-pins are 7.5mm but you can get the 8mm for cheap at Amazon and they work fine. I'll provide links below also for a decent push pin removal tool. Also I had the same problem but decided instead pf taking all that plastics off to make a removable piece so I could get at it any time I needed. Pics are also below. On a side note, I also had a stuck-open tank vent check valve that let gas run up the vent hose and dump into the frame where they have it stuck into. That also made for a very intense gas smell. That check valve is built into the tank and can't be replaced so I installed a secondary check valve on the vent line. I also added a filter ahead of it so any dust particles wouldn't get pulled in and screw-up the new check.

https://www.amazon.com/GOOACC-Fastener-Automotive-Furniture-Expansion/dp/B0040CYWX0/ref=sr_1_5?crid=M8KV065CO187&dib=eyJ2IjoiMSJ9.0TkfD0ULyazEbKHZTt076Az-3ZF1P6fVhR_B-Aur74J6efCm2_2pOOob-kUlF1zVp9Ik5gW-r93b6wEls2oAtBNcExfl5RtO3RbNyqkOS4h12_AkejELAwct1L1iMENsaaomsj_Ow_Ddb1UuX0fNmVho__GTtap-P5aMd6c4txEtm2-Zh0RgqI6tS5fYtSU8Vy5BO0bLSyw5cl2YhVByWPYvPiNiN6RRIpWE3-KOMHM.uiDITi5qB-BRK_rzIRLSYYrLfFR1D4u1a1ZprZyp91M&dib_tag=se&keywords=8mm%2Bpush%2Bpins&qid=1708454402&sprefix=8mm%2Bpush%2Bpins%2Caps%2C174&sr=8-5&th=1

https://www.amazon.com/ABN-Push-Pin-Remover-Tool/dp/B074P7NZX3/ref=sr_1_8?crid=3IB5HTG8KKIC2&dib=eyJ2IjoiMSJ9.Hr8bFt-QjZfBUEUFGymgmdz-jVWwbzfsIRzBnf1aQA079LU5sBmGgFOJYBeigXfo_b6QYRqbJczeWnlSHhUDHI09G-n2uhluAo3uA-WKSubqrJPbsAIE4rHtFbdGpzUp4rAsJC9e7SBPam7AmkJePntq9CylXRU2yhWx7tjvROzh0Hj6pkpQuYIrbY7UyBYFwciUI_fcNLgAiK4jsfbrR17U6JqfNHvwHSXaVhCXvmsN8Zn6bncbQh3IswT6BSgO4fBVynCiUHLtHEpAvGPLu8qh19p0gLtN84ByW9usDU4.Y5d9HLyJyL0cZHWweF_1ccspHAVBxqaeD5P1Xcc6jfM&dib_tag=se&keywords=push+pin+tool&qid=1708454449&sprefix=push+pin+tool%2Caps%2C151&sr=8-8

[MIcftrail]

After removing plastics to gain access from the side , I was able to use a strap wrench and I got about a quarter turn out of the ring. I can't see any more leaks right now and I guess I will have to wait for a hot summer day with a full tank of gas to really prove it out. Also they should have offset or angled the hose fittings on that top sender unit, there's a lot of strain on them hoses.
The push pin removal tool really works and it saved me a lot of time and anguish removing the panels but the replacement push pins from Amazon were slightly undersized and they were popping out without pulling the pin. I measured the OE pins and we need a 8.5 mm  pin to do the job.

[NMKawierider]

That weird on the pins but good to know. Apparently CFM has changed the size from 7.5 to 8.5mm after some year...lets call it 2020.

[jteam]

Ive tightened my '15's fuel pump and added the one way valve and the fuel smell is still present.

[NMKawierider]

Ive tightened my '15's fuel pump and added the one way valve and the fuel smell is still present.

Assuming the check valve is in the right direction, remember it has to let air in..not out, have you inspected everywhere for wet fuel? If so and found nothing I would have to thing the problem is somewhere out of sight...like maybe a crack in the top of the tank.One other place to look is the cage on the bottom of the passenger side. It "protects" the bottom outer edge of the fuel tank but gets bashed-in with about anything that hits it. Before I installed my belly plates I had to reach through and bend it back away from the tank because it was already against it. That could either crack it or wear into it over time. Something to look at anyway.