Fumes coming from fitting

[Tom T]

Hello all,

A brief synopsis of my problem.

For the last three months when I shut down my FXDXI, 1600 miles on it. After a run I park it in my garage. After a while I smell a strong oder of gas. This gas oder seeps through the whole house.

I took it to the dealer. After removing the gas tank checking all connections and pressure testing, installing it back onto the bike and let it sit for a day they could not find any leaks.

I took the bike back home and the fumes where still coming from somewhere.

So I checked all the above the dealer did. I found where the fumes are coming from. All late model Harley's with EFI have a chrome quick connect fitting under the fuel tank on the left side with a hose going to the throttle body. (Check out photo) The fumes are coming form the fitting. No liquid is leaking just fumes.

Yesterday I took the bike back told them where the fumes are coming from. The said they can't smell anything. I'm standing there and I can smell the fumes. They won't switch out the fitting because no liquid is leaking.

Well guys the liquid is not what ignites it's the fumes. I told them this they said the fitting has to be defective in order to change it. They will change it but not under warranty. They said that I could leave it and have a factory rep look at it. #1 I'm not paying for this out of my pocket. #2 how long will my bike be laid up at the dealer? I still want to ride before the snow and salt hits the road. Plus we have a few toys for tots rides going on here in the next few weeks.

I took the bike back home again. Gas fumes again. I thought of something to try in order to find out whats going on here. Last night I took unscented tissue paper cut it to fit around the fitting and taped it tight. I left it over night. This morning I removed it, guess what? It smells of gas not wet but really strong smell of gas.

My question. The fuel in the tank is under pressure because of the EFI.

Can the fitting under pressure not leak liquid but push out fumes through the O-ring seals? I need a definite answer with some proof so I can bring it back to the dealer. Did this fume problem ever happen to anyone here?

Thanks, Tom

I want to clarify the position of my dealer. At the time of my first post I stated that my dealer would not fix this under warranty. I was wrong. The person at the counter that told me this was mistaken. They are doing everything possible to make me happy. They want to switch out the parts I think is the problem. I don't want to just switch out parts . I want to find what is causing the strong gas/fumes smell and fix it so it doesn't come back. The GM even offered to take the bike home and park it in his garage over night because they can't smell anything in the shop.

I just want to find what is causing this with minimal dismantling of the same parts on my bike. This is why I came here for your help.

Tom


Update: I disconnected the fuel line coupler and put some lithium grease on the O-rings. The gas oder stopped.

Now there seems to be another area I think the strong fumes are coming from.

To make a point the fuel tank right now has only 1 1/2 gallons of fuel in it. This oder happens no matter how much fuel in the tank.

There is Continuous venting system that the tank uses to vent gas if the tank is over filled. One of the valves/vent is connected to a pan at the tank under the console. I removed it and put some grease on the O-ring and plugged it back in. There is a hose connected to this valve going to another valve about 1" up from it. Another hose is connected to the other end, this hose goes down the side of the frame to another valve, right under the neck. A hose connected to this valve goes under the tank across the frame back under the seat and down the frame in front of the swing arm. This is where the excess gas/fumes discharges out to the ground.

Now the service manual I have only shows two valves. The one under the console 1" away form the first valve/vent with the O-ring it does not show.

After I plugged the vent back in after about a minute I removed it to see if I put enough grease on it. When I removed it the bottom of the valve and the end of the hose was wet with gas.
The tank only has 1 1/2 gallons of gas. I put everything back together and took the bike for a ride. Got back home parked it and closed the garage door. The $%^&%$ fumes are still smelling up the whole house. I went under the bike and put my finger on the end of the discharge hose and the end is damp and I can smell the oder of gas. This is what's making me
think this is the cause.

Did HD have problems with this and add another valve? The fuel lines have pressure inside, tank does not. Could the tank be building up pressure some how? I live in IL so heat is not the problem. Why is the first valve/vent wet. The bike is not running so no agitating of the fuel.

Thanks, Tom

[TXCHOP]

Sorry to hear of your problem. The only thing similar i have had happen to me was on my dads Glide. The bike smelled of gas for a couple days but did not leak. The next week we went out on a sunday, filled up and waited for the rest of our friends. We were in the parking lot bs ing and i looked at his bike and the gas was seeping from the inner fiitting to the t/b. I had to fly up to the local dealer and swap it in the lot. The new style has been redesigned with a clamp instead if the old molded on style.

[road_king]

The fuel in the tank itself is not under pressure, the fuel lines in the tank and outside the tank are. If the gas smell you notice is coming from the fuel line, I suspect that it is actually leaking, but not enough to drip, since it is evaporating before it has a chance to do so.

[Hey Joe]

My bike smelled like gas everytime I stopped for the first couple thousand miles. It just kind of went away and hasnt smelled since.

[route66paul]

The dealer knows, he just doesn't want to replace the fittings and fuel lines. Tell them that you wanted to have this on record before it caught fire. They'll fix it.

[04FXDLI]

seems to me i read about a sevice bulletin on the fuel line popping off at that spot they should fix it but then again i hope you dont store your bike near anything that has a pilot light

[Tom T]

Does anyone really want to know the outcome of my famous fume problem?

(Please read my last update on my first post if confused)

I let the dealer do their thing for a couple of weeks so not to be a pest.

I stopped by the dealer yesterday to see what they found out from the MOCO.
Well for starters the service guy doesn't work there anymore. So no one knew what I was talking about. Even though they all saw me there three days in a row, two weeks ago. Finely I got a guy to look up my name on the computer and pointed out to him the technician that worked on my bike.

He walked over to the tech. and talked to him for a while then he came back and told me to go over and talk to him.
I went over and asked him what the MOCO said. He said that the parts in question are not serviceable and the hoses, vents and top plate come as one assembly.

I said now what? He told me that MOCO will not warranty it because I took it apart and I broke it. I broke noting. The vent is pushed into the hole, twisted into place and sealed with an o-ring. If you look at the pics. you can see how the valve fits into the hole. The tech. said that their hands are tied. If the MOCO won't pay the bill they can't switch out parts. And I'm the one that told them what's causing the fumes. They never found the problem them selves.

SOooooo, when I bought the bike I purchased the Extended Service Plan thinking if something happens after the factory warranty expires (next March)I would be protected three more years. Well I went back today and canceled the plan.
They are going to prorate the stupid thing so what, at least they won't be keeping all my money.

With all this said and done I still have this fume problem.

TomT

[Tom T]

Hello,

Update: If you are new to this Thread please read my first post.

Yesterday I took my FXDX back to the dealer after a long winter, to replace the fuel vent system that was causing the gas fumes. I was told the the hoses, vents and the top plate was for a carburetor bike not an EFI one.
The fuel pressure was venting through the fuel cap and any other place it could escape.

The oder of gas fumes are gone and I hope this is the last thing the MOCO did wrong assembling this bike. Early on I also had a weeping problem. The dealer checked the oil pump alignment and then checked the heads and found out the MOCO forgot all the O-rings.

I want to thank my dealer, and especially my mechanic. (Would like to mention their names but I'm afraid they would receive an MOCO reprisal) He pressured the MOCO to investigate this venting problem. They had no clue how the venting system worked and by the way was going to fluff it off. But my mechanic said that he was going to talk to the big guy if they did not fix their mistake and ask why the techs did not know how the vent system works.

They checked it out and found they put in the wrong parts when my bike was assembled at the plant.

The moral of this story is, if you have a problem with your bike don't give in, stand your ground, don't let the service guys intimidate you and become best buds with your mechanic. He will still be working there way after the service guys are gone.

tomt

[Ridewv]

Yesterday I took my FXDX back to the dealer after a long winter, to replace the fuel vent system that was causing the gas fumes. I was told the the hoses, vents and the top plate was for a carburetor bike not an EFI one.

Interesting. I have been noticing gas fumes around my 2004, FXDXI especially when close to it. I take it I'll have to remove the tank to see if it was vented correctly for a FI?

[Tom T]

IronButt,

You don't have to remove the tank.

Just take the trim ring off the tank (Must take off the seat for the screw at the bottom of the tank.) and the fuel cap trim ring. You will see the vent tube and valves. Look at my photos from my post. If you see the same mystery valve you might have the wrong top plate like mine. The EFI setup has only one long tube from the frame neck to the valve in the top plate.

Do not remove the valve from the top plate it has a special sealant.

If you have the wrong setup you might get the MOCO to fix it. Don't try and fix yourself.

Do not try to tighten the screws on the top plate they have a special sealant on them and are torqued down (20 in-lbs), if they get broken loose they will leak. All the screws will have to be replaced.

Any problems let me know. Tom T

[Ridewv]

Look at my photos from my post. If you see the same mystery valve you might have the wrong top plate like mine. The EFI setup has only one long tube from the frame neck to the valve in the top plate.

Mine looks the same as far as I can see. That could explain the slight gasoline fumes I'm getting.

Rick

[Tom T]

Rick,

I'm going to show my mechanic this. I will get back with you soon.

Tom t

[Tom T]

Hello Rick,

You need to check if there is a tube attached to the bottom of the vent attached to the top plate. You have to take off the gas cap and look into the gas tank with a long handled mirror and a flash light.

If the tube is there all you have to do is take off that mystery valve and insert a plastic tube in the hose. Or replace the whole hose from the neck to the vent.

If you have no tube the top plate will have to be replaced. If you still have warranty tell the dealer about the problem they should fix it. If not still pressure them. Tell them these are the wrong parts. Print out my Thread and show it to them.

These parts aren't serviceable. They can't be bought separately so do not take that vent out of the top plate. This will give the dealer/MOCO an out not to fix.

Let me know what happens.

Tom t

[Ridewv]

Tom,

Thanks for your help. I'll look into it after work since I won't be riding. The sunny, 75 degree weather is being replaced with a friggen cold front bringing light snow and temps in the 20's-30's!

Rick