1987 GL1200 Fuel Petcock - I Found a Rebuild Kit ! ! !
I found a rebuild kit for the one-year-only 87 GL1200 fuel petcock that works!!! :laugh:
It's installed on my '87 GL1200 and is working and not leaking! :laugh:
In case you don't already know, the 87 GL1200 petcock is a one-year-only petcock that was not put on any other Honda motorcycle. It is no longer available from Honda nor is there a rebuild kit for it that fits... until now!
Some history on the issue: The 1987 fuel petcock (PN 16950-ML8-601) is a different part than the fuel petcock (PN 16950-MG9-005) for a 1984, 1985, or 1986 GL1200. The fuel outlet on the 1987 petcock is 3/8" (10mm fuel hose), while the fuel outlet on the 84, 85, 86 is 1/4" (5.5mm fuel hose). The distance between the mounting screw holes is different: the 1987 petcock mounting holes are approximately 46mm apart,while the 84, 85, 86 petcock mounting holes are about 42mm apart. So they won't mount on an '87 fuel tank and vice-versa. The entire body of the 1987 fuel petcock is larger than an 84, 85, 86 fuel petcock. The 1987 petcock body diameter is 32mm. The 84, 85, 86 petcock body diameter is 28mm. The 4-hole gasket (PN 16955-268-020) that comes in a rebuild kit for the 84, 85, 86 fuel petcock is only 20mm in diameter... way too small for the 87 petcock, and the fuel transfer holes in it are too small as well.
I did some research and found out that there is a fuel petcock rebuild kit for some Honda ATVs that fits the 87 GL1200 fuel petcock and can be used to rebuild it.
The fuel petcock rebuild kit that works is for 1986-1989 TRX350 and 1989-1990 FL400R ATVs. The kits are made by Mikuni (the carburetor manufacturers) and they are available on eBay from various sellers. Here's the seller that I bought mine from:
Here are some pictures of the kit contents and the gasket installed in the petcock body.
The first picture shows the contents of the ATV petcock rebuild kit.
The second picture shows original 87 petcock gasket and the replacement petcock gasket that comes with the ATV petcock kit. As you can see, the OD of the original gasket (on the left) is slightly larger than the replacement gasket (on the right). But, the 4 holes are exactly the same size and the same distance apart, so it fits perfectly inside the petcock body.
The third picture shows the original 87 GL1200 gasket in the petcock body.
The fourth picture shows the ATV replacement gasket installed in the 87 GL1200 petcock body.
As you can see, it fits right on the four holes. It doesn't extend to the full ID of the petcock body, but it doesn't need to. It is held very firmly in place by the raised edges around the four hole towers in the body, and the sealing surfaces line up perfectly with the sealing surfaces on the bottom of the top piece of the valve body (the part with the lever on it that you use to turn the valve on and off).
So, you now have a kit you can use to rebuild your leaky 87 GL1200 fuel petcock!
NOTE: The 87 GL1200 fuel petcock was not meant to be rebuilt and is assembled with rivets not screws. So, yes, you have to drill out the rivets that hold the fuel petcock together to get it apart and then drill and tap the holes for the screws that come with the kit, but that is not that hard to do.
What do I win! :wink2:
How does the o-ring fit the top?
It is not a square profile o-ring like the original Honda o-ring, but a standard round profile o-ring.
It has a large enough profile so that it fits very tightly inside the body of the petcock when the valve top half its installed on is inserted into the body. It's a good tight fit and makes it a pretty stiff effort to rotate the valve from on to off. As the o-ring seats in with use, it will most likely loosen up a bit.
One other thing I learned is something that I suspected was correct. The main body OD o-ring will NEVER see gas unless the 4-hole gasket is leaking. If the 4-hole gasket is holding, no gas ever enters the main valve housing. Gas is either blocked off (OFF position) or sent through to the carbs (ON position), but gas never leaks internally into the petcock body unless the 4-hole gasket fails. The big main valve body o-ring is basically a fail-safe device to prevent gas from pouring out of the valve and onto the engine should the gasket spring a leak.
Interesting. Never thought of it that way but it seems feasible.
I have a couple spare units so I will be putting a kit in one of them soon.
For the space left because the gasket is smaller, couldn't you simply put a o-ring in there to fill the gap? Looks like one the same size as the one supplied would fit .
No, do not try to wedge an o-ring in there around the 4-hole gasket.
First, there is no need for it. The gasket is held very firmly in place in the valve body by the raised edges around each of the four holes. It sits in there tight as a duck's butt!
Second, if you do try to wedge an o-ring in there around the 4-hole gasket you run the risk of losing the seal of the 4-hole gasket and the valve will leak. Reason: any o-ring you put in there might be just a tad thicker than the 4-hole gasket. If it is, it will prevent the proper pressure from being applied to the sealing edges on the gasket when the valve is reassembled, and you'll get a leak. If it's too thin, it might wiggle around in place and end up causing the same problem.
The 4-hole gasket sits in there just fine without any other assistance. It seals and doesn't leak.
Cleaned out the bad picture posts, all are now viewable from the WingMan71's new Imgur.com account.
Awesome work, thank you. This is now a Sticky
Brilliant! Thanks for doing the research and providing us with the answers. I have an '87 Aspencade and the petcock just started leaking a little - right after I replaced the fuel filter and hoses between the petcock and filter but I'm sure my prying on the 30 year old hoses had nothing to do with it.
I did some searching around the interweb and couldn't find a GL1200 petcock rebuild kit. Now I know why.
Great to discover someone else already solved the problem.
Now I just hope the hosting account for the photos is kept up so this great write-up will be available for years to come.
Before i got my 87 Wing from the previous owner (last Monday) i was piling up infos and knowledge just to be ready to start the resto asap...
I found your article about the petcock...
Guess what I did first thing when I put my hands on the bike? You got it... tried the petcock and sure enough it was pouring gas on the OFF position...
Right there I told myself this guy deserves to go to paradise just for his find... 😉
I'll tell you, when it happened to my '87 and I started looking around for a petcock rebuild kit I immediately found out all the things stacked against my efforts (1-year only petcock, etc.). I thought I was doomed to never ride my '87 Gold Wing again.
I'm stubborn and refused to give up so I just kept looking and searching on the Internet until finally about a month later I was able to find this rebuild kit that works.
Why aren't we riding! :laugh:
there are no guarantees that Imgur.com will stay alive forever, we saw what happened to PhotoBucket.... I lost over 10,000 pictures there when they changed to a "for profit" Stealership format....
Would you please create an Album and name it '87 Petcock Repair
then upload the same photos to your new album,
then link to those photos again in a new post... in this thread
just label the photos appropriately as #1, #2, etc. so they can be referenced back to your original post.
nothing like having some insurance available.
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