1987 GL1200 Fuel Petcock - one year only - HELP! - Steve Saunders Goldwing Forums

 2Likes
Reply
 
LinkBack Thread Tools
post #1 of 23 (permalink) Old 02-28-2018, 02:25 PM Thread Starter
Senior Member
 
WingMan71's Avatar
 
Join Date: Apr 2008
Location: Travelers Rest, SC, USA
Year: 2006
Make: Honda
Model: GL1800, GL1200, GL1000
Posts: 727
1987 GL1200 Fuel Petcock - one year only - HELP!

Has anyone actually taken the fuel petcock on a 1987 GL1200 apart and put a rebuild kit 4-hole disc and gaskets in it?

I'm trying to find out of they use the same rebuild kit parts as a 1984, 1985, and 1986 GL1200 fuel petcock. If they don't, we 1987 owners are just plain screwed if our fuel petcocks spring a leak.

Here's what I've found out so far:

The 1987 fuel petcock (PN 16950-ML8-601) is definitely a different part than the fuel petcock (PN 16950-MG9-005) for a 1984, 1985, or 1986 GL1200.

The obvious things that are different are:

1. 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). So the fuel hoses that fit are not the same. (Not exactly a deal breaker.)

2. 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.

3. 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. So, they are 4mm smaller.

The 4-hole disc (PN 16955-268-020) that comes in a rebuild kit for the 84, 85, 86 fuel petcock is 20mm in diameter. That's the issue that worries me. Will that disc fit in a 1987 fuel petcock properly, or is the 4-hole disc for a 1987 fuel petcock actually larger in diameter to fit the larger fuel petcock and flow more fuel?

I have a rebuild kit for an 84,85, 86 GL1200 that includes the 4-hole disc (PN 16955-268-020). The '87 fuel petcocks are riveted together and not designed to be rebuilt. (Though many other Honda petcocks are as well, but can be drilled out, rebuilt, and reassembled with screws. I've done many that way.)

If I take mine apart and the 4-hole disc doesn't fit, I'm basically screwed. NO one, and I mean NO one has a 1987 GL1200 fuel petcock for sale on planet earth. I've checked all of my many sources, including vintage bike parts suppliers and my "special" one in Norway.

So, has anyone successfully taken apart a 1987 GL1200 fuel petcock and rebuilt it using a rebuild kit for an 84, 85, or 86?


Thanks for any advice or experience on this issue.

***

Bob
2006 Arctic White GL1800
1987 Black/Grey GL1200 Aspencade
1976 Special Candy Maroon GL1000 LTD
U.S. Navy SWO (1967-1976)
WingMan71 is offline  
Sponsored Links
Advertisement
 
post #2 of 23 (permalink) Old 02-28-2018, 03:37 PM
Moderator
 
Bike...and Dennis's Avatar
 
Join Date: Feb 2009
Location: Glendale, Arizona, USA
Model: 1987 GL1200 Interstate 290,000 miles
Posts: 21,739
Yes, I took mine apart and rotated the 4 hole thingy. Plus I put plumber's tape in the outer seal groove to stop it from leaking.

And no, the 4 hole seal that you can buy will not fit the '87. '87 is much larger.

The biggest challenge is drilling out the stud things that hold the two halves together, then drilling and tapping for reassembly.

You can try and find a used part on eBay, too, just is case.

I used to have some pics but can't find them now.
siouxindian likes this.

Why ain't we ridin'?
Bike...and Dennis is online now  
post #3 of 23 (permalink) Old 02-28-2018, 04:13 PM Thread Starter
Senior Member
 
WingMan71's Avatar
 
Join Date: Apr 2008
Location: Travelers Rest, SC, USA
Year: 2006
Make: Honda
Model: GL1800, GL1200, GL1000
Posts: 727
Quote:
Originally Posted by Bike...and Dennis View Post
Yes, I took mine apart and rotated the 4 hole thingy. Plus I put plumber's tape in the outer seal groove to stop it from leaking.

And no, the 4 hole seal that you can buy will not fit the '87. '87 is much larger.

The biggest challenge is drilling out the stud things that hold the two halves together, then drilling and tapping for reassembly.

You can try and find a used part on eBay, too, just is case.

I used to have some pics but can't find them now.
Thanks much Dennis! I was hoping you'd chime in on this problem.

At least that confirms that the 4-hole disc for the earlier GL1200s will not fit. I suspected that might be the case.

Mine is only leaking when in the OFF position and that just started recently. She doesn't get ridden as much as she used to so things will start stiffening up! Hah! Don't I know it! Same thing is happening to me!

I thought about rotating the 4-hole disc 180 degrees since that would flip the two holes in the disc that are actually being used. I may have to give that a try.

For now, I just don't turn the petcock off and no leaks. But that means only your float valves are keeping the fuel from overfilling the carbs and running into the cylinders and possibly causing a hydro-lock on the next attempted start-up. That would be BAD!

Thanks for the reply. I'll have to decide if I want to open her up!

Bob

Bob
2006 Arctic White GL1800
1987 Black/Grey GL1200 Aspencade
1976 Special Candy Maroon GL1000 LTD
U.S. Navy SWO (1967-1976)
WingMan71 is offline  
Sponsored Links
Advertisement
 
post #4 of 23 (permalink) Old 02-28-2018, 04:27 PM
Member
 
cihilb's Avatar
 
Join Date: Mar 2009
Location: Natrona Hts, Pa, USA
Model: 2012 Pearl White
Posts: 391
Quote:
Originally Posted by WingMan71 View Post
Thanks much Dennis! I was hoping you'd chime in on this problem.

At least that confirms that the 4-hole disc for the earlier GL1200s will not fit. I suspected that might be the case.

Mine is only leaking when in the OFF position and that just started recently. She doesn't get ridden as much as she used to so things will start stiffening up! Hah! Don't I know it! Same thing is happening to me!

I thought about rotating the 4-hole disc 180 degrees since that would flip the two holes in the disc that are actually being used. I may have to give that a try.

For now, I just don't turn the petcock off and no leaks. But that means only your float valves are keeping the fuel from overfilling the carbs and running into the cylinders and possibly causing a hydro-lock on the next attempted start-up. That would be BAD!

Thanks for the reply. I'll have to decide if I want to open her up!

Bob
If you leave the petcock on and it doesn't leak, why can't you put an inline valve after the petcock?
cihilb is offline  
post #5 of 23 (permalink) Old 02-28-2018, 05:11 PM Thread Starter
Senior Member
 
WingMan71's Avatar
 
Join Date: Apr 2008
Location: Travelers Rest, SC, USA
Year: 2006
Make: Honda
Model: GL1800, GL1200, GL1000
Posts: 727
Quote:
Originally Posted by cihilb View Post
If you leave the petcock on and it doesn't leak, why can't you put an inline valve after the petcock?
I could, and I've been looking for one. Only two places to put one:

1. Between the petcock and the fuel filter. That one would almost have to be a 90 degree angle valve to fit properly.

2. Between the fuel filter and the fuel pump. That's a really short piece of hose, only 3" long including what pushes onto the fittings at both ends, so probably only 2" of hose to work with.

If I could find something to fit in either of those two spots, that's what I would do for now. I kind of prefer finding a 90 degree valve that would mount in option #1 above. I've been looking, but so far no luck. Most of them too big or the wrong hose size.

I also wonder if a plastic petcock valve like you can get for lawn mowing equipment would be OK for this application or it it needs to be metal.

Hmmmm?????

Bob
2006 Arctic White GL1800
1987 Black/Grey GL1200 Aspencade
1976 Special Candy Maroon GL1000 LTD
U.S. Navy SWO (1967-1976)
WingMan71 is offline  
post #6 of 23 (permalink) Old 02-28-2018, 05:35 PM
Senior Member
 
DenverWinger's Avatar
 
Join Date: Jun 2017
Location: Denver CO
Year: 1993
Make: Honda
Model: GL1500 Aspencade 1980 GL1100 STD Vetter
Posts: 534
Maybe a vacuum-operated petcock valve from a 1500 could be made to fit somewhere?

1972 CL-350 (1980-1988) sold
1978 Suzuki GS-550 (1985-2005) sold
1977 GL1000 (2002-2006) sold
1980 GL1100 STD Vetter (2005-)
1993 GL1500 Aspencade (2017-)
1983 Trav-Lite Camper (2010-)
DenverWinger is offline  
post #7 of 23 (permalink) Old 02-28-2018, 05:43 PM
Moderator
 
Bike...and Dennis's Avatar
 
Join Date: Feb 2009
Location: Glendale, Arizona, USA
Model: 1987 GL1200 Interstate 290,000 miles
Posts: 21,739
There's really no room to put any extra stuff in there. And when I was looking I didn't find any valves with the correct size fittings.

Mine did the same thing and leaked only when turned off. That's why I used the Teflon tape. I couldn't find an o-ring to fit the groove between the two halves. Flipping or turning the 4 hole seal won't stop your leak.

Why ain't we ridin'?
Bike...and Dennis is online now  
post #8 of 23 (permalink) Old 02-28-2018, 05:54 PM Thread Starter
Senior Member
 
WingMan71's Avatar
 
Join Date: Apr 2008
Location: Travelers Rest, SC, USA
Year: 2006
Make: Honda
Model: GL1800, GL1200, GL1000
Posts: 727
Quote:
Originally Posted by Bike...and Dennis View Post
... when I was looking I didn't find any valves with the correct size fittings.
Same here. I'm still looking right now and am finding nice 90 degree inline fuel valves, but only with 1/4" fittings on them. Like this one:




If I could find one of those with 3/8" fittings, I could splice that into the longer hose on the left side between the fuel petcock and the fuel filter.

Gonna keep looking. Also gonna stop at a local hardware dealer that specializes in commercial yard equipment, some big stuff too. Maybe I can find a fuel valve with 3/8" fittings there.

I'll let you know if I find anything that works.

Bob
2006 Arctic White GL1800
1987 Black/Grey GL1200 Aspencade
1976 Special Candy Maroon GL1000 LTD
U.S. Navy SWO (1967-1976)
WingMan71 is offline  
post #9 of 23 (permalink) Old 02-28-2018, 06:01 PM
Moderator
 
Bike...and Dennis's Avatar
 
Join Date: Feb 2009
Location: Glendale, Arizona, USA
Model: 1987 GL1200 Interstate 290,000 miles
Posts: 21,739
Don't waste time with that. I can walk you through the repair. Do you have a drill press?

Why ain't we ridin'?
Bike...and Dennis is online now  
post #10 of 23 (permalink) Old 02-28-2018, 06:38 PM Thread Starter
Senior Member
 
WingMan71's Avatar
 
Join Date: Apr 2008
Location: Travelers Rest, SC, USA
Year: 2006
Make: Honda
Model: GL1800, GL1200, GL1000
Posts: 727
Quote:
Originally Posted by Bike...and Dennis View Post
Don't waste time with that. I can walk you through the repair. Do you have a drill press?
OK, color me confused. I thought you said that flipping or rotating the 4-hole disc would not work to rebuild the petcock.

I have repaired several other Honda (riveted) petcocks before, but the rebuild kit parts (disc and two seals) were made to fit them.

I have used a hand drill in the past to drill out the holes where the rivets were and then tap the holes for small screws. If I need to, I'll buy a small drill press.

What else is involved in the "repair" of the '87 petcock? I appreciate the benefit of your experience on this!

Thanks.

Bob
2006 Arctic White GL1800
1987 Black/Grey GL1200 Aspencade
1976 Special Candy Maroon GL1000 LTD
U.S. Navy SWO (1967-1976)
WingMan71 is offline  
Reply

  Steve Saunders Goldwing Forums > Forums > Goldwing Technical Forum

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Steve Saunders Goldwing Forums forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Similar Threads
Thread Thread Starter Forum Replies Last Post
GL1200 Limited fuel petcock jimh352 Goldwing Technical Forum 51 08-26-2017 12:56 PM
GL1200 petcock, no fuel seems to flow pollytrew Goldwing Technical Forum 111 12-17-2012 08:27 PM
GL1200 fuel petcock winger4life68 Goldwing Technical Forum 8 06-12-2012 11:41 AM
1987 FUEL PETCOCK Bike...and Dennis For Sale/Wanted Forum 2 08-01-2010 10:35 PM
1987 GL1200 Interstate NEED FUEL PUMP Hogrocker Goldwing Technical Forum 25 06-06-2007 01:17 PM

Posting Rules  
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome