1992 GL1500 Interstate fuel pump


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cwiekamp75
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Motorcycle: 1992 gl1500 Interstate

1992 GL1500 Interstate fuel pump

Post by cwiekamp75 » Thu Sep 14, 2017 12:14 pm



I've seen a few older posts on replacement fuel pumps in the forums, but what is a good alternative to the stock pump? Sorry if I'm being redundant and just haven't seen a recent thread on this. I've googled replacement pumps on ebay and seen some that say they are for my bike, but product reviews on the item indicate that they flow too much and are for fuel injected models.... Couple NAPA pumps I've seen listed here in older posts are discontinued... Any suggestions would be helpful.



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bluthundr31
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Location: Morgan Hill, CA.
Motorcycle: 1991 GL1500 Interstate (Cinnamon Beige)

Re: 1992 GL1500 Interstate fuel pump

Post by bluthundr31 » Thu Sep 14, 2017 2:44 pm

Welcome aboard Cwiekamp75!

I went through this problem about a month ago on my '91 Interstate, so I know your frustration.

If you're absolutely 100% positive that your pump is no good and you decide to use an aftermarket pump instead of checking eBay for an old used one, or a new one from Mother Honda, this is what I did and it has worked out to be an OUTSTANDING swap.

1. Fuel Pump- Napa/Carter P72190 ($61.23 Free shipping on Amazon) **It WAS $40 a month ago, WTH?
2. Fuel strainer/screen- Carter STS-8 ($9.52) Amazon **Also higher than a month ago!!! Someone is VERY greedy, heheh
3. 12" of 5/16" submersible (30R10 rating) rubber hose ; Gates 27093($15-20). got mine on eBay
4. (optional but HIGHLY recommended) New rubber BASE gasket ($10)

These components replaced my old OEM pump that was shot after sitting for 8-10 yrs in wet-storage.
It took about an hour to install the components and put it all back together. It was the best option for my situation, yours might be different.
Good luck and if I'll keep an eye on this if you decide to do it and need a little tip or two.

cwiekamp75
Posts: 19
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Location: Watertown, SD
Motorcycle: 1992 gl1500 Interstate

Re: 1992 GL1500 Interstate fuel pump

Post by cwiekamp75 » Thu Sep 14, 2017 3:43 pm

Thanks for the info. I"ll check into it and see what I find. I've got the pump mounting arm/pump pulled out. Tested the pump and it's seized. It's been sitting for a while, too. Drained the old gas and cleaned the rust out of the tank. One question, though... The air line that is inside the tank that hooks up to the OEM pump setup, does that need to be capped off or just leave it open as is?

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bluthundr31
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Re: 1992 GL1500 Interstate fuel pump

Post by bluthundr31 » Thu Sep 14, 2017 4:00 pm

It can be left off without any "consequences".
***NOTE: When you cut off the old pump from the "hangar/bracket", cut the wires close to the pump so that you leave long lengths attached to the hangar/bracket. It'll be helpful when you attach those wires to a new pump. AND, if you can carefully remove the rubber "boot/sleeve" around the pump that is under the "clamp", it might be useful in case the new one doesn't have a boot/sleeve.

Our situations couldn't be MORE identical. My tank had rust all over it too. You probably won't be able to fill the tank until AFTER you get the pump bracket mounted properly again, consider wiping down the inside of that tank after you clean it, with some Mystery Marvel oil. It'll leave a light coating of oil so that you avoid a "flash rust" problem. MMO is a great additive to your gas, so when you can fill the tank, you have some VERY GOOD help to clean the carbs and pistons. My carbs were not too bad but I fought a pilot jet clog for quite a while. Seafoam and/or MMO took care of the issue.

cwiekamp75
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Re: 1992 GL1500 Interstate fuel pump

Post by cwiekamp75 » Thu Sep 14, 2017 4:24 pm

OK. Thanks for the help...

Now, on to next issue, the one that started the whole project. Wouldn't start. Turns over fine, just won't fire. Yes, kill switch to Run. Investigating found the fuel pump, but also found that I have no spark after I tried dumping a little gas down the carbs and no hint of firing. Fuses all good. I've read that there are multiple possible culprits with this issue.

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bluthundr31
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Motorcycle: 1991 GL1500 Interstate (Cinnamon Beige)

Re: 1992 GL1500 Interstate fuel pump

Post by bluthundr31 » Thu Sep 14, 2017 4:37 pm

DANG, ,its like DeJaVu all over again.

Do you have a manual to troubleshoot the problem? Maybe a Clylmers or Honda manual?
They'll have a troubleshooting section for you to follow.

It'll probably tell you that the Bank Angle sensor will cause a "no-start" condition. When I checked mine, I found it to be bad and I had to by-pass it. It'll also probably point you to the kill switch connector to verify continuity in the three positions. While you're waiting for the pump, check those two components and verify they are not a contributing factor.

cwiekamp75
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Re: 1992 GL1500 Interstate fuel pump

Post by cwiekamp75 » Thu Sep 14, 2017 4:47 pm

Ya, have Honda manual. Exactly what you said is where I was going to start.

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bluthundr31
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Re: 1992 GL1500 Interstate fuel pump

Post by bluthundr31 » Thu Sep 14, 2017 4:55 pm

good, You're well on your way to getting that beast roadworthy.

Let us know how it goes.

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bluthundr31
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Re: 1992 GL1500 Interstate fuel pump

Post by bluthundr31 » Tue Sep 19, 2017 9:01 pm

How are you doing with that fuel pump problem cwiekamp75?
Shoot us an update when you get a chance, we'd all like to help u get back on the road again.

cwiekamp75
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Re: 1992 GL1500 Interstate fuel pump

Post by cwiekamp75 » Wed Sep 20, 2017 11:35 am

Been busy and haven't had much of a chance to do much with it. However, have gone through and completed some troubleshooting. Most is checking out OK. One question, tho, if I don't have the fuel pump hooked up will there be spark at the plugs? Thinking the ignition circuits go through the fuel pump?

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bluthundr31
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Re: 1992 GL1500 Interstate fuel pump

Post by bluthundr31 » Wed Sep 20, 2017 1:28 pm

You will get "spark" at the plugs whether or not the FP is in. If "no spark" occurs, its not related to the FP being removed, its something else.

Good luck, you'll do fine.

cwiekamp75
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Re: 1992 GL1500 Interstate fuel pump

Post by cwiekamp75 » Thu Sep 21, 2017 12:01 pm

Weak battery be the culprit? Has enough juice to turn over, but not enough for spark?

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bluthundr31
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Re: 1992 GL1500 Interstate fuel pump

Post by bluthundr31 » Thu Sep 21, 2017 3:01 pm

If the engine cranks, it should spark just fine if nothing else is wrong with the electronics.

If you're questioning the battery charge, put it on a 2.5Amp charger for a couple hours.
*NOTE: The higher amp chargers will FRY the battery if you're not watching it closely and checking each cell. After a couple hours on the 2.5Amp charger, you should see about 12.4-13.7 volts using a voltmeter across the pos. to neg. (unless its a sealed battery, loosen the threaded "caps" for gases to escape as it charges). A FULL charge from a dead/new battery, with a 2.5Amp charger, takes about 10 hrs.

cwiekamp75
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Re: 1992 GL1500 Interstate fuel pump

Post by cwiekamp75 » Fri Sep 22, 2017 11:51 am

ok. thanks. hopefully get back at it tonight/tomorrow.

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Erdeniz Umman
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Re: 1992 GL1500 Interstate fuel pump

Post by Erdeniz Umman » Fri Sep 22, 2017 12:33 pm

bluthundr31 wrote:
Thu Sep 21, 2017 3:01 pm
If the engine cranks, it should spark just fine if nothing else is wrong with the electronics.
....
Ideally it is true, however the ignition system is much more affected by the low voltage.

You may have a cranking capability but not enough voltage for the ignition. Note that, while using the reverse, the starter is controlled by a reduced voltage to adjust the bike speed.

A poor, loose, corroded contact, aging wires etc will cause some resistance which will drop the voltage, and the lost voltage will turn into heat.

So, check and clean the contacts on the ignition circuit according to the diagram given in the service manual. You should have at least 10-10.5 volts at the black/white wire at ICU/ECU input to get a spark during cranking and later of course. And don't forget to clean the grounding points.

If you measure the voltage there when not cranking (no load condition) you may have a higher reading but this should not mislead you. So, the most correct value for the ignition system will be measured when the battery is under load.

After checking the contacts, if you still have the starting problem, you may want to do the modification below.
http://www.goldwingfacts.com/forums/2-g ... olved.html

cwiekamp75
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Re: 1992 GL1500 Interstate fuel pump

Post by cwiekamp75 » Fri Sep 22, 2017 2:30 pm

Thanks for the info!!

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Mh434
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Re: 1992 GL1500 Interstate fuel pump

Post by Mh434 » Sat Sep 23, 2017 2:34 pm

cwiekamp75 wrote:
Thu Sep 21, 2017 12:01 pm
Weak battery be the culprit? Has enough juice to turn over, but not enough for spark?
That's a classic GL1500 issue. Battery is weak, yet still spins the engine over nicely - but there's not enough current left over to fire the ignition. A LO of us have had that happen!! If a freshly charged battery (or jumpering from another battery) allows it to fire up, then that's your problem.

OEM alternators are weak, too, so doing a lot of short runs etc. may not be enough to recharge the battery from its losses from being started.

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Charlie1Horse
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1992 GL1500I Interstate

Re: 1992 GL1500 Interstate fuel pump

Post by Charlie1Horse » Sat Sep 23, 2017 11:55 pm

Check the two wires under the kill switch. Miles and years of vibration at the handlebars will cause them to loosen and then you will have no spark or fuel. My 92 Interstate did just that. I removed the two screws under the switch and raised the kill switch to find both connections loose. Tightening them brought her back to life.

If your bank angle sensor tests defective have your local Honda shop check your VIN to see if it has had the BAS recall done. It is a safety recall so if the bike is still on the road and it hasn't been replaced they will order one and replace it for you FREE. I just had mine replaced recently.
Russell

Those who say it cannot be done should try not to interrupt those who are doing it.

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bluthundr31
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Re: 1992 GL1500 Interstate fuel pump

Post by bluthundr31 » Sun Sep 24, 2017 3:31 pm

Charlie1Horse wrote:
Sat Sep 23, 2017 11:55 pm
If your bank angle sensor tests defective have your local Honda shop check your VIN to see if it has had the BAS recall done. It is a safety recall so if the bike is still on the road and it hasn't been replaced they will order one and replace it for you FREE. I just had mine replaced recently.
If you see an "X" stamped on the frame lower tubing near the brake pedal then the recall has been done.

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Erdeniz Umman
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Re: 1992 GL1500 Interstate fuel pump

Post by Erdeniz Umman » Sun Sep 24, 2017 4:03 pm

Does the engine crank when you press the start button?
If it cranks then BAS is good.

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bluthundr31
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Motorcycle: 1991 GL1500 Interstate (Cinnamon Beige)

Re: 1992 GL1500 Interstate fuel pump

Post by bluthundr31 » Sun Sep 24, 2017 11:17 pm

My '91 interstate cranked over fine but the BAS failed the diagnostic testing. It's possible the '92 Interstate is different, but I haven't seen any evidence.

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Erdeniz Umman
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Re: 1992 GL1500 Interstate fuel pump

Post by Erdeniz Umman » Mon Sep 25, 2017 2:20 am

bluthundr31 wrote:
Sun Sep 24, 2017 11:17 pm
My '91 interstate cranked over fine but the BAS failed the diagnostic testing. It's possible the '92 Interstate is different, but I haven't seen any evidence.
Unfortunately I don't have the start diagram for 91 and 92 Interstate models, but I have for Asp and SE models shown below.

I believe the BAS connections are the same for Interstate and the Asp/SE models.

The Red/Wht wire is the ground going from the BAS to the relay 8 coil.
So, in order to crank the engine you will need the ground voltage at the relay 8 (relay 6 for 93-2000).


However, if you short the green and red/wht wires in the green BAS connector like below you will bypass the BAS and you can crank the engine without a BAS. Trikes especially need that modification.



cwiekamp75
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Motorcycle: 1992 gl1500 Interstate

Re: 1992 GL1500 Interstate fuel pump

Post by cwiekamp75 » Mon Sep 25, 2017 9:53 am

Has been turning over fine since I started this project, just do not seem to be getting spark.
I've pulled the BAS and performed the "tilt" test on it and it had the relay clicking as the manual indicated it should.
Pulled Kill switch and the screws were snug. I took them off and hit them with emery cloth, as I've been doing, now, with every connection I can that I take apart.

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virgilmobile
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Re: 1992 GL1500 Interstate fuel pump

Post by virgilmobile » Mon Sep 25, 2017 11:49 am

Not the easiest to get to but with no spark..the first test points are at the ignition module.
You will spy 2 wires that need your meter attached to....
After unplugging the module and inspecting the connections for corrosion..reattach the plug..
Locate the black/white wire (switched 12 volts) and stab your meter positive probe into the wire.
Locate the green wire (ground) and stab your meter negative probe in it...
Turn on the key and crank the engine...
The volts need to stay above 10 volts dc to get a good spark.

Also...
I do know the side stand switch is capable of killing the ignition if the module does not receive the neutral signal.
Neutral lamp on?Side stand down?

cwiekamp75
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Motorcycle: 1992 gl1500 Interstate

Re: 1992 GL1500 Interstate fuel pump

Post by cwiekamp75 » Mon Sep 25, 2017 12:51 pm

Neutral lamp is on. Side stand lamp works as the stand is raised and lowered.



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