GL1500 Fuel Filter & Add Ball type Fuel Valve


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CrystalPistol
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Joined: Wed Mar 10, 2010 9:07 pm
Location: Shenandoah Valley of Virginia
Motorcycle: 1997 GL1500SE/'98 Lehman Trike

GL1500 Fuel Filter & Add Ball type Fuel Valve

Post by CrystalPistol »



I installed a ball type fuel petcock and larger auto type fuel filter in line on 1997 Honda GL1500 Trike

A few years ago I decided to use a larger metal fuel filter, like used on some cars. I had found that the metal line from pump was 5/16" but the OEM hose expanded to 3/8" at the filter. What I did that day was make a 5/16-3/8 adapter and form metal lines that run the fuel from tank exit over in a steady curve down the left side top of tank to the rear of the tank where I transition with a short piece of 5/16" rubber line to connect to the fuel filter, then connect same way to more metal and run forwards up top of tank on the right side where it connected to a rubber line about 8" long to my adapter to step up to OEM grey Honda 3/8" curved hose to the vacuum petc0ck. The adapter resided where OEM filter once did. I simply took the one end of ball valve and pressed a piece of 3/8 copper tube over it, the ball valve is now my adapter too . I did this to both give me a bigger filter (Purolator F44663 … or equivilant) and put it in an easily accessed place for service (under seat rear, seat comes off fast with just 4 socket head bolts).

When a metal line ends, I started a bubble flare just to get a smooth bulge in the end to help seal my hoses, I also used a few clamps, but extra clamps or bubbled ends are very likely not really needed at the low pressures present.

I know that I can run fuel down in carbs by pulling the vacuum line off the OEM petc0ck, but I decided to put a ball type fuel valve there where it was easy to access with just opening the fuel door. The filter remains under the seat at rear of tank in a "void area".

I also removed the OEM vacuum petc0ck and bracket, slotted those two holes so in the future if it leaks (I can loosen the two lower screws with a short bit in 1/4 ratchet wrench through the gas door easily, pull it up a little ... and remove all 4 screws to replace innards in place.)

So now, I can starve the carbs prior to storage by manual ball valve through fuel door. I also have some new FI rated hose & clamps to install, but what is on it was great. Filter has a little over 1,000 miles use on it. I did replace the still good regular rubber fuel hose with FI rated hose I had bought for that … thinking it might well outlast the trike now.

The petc0ck had one removable end so I removed it, set the plastic like seal aside, sweat soldered that piece of 3/8 copper to the smaller 5/16 barb to seal it for sure (glad I removed the seal first) after sanding the plating off the brass, then I put it all back together, straight is "open" or "on" while 90 degrees is "off" or "closed". To be candid … and in hindsight, I will add: initially I took a short piece of 3/8" OD copper, used a tapered punch to just barely bell one end, I sanded the nickel off the 5/16" OD hose barb … then I used my vise to press the copper down on to the brass. It expanded being soft copper, but like a bullet pressed into a case, it was TIGHT … so if I had used some lock-tite or etc, there was no need to disassemble & sweat solder it. Likely no need for anything after pressing it on, but then I never just use two nails where I can use 3 or 4.


I didn't remove the OEM vacuum operated fuel valve because it is perfect for temporary parking like at meals, motels, gas stops, etc. The new petc0ck is for use to run the carbs dry before storage.



The current fuel filter is a cheap but still decent DriveWorks 44663, but I have a Purolator 44663 ordered that will replace it.





PS … I do have a fuel door, I just removed the two screws and set it aside out of my way.





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gford
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Re: GL1500 Fuel Filter & Add Ball type Fuel Valve

Post by gford »

Couldn't you run the carbs dry by removing the vacuum line to the fuel shut off valve?
gford
Posts: 110
Joined: Fri Feb 10, 2012 8:55 pm
Location: Canada
Motorcycle: 1999 Goldwing SE

Re: GL1500 Fuel Filter & Add Ball type Fuel Valve

Post by gford »

Sorry, I just noticed you mentioned removing the vacuum line in your post
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CrystalPistol
Posts: 1421
Joined: Wed Mar 10, 2010 9:07 pm
Location: Shenandoah Valley of Virginia
Motorcycle: 1997 GL1500SE/'98 Lehman Trike

Re: GL1500 Fuel Filter & Add Ball type Fuel Valve

Post by CrystalPistol »

gford wrote: Fri Apr 10, 2020 3:05 pm Couldn't you run the carbs dry by removing the vacuum line to the fuel shut off valve?
Sure you can.

I thought I even mentioned that?

I know I have done it before.

But … I had already rerouted lines and put in a bigger filter in an easy to access place not restricted by a gas door … and by putting the 3/8" tube over the one 5/16" barb to adapt it up, I can still bypass the Auto Fuel Valve by "the hose swap" method if the AFV ever does leak, and still have a shut off via ball valve. Maybe on a several days ride it comes in handy, if that leak happens (and it isn't unheard of to have it happen).
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Make Courtesy your "Code of the Road" …

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