Tips/advice for reinstalling GS1000 pipes

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  • GS1000G Shopper
    • Jan 2026

    #1

    Tips/advice for reinstalling GS1000 pipes

    I've come a long way with this 1981 GS1000G, the head has been repaired, it now has new rings, valve seals, and OEM gaskets. The head is on and the valves adjusted (good learning experience).

    Today I tried to tackle reinstalling the exhaust. I got the outer two on and the rear mounting bolts in place. For the inner two, I need like two other hands. The gaskets between the pipe & head don't stay in pace in the head, nor do the split rings that push against the pipe. I coated the split rings with anti-seize and this helped, but I can't get everything lined up just right w/o the gaskets falling off, so I'm looking for any tips on doing this.

    Thanks for any help.
  • Nessism
    Forum LongTimer
    GSResource Superstar
    Past Site Supporter
    Super Site Supporter
    • Mar 2006
    • 35787
    • Torrance, CA

    #2
    Some high temp silicone sealer on the exhaust gaskets helps hold them in place.
    Ed

    To measure is to know.

    Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

    Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

    Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

    KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

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    • GS1000G Shopper

      #3
      Great. Thanks for the tip.

      Comment

      • hampshirehog
        Forum LongTimer
        Past Site Supporter
        • Oct 2007
        • 12675
        • Hampshire. UK

        #4
        I use a dab of grease instead - does the same trick.
        79 GS1000S
        79 GS1000S (another one)
        80 GSX750
        80 GS550
        80 CB650 cafe racer
        75 PC50 - the one with OHV and pedals...
        75 TS100 - being ridden (suicidally) by my father

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        • GS1000G Shopper

          #5
          I ended up using a little more antiseize since I didn't have any hi temp silicone on hand. A little juggling & they're both in place.

          It's looking good, should have it ready to test out tonight or tomorrow.

          Comment

          • GS1000G Shopper

            #6
            I'm pleased to report it started up tonight. A lot of smoke, but this too shall pass. Sounds like I still have an exhaust leak at the head, but I'll work on that tomorrow.

            Comment

            • Nessism
              Forum LongTimer
              GSResource Superstar
              Past Site Supporter
              Super Site Supporter
              • Mar 2006
              • 35787
              • Torrance, CA

              #7
              I keep the rear muffler bolts and the clamps loose until all the bolts are tight at the head. You need to allow the head tubes to seat before constraining them by tightening the muffler and clamp bolts.
              Ed

              To measure is to know.

              Mikuni O-ring Kits For Sale...https://www.thegsresources.com/_foru...ts#post1703182

              Top Newbie Mistakes thread...http://www.thegsresources.com/_forum...d.php?t=171846

              Carb rebuild tutorial...https://gsarchive.bwringer.com/mtsac...d_Tutorial.pdf

              KZ750E Rebuild Thread...http://www.thegsresources.com/_forum...0-Resurrection

              Comment

              • Sandy
                Forum Guru
                Past Site Supporter
                • Feb 2004
                • 7503
                • Cranbrook, BC Canada

                #8
                For the half moon shaped collets I just use a small piece of masking tape to tape them together on one end sort of like a hinge. Drop them over the pipe just before you install the clamp and the tape burns off first time you start it. I've got the "G" exhaust on mine and if I remember correctly I installed the inner pipe to their respective mufflers first, then installed the mufflers. Didn't seem to give me any trouble doing it that way. Glad you got it on.
                '84 GS750EF (Oct 2015 BOM) '79 GS1000N (June 2007 BOM)

                Comment

                • GS1000G Shopper

                  #9
                  It was my stupid mistake (the usual kind). I had the split pieces in backwards! Got them reversed, and was re-tightening and one of the studs on #2 pulled out (this whole repair started due to a broken bolt on #3 exhaust).

                  One heli-coil repair later, and it is looking & sounding good, praise the Lord! Just a few more pieces to put back on & it should be good to go. Then I can be 21 on a brand new* red GS1000G again.

                  *New to me, plus the gauge cover, speedometer, and handlebars are new OEM parts.

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