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Tips/advice for reinstalling GS1000 pipes

  • Thread starter Thread starter GS1000G Shopper
  • Start date Start date
G

GS1000G Shopper

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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.
 
Some high temp silicone sealer on the exhaust gaskets helps hold them in place.
 
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.
 
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.
 
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.
 
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.
 
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). :mad:

One heli-coil repair later, and it is looking & sounding good, praise the Lord!:pray: 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. :D

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