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1979 GS1000 Rebuild

  • Thread starter Thread starter cmerck
  • Start date Start date
I went to your flickr page you linked to in one of the earlier posts... I started with the first pic and went through. Took a minute before I realized that the first pic was the latest. It made it seem like you were taking nice looking parts, stripping them down and then refinishing them to make them look crappy lol.

Looking good so far. Have you gotten into the engine at all? I'd suggest rebuilding the engine, reassembling, and then painting the whole shebang like Chuck did. I painted the individual engine components and then reassembled. Came out great, but then I saw Chuck's thread and was like "Ohhhhh....That looks much easier."
 
Not only is it easier painting after full reassembly, you don't get as much grease and oil on things as you wrench.
 
Don't worry, I haven't disappeared! I have been crazy busy the past few weeks and haven't touched the bike. Today that should change as I am preparing to work on the rear end of the bike. My new shocks came in and I have all new wheel components.
 
Hi all! As I write this I am uploading some new pictures of the progress that I have made on the bike. I have put the brake systems back together, installed the new rear shocks after drilling out and replacing the old studs that held the stock shocks in place. My next step is to work on the wiring harness. I will admit that wiring is not my strong point. The bad news is that several of the wires have been cut on this wiring harness from the previous owner. I will be repairing all of that as I go along. Does anyone have a good link to a schematic for the wiring harness?
 
Nice progress

You haven't downloaded a factory service manual from BassCliff's site?
 
Thanks BigT. So far I haven't downloaded one yet. I've been using a old paper copy the PO had. Unfortunately it's missing the electrical sections.
 
So I have been stuck on 2 issues for the past few weeks. The first being a broken exhaust stud that I cant get out. I want to fix that before I remount the engine on the bike. The other is that my wiring harness is very confusing and has been molested by the PO. I am afraid I need to replace it, as I have not been able to figure out most of the wiring harness connections. Any suggestions?
 
Harbor Freight sells a cheap LH drill bit set. Start with one of the smaller bits and work up, trying to stay centered in the old bolt. Work the bit sideways as needed to stay centered. As you get up to the larger sizes the old bolt will be a shell and it usually spins out when drilling.

The harness part isn't that hard as long as you have a place to spread it out. Suzuki dedicates certain colors to certain circuits so figuring out where you are on the harness as compared to the diagram isn't hard.
 
Last edited:
I use a dremel with a ball head engraving bit to create a divot dead center on the broken bolt. I've found that to be much easier, especially on an uneven surface.

Once you have a center divot, drill slowly with the LH bit.starting small and getting larger and deeper as you go
 
So I've been very busy the past few weeks. Not much work has been done to the bike. But I'm still stuck on the broken stuck header bolt. I'll most likely have to take the engine to a machine shop to get it fixed.

As for the wiring harness, this one is in horrible shape. I unfortunately have come to the realization that it needs to be replaced. Anyone know which harnesses will work with a 79 GS1000L?
 
As it turns out, I will be replacing the head. When I took it off to inspect the internals, there is a big crack in the center of it. As much as I would rather not buy one, it does solve multiple issues being replaced. Any recommendations on head gaskets?
 
cmerck said:
As it turns out, I will be replacing the head. When I took it off to inspect the internals, there is a big crack in the center of it. As much as I would rather not buy one, it does solve multiple issues being replaced. Any recommendations on head gaskets?
Click to expand...

Yes, OEM!!!!!!
 
I haven't made much progress the past couple weeks. That should change after tomorrow. I located a 79 GS1000 parts bike near me. The only issue is that it's shaft driven. Still gonna get it for the other parts I need.
 
cmerck said:
I haven't made much progress the past couple weeks. That should change after tomorrow. I located a 79 GS1000 parts bike near me. The only issue is that it's shaft driven. Still gonna get it for the other parts I need.
Click to expand...

Ok, there is no 79 GS 1000G. It can be a 80 GS 1000G, but it will have a different head with larger intake ports for the CV carbs on the 80 bike. Don't know what other parts you need, there may not be as much interchange as you think
 
Ahhhh, thanks Big T. I'm needing exhaust, head light, wiring harness, foot pegs. I was considering swapping the rear wheel, swing arm etc, in order to just use that engine setup. Would it fit in my frame?
 
Long time since my last post. I finally got back to working on the bike. However I have found myself thinking of getting a new engine. My govenor is bad(destroyed) by PO and I'm all but positive it's locked up. Anyone have experience working on the govenor on these?
 
What's a governor and do you have a factory service manual?
 
Sometimes the centrifugal advance unit is called a governor. If that's what we are talking about here then there shouldn't be a problem because you can just install a new one.
 
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