Falkonworks GS1000

[Falkonworks]

I just thought I would create a separate build thread here for another project I have going on. I know a lot of you guys (just like me) also like bikes other than just the Hayabusa, and thought maybe some of you might enjoy this.

I’m starting back up on my 1978 Suzuki GS1000. This was my first motorcycle and has been sitting for the last 6-7 years. I had the frame powder coated and repainted the bodywork back then and the bike never was reassembled.

Fast forward to now. I have finally decided to start working on it again and I wish I would’ve taken some more photos of it before I got into it but I’ve been quite busy. The next photos are from today as the bike currently sits. I sold another vehicle recently that was stored where the bikes are kept so now I have all kinds of space to work again.

I’ve changed my mind about a few different pieces to this restoration/restomod project in the years since staring it. It sits now with a GS850G tail, and I have matching side covers on the way. These will need to be modified to work with the GS1000 seat and tank but I think will give the bike a more finished look vs stock. I am thinking about using a Motogadget M Unit and the corresponding gauges and some slightly modernized OEM Suzuki switches to control everything. I also have some retro race wheels that will be going on in exchange for the original wire wheels that were on this bike. I do have plans for a front nose fairing as well but it won’t be the typical Wes Cooley style nose. That’s about it for the changes I plan to make.

The motor is currently out getting freshened up and the forks are disassembled and out getting sandblasted. I will be doing Cerakote on the tubes and on the wheels soon. Working on some modernized fork caps of my own design and completed the 3D printed prototypes tonight.

I’m super excited for this project and can’t wait to ride the bike again.

 

[Dnyce]

Love the gs1000 and 1100, but never again going back to one. Appreciate seeing someone really do one justice tho!

 

[zucchero]

Another great thread..!!Wishing you best of lucks.

 

[BigBSBusa]

Awesome! Love these projects. I'm sure this will be a beaut! I have a Yamaha XS750 cafe bike I have been thinking of restarting this winter.

 

[Falkonworks]

Spent the last couple days making some sample parts to try out on the bike.

I started with some modernized fork caps that are lower profile and look much cleaner.

I'm imagining the final pieces to be clear anodized with gold anodized center caps. I received the tubes from sandblasting and got my Cerakote yesterday as well. I might have them coated by the end of the week.

Next on the agenda was to get the tank aligned the way I want so I can start on the rest of the bodywork and seat.

My goal is to align the tank with the rear portion of the frame and body work so everything is flat and parallel. The design of the tank is very flat and straight but the original position is slightly downward angled towards the rear which always looked off to me. So, I made some tank lowering bushings that drop the tank 8.5mm in the front to start.

The bushings got the tank close to where I want it, but the rear still needs to be raised a little bit to get a true parallel alignment. I designed a bracket that raises the rear this afternoon and the test piece is printing right now. I expect this to work on the first try, and then I will continue working my way towards the rear of the bike and aligning everything as I go, starting with the seat.

I have decided to do away with the side hinging design of the seat which means grinding those hinges of the frame which sucks since its all brand new powdercoat but I guess that's just going to have to be ok. The hinges are in the way of the GS850G tail that I will be adding to the bike. So the plan now is to design a bracket for the seat pan so it will have a tab and a bracket with some sort of bolt on hold down or a quick release in the rear sort of like a GSXR/Hayabusa seat or a trunk mechanism maybe. We'll see what happens after I get the tank where I want it.

 

[Falkonworks]

Test fit the offset rear bracket for the tank and I like where it sits now. The front is lowered 8.5mm and the rear is raised 10-12mm. I never actually took a measurement. Just eyeballed where the original location matches up with the bottom of the oval hole in the tank as a reference and went for it.

I’m still going to have to do some messing around with the seat and tail to get everything aligned correctly. I’m still not sure how it will all look with the tank raised up above the rear frame lines and letting the tail have an offset in relation to the tank but I’m just figuring it out as I go. The GS850G side covers have a raised front corner that would interfere with the tank if it was not raised but holding them up with the tank sitting here, it looks like they might sit just perfect to match up with the bottom of the tank right now. I will just need to adjust the bumpers under the seat to get it at the correct height as well. I will be getting the OEM seat cut and reupholstered. I want the front to be lower similar to my bump seat on the Hayabusa. I think it will be nice for aesthetic purposes but also but general comfort daily riding the bike and feeling more planted sitting stationary on the bike.

 

[LC4CARL]

First class!

 

[Falkonworks]

I removed the hinges for the original GS1000 seat design to allow the 850 tail to be fitted.

I set the tail in place and did some rough alignment to get it to sit how I liked.

I took a measurement of that location and designed some mounting points and 3D printed them to test fit before having a set machined.

The tail fit exactly how I planned. It’s a tad bit shorter than what the original design would have been so I’m sure I will need to shorten the seat pan as well.

I’ll need to get the rear tank bracket and the tail mounting points machined here soon and I’ll move on to fitting the side covers.

 

[Falkonworks]

I wish I would have taken photos of the forks before the rebuild. These are from a different bike I have laying around and are pretty representative of what the GS1000 forks looked like before disassembly though for comparison.

Sandblasted and ready for coating after soaking in acetone overnight and baked in the oven.

I used Cerakote Glacier Silver

And here is after coating

I’ll be reassembling them in a week or so. I’m planning on internally lowering them a little bit so I’ll be making some spacers and cutting the spring down. Not sure how much yet.

 

[Berteric.]

Congratulations, very nice build. Pointed to follow.

The S version was an incredible bike.

S version.

 

[Oz22]

Big Project. Love the vice btw. Back in the day I had the GS 750, though it was bored out to an 810 or something. We had some good times together that bike and I. The suspension was always the weak point then I put some koni? shocks on the back and that stiffened it up. What's with the 'lowering'? What do you hope achieve there? We all ride different and I'll happily accept a harsher ride as a tradeoff for stability in the corners. Is the lowering going to stiffen up the front?

The spoked wheels look great on that bike, will you do a tubeless mod, or are they already tubeless, I can't remember? I was 19 and probably drunk a lot

 

[Falkonworks]

Big Project. Love the vice btw. Back in the day I had the GS 750, though it was bored out to an 810 or something. We had some good times together that bike and I. The suspension was always the weak point then I put some koni? shocks on the back and that stiffened it up. What's with the 'lowering'? What do you hope achieve there? We all ride different and I'll happily accept a harsher ride as a tradeoff for stability in the corners. Is the lowering going to stiffen up the front?

The spoked wheels look great on that bike, will you do a tubeless mod, or are they already tubeless, I can't remember? I was 19 and probably drunk a lot

I just want the bike to be overall lower. I’ll be internally lowering the forks and the rear shocks will be shorter as well. Ease of riding and walking around with the bike/backing up will be easier with it a little lower.

I actually have some 7 spoke wheels I’m planning on using. I have to do some work and then they’re getting gold Cerakote.

 

[Oz22]

Going to the 7-spoke, fair enough. After the GS I went across to Kawasaki, all my life, back and forward between those two. I had the Z1R-II which was basically an upgrade on the kwaka9, not much difference. I honestly couldn't go back to riding those though, far too addicted to the modern stuff. I hope my Gen-2 lasts and lasts, because I don't want to go any further forward either