The first thing to do is to drain the antifreeze from your sled.  The best way I have found to do this is to remove the silencer and exhaust pipe.  Unhook all of the cable ties that hold the coolant hose in place.  Put a short bucket or cut off an antifreeze jug into the belly pan where the silencer sat.  Then take the filler cap off the coolant fill spout and bend the hose towards the bucket to try to drain as much antifreeze out of the top of the engine as possible.  Then separate the hose from the coolant fill spout by removing one clamp.  You should, at this time, be able to pull the hose deeper into the belly pan and draw out more coolant.  After most of the coolant is out you can slightly raise the rear of the sled about a foot to draw out more coolant.  All coolants does not have to be removed to do this procedure.  Remove plug wires and spark plugs.  Remove coolant sensor from the top of the head by unsnapping the connector.  Take your 12mm ratchet and remove the nuts from the top of the head in a criss-cross fashion.  Once the nuts are removed pull the head straight off the jugs and be prepared for a little excess antifreeze to leak out.  Carefully lay the head off to the side as illustrated below.

 

Remove each of the gaskets.  Pay attention to the labeling on the gasket.  There is an "Up" stamped into the gaskets and the gasket is raised to the "Up" side.  Take each gasket and carefully drill out the rivet into two spots on each gasket.  Once the rivet is drilled out, you have now created 2 gaskets.  The metal plate that separated the 2 gaskets can be tossed.  You only need one layer for this mod.  Each engine set will do 2 sleds. If the gaskets are older and have shown signs of wear near the inner surface such as metal showing, new gaskets will be required.

 

Take each gasket and spray with High Tack Spray Gasket.  Do not saturate.  You just need a nice, even cover of spray.  Both sides of the gasket will need to be sprayed.  Gaskets only need to sit a few minutes and should be very tacky.

 

Make sure your engine gasket surfaces are free of dirt and antifreeze.  Place each gasket with the "Up" side up and if the gaskets are not labeled with "Up" side, the raised portion of the gasket should be up.

 

Carefully place the head back onto the newly sprayed gaskets.  Put your 12mm nuts back on and tighten in a criss-cross fashion to about 8 ft-lbs.  Then go back and torque to 17 ft-lbs in a criss-cross fashion.

You can now proceed with putting your  spark plugs and wire back on. Make sure you hook your coolant temp. sensor back up to the head. Hook your coolant hose back up and strap it back into its original position. Make sure the rear of the sled is back on the  ground and block up the front of the sled so the skis are about 12 inches off the ground.  Pour the coolant back into the filler cap VERY, VERY slow to prevent air bubbles in the cooling system.  If all the antifreeze does not go back into the coolant system it is possible you have an air bubble and you might have to bleed the system by removing the seat and cracking open the nut on the rear heat exchanger to let the air escape.  Put your pipe and silencer back on.

 

Once you are 100% sure all things are back in their original position and everything is tight and right, you can start the engine and let it get up to temperature.  Walk around and feel each of the heat exchangers to see if they are getting warm.  This should take a few minutes.  If all heat exchangers feel warm there should be no air bubbles in the cooling system.  Let the engine cool back down.  I would suggest wait about an hour.  Open up your coolant filler cap and top off your coolant.

 

This head gasket mod. requires premium fuel. Enjoy your new found power. A single or double layer can be used on 600/700sx/vmax with single pipe. A double layer is recommended on triple piped sx/vmax. Any questions feel free to email the Webmaster.

Totallyamaha is not responsible for any damages that these modifications may cause to your vehicle; any modifications are your responsibility if you choose to do so. We are providing information ONLY. Some of these modifications may VOID your warranty and that is your responsibility to look into. The Totallyamaha users have passed along most of the information found on this site. If you have any questions or concerns about anything on this site talk to your dealer before using any of the information. Totallyamaha will not be liable for any damages or personal injury from any modification performed from this site.