Hey guys just wondering how hard it is to replace a head gasket on a 800efi? I got it from a friend of mine and the bike runs real strong but he has had overheating issues in the past. I checked the oil and it is a little milky and there was very little coolant in the system (I'm thinking cracked head or headgasket). I do really like the bike and want to fix it; just ordered a clymer's manual for it online. Any other input would be greatly appreciated. I did check the thermostat and waterpump also and they seem fine. Thanks

 

Always disconnect the battery first. You can pull the head and cylinder while it's still in the frame. Make sure the rocker arms go back in the same position. If you're down that far I'd pull the cylinder and at least install new rings plus have the head and cylinder checked out at a machine shop for warping or any damage. They can always shave the head/cylinder down a little if needed. Then just use your manual for reassembly torque specs.

 

Thank you as always for your response Opt; that's what I wanted to know if I had to pull the motor or not. From what it sounds it's not a huge job but I will definately have the head & cylinder checked. Hopefully rings and a headgasket will put me back on the trail! Thanks again.