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Thread: Can I cut the headgasket to increase cooling capacity?

  1. #1
    Join Date
    Jan 2007
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    Utah
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    Can I cut the headgasket to increase cooling capacity?

    I got a new cometic head gasket for my '85 250r.
    The cooling port cutouts on the headgasket are smaller than the port openings on the cylinder jug and head. Can i cut out the port openings on the headgasket to match the size of those on the jug. I'm thinking it would increase the coolant flow and maybe run cooler. Has anyone ever done this before?
    My only concern was that maybe the reason the holes on the gasket where so small towards the rear, was becuase thats where the inlet hose is and that maybe it would force the coolant aroud the entire jug more instead of taking the shortest path between the two hoses and only cooling half the head.
    Any input would be nice.
    Also has anyone run the cometic headgasket compared to oem? Does oem have full sized cutouts, or only partial like cometic?
    THANKS
    A few wheelers, + an
    '73 Honda 49cc Mini Trail
    '85 200 Big WHEEL

    "Despite the cost of living, its still popular."

  2. #2
    Join Date
    Aug 2007
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    Moab, UT
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    They are the same size if I remember correctly. They do restrict flow for a reason though. If your coolant circulates too fast you could run into overheating issues.
    ADMIRIN' BOOBS AND BLASTIN' NEWBS

  3. #3
    Join Date
    Aug 2004
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    Phoenix
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    Leave it the way it is, Honda designed it that way for proper flow.
    Remove all the warning label and let nature take its course

  4. #4
    Join Date
    Sep 2003
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    i have a O ring cool head on my trx250r and it works fine. theres no gasket so the holes are wide open. i have not had any overheating problems.

    i was thinking of doing the same thing to my 85 atc250r when i have to rebiuld it next time.
    JASON LISKEY

    1985 atc 250r ---- finsh line axle,.fmf exhaust and rictor privateer silencer, prm grab bar.
    2008 KTM 525xc quad ----- HMF exhaust, HRE chromoly stem,
    86 trx 250r --- with after market chromoly frame and everything else done to it
    01 400ex --- with 86 trx 250r motor
    87 250x + 93 300ex both 350x powered
    2 = 86 atc 350x's
    86 atc 250r
    83 atc 185s --- from retired guy not ridden since 87
    Bandito framed 110 with 85 motor and yellow us90 fenders + tank

  5. #5
    edog's Avatar
    edog is offline I'm like an Original Gangsta...but a post whore instead. The day begins with 3WW
    Join Date
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    Keep it that way.

  6. #6
    Join Date
    Jan 2004
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    Palmetto,Florida
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    They did that to force more flow towards the HOT Exhaust Side.. Run Leaded High Octain Gas and it will cool it some
    "07" DR650 Suzuki Dual Sport

  7. #7
    Join Date
    Jan 2007
    Location
    Utah
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    Thanks for the replies. That was my original thought, but I wanted some more input on it just to be safe.
    A few wheelers, + an
    '73 Honda 49cc Mini Trail
    '85 200 Big WHEEL

    "Despite the cost of living, its still popular."

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