1. Drain coolant from old head.
2. Save gasket, o-ring, and bolts from both the top and bottom cooling inlets.
3. Remove head bolts and old head.
4. Remove temperature sensor and thermostat from original head. NOTE: RKT has found that removing the thermostat and PLUGGING the bypass line will result in more consistent and better performance from the engine. The thermostat is a high failure item that WILL cause severe engine damage when it fails.
5. Take the Torque-Line head and bolt, using the original bolts, the bottom cooling inlet and thermostat to the head cover. NOTE: Coat these bolts with pipe dope or Teflon tape before installing cooling inlet to head cover.
6. Coat the temperature sensor with pipe dope or Teflon tape and install into Torque-Line head cover.
7. Place 1/8” o-rings onto the 2 domes and set domes into head cover. NOTE: The 800 twin domes only fit 1 way. Line up the “X” on the domes with the “X” on the head cover. DO NOT FORCE DOMES INTO HEAD COVER.
8. Make sure original cylinder sealing o-rings are in place and in good condition.
9. Set assembled head assembly onto cylinders making sure not to displace the cylinder o-rings.
10. Torque head bolts in correct order to 22ft/lbs. Start at 18ft/lbs and then go to 22ft/lbs.
11. Connect bottom cooling hose to fitting and tighten hose clamp.
12. Fill head with 50/50 mix of anti-freeze and water through the top cooling inlet.
13. Using supplied bolts, new gasket, and new RKT mounting plate, place supplied o-ring in head cover groove and bolt top cooling housing through the plate and to the head cover. Torque these bolts to 12 to 15 ft/lbs.
14. Connect top cooling hose to fitting and tighten hose clamp.

Start engine and make sure that there is coolant flow, after the thermostat has opened. MAKE SURE that you have no air locks in cooling path.

JETTING

The DPM system will compensate for elevation and temperature changes. This DPM system must have the correct main jet to start with or you will be too lean or too rich.

RKT has found that even with the higher compression ratios, the Torque-Line Head needs less of a main jet than the OEM lower compression head. This, we feel, is due to the increase in combustion efficiency found with our head.  NOTE: We suggest starting with the stock main jet, then monitoring piston wash and spark plugs before determining the proper main jet. Please keep in mind, that there is no “one set-up for all” when dealing with performance parts. We have also found that these Series III engines do NOT exhibit the normal was patterns. OUR testing has shown that “no wash” does not suggest a lean condition.

Here is what we suggest for jetting FOR A COMPLETELY STOCK ENGINE: NOTE: This jetting specs are ONLY a suggestion.. FINAL jetting could be lower or higher

2001 800 ->  450 mains                 2003 REV models -> 360 mains
2002 800 ->  460 mains                2004-2005 REV models =>  350 mains                                                               
2001-2002 700 -> 420 mains        2006-2007 REV 800 HO Engine -> 380-390 mains
2000 700 ->  280 mains                2007 REV 800R Engine -> 440-450 mains
2008-2011 XP 800R engine -> 450-460 mains

THIS HEAD WAS DESIGNED TO RUN ON GOOD 92 OCTANE PUMP FUEL. WE DO NOT RECOMMEND CONVIENCE STORE FUELS. Bad fuel can cause detonation problems which can result in severe engine damage.

HAPPY SLEDDING!!!  And thanks for buying from RK Tek