I found a thread a while back (can't find it now) about a mis-fitting head gasket in the '09 models. I have a small leak in mine with less than 3000 miles and wondered if Kawasaki ever recognized the problem? If so what has to be done to get it replaced? Thanks for any input.

 

does it leak at the corners of the 1/2 circle at the cam ends? not unusual with dohc , only place you might need a little sealant or even grease

 

did it happen after a recent oil change?...too much oil?...if the "head gasket" is the rubber valve cover gasket with the two half circles, remove the valve cover, clean off all the glob of hardened factory silicone, reapply light sealant (little extra on the half circle), gasket back on if it looks good, and put the valve cover back on...check your oil levels...

might as well check your valve clearance while you have it open...

 

Some (most?) of the '09s had a valve cover gasket that shrinks when removed and cannot be reused.

 

i have one of the early '09 klx250sf...had no problem reusing...but, it sure was a pain scraping off all the factory silicone...couldn't believe how much the kawasaki factory used...

 

My 09 has no problems with the valve cover gasket FWIW. Since the 09's seem to have been in production from early 08 into 09 it might be somthing they changed mid-model year.

 

My '09 started leaking oil from the head cover gasket at maybe 6000 miles. I didn't do anything about it until I finally did a valve check/adjustement at 7407 miles. I just bought a new gasket ahead of time and replaced it. So far no leaks in 1700 miles since replacement.

 

What makes this gasket cost more than $30?

 

Profit!

 

They should nationalize Kawasaki. It is immoral to profit from peoples addictions.
My 09 was purchased in 08. The valve cover gasket leaked after a few thousand. You might as well just order one up, because they are a ***** to put the old one back on and no matter what you do it will leak again.