Just completed this Job of replacing the Head cover Gasket. Fairly easy job. The only issues I had was a ruptured gas line and all the tubes surrounding the cover. It is best to get a new gasket because the old one will not fit again once it is removed. Used Three Bond Liquid Gasket 1194 to seal it.

 

Old Thread I know but.. Put me on the 09 leaky valve cover list..
Yep 3400 miles and the R Frt half moon is weeping.. Dammit
Well I jumped on here and guess I will get a NEW gasket and go from there..

 

Seems like there isn't an 09 out there that is immune to this. Mine started leaking a bit a few months ago.

The new gasket seemed more pliable and "rubbery" but then again the old one was 5 years old.

 

When I did the cam mod I couldn't get the old gasket back on. So I superglued it to the valve cover just enough to get it on. Then used gasket seal on the half moons. Months later, no leaks.

 

Yep didn't plan on this. Don't know but seems like a bad design..
I'm going to look at this carefully and see If I can make a different gasket..
A friend of mine has a race shop for cars and Motorcycles.. He makes gaskets all the time out of that aluminum metal Felpro material.. So hmmm will see what he thinks.. I don't know just got to be a better solution.. Will see if so I will let everyone know

 

The gasket on the '09 shrinks period. After doing the big bore, you find out real quick. Be smart order a new gasket ahead of time. I noticed the new one doesn't shrink either after doing a couple valve clearance checks.

 

Agreed with RaceGass, just go buy the gasket. Your buddy might make gaskets for projects, but this isn't a simple flat-surface to flat-surface gasket fit. By far, the 'simplest' thing to do is buy one at the dealer.

 

^^^ yep agree..
My Indy can get OEM from Kawi. 16 bucks.. So that's what will do.. Just to bad
These fail so quick..

 

the 09 year is known to have bad gaskets. other years and replacements dont appear to have the issue since kawasaki fixed the problem.