09 KLX250S
1200+ miles
Pulled the valve cover and when trying to reinstall.... wth there is no way that it will fit again. I stretched and stretched it but no way it going to fit. No one has one in stock close by.... 3 to 5 days to get one in stock. Next time I pull it I'll have a new gasket just in case.

Is this common?

edit- heres a pic, the gasket is seated in the bottom left in its channel. Theres no way its gonna work!

 

If it can't be used, and as a last resort, try soaking it in brake fluid overnight. Just make sure you clean it all before install.

 

Yes, common prob with 09's, do search, some people got Kawi to reimburse.

Good luck

 

Thanks for the info. I'll have to talk to the salesman @ the dealership...see if its covered.
I must have missed those threads. Thanks

 

i had the same problem, super glue worked to hold it in place till i bolted it down.

 

Yep I have an 09 and it did the same thing. First it leaked a little around the half moons then it started leaking badly at the front.When I removed it it was shrunken down quite a bit. I replaced it with a new one and it fit perfect so far no more leaks.

 

You could try heating the gasket with a hair drying or putting it in hot water to expand it. Then quickly install it using a small amount of high temp silicone. Might work to get you back on the road sooner.

 

Should have tried the hot water trick, I bet that would have worked. Did the stretch armstrong to it but it broke - it was just about there too......

Oh well the dealer across town had a new one to me today after ordering on monday.

Thanks again