I believe some folks with the '09 models had out of spec valve cover gaskets. They basically shrunk, making re-use very difficult. I'm sure others can confirm. This problem was corrected, and I believe all those in stock parts from Kaw are correct. This was only on production bikes for that year if I remember correctly.

 

I avoided gasket issues by putting the cam cover back on when not working with the valves, like when I ordered shims. I pulled the cams out, put the cam cap back on snug, but not tight, then put the cover back on. It keeps the gasket in place without chance of shrinking. A bit of extra work, but no problem.

 

Thanks for the info and tips

 

That was my experience with my '09. Did the 600 mile valve adjustment, and could not get the valve cover gasket to seat correctly. Replaced the gasket and had no problem then, or with subsequent removal and re-assembly.

 

I just had my 2012 KLX250 in for a valve adjustment a few days ago and after 14,000 miles was still perfectly in spec.