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Discussion Starter #1
After performing a valve check I cleaned the valve cover thoroughly and buttoned everything up. Now the cover leaks from the front like the seal isn't even there. Is there some trick to getting the cover to seal up?

The cover was dirty and greasy before doing the check and the motor had evidence of moderate leaks as well, so I was quite careful to inspect and clean everything and torque the retaining screws properly. I put silicon grease on the oring seals for the screws but didn't do that for the cover gasket.

Any advice would be appreciated.
 

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You should use a gasket sealer like RTV Blue/Loctite Blue Maxx or something similar on the head gasket. Something which does not set hard, but definitely some form of sealer is recommended.
 

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Discussion Starter #3
You should use a gasket sealer like RTV Blue/Loctite Blue Maxx or something similar on the head gasket. Something which does not set hard, but definitely some form of sealer is recommended.
Thanks for that. Since the gasket is already bonded along the underside of the semi-circular features on each side of the cylinder head, I would guess that the RTV should be applied to the underside of the seal only, otherwise it would be tough to get the valve cover back off. Is this correct?
 

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I have found that a new valve cover seal every time is required....something about the rubber and heat cycles, it just doesn't like to seal a second time around. Every time I have tried re-using the seal I have had a leak....

Always leaks at the left front corner (lowest spot when on the side stand), maybe because the oil is pooled there while the bike is at rest. The mechanic at Biker's Rest (GA dealer) has found the same thing. We've been discussing it for a while.

Donsy's method will work, I am sure, but I don't like the mess. I follow the workbook instructions of sealant in the cam shaft cut-outs (half moons), but no where else.
 

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sealed?

i'm with Donsy, glue them!
i use high temp silicone every where, its too much work to do over......
kind of like valley gaskets on the intake manifold of a V-8

Ed, clean up is easy....use acetone or lacquer thinner and a brass brush

:f4::brutale:
 

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Discussion Starter #7
I have found that a new valve cover seal every time is required....something about the rubber and heat cycles, it just doesn't like to seal a second time around. Every time I have tried re-using the seal I have had a leak....
CAG mentioned that as well and if I had a new one I would use it for sure. Since I don't and want to ride sooner than the time it will take to get one, I have tried the sealing method using Permatex High Tack Gasket Sealant. It sets up but never hardens fully, so it seals but allows the gasket to be moved, so disassembly is dead easy. Kind of a cool product. I painted it in the groove of the cover and on the top front edge of the cylinder head under the seal. Seems to have worked.

What a pain, though. Many words were spoken in the sanctity of the garage. And some gestures. With both hands. I don't know whose idea it was to bond the seal on a portion of the bottom surface while having a complex contour tongue-and-groove alignment to the cover on the top surface with near zero clearance everywhere but they should be shot.

At least that is what I was thinking while trying to get the gasket to seat in the groove all the way around ...
 

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I agree about the silicone. Just a thin film both sides. Some of my gaskets I spray a good wet coat of copper high temp on them and let it dry. It's just enough to fill in those pesky little spots and will come off without alot of work. Always use new gaskets and O rings when reassembling and if possible torque in a two step criss cross pattern.
 
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