I wonder if Kawasaki just had a batch of bad valve cover gaskets. There have been a number of 09's that leak oil around the valve cover, mine one of them. That might explain the shrinkage too. I would think it would be pretty hard to tear that gasket, but I would ask to see the old part.

 

im going to mimic everyone else ans say its the fuel screw. try a half turn less. a bad batch of valve gaskets seams about right, my stock one leaked like a bitch, new one hasnt leaked a bit, but ill keep my fingers crossed on that one.

 

It's a known issue. It happened to me and I can assure you we were gentle with it while removing.

https://www.kawasakiforums.com/forum...er+gasket+glue

Cliffsta, if you are under warranty, they will replace it for you. If not, give it a shot. I think Kawasaki knows about the issue so they may replace it for free anyway.

That sumabich gasket is like $30 so I'd try and see.

 

Also, I FINALLY brought mine into the shop. I run the same setup as you, but I still had highway and WOT stutter. The shop ended up putting the clip on the lowest ring (needle in highest position) and said it seemed to run better that way, but didn't eliminate the stutter. Don't neglect the needle in the equation, though I think the needle isn't used while starting. Just remember that that is adjustable too.

 

Also Cliffsta, you posted in this thread. https://www.kawasakiforums.com/forum...ighway+stutter

You mean you've been putting up with it leaking allll this time??

 

Well the leak only got REALLY bad the last couple months, maybe the intense Louisiana heat finally got to it. The mech already ordered the gasket and my warantee just expired last week (go figure). So I doulbt the stealership gives me any money back. Soon as I get the bike back I'm gonna crank the A/F back a half a turn and see if it runs better in the heat. It idles kinda low in the woods or in a hot day.

I wish JD Jetting made a kit for our bikes, he included TWO needles... for different altitutdes / temperatures.

 

I've got JD's kit in my bike. Blue needle for winter, red needle for summer. And tweak the fuel screw or needle clip position occasionally during those transition months.

While that works and my jetting is usually crisp and spot-on, it does take a few tweaks here and there to keep it there.

 

My old man has the JD Jetting kit for his DRZ, he said he plays with the fuel screw in the different seasons. AHHH this waiting is driving me CRAZY I wanna get my bike back and RIDE.