Removed valve cover to fix the leak. The gasket is extremely difficult to get seated into the top groove of the valve cover. Laying the cover upside down and seating the gasket first is nearly useless as the gasket is not just seating, it's like it's too small.

What do I do? We tried soaking the gasket in hot water to loosen it and have it expand a little. Didn't work. Tried using painters tape and taping it to the cover and letting the sealant set. Didn't work.

My carb is jetted and my Muzzy is sitting here ready to go. I'm out at someone's house and would like to ride home.

The words "super glue" have been tossed around at this point...

Help!!

 

If I had to......

I get the gasket seated as best I could and cut the gasket with a razor to get the rest to seat...Let it sit in RTV and drop it on the jug with a slight bit of rtv on that.....Torque it 3 different times......

Lets say its 40 lbs...

1st torque setting 12 lbs
2nd 30lbs
3rd 40 lbs.....

Let sit 10 minutes and check again on 40lbs...Just an example for the torque setting

Hopefully there isnt much oil pressure up there so it shouldnt be too bad....Id order another gasket anyways........

Rocco

 

Superglued on the left side at the 4 corners and the inside curve.



The gasket is like $30..what a load of crap. The thing was literally too small for the groove. I don't know who designed it but the groove should be on the bottom, not the valve cover itself. Either way the gasket was too small.

The jetting needs work...but that's another thread. The new 2009 Muzzy looks good and fits OK. The turn signal is completely unaffected. It won't melt.
Leftover mystery bolt too. Love that.

Not me in the pic. Very good helper!

 

$30 what a ripoff. Thats as bad as the sticker on the radiator shroud being $43!! Glad you got it.

 

We need pixxars of the Muzzys on the 09! Its good to hear you believe it won't melt the turn signal, as well.

 

It was an all day tech day yesterday. I've got some pics. I need to take a break from the bike and spend some time with the girlfriend and take the dog to the dog park.

I'll be starting a new thread for the jetting on Thumpertalk. Maybe I'll leave that for there and add some pics to the "great humongous" thread here.

The gasket leaked...slightly. I could probably torque the cover a little more. I didn't know the specs when we had everything out. I'll fix it when I go to rejet.

I'm just surprised no one has run into this as taking the valve cover off is no big deal, but no one mentioned having any trouble putting it back.