I got my new to me 07 back from the dealer today. They changed the valve cover gasket under warranty and when I got home(30 miles) I noticed it was already leaking again. Could some one tell me the steps to adding the washers? I usually do all my own work but I havent taken anything off the 14 yet. Do I have to remove the lower, mid fairings and tank then have access to the bolts or is it more in depth than that? I really dont wont to leave it at the dealer anothe 6 days if its something I can fix in a couple of hours.

Where is the leak? See, we can't is the problem. So, you are going to strip what might be a pinched/dirty surface kind of leak you cannot solve.

If you do your own work, then strip the body away, have them look at their own work. You might have a stripped bolt now? I mean, probably not, but that supple rubber should seal like new. I have 12K without a hitch of a leak. It's not the parts, but the execution.

Now, you remove that cover, that baby is on you. Your word against theirs. You bring it back so they can see, "there it is," then it is not a new gasket on you. If you check their work for a pinch, how is it all of a sudden, we have a valve cover leak 3 years in changing to a less heat cycled rubber part?

* Last updated by: Hub on 4/12/2010 @ 4:31 PM *

Ya...look on the valve cover thread...you'll find your steps to fix it(I'll say again....."It's NOT the GASKET!!!!".Guys(including ME)have wasted our cash buying a gasket for it!.Mine was 66 bucks-yep,still leaked FROM THE DEALER INSTALL!!!!!(that didn't count labor).....how do I know it's not the gasket?Cause when ya get that little extra torque in there from the washers,she seals perfect!

* Last updated by: blue07 on 4/12/2010 @ 4:34 PM *

Sad. You might be right, blue, but I have one sitting here in package just for the 15k shim check. I plan to have a video 'how-to,' throw the dice you tell me I have to add a washer when this bike does not leak now. I'm not buying it.

I know,I know....You don't HAVE to do anything with anything.If ya bought a gasket-I'd say use it-fer sure.BUT....even if your present deal isn't seeping...you "may" want to avoid possible future work by just installing the washers.I'd guess-and that's ALL it is-is that probably 7 out of 10 14's have this issue.I've seen these threads on EVERY site I've gone to.This isn't something out of the ordinary for these bikes-My zx12 DID THE SAME THING.This is a common issue-should have been addressed by Kawi-but they're shops and mechanics are makin lots o'dough replacing these parts.And it's something that is "petty much" easy for a tech to do without tearing a customer's bike down.Easy Money.That's what I see....could be completely wrong of course.I'm glad you have one of the few that is holding up okay.Most don't.It's not like the engine's gonna blow because of it.It's just an easy catch for Kawi-hate to see it like that,but why else would they NOT correct such a simple situation?Just a thought.I might add though Hub....mine didn't start the deal till 20,000 miles.You MAY not have run it long enough yet for it to begin it's deal....Maybe?....How many miles on yer bike Rebus-if ya don't mind my askin?

I gotta say this though..it will continue to seep a minute amount of oil from under the lip for a few rides until that residue is completely gone.So it COULD appear like it's NOT fixed for a day or two of rides.If ya wipe er down well after each ride,you should see it taper off to a stop.

* Last updated by: blue07 on 4/12/2010 @ 4:54 PM *

It was coming from the left side and it is still coming from the left side. I thought about it being just residual oil so I cleaned it really well and am going to keep a check on it a few morre days before doing anything.
That is a good point hub. I dont want to void the warranty by doing anything myself so I may take it back and let them replace it and see if they will add the washers for me, that way I will still be covered. It sucks having to leave it another week.

It's sounds like I may have to run a simple technique to it. Say oil can be squeezed down to a millionth of an inch. Say that mechanic did not wipe the surfaces down to a complete dry [enough] contact. That oil [under the rubber] now is a wedge between the inside of the engine and the outside of the cover.

There now is this pressure pushing in at that wedge, adding a void to that gap is more oil about to be filled and pushed out. Take a piece of paper and just fold it to each corner. It has a look of a tear drop now. Now, let it go, watch the ends fold out on the table and lay flat. Same execution if you being at the center nuts, walk them down every 2 pounds till it's proper torque value. If the bolt calls for 8lbs-tq, then it's in increments of 2-4-6-8 times you go over that cover from the center out and either X-pattern the cover bolts or move out in square blocks. Start from the center and work your way out, not one side and go across or start at any old bolt. That is the technique I will use to see if we can have a leak-less cover without the washer helper.

I think it may have been residual oil. After a 80 mile ride yesterday I didnt notice any oil. Hopefully all is good.

I wasnt so lucky. I just picked it up from the dealer again. I told them about the bolt hole not being deep enough so they measured the hole and the bolt and said that was the problem. It wasnt getting enough compression on the gasket for it to seal. They replaced the gasket again and added 1.5mm shims so I should be good to go now.

"I won't leave it at the dealer's if it's something I can fix in a couple of hours"......"see WE CAN'T is the problem"...."It's not the parts,but the execution"......"GUYS...IT'S NOT THE GASKET"....."they measured the bolt and the hole and said it wasn't deep enough to compress for a good seal".I'm STILL full of shit.The fix is IN! Shims/washers?...did somebody say "so I should be good to go now"...yep,yer clear for takeoff Bro!

* Last updated by: blue07 on 6/4/2010 @ 3:35 PM *

He said he was going to report it to kawasaki. They suggested replacing the gasket again and that was it. I would have done it myself but it was covered under the ext warranty.

By no means was I criticizing you Reb.Not at all.You could have repaired it yourself using the washers,it's cool....they should be aware of it.And if that's what they were supposed to fix at first,then they need to get er done right for ya.You've got an 07.I've got an 07.If you check out the 2010 model year parts fiche,that gasket NOW has a DIFFERENT number than all previous years(except maybe 09's?)The problem exists at Kawasaki-the bolts and threads were not designed (or were they?)to last "forever" with the deterioration of the gasket.That's MY take on it.They got hundreds and hundreds of e-mails and angry customer complaints about this problem...you know they did.It's such a simple thing to correct,prospective buyers don't want a leaking cover on their new bike,or at all.Apparently the "new" gaskets are a tad thicker,allowing the needed squeeze ability to stay sealed.So they "kind of" addressed the problem without actually admitting,"hey,we miscalculated here".(meaning they'd most likely have to initiate a recall...which would mean lost dollars).At least you've managed to have the bolt/thread issue clarified by someone other than "an owner's opinion".I glad ya posted about your experience.And I'm glad you are now riding worry free about your oil leak.The gaskets are around 60 dollars-the washers,about3.50 tops.I don't know about you,but my experiences with dealer maintenance on my zx has been,well,not very encouraging.That gasket removal(not the washers)...is VERY time intensive and not as easy as it sounds.LOTS can go wrong if a guy doesn't REALLY know what he's doing and paying attention to his work.And like you found out,even experienced mechanics can get it wrong.When I had my valves checked,I took it to MY trusted mechanic-he used to work for Kawasaki,worked on my zx12 whenever it needed work.So my faith in him knowing what and how to do things right is very solid.He's worked on my 14 a few times now.But even with that,when he replaced the gasket during the valve check,it started leaking right away.It was a new gasket(for the 07 model year). I never said anything to him...cause I know these gasket/seal issues exist on our bikes.I just reinstalled the washers as before and called it good.If it starts leaking again,you know how to fix it fairly easily,so there ya go.My 12 also had a gasket seep,but I sold it before I ever got around to fixing it(it wasn't a bad leak anyway...just barely)

* Last updated by: blue07 on 6/4/2010 @ 7:53 PM *

I know you werent criticizing me. I have read the other threads where people didnt believe you.
I trust my local dealer, The owner used to work with me at the fire dept till he retired. The mechanic felt aweful that it came back. He even washed it for me. For the gasket, the mechanic spoke with me about it and according to him it is just a different material and not really any thicker. I guess thats why mine started leaking as soon as I left the dealer. I feel confident that they got it fixed this time.