Exhaust leak at the valve cover

I'm sure this will make me look like a tard, but thats OK.

I replaced my valve cover gasket and cam end seals and since replacement it has a significant exhaust leak on the front right and left sides of the valve cover gasket. I used some black RTV on the bottom and top of the cam end seals and left the gasket dry. Out of sheer frustration I took it back apart last night and tried it again with a different sealer and let it sit over night. Same freakin issue. I am proud of myself for not throwing wrenches last night but today. A real mood killer! Any ideas fellow motorcyclists? Thanks in advance!!!

Probably used the wrong gasket. A 1979-80 gasket is *not* the same gasket as a 1977-78. If you use the early gasket on the later engine you'll get exaust leaks.

Thanks. It appeared to be a perfect match. Are there any notable differences to look for on the gasket that I should look for? I'm going to go ahead and order another one from Z1 just in case.

what about using a black RTV sealant instead of the gasket?

Z1E's gasket

Imo it's best to install gasket completely dry onto perfectly clean spotless mating surfaces on both cover and head. Expend sufficient time and effort to do this right.

Use only a tiny dab of sealer (I use silicone out of a tube) around the end caps to keep them from leaking. Just a thin film is plenty. Sometimes, a set of brand new end caps is needed, but usually not.

Please forget any thoughts of using RTV sealant on the gasket or as -- Heaven forbid -- a substitute for the gasket. That stuff clogs oil journals, and should be kept out from under the valve cover at all costs.

Good Luck!

Thanks for all the scoop. Yeah I agree about making a gasket being a shady way to go but I figured I'd ask.

Sight unseen I went ahead and ordered the correct gasket from Z1. The gasket that is installed now is from another vendor and I don't recall being able to choose between year models. My bad. I'm going to take it apart tonight and compare the to pics (mucho thanks Patton!).

In case you don't see the difference, these 4 holes are sealed for the emissions ports on the 1980 engine.

RonKZ650 wrote:

In case you don't see the difference, these 4 holes are sealed for the emissions ports on the 1980 engine.

Yes, and make sure that you install it with those four holes on the exhaust cam (front) side of the head.

When I rebuilt my '82, I initially installed the gasket backwards. Without paying close attention, I assumed that it could go either way, like on my '78. After I fired it up, I had some real nasty oil leaks coming from the back side of the exhaust cam cover. Then I realized that the gasket was not a mirrored copy front & back. I flipped it over, and that took care of the problem. And yes, I felt like a tard. :blush:

Thanks!!!!

The tard factor was high that day. It's the wrong gasket. OOOPS! I'll write this one off as valuable experience. The proper gasket is on its way from Z1 so I should be good as long as I don't eat the gasket before I get it installed.

Thanks again ya'll!

Peace.