I did a little research on what is recommended to seal the cylinder head cover.

Here is a link to the Permatex catalog:

http://www.permatex.com/documents/AAM%20Catalog.PX0078E.pdf

If you go to page 72 (71 of 80), you'll see the cross reference for Suzuki Bond 1216 (recommended for this job in the Suzuki FSM).  It says that Permatex Ultra Grey (not to be confused with the Permatex MotoSeal® 1 Ultimate Gasket Maker Grey) is the recommended stuff to use for this job.  I'll be using it this time.

Regarding the rubber cap that goes on the top of the head, Suzuki does not call for a sealant here.  However, just about everyone here uses a sealant of some type on the plug.  I used Permatex Ultra Copper the last time I did this job, but the plug started leaking after about 5000 miles.  Note that this was with the old-style plug.

I've touted the Ultra Copper here in the past, but it's time to try something else.

I'll be putting in a new-style plug this time, and am going to try this stuff:

Permatex® Ultra Rubber Gasket Sealant & Dressing

I think it will also be good for sealing the camshaft end cap and even the o-rings on the valve inspection caps.

I'll let you guys know how everything works out.

I now open the floor for comments.

Past comments on using the new style plug with the modern silicones say "the little sucker goes in the hole right easy and in a half minute later it tries to pop right back out because the pre-cure silicone is so durn slick".

Issue is the new plug has a lot of retention compression and the wet silicone is slicker than bat shite -- there is more than enough slick there and plenty of force there to move that plug when your back is turned.

Solution for the others has been to put some significant amount of weight on top of the plug during the silicone's cure time so it stays down in the hole and in full compression.  It is important that silicone NOT see movement during its cure out (once it gets past the full liquid state) or you can get a leak on the rubber plug repair as the semi set silicone can develops tears and fissures if it moves after the set up starts.

Humidity in the air (moisture) and heat (temp) are the catalyst for silicone setting, so if you want to speed things along once you get it all clamped up then spray a little water on it.  It doesn't take much, just a spritz.  Then give it like 4 hours of clamp time to finish the set up completely.  

Having the head warm to the touch helps some, think on this if it is winter time and you are in a cold garage.  Got you a hair dryer or heat gun?  

Warm head and a spritz of water will get that lump of wet silicone full hard for you inside an hour, easy.

Oldfeller--FSO wrote on 07/11/09 at 10:01:04:


Old,

I'll be trying this stuff for the rubber plug:

Permatex® Ultra Rubber Gasket Sealant & Dressing

It is not silicone based, so maybe it won't be as slippery as the silicone sealants are.  It is supposed to eliminate "slippery" rubber gaskets and you are supposed to let it get tacky before installing the gasket.

Here is the Technical Data Sheet on the Ultra Rubber Gasket
Sealant & Dressing:

TDS

VHF,

I was a Permatex Ultra Copper guy for years, but my rubber plug (old style, BTW) started leaking after almost 5000 miles after I installed it using the Ultra Copper.

I found out that the Permatex Ultra Grey was a replacement for the Suzuki 1216 called for in the FSM, so I'm expecting good results with the Ultra Grey.

Re the Ultra Black:  Make sure you do your homework before using this on the head cover.  Here is an excerpt from the Technical Data Sheet for the Permatex® Ultra Black® Maximum Oil Resistance RTV Silicone Gasket Maker:

6. Assemble parts immediately while silicone is still wet.

7. Finger tighten flange only until material begins to seep
out the sides of the flange.

8. Allow to set for at least two hours and re-torque at least
one quarter to one half turn.

I'm not sure this is the best stuff for the head cover.