Dave
YaBB Moderator ModSquad
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SuzukiSavage.com Rocks!
Posts: 18115
Camp Springs, Kentucky
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First I think we need to be sure what you are calling the "valve cover".
There are oval inspection covers that you can remove using two bolts - one is on the front of the engine to allow you to adjust the exhaust valve clearance, and one is on the back of the engine to allow you to adjust the intake valve clearance. These covers have O-rings to seal the cover and keep the oil inside. Over time the rubber can harden and the covers can also become a bit warped. If these are leaking and snugging up the bolts doesn't help....buy new O-rings and check to see if the covers are flat. Get a piece of glass and a sheet of 360 or 400 wet/dry sandpaper and wet the paper, and rub the flat side of the cover on the sandpaper until the cover is smooth and shiny across the entire mating surface.
The top of the engine is called the "head cover", and it has about a dozen bolts holding it to the head.......it is the part that the oval covers described above are bolted to. This cover is sealed with an RTV sealant, and the head cover has to be taken off, cleaned and resealed if it is leaking. If your engine is black buy the Suzukibond sealant.....if your engine is silver buy the Hondabond or Threebond sealant as those are gray.
Resealing the head cover is a job is not horribly difficult of complex - but it does require that you have a basic amount of mechanical ability and understand that you can only tighten 6mm bolts a "little bit" - as the soft aluminum threads can easily be stripped if you overtighten them.
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