What is the proper way to put the clutch cover gasket on? I bought a new gasket but it still leaks. Do you put it around the clutch cover first and then put the cover back on or do you just put the gasket in the groove first?

 

I can only tell you what works for me.
I place the gasket into the grove lightly and then install the cover,I only put the screws in untill they touch the plastic and then go around and give them all about one full turn.I then start the engine and place my hand on the exhast of the cover and feel for leaks around the seal, Give a 1/4 turn more if you find one.
Hope it helps,
Zman

 

The gasket goes in the groove first.Make sure the gasket is in great shape before you waste your time installing it.The gasket only costs 6 bucks and is worth it just knowing its not distorted.Install your 3/8 screws and tighten them evenly.Buy some additional compression clips from Polaris at 50 cents each and install them arounds the cover once you have tightened the 3/8 screws.Install about 5 or 6 of these clips.Thats all there is to it,it will NOT leak if you follow my directions,

Bill

 

I installed a new gasket today but haven't been riding again yet to see if it leaks or not. I put the gasket in the groove first like you said. I will pick up some of those clips and put them on before I try it out.

 

Before I put the cover back on, I apply a light coating of grease to the gasket. I have taken the cover off many times, and still have the same gasket, and I have never had water in the clutch housing.