gen3 Thermostat Cover Leaking
Doing a recent bout of maintenance as I am coming up on 50k. Flushed out my coolant and then had an issue with my temp light coming on, my coolant then boiling out. Tried a few quick fixes, like radiator cap and checking hoses/air bubbles. Didn't fix it, so I went to replace my thermostat. Fun thing to swap out, I get the new one in and replace the cover but it began leaking from the lower right bolt area. I tried to tighten it, cracked the cover before hitting the 52ft lbs it suggested. So I bought a new one, new o-ring and reapplied. Still leaking from the same exact spot. But at $65 a pop for a new cover I am not wanting to tighten it up.
So my question is, what could be causing the leak? O-ring was new and looked fine, I removed the new one and cleaned everything off, reinstalled, still leaking. The manual states applying grease around the o-ring which the first one had but still leaked so not sure if that is it. Forgot it on the second install.
You guys have any suggestions on what to try? I'm tempted to apply some Permatex Water Pump & Thermostat liquid gasket but figured it best to check in with you all.
1st bike - 89 Katana 750 - sold
2nd bike - 95 zx750 ~ parts bike (selling)
3rd bike - 95 zx750 ~ sold
4th bike - 2005 z1000 ~ sold
5th bike - 2012 Z1000 - totaled at 120
6th bike - 2012 Z1000 - crashed & rebuilt *current*
Current: Full Arrow Race Exhaust - Bazazz FC - Renthal Fatbar Low - PSR Race Levers - Airbox Mod - Custom LED Taillight - Pro Grips Gel Grips - Gear Indicator - Sarge Seat - Crash Protection, frame, and exhaust sliders - Servo Buddy - Assorted little mods