KLR650 oil filter cover leak

[shards]

Just to put a closure (I hope) on this - I removed the cap, got rid of all the gasket-goo-gunk, cleaned the "O" ring dry, did NOT apply grease (as suggested in the Workshop Manual), and refitted the cap by applying finger pressure patiently (as suggested by a guy on klr650.net) and then went for a ride into Mt Maunganui to get the other "O" ring. NO LEAK. Just as well, because the "O" rings in the shop would not have fit anyway. So, I have ordered up a couple of extra Kawi "O" rings because I have decided to always use a new one when changing the filter.

If it doesn't leak again after my proposed 3 day ride this week, I'll be a happy chappy.

[Crisis management]

Well done, thats the way to assemble things mechanical, carefully!

If you get a chance take the cover (with the groove in it?) to someone that specialises in O-rings (hyraulic seal supplier is good) and they will measure the groove and get you the correct O-ring.
I suspect either the groove is out of tolerance or the cover is too flimsy to guarantee a good seal, talking to an expert will provide more answers than the parts guy at the bike shop.

I've spent the morning trying to get the back end out of a KTM, so your not alone in this world of mechanical mayhem.....