Been riding alot today and it seems dry and fine, so if you dont want to remove all carb,airfilter++ you can just tighten up the cover and apply gasket. Why couldnt they give us 1cm more and the cover would have come of easy. Amazing that the original gasket seal lasted 20years, it was the thinnest line i ever seen of gasket seal.

Glad you got it sorted ! How was it getting the sealant on with the cover in place?

Compared to taking of carb + airfilter box its easy, you can do sealent in half at the time and just lower the cover. Buy sealent tube with a long plastic in front like this
https://www.google.no/search?q=plast...19%3B560%3B385

Then its easier to get in the middle around the spark plug area, and remember stick a very small hole in the tube, the tinner the better when you lay the gasket out. The most critical area is in front where the oil is at all time when running because of the angle of engine. When it leaks you get the oil right down to the exhaust and believe me its not fun when you are standing in traffic with the burned oil smoke coming up in your face..

The one problem I see that could happen when doing it that way is getting sealer on the inside when messing with the second half. A drop of Silicon plugging up an oil orifice has caused quite a few engine failures.

You never know if there comes a drop of silicon on the inside anyway when you press the cover down, its impossible to know how much is squizing out. But remember the silicon when it sticks wont get off, the original sealent was outside the edge and has been there for 20years without doing any damage. And i recon when the oil from engine is cleaned by the oil filter before it comes back into the small holes. By the way the cover is still in the air when you do the second half, use the tank holders to secure it.

The manual I used to own warned of the danger of bits of silicone breaking away inside and blocking the oilways: the pump may not push them as far as the oil filter and basically you can end up with a "blocked artery" leading to a "coronary thrombosis", using medical terminology.

I dont know what you mean by bits, the sealer is like glue and sticks to everything you get in contact with. You can buy a fiber cam and check edges if you want to be shure how the inside edges looks like, but i wont!