After 25k checkup by the HD Dealer, my inspection cover is leaking. Took back to HD dealer. Still leaking. I tried installing new gasket - still leaks. Is it possible for the inspection cover to be warped? 2003 Wide Glide.......

 

Sounds like a gasket surface isn't clean enough to seal.

 

Used carb cleaner to clean all surfaces where the gasket touches.

 

Are you talking about the little cover for adjusting the primary chain tensioner? If so, yes, they can become deformed over time especially if over tightened.

Remove the cover, check it for flatness, and straighten as required.

If all else fails, throw away the gasket and use some RTV instead.