Author Chip in exhaust port  (Read 869 times)

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  • Offline jink21   us

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    Offline jink21

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    Chip in exhaust port
    on: Nov 26, 2023, 11.45 pm
    Nov 26, 2023, 11.45 pm
    Hi everyone, I recently chipped the exhaust port in cylinder #2 while removing the old copper exhaust gaskets.

    The chip is small and around a half-mil to a millimeter deep. It does not go to the edge.

    Could this chip cause any irreparable damage to the engine? Does this exhaust port need to be filled and re-ported?

    Photo is below and chip is circled in red. Thanks in advance.


  • Offline Cazzy_R   england

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    Re: Chip in exhaust port
    Reply #1 on: Nov 27, 2023, 08.53 pm
    Nov 27, 2023, 08.53 pm
    Be reet.  :028:

  • Offline zed9   us

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    Re: Chip in exhaust port
    Reply #2 on: Nov 29, 2023, 03.18 am
    Nov 29, 2023, 03.18 am
    Itís fine.
    You can always add high temp silicone to ensure a good seal.
    I was replacing those donuts on another Kawasaki and was stunned to see silicone from the factory on the underside of those gaskets. And the silicone was still pliable after 6000 miles and many years.

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    Offline jink21

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    Re: Chip in exhaust port
    Reply #3 on: Nov 30, 2023, 04.32 am
    Nov 30, 2023, 04.32 am
    Thank you for this info. I'm pondering "filling" the small chip with some copper RTV.

    My question is what will happen to any excess that is "squeezed" out when I torque down the header pipes?

    Will the paste just burn up if it's in the exhaust path?

  • Offline zed9   us

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    Re: Chip in exhaust port
    Reply #4 on: Nov 30, 2023, 02.29 pm
    Nov 30, 2023, 02.29 pm
    *Originally Posted by jink21 [+]
    Thank you for this info. I'm pondering "filling" the small chip with some copper RTV.

    My question is what will happen to any excess that is "squeezed" out when I torque down the header pipes?

    Will the paste just burn up if it's in the exhaust path?

    All youíll need is a little smear. What I saw was mostly on the outside so any excess on the inside may have been burned off and sent on its way out the exhaust pipe. But being a factory install, they are pretty good at applying the right amount.
    When I reinstalled the same copper gaskets, I did so without reapplying any silicone and never had a leak even years later.

    If there are any sharp edges on your chip Iíd round them out so as not to propagate any cracks. Aluminum does not like square, sharp edges.

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    Re: Chip in exhaust port
    Reply #5 on: Nov 30, 2023, 04.39 pm
    Nov 30, 2023, 04.39 pm
     The gasket goo just keeps the copper rings in place during assembly. Can't be having them dropping out on the assembly line.
     The soft copper rings will comply to minor imperfections in the gasket face.
     Be reet.

  • Offline jink21   us

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    Re: Chip in exhaust port
    Reply #6 on: Nov 30, 2023, 05.58 pm
    Nov 30, 2023, 05.58 pm
    *Originally Posted by zed9 [+]
    All youíll need is a little smear. What I saw was mostly on the outside so any excess on the inside may have been burned off and sent on its way out the exhaust pipe. But being a factory install, they are pretty good at applying the right amount.
    When I reinstalled the same copper gaskets, I did so without reapplying any silicone and never had a leak even years later.

    If there are any sharp edges on your chip Iíd round them out so as not to propagate any cracks. Aluminum does not like square, sharp edges.

    Thank you Zed, that is helpful to know.

    In terms of rounding out the edges of my chips, what would you use to do that? Below is a better photo and I've circled the chips in red.



    The chips are quite small and shallow, so if I do need rounding, I'm struggling to think of any tool that would be up for the job.

    I also wanted to see if you think the edges are sharp enough to warrant any rounding.

    Thanks again for your help.

  • Offline zed9   us

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    Re: Chip in exhaust port
    Reply #7 on: Nov 30, 2023, 07.15 pm
    Nov 30, 2023, 07.15 pm
    A small flat screwdriver or chisel will work. Just scrape at the edges til you canít feel anything then some high temp sealant and youíre good.
    You just donít want to create a path for the exhaust gases to sneak by. When you get it running again, feel and listen for a leak.