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Pulled off the exhaust header on left rear side.
In part because it seemed to be seated about 2 mm deeper into the head than the other three headers.
Noted some so-to-speak not too pretty looking wear on the aluminum where header touches/connects to head.

We haven't owned this 912 for it's whole life, remembered that on some engines that exhaust ports on aluminum heads sometimes have a steel seat.

Wondered does the exhaust port where it exits the head normally have some kind of steel seat or does the exhaust manifold seat directly onto the aluminum head? If so, one of ours is missing.

I suppose we COULD pull off one of the other exhaust headers and see if they have steel seats, but less work to just ask.
Betting one or more of you Rotax gurus would have a straightforward answer.
And if the answer is "yes, you have a missing seat" have some ideas for remedies.

Appreciate all replies.
  • Re: Does exhaust port where it exits head normally have some kind of steel seat?

    by » 5 years ago


    The Header Pipe that connects to the Head has a "Falred Ferrule" about 1/2" from the end.
    The pipe is solidly clamped to the head and NO Relative Motion is to be expected.
    No Motion = No Wear.
    Where the header pipe meets the Muffler, the Pipe is Falred into a Virtual Ball joint that is held together by the Exhaust springs.
    This joint need regular lubrication with Copper (High Temperature) Anti-Seize Compound.

    It sounds like the Head end of the pipe was loose and the Muffler end was Seized.

    Bill Hertzel
    Rotax 912is
    North Ridgeville, OH, USA
    Clicking the "Thank You" is Always Appreciated by Everyone.


  • Re: Does exhaust port where it exits head normally have some kind of steel seat?

    by » 5 years ago


    Short partial update for any interested:
    First.... I can't praise enough the engineers and staff at CKT Engineering in England (the makers of our exhaust system.) They gave us excellent communications, and shipped us about maybe $150 of free parts (stainless steel insert to seat in the exhaust port on the manifold and a new custom fabricated stainless steel header.
    To makes a long story short...Per their advice we seated the sleeve using a JB-weld type epoxy (Gorilla Weld) between the sleeve and the exhaust manifold. Permatex Ultra High temp copper slilicone type gasket paste between the header and the sleeve.

    All issues resolved.. has been test flown many hours.

    Thank you said by: Wayne Fowler, RotaxOwner Admin

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