The stock 2002 Honda
airbox is perhaps the weakest link in the production of the CR125, CR250 and the
CRF450. A good idea when prepping any new bike, is to re-seal the airbox to
airboot junction, by using a good silicone sealant. But in this case, the Hondas
have an especially weak airbox seal; nearly to the point where it can't really
be fixed properly. PC Racing developed a kit which provides a gasket to install
between the airbox and the airboot, along with a thick, foam-like seal to be
installed where the air filter seats to the airbox. The foam seal also
alleviates another problem regarding the Honda airbox, which will be explained
below.
Remove
the subframe assembly, separating the airbox from the subframe. |
|
|
Now
disassemble the airbox assembly, which consists of the airbox,
backing plate and the airboot. |
|
It
is very important to completely remove the factory glue from the sealing
surface between the airbox and the airboot. Do this by using an adhesive
remover such as a 3M product. Contact cleaner will work as well. |
|
|
Now
that the surface is clean, its time to install the gasket which
goes between the airbox and the airboot (the thinner gasket of
the two). First be sure that the mounting inserts are no higher
than 3mm (or 2 dimes.) If they are higher, trim them down with a
razor blade. |
|
Place
the gasket on the airbox, stretching the holes over the inserts as
shown. |
|
|
Next
place the new machined aluminum backing plate over the airboot.
Then attach the airboot to the airbox via the stock screws. Take
extra care to not strip the screws; remember that you are using
a metal screw in plastic.Tighten each screw down in a cross
pattern, until each is snug. |
|
The
other thicker gasket serves two purposes, in the 02 Honda's case. 1) It
allows for a good airfilter to airbox seal without the use of grease. 2)
Solves the sealing problem as a result of the protruding airboot mounts
as shown in the photo. |
|
|
|