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. |
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Now disassemble the airbox
assembly, which consists of the airbox, backing plate and the
airboot. |
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| 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. |
 |
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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. |
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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. |
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Re-install the air filter,
along with reversing the dis-assembly process, and you are back on
the trail! |
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When it was all said and done, the Pro-Seal kit
was clearly a good choice. The most important thing you can do to
keep a motor running at it's best, is to keep the dirt out; which
is exactly what the PC kit does. PC capitalized on an error at the
Honda factory, and has carried through with it's intent.
- Update!
- We are having problems with keeping our airbox free of
dirt, check the Testing
Notes section to remain up to date on what progresses as the
cause.
PC Racing CRF Pro-Seal
Kit
Price as tested: $44.95 |
| Holeshot |
Endo |
- No more filter rim grease needed
- Possibly solves the relatively poor
design flaw of the '02 Honda airboxes
- Seals the gap between the airboot and the
airbox
- Solid aluminum retaining ring; compared to the
thin OEM metal steel unit.
|
- The kit contains nothing more than 2 gaskets
and a aluminum ring...a little pricey for what you get
|
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Rating System
1 = poor / 10 = excellent |
For information regarding the PC Racing Pro-Seal
kit, see www.pcracingusa.com. If you have any questions, opinions or
comments, let us know! Kevin Gorzny |
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