09 800 CFI Assault
I just did this to my 09 800 CFI.
I removed the airbox, and split it apart, careful to preserve the tabs. To do this I used a razor to bevel the rear locking edge, of the tabs to help them slide out.
Next I smoothed out the prymarks left from my small flat bar, used to separate the case halves. I just used a dulled flat blade screwdriver to reform the ridge that is on the edge of one half, to preserve this factory lip/groove fit.
Next, I read up on sealants and it seems that some silicone is not sensor safe, and my engine has what I think is a Mass Air Flow Sensor in the airbox, but more importantly an 02 sensor in the pipe. (It is an o2 sensor right?
) any how, the silicone can "off gas" and coat your o2 sensor leading to premature failure of the sensor and lost performance, and in rare cases engine damage.
Having said that, I went with Ultra Black RTV, High Temp. Sensor Safe sealant. And layed a bead on one half, and also put some on the upper side of the slot that the air horns sit in, to seal those chambers from each other, and prevent anymore chattering evident on the air horn plate.
I then placed the air horn assembly into the groove, placed the other half on top and lightly snapped them together, and let the sealant set up with the airbox in the "relaxed" state, meaning I did not clamp it all together, as I don't think that RTV has all that good of adhesive strength, And I did not it want to pull apart bouncing down the trail.
I then noticed that the boots that seal the throttle bodies to the airbox have an alternate push lock hole, that needs to be sealed as well, no sense sealing everything up and leaving those two 1/4" holes. Look carefully, they are under the boots, but will let air in. I also smoothed the pushed out RTV along the outer ridge, just for a little more security, and then finished it off with the reflective heat tape.
I could not fit a piece of rubber under the box, though, it simply would not mount on the throttle bodies again.
The only trick I learned is when reinstalling the air box, don't hook any of the fuel and fuel filter lines onto the airbox, until the boots are tight to the throttle bodies.
I also sealed my headlight, and my intake plenum.
One rule of thumb I use also for intake/pre filter area is to add filters/intake area until you can't see the prefilter material "suck in" when you blip your throttle.
Sorry no pics.
