Resealing the Air Box Boots on the PC800

A problem that more and more PC800 owners are experiencing is oil leaks from the air box boots.  The boots connect the air box to the carburetors.  They are glued into the air box.  Over time, this glue eventually fails.

Usually excess oil vapor and overfilled oil is drawn up from the crank case and into the air box where it mixes with incoming air that then is burned in the engine.  The tube you see that connects between the air box main body and the lower boot in the photo above developed a large leak.  In order to fix it, I used some silicone that I found at the auto parts store.  It was rated as being very heat resistant and plastic compatible.  The stuff had a horrible smell.  I had to keep all of my windows open while working with it.  One note of caution is that gluing should be done where you can make sure that the air box will still fit onto the carbs correctly.  I didn’t do that and had to manhandle the air box back onto the carbs.

Air Box Oil Leak and Tightening the Oil Filter

 

I’ve been having oil leak from my PC for several months now.  Last year, I ended up having to replace the seal around the shift rod.  This time it doesn’t look like it’s coming from there.  Instead, I found two separate places that oil was leaking from.  The oil filter had become loose and appears to be the main source of oil.  I tightened it nearly a full turn.  Also the air box has developed a bit of a leak.

 

 

The telltale signs of an oil leak.

 

 

 

Oil was leaking from where I’m pointing my finger at.  The carb boots in the air box are not an integral part of the air box.  They are molded separately and then inserted after the fact.  Some sort of glue is used to seal them.  The glue on mine has gone bad.  I cleaned it up as best I could and re-installed it for now.  In a few weeks when I replace the air box with something different, I will make sure the new air box does not have a leak.  Incidentally, the reason that oil is coming out of the air box is because of the crank case breather tube.