How to Install a Pro Moto Billet Spark Arrestor on Honda CRF450R (2004-2008)

The Pro Moto Billet PMB-01-1104 Spark Arrestor is designed to convert the stock muffler on the 2004-2008 Honda CRF450R into a U.S.F.S. approved spark arrested muffler. This version is formatted for easy use on CRFsOnly.com and follows the manufacturer installation process.

Before You Start

• Read all instructions carefully before beginning installation.
• If you do not have all required tools or are not comfortable performing the work, have the spark arrestor installed by a qualified technician.
• The inner core must be trimmed correctly to avoid damaging the spark arrestor screen.

Parts Included

• 1 Spark Arrestor Base
• 1 Nozzle
• 1 Screen
• 3 M6 Bolts
• 8 Self-tapping Screws

Tools Required

• Drill
• 13/64" drill bit
• Flat screwdriver
• Hammer
• Allen wrenches
• Center punch
• High-temp silicone sealant
• Hacksaw

Step-by-Step Installation

Step 1: Drill Out the Stock Rivets

Using a 13/64" drill bit, drill out the existing rivets that hold the stock end cap in place. Be sure to fully remove the rivet heads.

Step 2: Punch Out the Rivet Bodies

Use a center punch or similar tool with a hammer to push the remaining rivet pieces through the holes and out of the stock end cap.

Step 3: Remove the Stock End Cap

Pull the stock end cap out of the muffler. If it is difficult to remove, using a heat gun on the canister sleeve may help. If there is packing material inside the old end cap, transfer it to the new spark arrestor base.

Step 4: Clean Out Old Rivet Debris

Remove all old rivet pieces from the packing material inside the muffler canister.

Step 5: Trim the Inner Core

Cut off the portion of the inner core that extends past the muffler so it is flush with the outer aluminum canister. A hacksaw works well for this. Be careful not to cut into the aluminum canister. The inner core must be flush so the spark arrestor screen is not damaged during installation.

Step 6: Apply Silicone Sealant

Smear a small amount of high-temp silicone sealant onto the stepped portion of the new spark arrestor base.

Step 7: Install the New Spark Arrestor Base

Install the new spark arrestor base and make sure it is pushed tightly against the muffler. Drill a 13/64" hole at each rivet location and install one self-tapping screw at a time. Each time you drill and install a screw, make sure the base stays tight against the muffler. Using lubricant on the self-tapping screws is recommended.

Step 8: Clean Excess Sealant

Wipe away any excess silicone sealant after the base is installed.

Step 9: Install the Screen and End Cap

Insert the spark arrestor screen, then install the end cap/nozzle and tighten it using the supplied M6 bolts.

Step 10: Inspect and Maintain the Screen

Clean and inspect the spark arrestor screen regularly. The manufacturer recommends checking it each time you clean your air filter or change your oil.

Important Safety Notice

Check the condition of the spark arrestor screen often. A spark arrestor with holes in the screen will not function properly and should be serviced immediately.

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