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O2 sensor removal problem

H

husker_in_kc

Just got it firing!
Joined
Oct 20, 2011
Messages
13
So was working on the Norge installing installing the new O2 sensors with Todds upgrade kit and had one heck of a time getting one of the O2 sensors out. I had to wrench rather hard every bit to get it out. Was thinking it was really bad crossed threaded at the factory or something. When I was finally able to extract it this is what I found.

One




Rolling the sensor over.


Three

Its interesting to see half of it cover in carbon, dented in and dull and to see the other part of it ripped apart by removing it.


I used my finger to inspect the O2 sensor hole in the header and felt some pieces of something fall back down into the pipe and felt a protrusion in the hole that can be seen in the bottom right side.

Four

It appears the thread-o-let (not sure the term in this case but that's what it is in the I&C world) did not line up with the hole in the pipe very well.

Soo the question is what now? Can I just try and file the lip down? Do I need to pull of the pipe so I don't get stuff down stream to plug up the catalytic converter?

Other question is how the heck did they get it in to start with.
 
You could remove the pipe to be sure, or if there is room have a vacuum cleaner tip near the hole when you file that lip down.
 
Something like a Dremel tool would be best, rather than a file, you could avoid damaging the thread easier that way. It would be safer to remove the pipe and probably easier in the long term.
 
Wow, first I've ever seen like that, thanks for posting the pics.
I second the dremel, and FWIW, I'd recommend removing the exhaust to do this, and blowing it out before firing the bike.
 
I ended up pulling the exhaust off, it was easier then I anticipated. Filed down the protrusion so the new sensor went in easy.

I am curious on the assembly procedure, it looks as if the O2 sensor was already pre-assembeled to the fitting. This assembly is then put into the exhaust and then welded. Seems to be the only way to explain the dent on the first picture that was covered in carbon and how the other 3/4ths of the sensor got tore up on the removal.
 
husker_in_kc said:
I ended up pulling the exhaust off, it was easier then I anticipated. Filed down the protrusion so the new sensor went in easy.

I am curious on the assembly procedure, it looks as if the O2 sensor was already pre-assembeled to the fitting. This assembly is then put into the exhaust and then welded. Seems to be the only way to explain the dent on the first picture that was covered in carbon and how the other 3/4ths of the sensor got tore up on the removal.
Click to expand...


Probably not assembled that way. Hole drilled, bung welded on, then sensor installed. The factory uses many air tools so the guy probably didn't even notice (or care).
 
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