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[porthole]

Is the pipe inside the diameter of the threaded area of the mounting bung? If so, then yes it should be cleared out of the way

Just enough where it looks like the sensor may be touching it.

Duane, strictly in the FWIW department Fatcats are on all three bikes here.  All with systems that use that same Bosch sensor (EMS on the SEEG and SERK and the T-Max Marelli conversion on the old SERG).  My plugs all look even.  On the SERG and the SEEG have had occasion to actually see the valves and sensors while doing other things after they'd been in servicve for many miles.  They too are even or very very close to it. 

Don, can you compare the bung location on  my pipe to your 3?

[Twolanerider]

Don, can you compare the bung location on  my pipe to your 3?

Just from the visual they look at least similar.  Though it would be impossible to compare precise angles.  Try to give some specific measurements from obvious fixed points to a center point of each bung and will compare as well as I can.

[porthole]

Just from the visual they look at least similar.  Though it would be impossible to compare precise angles.  Try to give some specific measurements from obvious fixed points to a center point of each bung and will compare as well as I can.

That's not necessary. But if you can get an idea of the length of the bung, that may help.

I have a HSS 1" counter bore and removable 5/8" pilot coming today or tomorrow. See if I can mess up my pipes.

[Steve Cole]

The easy way to check this is to use a piece of safety wire (~6") and bend about 1/8" over about 70 deg. Stick the wire through the mounting bung and hook the bent part of the wire on the ID of the pipe. Use a marker to mark the wire flush with the top of the bung. Do this for both the long and short side. Now take out a piece of paper and draw a vertical line about 3/4" long. At the top of the line use your wire and line up one of your two marks on the wire with the line then go horizontally over to the hook part and put a dot on the paper. Repeat the same with the other mark at the bottom of your vertical line. Now take a ruler and draw a straight line to connect the two dots. This gives you the perfect size of your O2 bungs on a piece of paper and you can lay the O2 sensor right on top of it to really see whats truely going inside of the pipe! Just line up the gasket part with your vertical line and see what sticks past the line that you connected the dots.

[porthole]

Ok, I had to read that 3-4 times to figure if out.
Will give it a try in a bit.
Got my fancy  counter bore and pilot, and the pilot doesnt fit.........

[Twolanerider]

Ok, I had to read that 3-4 times to figure if out.
Will give it a try in a bit.
Got my fancy  counter bore and pilot, and the pilot doesnt fit.........

That'll be more accurate than a comparative measure I'd give you too. 

[Steve Cole]

What I have in my head doesn't always come out so good when it gets typed. If you have any questions ask away and I will answer them.

[HOGMIKE]

.

Have you ever checked your gas mileage?
Just thinking you are running a little on the rich side!
 

[porthole]

What I have in my head doesn't always come out so good when it gets typed. If you have any questions ask away and I will answer them.

I figured it out - I think

Front O2,
"O" = originals location
"N" = new

[porthole]

Rear

[porthole]

Counter bore with replaceable pilot.

This tool required a 3/16" pilot bore shank.
The pilot I got was exactly 3/"16" and the counter bore was drilled for 3/16", so the pilot did not fit.
Took 20 minutes chuckled into a drill press and some "

[porthole]

.

[cvobiker]

Oh chit... This is defiantly O2 surgery... Good luck, this is becoming very interesting to follow.... 

[Steve Cole]

Your picture pretty much shows it all. It's NOT the O2 sensors or the ECM's fault when it doesn't work right when they are not mounted correctly.

[porthole]

So, here are 4 pictures of my O2 sensors. My question, are these the sensors that pull the O2 reference air through the harness?
It is obvious these sensors have a harness that is sealed almost up to the wire connector.

If so, that could be another issue, having the sensor harness wire tied tight to the frame could block any reference air from getting to the sensor.