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[patsfan]

I'm in the middle of the Rev Performance EMS install and everything seems pretty straight forward, however.....
I'm having a helluva time getting the RP rear O2 sensor threaded in the bung. The RP sensor external shaft is longer than the stock and its very tight to the case. Just when I think I have it started, it comes right out. I'm not kidding, I just spent over 1 hour on that sensor alone and have the scraped knuckles to prove it.
Does anyone have any ideas? tips?
BTW, the front sensor threaded in fine.

[sadunbar]

I'm in the middle of the Rev Performance EMS install and everything seems pretty straight forward, however.....
I'm having a helluva time getting the RP rear O2 sensor threaded in the bung. The RP sensor external shaft is longer than the stock and its very tight to the case. Just when I think I have it started, it comes right out. I'm not kidding, I just spent over 1 hour on that sensor alone and have the scraped knuckles to prove it.
Does anyone have any ideas? tips?
BTW, the front sensor threaded in fine.

The stock O2 sensors are narrow band.  The Rev. Perf. sensors are wide band.  Wide band sensors are longer than narrow band.  

Are these stock pipes or aftermarket?  If the sensor is going to touch the case when installed, you may need to relocate the bung.  If your pipes are stock, then I would suggest you just take your time and be careful.   You may want to get a thread tap and make sure the bung threads in the pipe are still intact.  Cleaning the threads out may make it easier to get the sensor started.  You sure don't want to cross thread the sensor into the pipe and ruin the threads.  You'll want to use O2 sensor safe anti-seize lubricant on the sensor threads also.  After cleaning out the threads, if you still can't get it started, remove the pipe, install the sensor, then re-install the pipe...  Be sure you have clearance to your case when installed.

By the way, the title of your thread makes it sound like a Rev. Perf. EMS problem...which it isn't.  Kind of a bit of unwarranted bad advertisement for the EMS.  It's an issue threading a O2 sensor into your pipe...  You may want to consider re-naming your thread...

And Welcome to the site!     Glad you have joined us.  

[patsfan]

The stock O2 sensors are narrow band.  The Rev. Perf. sensors are wide band.  Wide band sensors are longer than narrow band.  

Are these stock pipes or aftermarket?  If the sensor is going to touch the case when installed, you may need to relocate the bung.  If your pipes are stock, then I would suggest you just take your time and be careful.   You may want to get a thread tap and make sure the bung threads in the pipe are still intact.  Cleaning the threads out may make it easier to get the sensor started.  You sure don't want to cross thread the sensor into the pipe and ruin the threads.  You'll want to use O2 sensor safe anti-seize lubricant on the sensor threads also.  After cleaning out the threads, if you still can't get it started, remove the pipe, install the sensor, then re-install the pipe...  Be sure you have clearance to your case when installed.

By the way, the title of your thread makes it sound like a Rev. Perf. EMS problem...which it isn't.  Kind of a bit of unwarranted bad advertisement for the EMS.  It's an issue threading a O2 sensor into your pipe...  You may want to consider re-naming your thread...

And Welcome to the site!     Glad you have joined us

Thanks for the reply and all good points taken. Should have introduced myself as I'm not a newbie to Harley forums, been following the RP threads here lately and posted in a state of frustration. Yep, not an RP problem, just an installer problem looking for a tip I may have overlooked.
I do have stock pipes and there is enough clearance, just very tight. I had thought of all your suggestions and will try again tomorrow with the tap and lube steps. I'm installing some new muffs anyway, so if need be, will loosen the head pipes and pull out far enough to try and get a better bite on it.

[mattm]

You can pick up an inexpensive 18mm thread chaser from Harbor Freight that works pretty well for this.  Good luck.

[patsfan]

Just a quick update on this. I chased the threads and used anti-sieze and still no go. Wound up pulling the heads and out just enough to get a couple extra inches of clearance and she went right in. On my 08, with the longer wide band sensor, the pigtail was just binding to much on the case to get it in. A little more work than expected but all's well that ends well. Now to get the new muffs on and the front end back together, I'll be able to see how this tuner performs.

[Unbalanced]

Good luck with the build, do hope the antiseize was lead free    

[patsfan]

Good luck with the build, do hope the antiseize was lead free    

Labeled as "sensor safe" I should be OK.

[Unbalanced]

That should work.

[mattm]

Glad to hear you got the sensor installed.  Be sure to let us know how the revperf ems works out for you.

[rheiner]

that sounds pretty radical that you need to pull the heads to get an O2 sensor in. Both heads? I thought you were having problems with just one sensor?

[Twolanerider]

that sounds pretty radical that you need to pull the heads to get an O2 sensor in. Both heads? I thought you were having problems with just one sensor?

Can't know until the gent says so himself of course; but my guess is he mean head pipe rather than the cylinder head.

[grc]

Can't know until the gent says so himself of course; but my guess is he mean head pipe rather than the cylinder head.

    

That would be my guess as well.  And he wouldn't be the first person to have to remove a headpipe to install an O² sensor.


Jerry

[patsfan]

Yes, just the rear sensor gave me problems. Just had to loosen the headpipes enough to pull em out a couple inches.