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Discussion Starter #1
Any tips for getting the O2 sensor to break loose. So far it has not responded to a wrench and is still in excellent shape (no rounded corners). I did give it a couple of doses of penetrating oil and heated the bung with a propane torch and its still stuck. Just didn't know if I should get the cheater pipe and get more serious. I was concerned that I would bend something that was not intended to be adjusted.
 

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I'm sure someone will come to your aid shortly, the sites motor heads are getting older and it takes them a little longer to respond these days. :grin:
 

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Mine was difficult to break loose as well. You're on the right track with the heat, but I would recommend using foil as a heat shield for wires in the proximity. You may want to use a penetrating oil for several days if you are uncomfortable with exerting extra force. However you're not likely to damage the exhaust before you damage the o2 sensor which could be removed with a pipe wrench if necessary. also some have found it extremely helpful to use a string prior to removal of the wiring as a fish to install the new plug.
 

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Buy a cheap deep well impact socket on EBay and take a grinder and cut a slot up one side about an inch. Use the slot for the wires and put the socket on, now you can use a long handled breaker bar. Use all those good penetrating fluids too. Maybe try the loctite spray one that chills as it lubes. Slow pressure on the wrench is not as good as sudden.
 

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Discussion Starter #6
Thanks for the help. Overnight and the penetrating oil must have done it job. Short cheater didn't hurt either.
Next issue I bought a Bosch replacement O2 sensor with a connector kit. The wire colors are black, gray and two whites just like the original sensor. You have to reuse the connector the bike side. The question is are the whites common to each other?
 

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Thanks for the help. Overnight and the penetrating oil must have done it job. Short cheater didn't hurt either.
Next issue I bought a Bosch replacement O2 sensor with a connector kit. The wire colors are black, gray and two whites just like the original sensor. You have to reuse the connector the bike side. The question is are the whites common to each other?
I have installed the same BOSH universal O2-sensor 2 years ago. Works well, but you have to be patient and meticulous with the small connectors.

Both white wires are for heating element (inside sensor) and can be matched with either/any of the 2 white wires on new sensor. This type of heating element has no polarity.
 

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Discussion Starter #8
Good news. Looks like I'm good to go. Your right about being time consuming. It takes a while to make up the connections. Thanks for the response.
 

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Yes, black to black, grey to grey and whites don't matter.
 

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Had exhaust out so decided to replace o2 sensor, WOW!

heated then wrench then heated lots of pb blaster ect still ng.

I ended up breaking hex part with wires off, twisted off.
Still had not budged, so then tried easy out, just wiggled.

So I drilled out a bit larger hole, the jug saw with metal blade in 2 spots, now going to use o2 sensor thread chaser to clean rust off threads. Funny no other bolts on bike had this much corrosion.

Looks like no thread damage, just annoying, bought new one at autozone $80, cheaper online, but did not want to wait.

used bosch part# to find it there

much cheaper than this site

Bosch - K1200 Oxygen Sensor
 

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Had exhaust out so decided to replace o2 sensor, WOW!

heated then wrench then heated lots of pb blaster ect still ng.

I ended up breaking hex part with wires off, twisted off.
Still had not budged, so then tried easy out, just wiggled.

So I drilled out a bit larger hole, the jug saw with metal blade in 2 spots, now going to use o2 sensor thread chaser to clean rust off threads. Funny no other bolts on bike had this much corrosion.

Looks like no thread damage, just annoying, bought new one at autozone $80, cheaper online, but did not want to wait.

used bosch part# to find it there

much cheaper than this site

Bosch - K1200 Oxygen Sensor
Do you have the BOSCH part number handy for the rest of us and did it have the correct plug on the end? I know many have used the universal and cur/spliced the wires.

And for the masses, add some more anti seize than comes on it so you don't have to go through that again if it fails.
 

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bosch part#11 78 1 742 051


looked up bosch part number(see link above), gave it to autozone, they looked it up. Got new bosch sensor with correct plug for $80, they last at least 60K.

Autozone also registers you with 1 year warranty

Had to remove old stuck one, it was practically welded in.
Hear PB etc NG, ended up breaking off nut part, the drilled out, easy out failed.

after drilling I used Jig saw metal blade to cut out threads.
The used chisle to break the rest of it, no ruined threads.
The $9 at napa bought o2 sensor thread chaser, a little wd40 and that tool made threads like new.
 

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bosch plays games with parts, numbers and prices

o2 sensor same one ranges from over $300 to $50
Bosch fuel pump for volvo same pump price range $150 to over $550

they take all the money they can, and do not believe parts are different from dealer, just more middle men involved.
 

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Do you have the BOSCH part number handy for the rest of us and did it have the correct plug on the end? I know many have used the universal and cur/spliced the wires.

And for the masses, add some more anti seize than comes on it so you don't have to go through that again if it fails.
See picture. Plug compatible.
 

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Amazon has the Bosch 13475 Oxygen Sensor, OE Type Fitment for $71. Complete with plug so no need to cut and solder. Also available is an offset puller for O2 sensors $11.
 

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yes offset puller should work, but if its frozen like mine, torch then drill then saw, NOT FUN.

bikes see moisture, then cat creates it so there is rust on inside and out, contant heat then cool makes it welded in, my friends car was the same.

Get the o2 sensor thread chaser also, or buy both tools local and bring back if you dont need them
 

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yes offset puller should work, but if its frozen like mine, torch then drill then saw, NOT FUN.

bikes see moisture, then cat creates it so there is rust on inside and out, contant heat then cool makes it welded in, my friends car was the same.

Get the o2 sensor thread chaser also, or buy both tools local and bring back if you dont need them
I used an O2 sensor socket when removing mine. I had also let it soak for 2-3 days in WD-40 with a fresh hit of WD-40 each day. Mine came loose amazing easily, but then I have only 54,000 miles on mine. A higher mileage bike would likely be progressively more difficult as, as you say, the [email protected] sensor lives in a harsh environment to say the least.

I didn't need to use heat as mine came loose with just a 1/2" breaker bar, no need even for a cheater pipe. Had it not, heat was my next step and then the 2' cheater pipe after that. Fortunately, no need in my case.
 

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the rounded top o2 is what my original and new one from autozone looked like
 
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