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Roy
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And it was a nightmare!! Suzuki QC strikes again on the Bandit
What looked to be a simple unscrew screw back in turned into a 4 hour ordeal thanks to some crappy work by a sleepy factory guy. I suspect this was what made my sensor erratic all along. Dealer got my sensor replaceded under warranty back a month ago, I just got around to messing with it. We had tried to swap a ECM to cure the dreaded surge my bike has had since day one that did not work so we said lets replace the sensor while its under warranty. This thing cost about $200 bucks dealer cost on it is $125 Suzuki picked up the tab. So I go to unscrew the original, **** it seems tighter than 18 ft. lbs so I came out a little went in a little until it snapped off
I was pissed now I have a hole into my exhaust. I thought since I have been using the O2 bypass I'd just plug the hole with a self tapping screw. The sensor has porcelin in the middle so when it snapped that all came out but the metal thread collar of the sensor was left in the pipes threaded hole. I said no I am getting that thing out. So I got a reverse ease out tapped it in and began to back the remaining threads out. It was extremely tight and I had a wrench break trying to turn the ease out. Fnally it came out and guess what, it was cross threaded to begin with and the friggin threads of the pipe came out with the sensor threads. I looked further into the pipes threaded hole and the remaing pipes fine threads do not match the sensors coarse threads so what they are doing it impacting a incorrect threaded sensor into a fine threaded hole. Does not make sense but I am sure it has to do with somebody saving some money along the way, cheaper sensor found on the market only after the pipe maker had the more expensive sensor already threaded for fine threads. Okay so what do I do, new sensor came with anti-sieze already on the threads I thought that was a bit weird. So I cleaned out the hole and inserted the new sensor. To my suprise it begin to thread into the pipe with ease until the last few turns to the crush washer. 18 ft. lbs is spec and I did not excede that to the best of my knowledge. Tight working area by the way would be easier with pipe off the bike but that is another 2 hour ordeal I was not ready for. So its in and I fired it up and took a quick spin. To my suprise it rode just like the O2 was bypassed
I still cannot believe it. I plan on riding it here in a hour or so more but as of right now it did not surge at light throttle openings at all. I can't tell the difference between the O2 bypassed and new sensor hooked up online. So are they busting these sensors installing them, my guess is yes they are. It does not take much to bust the porcelin inside the sensor and wire. I looked at the busted one up close. With the difference in the thread pattern I can see how when new this could go wrong on this install. I was careful to not jar the sensor with the wrench at all during my install or force it in. If I had more time and the pipe was off the bike I might have tried to source a tap for the sensors thread pitch but what the heck it self tapped itself and if this does not work in the end the hole is still plugged and I go back to the O2 bypass.
I am bored I need 6 more motorcycles to work on in my free time. j/k I have a 600 racebike tore down to engine and frame right now so no I am occupied.
YMMV
What looked to be a simple unscrew screw back in turned into a 4 hour ordeal thanks to some crappy work by a sleepy factory guy. I suspect this was what made my sensor erratic all along. Dealer got my sensor replaceded under warranty back a month ago, I just got around to messing with it. We had tried to swap a ECM to cure the dreaded surge my bike has had since day one that did not work so we said lets replace the sensor while its under warranty. This thing cost about $200 bucks dealer cost on it is $125 Suzuki picked up the tab. So I go to unscrew the original, **** it seems tighter than 18 ft. lbs so I came out a little went in a little until it snapped off I was pissed now I have a hole into my exhaust. I thought since I have been using the O2 bypass I'd just plug the hole with a self tapping screw. The sensor has porcelin in the middle so when it snapped that all came out but the metal thread collar of the sensor was left in the pipes threaded hole. I said no I am getting that thing out. So I got a reverse ease out tapped it in and began to back the remaining threads out. It was extremely tight and I had a wrench break trying to turn the ease out. Fnally it came out and guess what, it was cross threaded to begin with and the friggin threads of the pipe came out with the sensor threads. I looked further into the pipes threaded hole and the remaing pipes fine threads do not match the sensors coarse threads so what they are doing it impacting a incorrect threaded sensor into a fine threaded hole. Does not make sense but I am sure it has to do with somebody saving some money along the way, cheaper sensor found on the market only after the pipe maker had the more expensive sensor already threaded for fine threads. Okay so what do I do, new sensor came with anti-sieze already on the threads I thought that was a bit weird. So I cleaned out the hole and inserted the new sensor. To my suprise it begin to thread into the pipe with ease until the last few turns to the crush washer. 18 ft. lbs is spec and I did not excede that to the best of my knowledge. Tight working area by the way would be easier with pipe off the bike but that is another 2 hour ordeal I was not ready for. So its in and I fired it up and took a quick spin. To my suprise it rode just like the O2 was bypassed I still cannot believe it. I plan on riding it here in a hour or so more but as of right now it did not surge at light throttle openings at all. I can't tell the difference between the O2 bypassed and new sensor hooked up online. So are they busting these sensors installing them, my guess is yes they are. It does not take much to bust the porcelin inside the sensor and wire. I looked at the busted one up close. With the difference in the thread pattern I can see how when new this could go wrong on this install. I was careful to not jar the sensor with the wrench at all during my install or force it in. If I had more time and the pipe was off the bike I might have tried to source a tap for the sensors thread pitch but what the heck it self tapped itself and if this does not work in the end the hole is still plugged and I go back to the O2 bypass.I am bored I need 6 more motorcycles to work on in my free time. j/k I have a 600 racebike tore down to engine and frame right now so no I am occupied.
YMMV
It had a square shank, just drive it in, then twist it with a wrench.....repeat a few hundred times, you're done.
Anyway could not ride sunday or today tropical storm "Fay" has been parked here for two days dumping rain close to 2 inches locally. I hope to be back on the 1250 commuting at least by tuesday of this week.