EXHAUST OXYGEN SENSOR (WIDE BAND O2) BUNG DRILL AND TAP TOOL KIT

J065622017-09-28

GENERAL

Kit Number

14900105

Models

For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).

Additional Tools and Materials Required

The following items are required for proper application of this kit:

Drill press with 1/2 inch chuck
Drill press vise
Clean shop rags
Cutting fluid/oil
Grease

Kit Contents

See Figure 4 and Table 1.

DRILLING AND TAPPING PROCEDURE

WARNING

Wear safety glasses or goggles while drilling. Flying debris could result in serious eye injury. (00565b)

NOTE

Perform the following procedure on both front and rear oxygen sensor bungs.

Drill the Hole

NOTE

Drilling material may cause damage to catalyst system if proper precaution IS NOT taken to prevent debris from entering exhaust system.

The use of mechanical fingers, coat hanger or welding rod tied to shop rag will ease insertion and removal of rag.

Insert clean shop rag into each end of exhaust pipe past oxygen sensor bung. This will help stop and catch all drilling debris.

Set drill press spindle speed to SLOWEST setting.

Refer to Table 1. Install piloted drill bit (1) into drill press chuck.

See Figure 1. With the drill press NOT running:

a. Position exhaust pipe (3) into drill press vise (2).

b. Lower drill press chuck and position piloted drill bit (1) into exhaust pipe bung.

NOTE

Pilot tip of drill bit must be completely square and fully-inserted into bung.

c. Clamp down drill press vise to exhaust pipe.

d. Raise and lower drill press chuck to check for drill pattern.

1	Piloted drill bit
2	Drill press vise
3	Exhaust pipe

Figure 1. Drilling Exhaust Pipe

With the drill press running:

a. Apply cutting fluid to the drill bit and hole as necessary.

b. Drill through oxygen sensor bung.

Repeat procedure for other oxygen sensor bung.

Wipe off excessive drilling debris. Leave shop rags in exhaust pipe.

Tap the Hole

See Figure 2. Assemble tap to tap handle:

a. Insert tap (3) into tap handle (1).

b. Secure tap with set screw (4) of tap handle. Ensure tap is oriented so that the set screw engages the flat of the tap.

c. Apply grease (2) to end of tap.

1	Tap handle
2	Grease
3	Tap
4	Set screw

Figure 2. Tap Holder Assembly

See Figure 3. Position and clamp exhaust pipe (4) into bench vise (3).

NOTE

Pilot tip of tap (2) must be completely square and fully-inserted into bung.

Insert pilot tip of tap (2) into oxygen sensor bung (1).

1	Oxygen sensor bung
2	Pilot tip of tap
3	Bench vise
4	Exhaust pipe

Figure 3. Tapping Exhaust Pipe

NOTE

Apply cutting fluid to tap and hole as necessary while tapping.

Start tap by applying slight downward pressure while turning in a clockwise direction.

Continue to turn tap clockwise until tap has bottomed out, as indicated by increased resistance. Do NOT force tap.

Back tap out by turning tap counterclockwise, 1 - 2 turns, then blow out debris using low-pressure compressed air.

Repeat Steps 5 and 6 until threads have been completely cut into oxygen sensor bung.

Turn tap counterclockwise and remove tap.

Blow off debris using low-pressure compressed air and remove exhaust pipe from bench vise.

10.

NOTE

Tip end of exhaust pipe toward the ground when removing shop rags. This will assure cutting material debris will not fall into exhaust system.

Remove shop rags from exhaust pipe.

11.

Clean off cutting fluid and grease:

a. Position exhaust so fluid runs out of pipe.

b. Use PJ1® cleaner or equivalent to remove all traces of contaminants from thread area.

SERVICE PARTS

Figure 4. Kit Contents for Exhaust Oxygen Sensor (wide Band O2) Bung Drill And Tap Tool

Table 1. Service Parts

Item	Description (Quantity)	Part Number
1	41/64- in Piloted drill bit, exhaust O2 sensor bung	14900104
2	Tap handle	14900106
3	M18 x 1.5 Piloted tap, exhaust O2 sensor bung	14900103