I'm install a Thundermax tuner with wide band O2 sensors on my bike. I'm running a PC-V now with Oxygen sensor plugs in my 2009 D&D Fat Cat now. I removed the front plug no problem. Went to remove the back one and it's frozen in the pipe. I tried using more force to break it loose and rounded out the allen wrench head on it. Any ideas how to get it out now without removing the pipe? It's in a very tite place behind the rear head on the bike. here's a couple of pixs:

 

Try a easy out?

 

Easiest now will be to remove the header and try a vice grip(add some heat to the bung before you turn)....and/or weld a large nut(weld inside where the threads are, let it cool) and turn it out. If you can cover everything with an anti spatter blanket you could probably weld it in place and use a socket on it then. If you try to weld it in place disconnect the battery and I would also unhook the ecm.

 

if you cant get it out, take the pipe off and take to a muffler shop or a welding shop and they will be able to get it out for you.

 

and when done, remember to use antiseize on the new o2 sensors or bungs in the future

mike

 

Thanks for the replies. I don't think I have enough room to try and use an easy out. I don't have any welding equipment so looks like the pipe will have to come off. Good idea about welding a nut to it. I was thinking that also.
I have been thinking about replace the 2-1 with a x pipe anyway. I just wanted to see how the Thundermax ran with the Fat Cat. I guess this makes my decision for me.Thanks for the replies. Rick

 

Have you tried penetrating oil yet?

 

You can also take a die grinder to it and cut a slot into the top of the plug, and use a straight slotted long screw driver in the slot you cut to get it out. That with some heat should be enough.

 

" If you try to weld it in place disconnect the battery and I would also unhook the ecm "

 

penetrating lubricant, repeat overnight and
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