Figure 4-62. O2 sensor locations: XL models: 1. Front O2 sensor; 2. Rear O2 sensor
Removal
| PART NUMBER | TOOL NAME |
| HD-48262 | OXYGEN SENSOR SOCKET |
| HD-48647 | OXYGEN SENSOR SOCKET |
1. All Models: See Figure 4-63. Disconnect the front O2 sensor connector:
- a. Remove the frame clip (2).
- b. Disconnect the sensor pin connector [138A] housing (3) from the socket connector [138B] housing.
Figure 4-63. Front O2 sensor and connector (XL shown): 1. Front O2 sensor; 2. Frame clip; 3. O2 sensor connector [138]
2. XL Models: See Figure 4-64. Disconnect the rear O2 sensor connector:
- a. Remove the rear O2 sensor connector [137] (2) from the ECM caddy (1).
- b. Disconnect the rear O2 sensor pin connector [137A] housing from the socket connector [137B] housing.
Figure 4-64. Rear oxygen sensor: XL models: 1. ECM caddy cover; 2. O2 sensor
3. XR 1200X: Disconnect the rear O2 sensor pin connector [137A] housing from the socket connector [137B] housing.
Note. If O2 sensors are to be reused:
- Mark each sensor FRONT or REAR.
- Do not damage the sensor wire harness.
4. Remove the front and rear sensor:
- a. XL Models: Use the OXYGEN SENSOR SOCKET (Part No. HD-48262).
- b. XR 1200X: Use the OXYGEN SENSOR SOCKET (Part No. HD-48647).
Installation
| PART NUMBER | TOOL NAME |
| HD-48262 | OXYGEN SENSOR SOCKET |
| HD-48647 | OXYGEN SENSOR SOCKET |
| FASTENER | TORQUE VALUE | |
| O2 sensor | 29-44 ft·lbs | 39.3-59.7 Nm |
Notes:
- Do not install O2 sensors that have been dropped or impacted by other components. Damage to the sensor element may have occurred.
- New O2 sensors have threads coated with anti-seize material.
- If a sensor is being reused, apply a thin coat of ANTISEIZE LUBRICANT to the sensor threads and install new seal rings.
- Do not use any other grease or sealant product on sensor threads.
1. Install the front and rear sensors:
- a. XL Models: Use the OXYGEN SENSOR SOCKET (Part No. HD-48262) to install the front and rear O2 sensors.
- b. XR 1200X: Use the OXYGEN SENSOR SOCKET (Part No. HD-48647) to install the front and rear O2 sensors.
2. Tighten to 29-44 ft·lbs (39.3-59.7 Nm).
Note. The O2 connector must be clean and free of any dielectric grease.
3. All Models: Route the front O2 wire harness:
- a. Connect the pin and socket connector [138] housings.
- b. Install the frame clip over the sensor harness, clutch cable, and wiring harness on left frame down tube.
Note. Route rear O2 sensor harness toward left side in a loop away from the exhaust system. Avoid contact with exhaust port or exhaust pipe.
4. XL Models: Route the rear O2 sensor wire harness:
- a. Connect the pin and socket connector [137] housings.
- b. Route the wire harness and snap the connector into the ECM caddy.
- c. Slide the caddy into place and tighten the fastener.
5. XR 1200X: Route sensor harness and connect pin and socket connector [137] housings.