The Struggle is Real: Trying to Keep a Triumph 955i Tiger on the Road

The 'Idle Speed Control Valve Housing' (Part Number: T1241064) continues to be a pain in my ass. This housing sits behind the throttle body on my 2003 Triumph Tiger 955i and it seems Triumph isn't supporting them anymore. My local dealer shrugged and said it isn't available any more, so I went further afield.

Blackfoot Motosports in Calgary's site seemed to suggest that they could provide this complex plastic piece that doesn't enjoy Canada's extreme temperature swings (I've gone through 2 of them so far). So I ordered it! Guess what:

That an O-ring should take 3 weeks is one thing, but the housing is obsolete? On a bike that's only just 20 years old? So, I did a little research. It turns out this product fits 84 vehicle variants across four Triumph Models between 1993 and 2020. A part that was in use on models four years ago is obsolete? That doesn't sound right.

No matter where I look the story is the same: this key part of the idle control system on thousands of bikes isn't available?  Being a determined sort, I looked to ebay for options and came across Bike Spares Barn in the UK. They take bikes traded in at dealers that are still running and on the road and dismantle them for parts, which is what I'm reduced to using with my Triumph.

They had a throttle body with the needed idle control housing on it along with an airbox. My airbox isn't in great shape so I got both parts. They worked out with shipping to be about $300CAD. It took a good 3 weeks for the parts to get here (I ordered right after the holidays so I can't really fault the timeline). The seller was very communicative with what was going on so, unlike some ordering experiences, I was never left wondering where things were.

The box finally arrived and looked like someone had been playing football with it. Two corners were mashed in and a piece of the airbox was sticking out of the box. I unwrapped it and everything looked OK so I began to clean and dismantle everything. The airbox was a good idea, this one is in much better shape than my 24 Canadian winters one, but the throttle body didn't fare so well. 

Inevitably, the only broken piece on the damned thing was the fragile idle housing, which was cracked around the base in exactly the same place that the one I'm trying to replace is.

So, I'm back where I started, but with a spare throttle body and two broken idle housings. This damned thing is so complicated that fabricating an alternative isn't likely. The three pipes on the bottom go out to each throttle body and servo sits inside that is moved up and down electrically adjusting the vacuum so passages open up to each throttle and modulate the idle so the bike doesn't stall. When this complex and fragile piece doesn't work as it should the bike hesitates on acceleration and stalls.

Obviously this wasn't the case because the bike it came from was working fine (they tested it before dismantling it), but it didn't survive ebay's international shipping service. I asked Bike Spares Barn what to do and they said to go through ebay's return/refund process, but ebay is cagey about sharing that anyware. Fortunately Peter at Bike Spares Barn helped me navigate the obfuscation and we've now gotten me a refund... but I'm still stuck without this part.

I've asked before and I'll say it again: if you're not willing or able to support your own machines, Triumph Motorbikes, how about sharing publicly the CAD files on this part so after market and crafty types like myself can fabricate our own? With the right fuel resistant plastic in a 3d printer, I could knock up my own version. But before I did I'd reinforce the model and design something more robust so I'm not left out in the cold again.

The happy face getting the solution to my problem in (the box on the bench)... then, well, you know what happened.