Triumph 955i Stalling Issues Part 3, between a rock and a hard place

This started in June with intermittent stalling.  I've done all the obvious things like spark plugs, fuel and air filters, but the problem persisted intermittently, so I had another go at it in July.  The Tiger has been my go-to ride for over four years now.  I've put over twenty-seven thousand kilometres on it, and up until this year it's been as dependable as a sunrise.

This week I chased down some other possible electrical issues.  The ECU was covered in muck so I cleaned it up and sealed the plastic underbody around it so it won't get mucky again any time soon.  I then found out how to test the ECU relay under the seat:

That's the main how-to test Triumph 955i relays video, here are the two follow up videos: https://www.youtube.com/watch?v=TwkhX461GjM   https://www.youtube.com/watch?v=cDmh7FdpDDQ

Everything else is sorted on the bike, so I'm down to the valves, which I really should have done in the winter.  I'm now between a rock and a hard place since I'm not sure I'm hanging on to the Tiger and it takes weird, old 25mm over bucket shims that Japanese bikes haven't used since the '80s.  Modern bikes use much smaller under bucket shims.   My nearest dealer is far away and dropping off the bike there would be a real hassle, so I'm looking at getting the Triumph valve shim removal tool T3880012.  But you don't need that if you're willing to remove the cams, so now I'm elbow deep into pulling most of the top end out if I want to avoid getting a special tool for a bike I'm selling on. 

On the other hand, one of the reasons I got into bikes was to get back into mechanics, and any self respecting rider should know how to do valves, so I'm kinda keen to do the job since I haven't done it yet.  I'm just shying away from sidelining my long distance motorbike in the middle of a too-short Canadian riding season while I wait for COVID crippled parts delivery on a 17 year old European bike.  The valves need doing anyway, but doing them might still not sort out the stalling issue, which would be very aggravating.

If I can move the Honda on I'd get the C14 Concours I've been eyeing and then the Tiger could take as much spa time as it needed.  I just had the Honda up for a few days in the four thousands, which is high for what it is, and only got an offer for a trade.  I'm going to put it up this week in the threes and see if it goes, then I can do some shuffling and take the weight of expectations off the old Tiger.

Motorcycle Valve Adjustment Research:

Good primer on valve clearance from Revzilla:  https://www.revzilla.com/common-tread/why-do-bikes-use-shim-under-bucket-valve-adjusters

Why higher revving bike engines have bikes have solid rather than hydraulic valve lifters that need adjusting (cars and Harleys rev less and so use hydraulic/self adjusting valve lifters:  https://www.quora.com/Why-do-motorcycles-require-valve-adjustments-when-automobiles-dont-require-them

https://www.bikesrepublic.com/featured/checking-bikes-valve-clearance-important/
Why checking your valve adjustment is important.

Triumph 955i specific valve clearance primer:  https://www.canyonchasers.net/2006/02/triumph-t955i-valve-adjustment-tips-tricks/

Local advice on how hard it is to find 25mm shims for the Triumph 955i engine: https://www.gtamotorcycle.com/xf/threads/help-looking-for-25mm-valve-shims.201738/

Some 955i engines are under bucket shims, the Tiger has over bucket shims (which is why the tool is needed if you don't want to remove the cam):  https://www.triumphrat.net/threads/05-955i-valve-shims.6986/

Good advice on when to do your valve clearances (when you stop hearing the valves 'rustle'): https://www.mikesxs.net/25mm-valve-shims-sizes-2-30-to-3-10-honda-yamaha-triumph.html

Shim sizing on 955i Triumphs (25mm over bucket shims are hard to find!):  https://www.triumphrat.net/threads/2000-955i-shim-diameter.230758/


BikeBandit has the tool (1-2 week wait, and a 25mm shim set for $335US/$455CAD because even though the US is making a mess of COVID19, their currency seems to be immune to their poor management.

At this point I'm stuck between over four hundred bucks in tools, parts and the opportunity to do my first valve adjustment and whatever Inglis Cycle gets back to me with costs wise - though that'll also include having to get it over 140kms down there and get it back again on another day.  If they get back to me with a price north of $600 and a long delay in getting it done, I'll be going after the tools to DIY it, though I don't want to go crazy with a fancy set of 25mm shims when most modern bikes don't seem to use these big over bucket shims any more.

I'd go with Fortnine, but for some reason they're selling the identical shim kit to BikeBandit ($179US/$243CAD) for $278CAD. 

If I can move the Honda, I could get the C14 Concours and then have time to work on the Tiger without depending on it as my main long distance tool.  On the other hand, selling the Honda means I've just sold the only bike that's working right at the moment.  The Tiger picked a bad time during the summer of COVID to tighten up on me, though I'm well past when the valves should have been checked so I only really have myself to blame.

Installing LED indicators on a 2003 Triumph Tiger 955i

I've done a few LED light upgrades on motorcycles to date, so updating the indicators on my trusty 2003 Triumph Tiger 955i isn't producing many surprises.  Unlike the Kawasaki Heavy Industries ZG1K project bike last time, the Triumph doesn't use standard automotive blinker relays, so the cheap and cheerful option I went with last time from Amazon doesn't have the same pinouts.  Fortunately, the blinker relay is easy to get to on the Tiger (pic right).

The stock, German made Hella blinkgeber 4db 003 750-36 indicator relay swaps the positive and negative terminals from the Japanese standard ones, so it isn't a plug and play swap for a cheap, Chinese relay from Amazon.

Like most relays built for standard bulbs, it speeds up when it senses a lack of resistance (ie: a blown bulb) so you know when you've got a bulb out because it ticks fast.  LEDs are so much more efficient than standard bulbs that they act like a blown bulb, so you end up with hyper-flashing where your indicators are blinking silly fast.

While looking around for a plug and play alternative that wouldn't have me making a rat's nest out of a neat wiring loom, I came across superbrightLEDs.com and their primer on hyperflashing...

Looking through their site, I found an indicator relay that would be a straight swap on my Euro-awkward bike.  The price is pretty much the same as the Chinese part on Amazon, but then you get stung with shipping that is more than the cost of the part (Amazon shipping was covered).  They promise that this will work with LEDs, which I'm a bit cautious about because the other ones I've purchased have a potentiometer (dial control) on them that lets you adjust to the speed you want, and this one doesn't.

It's suggested in places that you can swap the power and ground, but a number of people seem to have had problems with that on various bikes, so I bit the bullet and ended up with a $24USD bill where it would have been $12CAD (shipping included) on Amazon.  I'm hoping I'm getting a higher quality piece for all that extra outlay (the superbrightLED one has a 2 year warranty on it whereas the Amazon one didn't).  The part is on its way, so I should be able to finish the indicator upgrade in early January.

The rest of the wiring has been pretty straightforward.  The LED set I purchased from AliExpress (my first time using them - shipping wasn't quick but everything got here eventually and the prices are amazing), worked fine when the system was doing 4 way flashers, but went into hyperblinking when I indicated.  It's an easy wiring in, but again the Euro-awkward nature of the bike means it didn't have standard sized spade clips and I had to cut the old ones off and use replacements which were way harder to find than they should have been.

Your 21st Century Hardware store sells you things, just none
of them are tools or, you know, hardware...

As an aside, have you noticed that hardware stores don't carry hardware any more?  A trip to my local hardware shops was more like going to home decorating shops with lots of pretty things but no actual hardware.  I ended up at an automotive specialty retailer to find electrical connectors.  Hardware stores are now just glorified department stores.  You can't survive as a hardware retailer in a world where no one fixes anything.

Anyway, onwards and upwards.  After the Tiger, the Honda CBR900RR Fireblade project is getting the same treatment, so I'm going to have to figure out what indicator relay Honda went with.  Hopefully it isn't as Euro-awkward as the Triumph.  I've always wondered why they don't include an LED friendly relay in the LED lighting kits for motorcycles, but with everyone using different variations on the indicator relay, you'd be selling people parts that might not fit their situation.

The middle block is the indicator relay on a 955i Triumph Tiger.  It's easy to get to
with only a black, plastic cover to remove.  With any luck, my expensive LED indicator
relay will do the trick and plug right in there.