Going Aftermarket with Kawasaki GTR1400/C14 Tire Pressure Sensors

I soldered a new battery into the rear temperature sensor on the Concours when I changed the back tire last year after picking up a puncture. The front was starting to get sluggish when connecting wirelessly, suggesting the battery was dying and the front tire was due a change, so I did that one in the fall. Unfortunately the sensor didn't pick up signal after reinstallation. Rather than beat up that old sensor again I started looking for alternative options.

I love a good hack, and Big Red walks you through one here on how to take aftermarket tire pressure sensors, program them to your stock Kawasaki and then use them instead of expensive stock items. The coding unit is $230, but works on anything, meaning I'm not beholden to a dealer for tire pressure sensors on the cars in the future either. A pack of 2 sensors is $95, so all together a full sensor replacement on the bike including the tool needed to program them was $325. The stock sensors are $258 each, so an eye watering $516 for the pair. $200 cheaper and I have the tool that's usable across a wide range of vehicles. That's my kind of hack!

How did it go? After all the frustrations with the Tiger and Triumph, the C14 reminded me how nice it is to work on a bike that's supported by its manufacturer, riders and the aftermarket.. When I compare the thriving online communities at COG and other online forums that support Kawasaki ownership, I can only think, 'way to go team green.' By comparison I read a post on one of the Triumph forums that said, 'these forums are dead. Everyone is giving up on these old bikes..." Except the bikes in question are not that old.

When I walked into my local Kawasaki dealer and ordered parts for my mid-nineties C10 there a few years ago there was never an issue. If I hop into an online forum for the Kwak I see an active community full of ideas and support.  Most of the Hinckley Triumph forums for anything over 15 years old are derelict. The posts on them are at least five years old giving you some idea of what trying to keep an older Hinckley Triumph on the road is like (ie: impossible - the manufacture considers them disposable bikes). It makes me question owning another one, which is a real shame because I wanted to believe in the brand, but they only market their history, they don't honour it by supporting owners in keeping old Hinckley machines in motion.

Back in the land of the living, Big Red's walkthrough was spot on. I popped one side of the new front tire off the rim and removed the 14 year old sensor. I couldn't see why it wasn't getting power - my soldering looked good - maybe a bad battery? No matter, new parts are going in.

If you know Big Red's Mazda 3 2004 sensor hack matches Concours ones, then the rest is straightforward. I set the MaxiTPMS unit to the Mazda settings and then put in the ID number from the old C14 sensor. The wireless upload only took a few seconds.

I could also check the sensor once it was programmed, which gave me some piece of mind before putting it all back in the tire. Though an alternative is to set the sensor when it's installed, which is also an option (the programming unit could still see and modify the sensor in situ). This also means I can test and even reset sensors without having to pull the tire in the future!

The whole process was straightforward, aided by a warm March day where I could leave the tire in the sun while I set the sensor. Warm tires are much easier to stretch over the rim!

I installed the new sensor which fits snugly in the rim. All the parts including the tool from Autel felt like quality pieces that will last. With the tire reinflated I put the wheel back in and torqued everything to spec while also making sure everything was grease free (especially the brake bits).

I took it up the street with the intention of riding around the block because that's how long it usually takes to get the dash reading the wheel pressures, but this new sensor had it showing in seconds - before I even got a hundred yards up the road. I checked it against the digital tire pressure gauge and it's right on the money in terms of accuracy.

It felt good to have a win in the garage after banging my head against the Tiger for so long. Speaking of which, I recently attempted to plastic weld the part they won't supply any more and as I was putting it back together the wiring broke off on the fuel level unit (because I've had the tank off so many f***ing times!).

I'm so bloody minded I'm going to try and solder the wire back on even though it broke in the worst possible spot (right at the unit so there isn't much to work with). The stock unit probably isn't available and is a salty $155 even if it is.  I'm doing this in part just to see if the latest attempt at keeping the old thing in motion works. The plastic welding on the idle speed control valve (which they don't even list in parts now) went well and the piece seems serviceable. I want to see if it works.

If I had more time I'd see if I could find an industrial CAD shop who could 3d scan it and then get me a file that I could use to 3d print a replacement. What would be even nicer would be if Triumph shared that CAD file with us all since they aren't bothered to produce the part anymore. With a bit of collaboration, the aftermarket could help keep older Hinckley Triumphs in motion.

As much as it pains me, I think I'm going to take Triumph's hint and let the Tiger go... which is something I never thought I'd say. So much for my goal of hitting 100k with it.

Links

Big Red's how to: https://zggtr.org/index.php?topic=25416.0

The parts you need: https://www.amazon.ca/dp/B07YYDDXXH?smid=A2S0RW9CKA3NU3&ref_=chk_typ_imgToDp&th=1

https://www.amazon.ca/dp/B09QC4T48J?psc=1&smid=A3AMY38QRT4FIZ&ref_=chk_typ_imgToDp

What not to do...

$258 each for stock: https://www.blackfootonline.ca/sensor-tpms-315mhz-21176-1179

$175 US + shipping + customs on eBay: https://www.ebay.com/itm/175070359610

It is actually nuclear powered - the plutonium goes in under than panel, like on Doc Brown's DeLorean...

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.

Finding Your Way Around OEM's Giving Up on Parts Support: Triumph 955i Fuel Injection Seals

With Triumph giving up on my Tiger before I'm prepared to, I'm going to document the research and give details on what works when you're trying to keep a Triumph 955i's fuel system working by replacing old o-rings.

This has involved a crash course in o-rings and engine operating temperatures. As I work out a fix here I'll post details on o-ring sizing, what type works and include data on measuring the intake manifold at temperature.

It's been all Concours for the past few weeks while the Tiger is laid up. I'm hoping to get the fuel system sorted before the snows fly and I have to wait for next year.

Here are the measurements for the upper and lower fuel injector seals. The classy move by Triumph would be to open source publish the technical details for all the parts they no longer support so that the rest of us can get on with keeping the history of the marquee alive. With that in mind, here are the deets for the upper and lower fuel injector o-rings:

The thick ones go on top where the fuel injector meets the rail. My best guess is 3mm thick by 1.5cm outer circumference.

The skinny ones go on the bottom where the fuel injector slides into the intake manifold.

My best guess there is 2mm wide by 1.4mm outer circumference. 

Unfortunately, buying off the shelf boxes of o-rings isn't likely to get you anything that fits. The two below from Amazon didn't. This thing looks handy: https://www.allorings.com/O-Ring-AS568-Standard-Size-Chart.

The Tiger is a metric bike, so I'll work in mm (if Triumph went imperial on o-ring, what the actual f***). The thicker o-ring is 1.5cm or 15mm outside diameter (OD) and (I think) about 3.5mm cross section (CS). Looking at that chart, the #203 is a 14.58mm outer diameter with a 3.53mm cross section. That makes it mighty close. What would be nicer would be if Triumph just came out and gave us the precise sizes for these parts it has discontinued. Triumph?

The thinner one is also a 1.5 (ish) mm outer diameter (15mm-ish), but the cross section is thinner - perhaps two and a bit mm, and they have a 2.62mm cross section standard o-ring size. You'd have to hope Triumph didn't make bespoke o-rings for their fuel injectors, right? For the skinny o-ring I think I'd take a swing at the 2.62mm cross section / 14.43mm (1.443cm) size.

The All O-Rings site also has a good description of the materials you want to get your o-rings in. Nitrile and Viton are what I went with in the pointless Amazon order, but those are the materials you want in a fuel heavy application like this.

That's the configurator (right) - pretty straightforward, but it sounds like they manufacture each order, which probably won't make this a viable solution for someone just trying to keep their old Triumph on the road.

If only there was some kind of network of retailers who supported Triumph motorcycles who could order this parts to help their customers keep their older Triumphs rolling... some kind of 'dealer' network who understand how parts work and how to order this sort of thing in large enough quantities to make a profit while offering customers what they need.

RESOURCES

How hot motorcycle engines runs: https://blog.amsoil.com/extreme-heat-is-hard-on-your-motorcycle/

Buna (Nitrile or NBR) o-rings: https://sealingdevices.com/o-rings/buna-n-o-rings/

Viton vs. Nitrile o-rings: https://www.nes-ips.com/viton-vs-nitrile-o-rings/

All O-Rings https://www.allorings.com/

They have sizing tools! https://www.allorings.com/o-ring-kits-and-accessories/o-ring-sizing-tools

I'd prefer to use All O-Rings for the parts, but they might be a B2B type of thing, and I'm not a B.

Amazon's kits:

Turns out Amazon's shot-in-the-dark kits didn't work either. There's more to this o-ring sizing caper to come. I wish I could just 3d print the nitrile o-rings I was looking for (doesn't look like it's additive manufacturing friendly).

Discontinued Tigers and Triumph Supporting its Riders

If you follow the blog you'll know I'm on a mission to get my 2003 Triumph Tiger 955i to roll over into six figures on the odometer. I picked up the bike with under forty-K on it and have done the majority of the now high miles on it. Over that time I've had an ongoing battle with the early fuel injection on the bike, but other than that it has been my preferred ride even as a series of other bikes passed through the garage.

Once again the fueling has gone off on the bike just as I was hoping to push it over the 100k mark in its 20th year on the road. If I lived somewhere where the weather wasn't trying to kill me for four months of each year this would be an easier goal, but trying to do it in Canada where the bike has to sit through minus forty winters and then navigate the frost heaved results in our too-short riding season? It's technical a flex I'm up for, but it's a shame that Triumph isn't.

I tried the usual solution of rebalancing the fuel injectors, but the bike is still stalling out and running rough. I checked the valves less than 15k ago so that isn't likely it. If it isn't throttle body balancing, which the bike is prone to needing, perhaps it's time to, at over 90k, to finally replace the o-rings and gaskets in the fuel injection system, but Triumph tells me that the majority of these parts are discontinued.

One of the reasons I enjoy the old Tiger is that it still catches eyes and prompts conversation when I'm out and about. Another reason I like it is that it can pretty much do anything (I've trail ridden on it and done multi-thousand mile two-up road trips too). It fits me better than anything I've ridden, is fun to chuck around in corners and has handled axle deep mud when I needed it to. The engine is full of character and pulls well even two up and, considering the miles it has done, the amount of TLC needed isn't unreasonable. I'd love to keep this bike going indefinitely, it's a shame that Triumph don't feel the same way.

I had a chat with the dealer (who isn't particularly local, it's a 170 mile round trip to go there physically - I usually get parts delivered), and they said that this is a problem with Triumph - they don't support their older machines. He then went on to say I couldn't use generic o-rings because the Triumph parts are strangely size specific. I'm going to try anyway because I really want to be able to jump on my old Tiger and ride.

Suzuki runs a successful vintage parts program so I'm not sure why Triumph wouldn't want to do the same to keep their bikes on the road, especially when they lean on brand heritage marketing so much.

Here's Nick Bloor's take on it:

Never standing still, always pushing to get the best from ourselves, for our riders. Building iconic motorcycles that celebrate our past while embracing the future through bold design, original styling, purposeful engineering and a genuine passion for the ride.
Always focused on delivering complete riding experience, creating bikes with the perfect balance of power, handling and style that totally involve the rider and bring out the best in them. 
This is our passion and our obsession. 
We are chasing the same thing as our riders THE PERFECT RIDE.
Nick Bloor
CEO Triumph Motorcycles

All good stuff, but maybe focus a bit more on celebrating Triumph's past, Nick? That includes the bikes your reborn Triumph have been making since the nineties. For some of us you created that perfect ride a while back.

When you market on brand history and provenance, shouldn't you support brand history and provenance? I'm coming at this hard because I want to believe... and keep my (not so) old Triumph rolling.

Winter Maintenance: Fuel Injectors on a 955i Triumph

 It's been a busy winter and I haven't gotten as much done in the garage as I'd hoped, but breaks in the gloom are beginning to appear so I spent the weekend getting the Tiger sorted and giving plastic welding my first go.

2003 Triumph Tiger 955i Fuel Injector Maintenance

The old Tiger is up at about 90k on the odometer. I did a deep maintenance a couple of winters back (swing arm out, everything gone over from the wheels up) and that seemed to solve most issues, except the fuel injection. These early electronic fuel injection systems in 955i Triumphs is touchy. What I've found that worked is to pull the injectors each winter and deep clean them in the ultrasonic bath, so that's what last weekend was.

Injectors out! I put the end without the electrical connector into the ultrasonic cleaner and give it 10 minutes at 60°C. Once out I clean them up and back in they go. No hesitation or idling problems since.

That vacuum run stepper motor (upper left) is what manages the idle control system - it's touchy! Make sure you've got good vacuum hoses (the black ribbed ones in the pic) and the gasket for the stepper motor is in good shape, or you'll be stalling... a lot. I'm sorting a threaded holder for the fuel injectors here.

Tank off gave me a chance to sort out the airbox, which I now seal with gasket material. At almost 90k, maintenance takes on jobs like rethreading bolts and gasketing tired airboxes to keep everything tight.

Found a stowaway on the airbox under the gas tank. Probably good luck?

Tiger is back together again and ready to take a run at 100k in it's 20th season.

How well did it work? We had a break in the polar vortex (it was -30° last week). In 5°C we went for a blast up and down the nearby river roads and it felt sharp. Doing that bit extra with an older high mileage bike when it comes to maintenance is the key to a happy riding season.

Baffling 1970s British Wheel Engineering

I had a go at mounting new tires on the 1971 Bonneville project rims today, and what a pain in that ass that has turned into.  The rear tire is a mess of strange engineering decisions, including 3 holes for the inner tube valve, two of which are filled with rubber/metal pads with valve stem sized bolts sticking out of them.  Why they would do this is beyond me.  It creates a needlessly heavy wheel just where you don't want it (where centrifugal force amplifies it at the rim when it spins).  Perhaps it has something to do with the spokes and creating a true (round) wheel by adding weight?  The rear tire went on easily enough, but the inner tube was a pain to get the valve in place and it doesn't seem to be taking air.  I'll have to take that apart again and figure out what the hell is going on.

Also in bizarro British '70s engineering world, the front wheel has the valve stem hole drilled in the worst possible location, right near two spokes, which makes putting the compressor's tire inflation nozzle on it impossible.  There are spaces all around the rim where the hole could have been drilled to allow for easier access, but the Meriden Triumph 'technician' threw it in there.  If there is an engineering reason for it, it's beyond me.  Putting the hole in the space between more distant spokes shouldn't hurt the durability, but they didn't do that.

I've done inner tubes and tires for my modern Triumph Tiger recently, and just did a tubeless tire on the Kawasaki (complete with tire sensor hack), so this shouldn't have been the faff that it has turned into.  I ended up leaving both rims sitting in the garage.  I'll come back to it another day when I'm less frustrated by it.

Period tires from Revco look good on the rims, but the rear won't take air and I can't get any into the front.  Damn it.

Here's some old Triumph 'character' and a bit of moto philosophy to remind me why I'm doing this...

A Cure For Your Insanity Part 1: East Across Ontario

Due to financial constraints and various responsibilities I'd almost talked myself out of going to visit an old friend (we've known each other since he was 13) at his 50th birthday party last weekend, but I'm so glad I didn't.  Seeing the old faces and catching up was brilliant, but so was the chance to be out in the wind for days on my bike.  Sometimes it takes stepping away from your place in the world to gain the perspective you need to better understand it.

I left on a Friday morning as the sun beat down and temperatures started to rise.  I'd intended to take the Kawasaki but it picked up a flat last week and replacement tire isn't in yet so I turned to the trusty nearly 20 year old/84k Triumph Tiger to take me away.  Following standard GTA avoidance protocols I headed east instead of south to the crowded and manic highways of Toronto, which Google Maps always prompts me towards (getting there five minutes sooner is much more important than your mental health!).  Other than a traffic light in Centre Wellington not seeing me waiting (they're quick to road-tax me but slow to recognize motorcycles as a vehicle - I ended up putting the kickstand down and running over to the pedestrian button to change the light), it was clear sailing out of my increasingly crowded and poorly infrastructured home county.

Riding into the rising sun I made good time until I hit Newmarket, which was all poorly timed traffic lights and frantic citiots rushing to get one car ahead.  I was going to stop for a coffee but nothing presented itself in the strip-mall cookie-cutter desert of GTA expansion and rather than grate on about wearing masks all the time I preferred to just avoid the masses, so I pressed on out the other side and back into the country, except the country is now plastered with gravel trucks grumbling in and out of construction sites to build more housing for the ever expanding Greater Toronto Area.

I'd been on the road about two hours when I rounded the end of Lake Scugog on the Port Perry causeway and pressed on towards Peterborough.  At a four way intersection someone in a trophy truck (top of the line full-sized pickup with bling wheels and chrome that will never do a day of work in its life) ran the red light making a right hand turn in front of me.  I edged over in my lane ready to do something more drastic but he stopped.  The lead rider in a gaggle of Harleys coming the other way started making angry monkey gestures because he felt that I was encroaching on his lane (which he was cutting the corner on).  It's one of those things about riding in the insanity of Southern Ontario: everyone is very keen to tell you what you should be doing rather than making better decisions themselves.

I pushed on, hoping to get beyond the gravitational suck of Toronto driving culture.  Construction on the highway into Peterborough slowed things up again as people in massive SUVs rushed up the soon to be closed left hand lane to get a few cars ahead (and cause miles of backup), but if you're not driving a massive SUV and butting in line you're not doing it right.

Finally on Highway 7, I continued east toward Ottawa aiming for the Iron Rooster about halfway along the day one map.  Traffic thinned out and everyone settled into a less manic rush as the (sh)city fell behind.  After a stop in Marmora for gas I didn't really need but a stretch I did, I rolled on to the Iron Rooster for lunch.  I haven't seen any Ontario Provincial Police presence in my community for weeks, but on Hwy 7 there were multi-car speed traps set up every 300 feet or so.  By the time I stopped for lunch I'd seen over 20 police vehicles.  By the time I got to Osgoode (south of Ottawa) the number was over 50.  It's nice to know that the OPP is focused on bonus tax collection and making sure the insurance industry is getting its pound of flesh rather than looking after the communities it claims to police.

The Iron Rooster is a cool spot right off the highway with a big parking lot and indoor/outdoor seating that helps ease any covid anxieties (they roll up multiple doors to make the inside outside).  The entire place is motorcycle themed and specializes in rotisserie chicken in various sandwiches.  That focus makes for good food and I enjoyed "The Rossi" which was a "Rotisserie chicken tossed in pesto mayo with tomato, avocado and havarti cheese" on a toasted brioche bun, locally cut fries too, nice!

Moto-inspired philosophy on the wall...

A wee museum with some interesting old bikes in it and the walls covered in posters including everything from The Great Escape to On Any Sunday and Easy Rider - it was a great stop!

A 1918 BSA!

Coming out of the restaurant I ran into three native women who were out for a ride on their Indian motorcycles.  One of the nice things about riding is that it tends to remove the social barriers that prevent us from talking to each other.  We struck up a conversation about our bikes and I asked them if the name bothered them and they shrugged, saying it was a historical brand and they liked how the company represented their culture, and they loved the bikes (all three were on variations of Indian Scouts).  We then had a good talk about why we enjoyed riding so much.  Being out in the world on a bike puts you in touch with the thermoclines you're passing through and we all dug that you can feel the air and smell the smells when out in the wind; it puts you in touch with Turtle Island.

A distance was starting to form in my mind from where I've been feeling stuck in the village we moved into that is rapidly being converted into an urban subdivision.  As I rode away from the Rooster with a full stomach and some perspective, the old bones of the earth started to appear in the form of the Canadian Shield, poking up between pines and lakes (if you could see past all the police parked on the side of the road).

I had the smartphone clamped on the handlebars and when it wasn't barking instructions at me it was flashing speed trap warnings.  I used to drive Highway 7 quite often when I lived in Ottawa and the lakes, woods and stony Shield were always my favourite parts of the drive.  Fast food restaurants now litter the route and the prettiness is being chased away by an influx of people.  Those chain restaurants have done a good job of chasing small town diners out of business as well.  One of the magical things about urban expansion is that everywhere starts to look the same after a while.

Traffic was light and I made the occasional pass, but between the police blitz and volume of traffic, Highway 7 isn't the picturesque alternative to the 401 that it once was.  I wasn't in a rush to get to Osgoode but I found the smartphone's manic attention getting behaviour exhausting and when I did occasionally see a place I might stop it I found myself pushing on to keep to with the schedule Google had decided for me.  I finally turned it off and found I could enjoy the scenery and the ride more without all that noise.

Six and a half hours in I stopped in Perth to hang the phone back up and guide me in to Osgoode.  I rode past a the only non-franchise local coffee shop I'd seen on the entire ride because it was neck deep in construction and the phone was barking alternatives at me all through town.  As the sun started to stretch out the shadows I made my way into Osgoode on back roads and finally to a friend's place I could stop at for the night.

The ride east was enlightening and it started a process that has me rethinking many of the habits I've fallen into because of where I live.  There is a manic oneupmanship that is a central tenet of Southern Ontario driving culture, and it's something that makes everyone who buys into it supremely unhappy and stressed.  Getting one car ahead, even if it's wasteful and potentially dangerous is everyone's goal.

From many miles away I was thinking back to where I live as I rode the final miles of this Friday across Ontario.  Construction noises start before 7am every day.  Sitting outside for a morning coffee has you surrounded by the stucato gun shots of nail guns in the new housing division next to us harmonizing with layers of beeping from various heavy equipment backing up again and again.  This morning that was eventually drowned out by our neighbour's professional lawn service getting their industrial grade (helicopter-loud) lawn mower out (at 7:30 in the morning) to trim their golf-course perfect lawn.  With that never ending noise, dust and with thousands of new people moving into the area, my quiet village is no longer either of those things.  Looking back on it from that great distance across the province I wondered if I'm holding on too tight to something that simply isn't there any more.

Part 2

Part 3