Issues fixed under warranty

[toast449]

I'm officially a study case. 20.000 km, 5 front brake disc sets replaced. Not my dealer or Husqvarna understand what's going on. I don't wash my bike immediately after intense braking, and it's not like I ride that harshly. They even swapped the whole front rim last time, so now we're trying a completely different brake disk manufacturer. Will report back once they are installed and tested for a few thousand kms if this finally solves anything

You have any machinist measuring tools? If you put a dial gauge on a magnetic mount on the brake caliper and set the tip of the gauge against the rotor I would be very curious if you see zero runout.

 

[Tom]

I'm officially a study case. 20.000 km, 5 front brake disc sets replaced. Not my dealer or Husqvarna understand what's going on. I don't wash my bike immediately after intense braking, and it's not like I ride that harshly. They even swapped the whole front rim last time, so now we're trying a completely different brake disk manufacturer. Will report back once they are installed and tested for a few thousand kms if this finally solves anything.

Damn, this is beyond disappointing! I do really hope they'll get it fixed! The Brembo discs are working absolutely fine.

 

[Tom]

You have any machinist measuring tools? If you put a dial gauge on a magnetic mount on the brake caliper and set the tip of the gauge against the rotor I would be very curious if you see zero runout.

Since the brake discs are floating, a minimal tolerance shouldn't really be relevant at all.
I suspect that the material of many Galfer brake discs is simply faulty/unsuitable and warps due to the heat during braking.

 

[toast449]

Discs are floating for expansion, not transverse motion. I'm wondering if the hub isn't perfectly perpendicular to the axle. You wouldn't notice it as a wobble in the wheel with a tire on it, but a couple thousandths of wobble on the disc vs pad face would be an issue. If they machine a batch with an axle error it would explain why some people have had this issue.

 

[Tom]

The problem exists on various KTM models (with alloy wheels and also with spoked wheels), all equipped with Galfer brake discs. Several people have repeatedly received new Galfer brake discs, only to have them warp again. The mounting surfaces of the rims were also machined flat on several bikes; yet the brake discs still warped. Some then installed brake discs from a different manufacturer and only then were they able to truly resolve the problem.

 

[toast449]

I didn't know about switching rotors making it better. Even if the rim rotor mount surface was machine flat I would assume it was done with a setup that assumed perpendicularity between the axle and the flat part of the hub, so that still wouldn't fix an error where the axle path was machine incorrectly (ie the only real way to do that would be on an absolutely massive lathe, not a mill).

 

[Tom]

I have no personal experience with the brake-problem and also don't know how the machining of the contact surfaces was carried out. I got the information from two KTM forums when I was researching for the 320mm brake discs.

 

[CRK]

My front discs are acting up again so my dealer will have a look at it again. Also my dashboard is flickering and showing stacking GUI elements whenever its cold outside. Another thing that has popped up is that neutral as well as getting it into second gear is a lot harder than when the bike was new. Finally the retaining ring by the quickshifter is very rusty, almost rusted through.