Copied from the 790 R Suspension thread, we posted our thoughts last week. I've been meaning to chime in on this thread for some time. We have put a ton of time and effort into the 790 Adventure with both OEM components and the Xplor Pro Components and we are just about to go live with our offerings. We have seen a vast number of failures, some of our clients/friends have had multiple failures (one has had 4/5 failures in 4500 miles, each time the unit has been addressed by KTM or WP directly). Of the 30 or so we have seen through our shop so far we have seen a multitude of failure points such as scorn shock bodies, piston bushings destroyed, seals folded over, separator piston failures, separator piston o-ring failures as well as a few others items. With the variance in build data (reservoir pressure's) as well units we have inspected here in the shop having a variety of build specifications our initial thoughts were that it was a side load issue hence the wear on the shock body in the manner that we have seen. We (and I am sure George will chime in) see a number of shock body failures on WP units, link Husky and KTM's blow through the piston bushes fairly quickly and the tube gets destroyed. On the 1090/1290 ADV-R we have seen distorted shock tubes and rebound cap's bent inwards (towards seal head) which in turn flares the bottom of the shock tube out allowing the rebound cap to fall on the bump rubber destroying the bottom of the shock tube. In other words the issues with the 790 is not something new, but the failure point is. The shock seal (two-piece seal) is the same that has been used since 2007. We’ve heard rumors of a bad batch of seals, but in our opinion, this is not the case. We’ve heard of and seen products to address the heat coming off the catalytic converter may be a solution. We have tested units with de-cat bikes and OEM and shock temperatures have not fluctuated all that significantly in the testing we have done. These units run hot by design, they changed some of the internal components that generate more heat as opposed to previous WP units in the ADV segment. These item changes are to increase certain aspects of the suspension performance. At this year’s KTM Adventure Rider Rally in Breckenridge there was in the range of 7-9 failures during the event. It is not isolated only to hardcore enduro type riders, but is also happening to riders who have only ridden pavement, average BDR style riders, very skilled aggressive off-road riders and everything in between. An interesting point is that the XPLOR Pro Components are not seeing the failure issues we have seen with the OEM components to our knowledge, therefore the issue is once again isolated. Keep in mind the failure points seen have been all over the board, but we feel it is a combination of a few items: With the standard settings these applications come with we are seeing more riders forgoing the installation of proper springs for their height and weight. This drastically alters handling and suspension performance, therefore, if you do not fall within the 165-187 lb. weight rating in full gear you are not seeing the handling characteristics, nor the suspension performance the bike was designed to provide. We have seen a variance in reservoir pressure of both 15 & 16 bar. With these issues we have our thoughts on why the variance exists in both the service manuals and in units we’ve had in hand, but those questions will go unanswered I'm sure. We feel the reason for the failure points have been narrowed down to a few items specifically. We have units in the field testing as I type this, but will not know for certain until the R&D aspect of the fix is confirmed. Dyno testing has proven to not be the end-all in R&D for us so we are doing real word tests with a variety of test subjects in order to put the units through their paces. If anyone has any questions in regards to OEM components, OEM components setup or XPLOR Pro Components please feel free to give us a ring at the shop or shoot us a message. We have our stock of springs and items ready to be released here shortly. I'm sure I missed a few questions as this thread has gotten pretty detailed, but please feel free to include us in any further conversation regarding the matter. All the best, Alex M.