Front Disc Warping

Discussion in 'Hard. Core. (1090/1190/1290)' started by lukeinlondon, Feb 5, 2018.

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Has you front disc warped and were KTM willing to repair under warranty?

  1. Yes

    31.3%
  2. No

    68.8%
  1. lukeinlondon

    lukeinlondon LC GSA/Helix

    Joined:
    Feb 8, 2010
    Oddometer:
    1,003
    Location:
    London
    Hi all, less than 12 months of owning the bike my front disc started pulsating when I would use it, stopping around town became..wavy and not precise.

    KTM shop said the Disc had warped but KTM would not fix under warranty. cost to me of about £400.

    I spoke to KTM who said they don't have to fix it as it is 'within tolerance' e.g it is not dangerous I guess.

    I have heard some people share that KTM did repair it for them. I thought it would be helpful to consolidate people's experience which hopefully can be reflected back to KTM to make sure this is being addressed.
    #1
  2. Lettikka

    Lettikka Been here awhile

    Joined:
    Oct 18, 2016
    Oddometer:
    504
    Did you consider taking the disc to a machine shop and having it planed? They can use a cross cut machine like they would on a flywheel or pressure plate to make it perfectly flat again. Pretty cheap too. About $40
    #2
    DOGSROOT likes this.
  3. Zuber

    Zuber Zoob Supporter

    Joined:
    Sep 28, 2004
    Oddometer:
    8,251
    Location:
    West of the West, Oregon
    I've worked on many KTM's where the owner complained about a 'warped disk'. In every case it was the surface texture of the disk causing the problem. Most looked like the bike was parked while the disk was wet and the pads etched their profile into the disk. Bikes with the new radial calipers were worse.
    The fix every time is to sand the disks with a coarse abrasive, like 80 grit. Clean with brake clean chemicals and break them in. My break in is to ride it easy for a while, touch the brake every 5 minutes or so, then after the braking action starts to come up (maybe 20 miles), do several high speed stops. Keep riding after these to let it cool down.
    #3
  4. whipit1k

    whipit1k Long timer

    Joined:
    Jun 26, 2005
    Oddometer:
    1,183
    Location:
    nc/wv/ct depending...
    My front rotors are warped. No, there is no rust/debris/crap on the disks. they are warped, period. 17 SAR 1290
    #4
    F650Dakar_Norway and Lewilewi like this.
  5. Mac Ka

    Mac Ka Been here awhile

    Joined:
    Dec 14, 2015
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    844
    Location:
    XcTt6yMr$
    Had this happen on my KTM950SM, 2004 Gen 1 Tuono, 2007 Gen 2 Tuono and my 2009 XT660Z. All were fixed by cleaning the bobbins on the rotors. Dirty bobbins stop the 'floating' disc, seizing it in the area of one or two bobbins. Plenty of vids on youtube.
    #5
    Joe and Jay... like this.
  6. Zuber

    Zuber Zoob Supporter

    Joined:
    Sep 28, 2004
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    Location:
    West of the West, Oregon
    In extreme cases, the etched surface still creates a pulse. There is an etched surface on both disks and it lines up so the pads pass over both these at the same time. To help fix this, I pull one disk and rotate it 180 degrees, so now it will only grab the spot on one disk at a time.
    #6
    Tomdog likes this.
  7. motomuppet

    motomuppet Been here awhile

    Joined:
    Jan 26, 2010
    Oddometer:
    520
    Location:
    Singapore
    First track day I did on my 1190r (2014 model) at Sepang caused my discs to warp...The dealer replaced the discs under warranty...the mechanic said it was not uncommon. Have done several track days since and the discs have been fine since. About 50,000km on the bike so far.
    #7
  8. gsuks

    gsuks Long timer

    Joined:
    Oct 13, 2014
    Oddometer:
    1,853
    Location:
    wilnis de ronde venen nederland
    I have had two sets warp
    The first oem set that warped I replaced with oem again they warped as well.
    I replaced those with
    Galfer wave discs which have been perfect for over 30000km

    Each time they were refunded by KTM NL discs only not pads

    Verstuurd vanaf mijn SM-G935F met Tapatalk
    #8
    F650Dakar_Norway and 4bikes like this.
  9. Jojje62

    Jojje62 Adventurer

    Joined:
    Nov 14, 2016
    Oddometer:
    29
    Location:
    Sweden
    First post :-)

    KTM 1290SA -16
    I had strong vibration at about 5000 km, it was so bad that it even became difficult to stop with the presicion.
    I sandblasted my discs and mounted EBC FA244HH pads.
    And have now driven 10,000 km without any problems.
    #9
  10. Roadtripy

    Roadtripy Asjemenou

    Joined:
    Apr 25, 2014
    Oddometer:
    35
    Location:
    Bottom of the Sea
    Same, same for me, only the second time I replaced them for Moto-Master disc. KTM NL paid for discs.
    #10
  11. gsuks

    gsuks Long timer

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    How are the Moto master disc working out?

    I have a moto master on the rear

    Verstuurd vanaf mijn SM-G935F met Tapatalk
    #11
  12. kaertner

    kaertner Long timer

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    May 30, 2017
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    Mine were changed under warranty at 16000kms, all done by dealer I bought the bike from in Germany. No questions asked, they test rode the bike, had a close r look,and said yep, no problem. Got new pads included also.
    #12
  13. Roadtripy

    Roadtripy Asjemenou

    Joined:
    Apr 25, 2014
    Oddometer:
    35
    Location:
    Bottom of the Sea
    I have the Moto-masters front discs on my 1190R for 32K without any issues. Stopping power is great.
    #13
  14. Roadtripy

    Roadtripy Asjemenou

    Joined:
    Apr 25, 2014
    Oddometer:
    35
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    Bottom of the Sea
    3A7782D2-F27E-4BC1-B345-6084E811E4C2.jpeg
    #14
    lukeinlondon likes this.
  15. GeorgeD

    GeorgeD Been here awhile

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    May 21, 2013
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    699
    Location:
    Sweden
    Nice for you, a happy rider & customer as it was "changed under warranty".
    But in the end you are not aware if KTM approved it as warranty or your dealer took the cost to keep you happy and satisfied? Do you happen to know this?
    #15
  16. kaertner

    kaertner Long timer

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    dealer told me it was a warranty issue. If he said that just to keep me happy, I don't really care, same effect, discs and pads changed all for free. He did inspect the pads to see if there was any 'abuse' of the brakes (maybe track day abuse) but clearly didn't find any
    #16
  17. Its not Ginger!

    Its not Ginger! Long timer

    Joined:
    Jun 9, 2016
    Oddometer:
    1,249
    Location:
    Oxford, UK
    Mine has a very slight "grab" at low speeds, dealer reckons no sign of warp, I had cleaned bobbins (which seemed OK as the disc was easy to move around by hand pre-clean) so will now try and rub them down a bit, and if that fails spin one around 180 degrees.

    TBH it is only noticeable at low speeds when braking gently, no pulsing of lever or hammering action when hard on brakes so if it is a warp it is (currently) very small.
    #17
  18. Capo Rick

    Capo Rick Please understand... Supporter

    Joined:
    Dec 30, 2005
    Oddometer:
    3,189
    Location:
    NoPo Oregon
    I used to subscribe to the “ clean them and they will be fine” school, for years, when my brakes started to pulse, but my 1190 R kicked my ass and I never got the OEM rotors to feel smooth after about 8k miles. I replaced them ( $$) with Braking Wave rotors about 10k miles ago, and consider it money well spent.
    [​IMG]
    #18
  19. KTMatt

    KTMatt Long timer

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    Sep 11, 2006
    Oddometer:
    1,021
    Location:
    Wollongong NSW Australia
    First set replaced at around 13000km second set around 21000km then again at a bit over 30000km but this time with a new wheel aswell and not at 43000km they're starting to do it again. All replaced under warranty.
    #19
  20. whipit1k

    whipit1k Long timer

    Joined:
    Jun 26, 2005
    Oddometer:
    1,183
    Location:
    nc/wv/ct depending...
    amazing. My dealer tells me that KTM will not even consider warranty replacement of brake rotors because they are a wear item....on a bike that was 5 months old when I first mentioned the issue lol right
    #20
    xsvspd3 likes this.