Front Brakes Issues Resolved

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wills
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Front Brakes Issues Resolved

Postby wills » Sat Aug 20, 2016 11:16 pm

Seeing how so many have had the front rotors warp and the OEM replacements not solving the problem, I sourced from another manufacturer. Mine warped and I also had the "noise" so I bought the Galfer rotors and pads. No noise, brakes work as well as before plus I could buy them for less than the OEM junk. I have had Galfer on my Concours 14 for a couple of years and they work great, no noise or rotor issues. Don't look bad either!

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crazyinp
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Re: Front Brakes Issues Resolved

Postby crazyinp » Sun Aug 21, 2016 1:08 am

Any details on where you got them from?
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wills
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Re: Front Brakes Issues Resolved

Postby wills » Sun Aug 21, 2016 1:58 am

Ebay seller Motorcycleparts2u
If he does not have it listed, he can order any Galfer part.
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scamb66
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Re: Front Brakes Issues Resolved

Postby scamb66 » Sun Aug 21, 2016 3:23 am

Be keen to see how these perform over time. Mine are shithouse and cant wait for a decent replacement.
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DukeNukem999
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Re: Front Brakes Issues Resolved

Postby DukeNukem999 » Sun Aug 21, 2016 6:45 am

They look nice, hope they prove to be robust in the long term. Might go that way myself one day.
2010 SD, Rottweiler intake / SAS removal, Akrapovic slipons, ergo seat, Scott's oil filter, factory alarm, SDR levers, Shorai (LiFePO4) battery, oem 16T / KTM Supersprox 40T, RK GB525GXW chain, Michelin Pilot Road 4 rear / Pilot Power 3 front.

wills
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Re: Front Brakes Issues Resolved

Postby wills » Sun Aug 21, 2016 2:56 pm

The rotors on my Connie have over 40k miles on second set of pads...working great no warping. If they can stop that heavy beast they should last on this one!
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tango2
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Re: Front Brakes Issues Resolved

Postby tango2 » Mon Aug 22, 2016 7:32 pm

Thanks for the info. I'll put them on the list :D

murphc13
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Re: Front Brakes Issues Resolved

Postby murphc13 » Fri Aug 26, 2016 4:33 am

The stock wavey rotors on the 2016 SDR SE are Galfers!!!

mntbighker
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Re: Front Brakes Issues Resolved

Postby mntbighker » Fri Aug 26, 2016 7:59 am

murphc13 wrote:The stock wavey rotors on the 2016 SDR SE are Galfers!!!


Wonder how the prices compare between the KTM version and the aftermarket version?
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wills
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Re: Front Brakes Issues Resolved

Postby wills » Mon Oct 10, 2016 7:35 pm

Well a thousand miles on these new brakes and no warping yet. Also the noise when you push the bike is gone, except when the brakes are hot. So far so good.
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Joe Biker
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Re: Front Brakes Issues Resolved

Postby Joe Biker » Mon Oct 10, 2016 11:33 pm

wills wrote:Well a thousand miles on these new brakes and no warping yet. Also the noise when you push the bike is gone, except when the brakes are hot. So far so good.


If you still get the noise hot you have a sticky caliper.
I change both rotors with gaifers n even change the front wheel
noise only stopped after a caliper change
Now hot or cold no noise or rubbing pads 8)

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Re: Front Brakes Issues Resolved

Postby wills » Sat Oct 15, 2016 3:44 pm

Not concerned about the noise, just the performance. I also noticed KTM Powerparts rotors look very similar :roll:
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Re: Front Brakes Issues Resolved

Postby grommet » Wed Jan 04, 2017 3:22 am

On this subject - I got a set of aftermarket rotors, and they warped within a few miles. I concluded the rotors could not possibly be the problem, as they never even got hot.

I carefully checked the wheels where the rotors mount, and discovered a casting defect that I'm certain caused the warpage in the OEMs and the aftermarket rotors. It was a small ridge right in the corner of the area where the flat part of the land meets the cylindrical area. I was surprised that these mounting surfaces are not machined, but then it made perfect sense that so many people have the same problem.

So to fix it I just filed down the ridge. It was present on only two of the mount points; the rest were fine. This defect was only present on the left side of the wheel. I had previously verified that the rotor on the left was warped with a dial indicator. The right side was true to within .004" (.1mm)

After the fix, I've had zero issues and the rotors are nice and smooth now.

Here is a photo to illustrate the area in which the defect can be found. (understand this is not an image of our wheel. It simply shows the area of interest as an example)

Image


Too bad our wheels are not machined in this area like the one in the photo. If they were machined, this problem would probably not exist at all.

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DukeNukem999
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Re: Front Brakes Issues Resolved

Postby DukeNukem999 » Thu Jan 05, 2017 1:17 am

Cheers for the info.. great find !.
2010 SD, Rottweiler intake / SAS removal, Akrapovic slipons, ergo seat, Scott's oil filter, factory alarm, SDR levers, Shorai (LiFePO4) battery, oem 16T / KTM Supersprox 40T, RK GB525GXW chain, Michelin Pilot Road 4 rear / Pilot Power 3 front.

chrisRR
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Re: Front Brakes Issues Resolved

Postby chrisRR » Fri Mar 24, 2017 10:34 pm

Excellent stuff. Was wondering if the mount surface might be the issue. I've got new wave rotors to fit and wasn't going to put them on until the mounting surfaces were checked. Do they need surface skimming in a big lathe perhaps?

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ilmothefinn
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Re: Front Brakes Issues Resolved

Postby ilmothefinn » Tue Mar 28, 2017 8:56 am

Well, actually it is on a large lathe... Just measure the distance of mount points when brake rotor is off and wheel in its place, act accordingly... File or what ever does the job... Shall try to remember this when next time replacing rotors (don't bother now, they are still ok)...
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scamb66
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Re: Front Brakes Issues Resolved

Postby scamb66 » Fri Jul 07, 2017 11:03 pm

Finally got off my arse and removed the rotors with the wheel still on the bike.
I filed down the portion that grommet had indicated in the above photo and the difference it made was amazing.
I had 0.012" run out previously, not sure what it is now but I can wheel it around and it no longer makes any noise and no longer pulses on slow braking.
Thanks grommet.
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ttraynor
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Re: Front Brakes Issues Resolved

Postby ttraynor » Tue Jul 18, 2017 6:54 pm

OK--So I replaced my stock 2017 wheels/discs which were working perfect with my BST's and Galfers from my old supeduke 1290 I had--and there is warpage! Guess I'll check the BST rotor landings for junk or interference.

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Re: Front Brakes Issues Resolved

Postby abc » Fri Oct 13, 2017 10:53 am

I can also report that I have always had issues with my front disks. It was the classic "feeling like they were warped when moving the bike around my shed" so once I found the time I stripped everything apart and measured and inspected everything.
My experience was similar to "grommets" and "scram66" in that the mounting surface on the wheel was the problem. I had enough clearance where the inside diameter of the disc met the step on the wheel flange so next I checked the mounting faces and found run out of 0.015". Doesn't sound like much but it is of course multiplied as the diameter increases and you move away from the wheels rotation axis.
I set the wheel up and re machined the face true by removing 0.002", cleaned and re tapped all the old loctite from the threads and everywhere else and reassembled.
I suspect this poor quality control ( really production tolerances) is why the original rotors warped and lucky for me were replaced under warranty about 1 year ago, only to have the problem return.
The final result is the issue is now fixed. Thanks to those that have contributed to the solution and provided the feedback.
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Savage
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Re: Front Brakes Issues Resolved

Postby Savage » Sat Oct 14, 2017 2:37 am

scamb66 wrote:Finally got off my arse and removed the rotors with the wheel still on the bike.
I filed down the portion that grommet had indicated in the above photo and the difference it made was amazing.
I had 0.012" run out previously, not sure what it is now but I can wheel it around and it no longer makes any noise and no longer pulses on slow braking.
Thanks grommet.


Great.

I have a new to my '17 model.
Done 4,000 km, come from a speed Triple, it has the wavey disc brakes on it, and noticed it pulses when slow braking, annoying the crap out of me, thinking perhaps this is normal for a KTM.

Will go and do this now!

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Twist
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Re: Front Brakes Issues Resolved

Postby Twist » Sun Nov 05, 2017 2:37 pm

The problem I have with my '16 1290R is not so much that I get much pulsing. It's that the front brakes at low parking lot speed are so grabby as to be dangerous to use. Any pressure on the front brake lever will stop the front wheel and there's no low speed feel to them. I know it's good practice to use the rear brake in low speed maneuvering but still, there's just no feel at anything below about 10 mph and it's like an on/off switch. Would changing the pads help?
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Re: Front Brakes Issues Resolved

Postby michaeln » Sun Nov 05, 2017 6:24 pm

Use just one finger to pull the lever.

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Re: Front Brakes Issues Resolved

Postby michaeln » Sun Nov 05, 2017 8:44 pm

I too switched to the PP/Galfer wave rotors and the moaning and groaning of the brakes went away. I put on EBC pads too, these are now the finest brakes I have ever experienced:

Image

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Re: Front Brakes Issues Resolved

Postby Savage » Mon Nov 06, 2017 10:55 pm

After filling lightly where the discs mount on, I no longer get any pulsing when braking.

I couldn't see any issues before hand but went and filed anyway.
Glad I did!

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scamb66
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Re: Front Brakes Issues Resolved

Postby scamb66 » Thu Nov 09, 2017 12:00 am

Savage wrote:After filling lightly where the discs mount on, I no longer get any pulsing when braking.

I couldn't see any issues before hand but went and filed anyway.
Glad I did!

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Savage isn't yours a 2017 model?
Thought KTM would have sorted this by now?
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