Solving the rear crash pad issue.

In the post Day 34 – Problems with fitting the PowerParts rear crash pad set I described a problem which had arisen with fitting the rear crash pad set.

Before I go any further I need to correct something in the original post, i.e. that “the tab to opposite tab distance is 28 mm and so would perfectly hold the bobbin in place on a front wheel retaining nut which is 27 mm across the flats.  Could the problem be so simple that the wrong retaining nut was used when designing the bobbin??” .  On rechecking the measurements, I noticed that the tab to tab distance was in fact 26 mm rather than 28 mm, and that therefore the bobbin would not fit even on the smaller front axle spindle retaining nut. 

After an exchange of e-mail between Alfie Cox Racing, KTM SA and Mattighofen, KTM SA asked Alfie to get my bike in to see exactly what the problem was.  Alfie, being Alfie, went one step further and arrived at my home on Tuesday to look at the issue and save me a trip!

I was relieved that Alfie agreed with my assessment and that something was seriously amiss in the design of the part.

Alfie’s proposed solution was to take the bobbin away and get it machined so that the tab to tab distance was 32 mm, thus allowing it to slip over and seat properly on the spindle retaining nut.

Alfie was back first thing on Wednesday with the machined pad which now looked like this:

The machining allowed the pad to fit perfectly over the spindle nut, but the inner surface was now completely flush with the swing arm and didn’t quite match the left pad which had a small gap between the inner surface and the swing arm.  Amazingly, a simple and immediate solution was found – an M6 fender washer fitted perfectly and spaced the pad out slightly.

The KTM supplied screws were also now too long and these were replaced by M6 x 30 stainless steel items.

The pad with the M6 fender washer inserted. On the left, the replacement screw.


The now properly fitting crash pad.

Subsequently, I’ve been told that KTM now concede that there is a problem, that the design of the pads will be modified and that I will get a replacement set when this has been done.  That’s good I suppose, but what I don’t understand is why the guys at Mattighofen didn’t originally immediately walk over to engineering with a crash pad set and see for themselves what the problem was?

A last comment.  I continue to be amazed at the lengths to which Alfie Cox will go to attend to problems with the minimum of inconvenience to customers.  Service like this is truly rare these days.


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