KTM Factory Tour: Great!

My wife and I recently attended the tour of the Werk in Mattighofen. We really enjoyed the tour. As SD owners (wife - 1290R and I - 990 SDR ) it really gave us an increased appreciation for our bikes (inherent issues notwithstanding ). What stood out for us was the contrast to the factory tours we attended at Triumph and Ducati (both over 10 years ago). The level of automation was significantly higher at those factories. KTM involve much more hand assembly and manufactur of components. Maybe a two-edged sword? Anyway, we came away more personally "connected ", which I guess is the point of the tour. Interestingly, staff do not have production quotas and may take short breaks when they feel like it, in addition to those scheduled. I was especially Facinated by the assembly of the cylinder heads. Setting the valve clearance took all of 5 seconds! Per head. Every engine is test run first after initial assembly up to 2/3 rpm limit. Then once again after final assembly of the motorcycle prior to packaging for shipment. We were able to view the final dyno run of several 1290Rs. Run through the gears, just not to the red line limits like your local tuner. KTM do intend to open a museum. In close proximity to the factory are Mahle (pistons ) and WP (suspension components, frames etc...) manufacturing facilities. R & D involve 1/3 of technical staff.

Highly recommend taking the tour when in Austria. Easy to set up via email.

PS: Curious observation : First thing that occurred after a 1290R was rolled out of the final dyno run was one guy tilted the bike up on its side stand elevating the rear wheel while the test rider grabbed the wheel and gave it a good shake. SOP from day one or a response? Or maybe just because it was an orange one!

Great to have done the tour!

In regards to testing the rear wheel.
If they (KTM) would have listened to anyone having the problem they would have know that there is no need to lift the bike. The play is more apparent with the wheel on the ground.
If KTM is aware of the problem why are there still bikes appearing at the dealers with play?
If KTM is aware of the problem why are there still replacement hub assemblies-axles arriving at the dealers that are faulty?

Edit: Sorry got bitching again... just pisses me off that they don't fix it properly.
Hope you had a great ride and Austria has some magic roads that suit the SD!

KTM GUY: No problem. I understand your and others frustration.

My wife's bike also has a slight bit of play. She brought up the issue with the tour guide who had been with the company for well over 30 years. He personally wasn't aware as he is retired but he did ask in the technical department. In a very indirect way, he communicated to us that the company is aware of the issue and is working on a solution. Without entering the debate as I have far to little knowledge on the subject, I am confident that KTM will ultimately do what is correct as it's a first class operation. I can only imagine that there are an absolute myriad of issues that need to be resolved, especially considering the vast number of different regulatory entities that need be satisfied before a world wide proactive solution is decided on. Until that time, my wife has officially registered the issue with her dealer and until the solution if any is required, is decided on, she will continue to ride the shit out of the bike. She has been the fortunate owner of many bikes over the years. And I have had to listen to her whine and complain about this and that. This is the first bike that I have heard nothing but praise. Which for me speaks volumes and "almost " makes me want to divorce the SDR. I said almost.

Comrade Wallycycle: Thanks for that report.

Would you be so good as to post the actual email address in case others wish to do the same.

Just to clarify, I think you are saying that R&D has a third of the technical staff rather than 1-3 people. The reason I ask is that years ago I spent a morning with a startup called Borland International in Scotts Valley USA. At the time I was a little surprised when I was introduced the guy that looked after their spreadsheet product. When I say the guy, I mean THE guy - he was it!

What was the process for setting the valve clearances? Measure the overall and shove in or machine a shim to fit?

I had a tour of the KTM factory in India.

Comrades: Unfortunately there are many things in life that date me ...

Indeed, when I pull up at biker hangouts on the 1290 things look quite bright. Then when I take off the helmet I seem to detect a certain lack of interest in the incumbent Such is life, but at least I get to ride it

Your right about the relative levels of vehicle manufacturing. Just the week before touring KTM, we did the Mercedes and Porsche factory tours. Mercedes level of automation of actual vehicle assembly in Sindelfingen was unbelievable. And the robotic assembly and welding of components was awe inspiring. In contrast, the Porsche assembly line in Zuffenhausen was at a much more relaxed pace and appeared to involve more hand assembly. It was just a lot slower than at Mercedes.

I don't think car plants and bike plants are comparable from an automaton perspective

Recently saw Mega Factories episode on MV Agusta, little bit old as it was on the F3 production but was surprised actually how hands on it actually was, even the frames were hand welded in a jig. In reality only the engine, frame and assembly was carried out there with everything else out sourced. Imagine KTM would be no different. Seriously look at some of the welds on the 1290, could only be done by hand.

Did you see the blind guy that's in charge of the gasket assembly??

A factory tour would be interesting