After putting a couple of hours on my 525 I decided to fine tooth comb it to see if I could find anything to warrant taking advantage of the 30 day warranty. During the thorough rectal examination I came to the conclusion that although some of the plastic seems to be put together with lego, the overall build quality is indeed something impressive (its my first KTM). That said, I did find one significant issue: one of the pins for the floating rotor was rubbing on the caliper - on both front brakes. There is hardly any clearance between the pins and one part of the caliper and, in my case, can rub. If left too long, the ring of the pin can wear off allowing the pin to easily leave the rotor and, well, you know the rest…Have a look at the caliper in the picture – this is the wear after about 2.5 hours of riding. The fix is a simple smoothing of the caliper with a die grinder, provided the pin hasn't worn to the point that a new rotor is needed. There are virtually no symptoms, so it is worth taking a quick look at the calipers to make sure your pins aren't getting violated.
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