Report processing quality

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Report processing quality
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Report processing quality

Report processing quality
Under the microscope

MOTORRAD took a closer look at five different machines that have one thing in common: the price of around 10,000 euros. The dimensional accuracy of the frame, the paint quality and important processing details are convincing?

Matthias Schroter

11/19/2003

Everything was better in the past anyway. It’s correct. But only sometimes. Even if a lot has been transfigured over the years: the beginning of the eighties was the processing quality of motorcycles ?? From today’s perspective ?? partly horrible. But not because the manufacturers didn’t want to do it better. No, they simply lacked the opportunity. In particular, the Japanese large-scale production could, for example
do not guarantee dimensionally accurate frames ex works. They were the exception, which MOTORRAD discovered in 1983 in a large test together with the Allianz Center for Technology.
And today? What do the manufacturers offer you for around 10,000 euros? What are the weak points, are there major differences between Japan and the rest of the world? A snapshot of the quality of workmanship, divided into three criteria: paintwork, dimensional accuracy of the frame and the swing arm as well as a general assessment of the candidates. BMW R 1150 R., Ducati The Supersport 800 and Triumph Sprint RS hold up the resurrected European flag, the Harley-Davidson Sportster 1200 Sport stands for the most popular American motorcycle construction. And the Honda CBR 600 RR is currently without a doubt the spearhead of the Japanese 600 supersport armada.
Whereby a result before the
In-depth investigation of the five is clear: These days, renowned motorcycle manufacturers can no longer allow themselves to blunder. The report should
help to sharpen the eye for details. Build quality plays an eminently
important role is at the same time a broad one
Field. It is enough ?? among other things ?? of the
Selection of the materials, the definition of suitable tolerances, surface protection and quality management through to the final inspection.

Paint quality
This very complex topic cannot be fully explored. Even the elaborate MOTORCYCLE long-distance test ultimately only provides information about
the quality of a single machine. A current example: the Yamaha FJR 1300. For example, the master body construction master Jens Kopp (see box on page 32), who checked the paint quality of the five machines on behalf of MOTORRAD, attested that the FJR 1300 had excellent paint quality after its 100,000-kilometer marathon. On the other hand, some FJR drivers criticized the readers’ letters, Yamaha admitted
Series start to have problems with new, water-soluble paints.
So it’s all the more important to take a closer look before buying. Nobody can fool a professional like Meister Kopp. What he sees in the test candidates conjures up an appreciative one
Smile on the face. “They know their trade, I like all five very much.” Especially the Honda, but also the
Ducati have done it to him. With the Italian, he is fascinated by the tubular space frame. “Difficult to paint, they do that in an electrostatic process.”
The Triumph shows that nothing escapes his critical eye: “I quickly noticed three dust inclusions on the tank,” he explains. These are barely recognizable to the layman, which is why he immediately qualifies: “Not worth mentioning.” »Almost a millimeter of material thickness, you can’t paint that thick, that’s a lot beforehand
has been repaired. «A loss of quality? “No, the paintwork is, like the others, above average, the level can be compared with that of high-priced car manufacturers.”

Frame measurement
Rainer Schafer, master two-wheel mechanic and professional surveyor, is following suit
an afternoon of concentrated work is also an extremely positive result. Together with his business partner Bernd Scheibner, he developed the m.a.x. frame measurement system (see box below). After his measurements it is clear: mass production and dimensional accuracy are not mutually exclusive? on the contrary. “We only get to see real botched ex-works from a few scooter manufacturers and hardware store motorcycles,” says Schafer, “on the other hand, the production at the well-known manufacturers has now reached such a high standard that the quality goals that they set themselves are actually achieved become.”

In detail
Paintwork in top quality throughout, all frames except for the chassis of the
Harley true to size. So the first two points of the check fall a lot
pleasing. That leaves the third part, a general appraisal (see also »In detail« from page 34). here
small but subtle differences become apparent. The fairing parts of the Honda have a high accuracy of fit, while the gap dimensions on the Triumph and the BMW are very different, and the Bavarians leave it alone
Take little care when laying cables. Both do not affect the function, but announce ?? Despite all the time pressure during assembly? of little attention to detail. In the case of the Honda and Harley, this applies to the screws, the quality and selection of which are sometimes not convincing.
Now and then the devil is also infected
in small details: The Ducati’s tank, which can be flipped up quickly, is actually a practical thing. But fuel flows out through the overflow. Apart from that, the rustic twin is a consistently well-made motorcycle. You won’t find the neatly drawn weld seams on its tubular space frame on the significantly more expensive 999.
The bottom line is that they give each other
Manufacturers of test candidates no longer have as much quality in terms of quality as they did a decade ago. That
The level is astonishingly high in all five. The solidly made one works Harley-Davidson In some points it is still somewhat coarse compared to the others, but this is ultimately part of the brand image. In the frame measurement, however, it was the only one with a value above the tolerance. The development at Triumph in recent years has been very positive. The English rely on high-quality supplier parts and manufacture, if necessary, in-house. From 2002, for example, this applies to almost all paneling parts. Triumph wants to guarantee an improved quality in this way. The Sprint RS no longer benefits from this. To the regret of many fans, the touring athlete dropped out of the model range in 2004.

Paint quality

Jens Kopp checks the paintwork of the tank, the add-on parts and the frame according to the following criteria: paint level (uniformity), degree of gloss, paint finish and dust inclusions. He determines the thickness of the paint layer electronically. The device sends an impulse which is reflected by the steel. Because the Triumph has a tank and the Honda has a plastic tank cover, no measurement was possible on the tank. The paint thickness on the five models varies from 120 µ (Harley-Davidson Sportster 1200 frame) to 240 µ (tank BMW R 1150 R), so it is significantly thicker than that of cars (90 to 120 µ). But more paint does not necessarily mean better quality. In the case of the checked machines, however, the expert’s judgment is clear: very good.

In detail: BMW R 1150 R.

When judging the popular BMW R 1150 R (10200 euros) bothered the too large gap in the right tank panel. Also not a feast for the eyes: the simple outriggers for the passenger footrests. The sloppy laying of cables, especially conspicuous in the steering head area, does not impair their function, but does not indicate excessive care. They prove that the Bavarians can do different things with the successful weld seam on the trailing arm and the finely crafted, play-free shift linkage. Also of above-average quality: instruments, handles and switches.

The measurement method m.a.x.

At m.a.x. it is a computer-controlled, photogrammetric measuring process (www.scheibner.de). The bracket with two electronic measuring cameras is picked up by centering pins in the swing arm. The target body with the infrared illuminated measuring marks is attached to the upper triple clamp. A PC takes over the control and calculation of the measurement. The measuring marks on the front fork describe a circular path around the axis of rotation (steering axis). While the handlebars are turned, the cameras record and calculate the exact position of these marks. An additional laser enables the rear frame and the swing arm to be measured quickly. The tolerances in the table are based on experience and information from some European manufacturers, including BMW. Schafer does not consider the significant deviation in the rear wheel offset of the Harley-Davidson to be critical: »This may be due to the spacer bushings used, but it can also be wanted in order to achieve a greater distance between the toothed belt and the rear wheel. ??

In detail: Ducati SS 800

The Ducati Supersport 800 (9800 euros) is particularly convincing of the practical details. Your tank can be easily folded up for maintenance work thanks to the quick release, so the battery is quickly accessible. When the keg is full, however, a lot of gasoline pours out through the overflow. There is also nothing to complain about with the fork bridge and the powerful clamps of the handlebars. Instruments and switches are of a good standard. The filigree aluminum footrest system also knows how to please. The cheap cable ties decorate the tubular steel frame with its handsome welds, however, little. The gap at the seat hump is too small. Standard steel braided lines with robust stainless steel fittings, on the other hand, are very welcome.

In detail: Honda CBR 600 RR

Honda’s super sports car (10240 euros) also shines with external values. For example with high-quality plastic parts. They are carefully manufactured, which can be recognized by a very high accuracy of fit and accurate gap dimensions. The aluminum swing arm is an eye-catcher, the same applies to the backlash-free shift linkage and the rear frame. It appears that Honda has made huge savings on the cheap hexagonal screws that are used, for example, in highly stressed areas such as the standpipe or axle clamps. They are simply a nuisance, as is the clutch cable that rubs against the aluminum frame.

In detail: Triumph Sprint RS

Anyone who still assumes that Triumph is somewhat crude workmanship will be punished by the Sprint RS (10600 euros). The English have learned a lot. Only a few details tell of the old days. For example, a very awkwardly relocated clutch cable or the antiquated speedometer drive on the front wheel. Many high-quality parts compensate for this. Sheathed steel braided brake lines or a DID chain make the controller shudder, but delight the valued customers. The noble made counterweights on the handlebar halves will still shine discreetly even after many years. And the angled valve on the front wheel makes checking the air pressure a lot easier.

In detail: Harley-Davidson Sportster 1200 Sport

The Harley-Davidson Sportster 1200 Sport (10555 euros) brings together a tangle of screws in the steering head area and on the triple clamps: hexagon, two pan head (Torx and Allen), cylindrical Allen and cylindrical Torx. Two varieties would actually be completely sufficient. The laying of the various lines is much tidier. Apart from the two ignition cables, they are discreetly hidden in an exemplary manner. Also made noble: the front wheel hub turned from solid. Less edifying: the primitive pillion footrest attached directly to the swing arm. In addition, the rear muffler gets the exhaust of the front counterpart, not nice either.

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