2019 KTM 790 Adventure R

The defect

KTM North America, Inc. (KTM) is recalling certain 2019-2020 KTM 790 Adventure and 790 Adventure R, and 2020 KTM 790 Adventure R Rally motorcycles. The front brake master cylinder piston return spring may be too weak to return the brake piston to its original position, reducing the functionality of the front brake.

The risk

A front brake with reduced functionality may increase the distance required to stop as well as the risk of a crash or injury.

The remedy

Dealers will replace the return spring, free of charge. Owner notification letters were mailed May 21, 2021. Owners may contact KTM customer service at 1-888-985-6090. KTM's number for this recall is KTM2106.

KTM North America, Inc. · up to 3,707 vehicles across all model years covered

The defect

KTM North America, Inc. (KTM) is recalling certain 2019-2020 790 Adventure and 790 Adventure R motorcycles. The rear brake hose may overheat, causing the rear brake system to fail.

The risk

If the rear brake system fails, there would be reduced braking ability, increasing the risk of a crash or injury.

The remedy

KTM will notify owners, and dealers will install a new rear brake line, free of charge. The recall began April 28, 2020. Owners may contact KTM customer service at 1-888-985-6090. KTM's number for this recall is TB2011.

KTM North America, Inc. · up to 3,164 vehicles across all model years covered

At only 9000 miles, intake camshaft and follower catastrophically damaged. Routine valve clearance check at 4th oil change (much more frequent than recommended). KTM ultimately provided the parts as “goodwill”, but refused to cover labour. Numerous other reports of similar failures being reported in group forums. Also note that clutch also failed catastrophically at 3k miles. Similar situation where KTM covered parts under “goodwill”, but not labour. Similarly: there have been hundreds of others sharing stories of same failure. Bike was purchased while I was living in Texas, but failures occurred in Canada, where I have relocated and imported the bike.

NHTSA complaint 11581180. Filed by an owner and not verified by NHTSA or by us.

The Display screen that offers all the info for the motorcycle has condensation inside. The motorcycle is always garaged other than when it's being ridden. There is still condensation inside the display. Sometimes vital motorcycle information isn't visible, such as ABS mode, Traction control mode, speed, rpm, etc. Vehicle has not been inspected. Through the forums I have heard many stories of others having the same issue and dealers replacing the screen in some cases if the condensation is bad enough but the issue usually returns.

NHTSA complaint 11448739. Filed by an owner and not verified by NHTSA or by us.

Hello, I purchased this motorcycle new in July 2019. It currently has 9,100 miles. Since new it takes a minimum of 3-4 times to start and stay running at first start of the day. After that it starts easy and on the first try. Temperature at first start has been anywhere from upper 30's° to upper 70's°. Altitude from 500' - 4,500', basically starts the same in all instances. It seems as if it's only running on one cylinder and then "chuffs" and dies. Repeat, repeat, repeat. When it finally "catches" R.P.M. will rise up around 1,500ish R.P.M. and run smoothly. On its first few attempts the engine will barely make it to 900-1,000 R.P.M. before dying. Thank you for your assistance with this …

NHTSA complaint 11445681, quoted in part. Filed by an owner and not verified by NHTSA or by us.

AT APPROX 5K MILES MY FRONT BRAKE STARTED GRABBING AND PULSING AT LOW SPEEDS UNDER CONSTANT LEVER PRESSURE. IT EVENTUAL GOT SO BAD THAT I FELT I COULDNT SAFELY CONTROL THE BIKE WHEN USING THE FRONT BRAKE AT LOW SPEEDS. THE DEALER WAS ABLE TO GET A WARRANTY REPLACEMENT OF THE DISKS AND PADS. APPROXIMATELY 5K MILES LATER THE PROBLEM HAS REOCCURED. THIS TIME KTM REFUSED TO COVER THE COST SO THE DEALER SUGGESTED I TRY A 3RD PARTY DISK AND PAD REPLACEMENT. ONLINE AT ADVRIDER.COM, A MOTORCYCLE FORUM THERE ARE 16 PAGES OF POSTS INCLUDING VIDEO'S WITH SEVERAL INSTANCES OF RIDERS HAVE THEIR FRONT BRAKES LOCK UP WHILE RIDING AND NOT BEING APPLIED RESULTING IN THE RIDER BEING THROWN OFF THE BIKE. I …

NHTSA complaint 11383590, quoted in part. Filed by an owner and not verified by NHTSA or by us.

2,000 miles

THE MOTORCYCLE FRONT BRAKES STARTED PULSING AND GRABBING DURING BRAKING AT ALL SPEEDS. IT WAS MORE NOTICEABLE AT SPEEDS BELOW 20MPH WHEN COMING TO A COMPLETE STOP.

NHTSA complaint 11382783. Filed by an owner and not verified by NHTSA or by us.

10,000 miles

MY BIKE HAS HAD AND STILL DOES HAVE MULTIPLE PROBLEMS SHOCK FAILED TWICE, REAR BRAKE HOSE MELTED AND MADE BRAKES UNUSABLE WHILE I WAS ON A TRIP IN MEXICO FRONT BRAKES EXPERIENCED PULSATING SENSATION THAT PROGRESSIVELY GOT WORSE, KTM REPLACE THE BRAKE ROTORS AND FRONT WHEEL HUB, THE COUNTER SHAFT SPROCKET LEAKED OIL, KTM REPAIRED IT, BUT IT'S LEAKING AGAIN, THE ENGINE USES A QUART OF OIL EVERY 150 MILES A BOLT ON THE STEERING HEAD BROKE WHILE I WAS RIDING CAUSING A LOOSE SENSATION IN THE STEERING

NHTSA complaint 11382801. Filed by an owner and not verified by NHTSA or by us.