2019 KTM 790 Adventure

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

August 14, 2024. My KTM 790 Adventure left me stranded on side of highway due to motor failure. 14,440 miles on odometer. Oil pressure light on dash lit up. 3rd oil change of its life. Had bike towed home and then dropped off at dealer on Sept 7th 2024 and the inspection was performed on 9-25-24, was charged for valve inspection. Dealer agreed valves, lifters and head were damaged and matched my description of failure. Case was opened with KTM USA , KTM denied me their 'Goodwill scheme" due to dust/dirt in motor. Appeal filed with KTM and that was also denied. This is a known faulty head in the motor that left me stranded on the side of a major highway. I received back at time of pickup a …

NHTSA complaint 11627611, quoted in part. Filed by an owner and not verified by NHTSA or by us.

Failed brake light switches cause brake light to not operate. Fails state safety inspection .

NHTSA complaint 11591382. Filed by an owner and not verified by NHTSA or by us.

The brake light doesn't illuminate unless excessive brake pressure is used. During normal braking the light doesn't illuminate at all when using the front or rear brake. It is available for inspection upon request. My safety and safety of others has been put at risk because other motorists will not know that i'm braking since the light doesn't illuminate. The problem has been reproduced by me. The KTM dealer will not offer free diagnostics for this even though there have been two other brake recalls for this model. This has only been inspected by me and multiple other owners who hav encountered the same issue. There were no warnings or symptoms prior to the issue.

NHTSA complaint 11495399. Filed by an owner and not verified by NHTSA or by us.

The clutch quit engaging while in traffic and I was nearly stranded on I-25 in stop and go traffic. I was able to nurse it along to a nearby parking lot with the clutch slipping very badly. I could have easily been rear ended. I took it apart and found the wet-clutch system was not getting any oil, it was completely dry. I bought a new clutch pack and cleaned the oil jet that supplies the clutch with oil. The clutch worked fine after oiling and installing it. It started slipping badly only a few hundred miles later. I took it apart and the clutch was completely dry again and the clutch oil jet was clogged. I replaced the stock clutch oil jet with an enlarged one and it has worked for 500 …

NHTSA complaint 11480069, quoted in part. Filed by an owner and not verified by NHTSA or by us.

2,382 miles

The contact owns a 2019 KTM 790 Adventure Motorcycle. The contact stated that several attempts were needed to start the vehicle. While driving at low speeds and applying the throttle, the vehicle stalled. The vehicle was taken to the local dealer five times where it was diagnosed that a new fuel pump, new fuel hose, clamps, fuel line, fuel connector, fuel injectors and smog kit and power-washed tank were needed. Additionally, there was build-up in the throttle body. The vehicle was repaired however, the failure recurred. The manufacturer was notified but, no further assistance was provided. The approximate failure mileage was 2,382.

NHTSA complaint 11448395. Filed by an owner and not verified by NHTSA or by us.

3,000 miles

I PUURCHASED THE MOTORCYCLE NEW ON 11/19/19. AFTER 3K MILES THE FRONT WHEEL AND SUSPENSION BEGAN LURCHING SEVERELY WHEN THE FRONT BRAKE IS APPLIED IN MOTION ON CITY STREETS. AT SLOW SPEEDS WHEN APPROACHING A STOP SIGN/LIGHT THE LURCHING IS WORSE TO THE POINT WHERE I CAN ONLY USE THE REAR BRAKE TO STOP THE MACHINE. I HAVE NEARLY LOST CONTROL OF THE MOTORCYCLE ON SEVERAL OCCASSIONS WHEN TURNING ON PAVEMENT AT LOW SPEED DUE TO THE SEVERE LURCHING WHEN APPLYING THE FRONT BRAKE. IF REQUIRED TO USE THE FRONT BRAKE IN STOP AND GO TRAFFIC THE CONDITION IS SUCH THAT THE MOTORCYCLE CANNOT BE STOPPED EFFECTIVELY WITHOUT LOSING CONTROL, THEREFORE I CAN ONLY USE THE REAR BRAKE WHICH GREATLY INCREASES …

NHTSA complaint 11384998, quoted in part. Filed by an owner and not verified by NHTSA or by us.