2020 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

At approximately 14,700 Miles, the motor on the bike shut off abruptly while riding at 60 mph down the road while negotiating a blind curve. The vehicle was catastrophically disabled with no warning sounds, lights, or codes and left me stranded in an area with limited cell reception and in a blind spot for approaching vehicles with no shoulder to safely park on. The bike had not yet seen its first scheduled maintenance interval (manufacturer recommends 18,000 miles) and had received multiple oil changes well before scheduled intervals. No aftermarket modifications were done to the engine, air, fuel or other pertinent systems. Upon disassembling the motor for inspection, there was …

NHTSA complaint 11578500, quoted in part. Filed by an owner and not verified by NHTSA or by us.

Engine requires multiple tries to start when cold due to inadequate fuel supply from fuel sensors or fuel injectors. A recurring issue, this happens upon starting every time the engine is cold. This is a known issue by KTM. When the bike was returned to dealer, they reset the sensors and the bike operated normally for a short time and then returned to faulty starting procedure. The starting issue places an inordinate drain on the battery putting the rider at risk of being stranded.

NHTSA complaint 11528245. Filed by an owner and not verified by NHTSA or by us.

Riding at a constant speed in either 3rd or 4th gear, approx. 30-40mph. Was preparing to make a left turn in the left turn lane so began decelerating by downshifting through all gears until reaching neutral. Once I got to neutral, the engine stalled within 1 or 2 seconds later. Light braking was being applied during this event. Engine stalled while motorcycle was still in motion, approx around 10-20mph. Used brakes to completely stop motorcycle and restarted it without issue. There are lots of discussions about this engine stalling issue in forums online.

NHTSA complaint 11522598. Filed by an owner and not verified by NHTSA or by us.

The main rear shock shaft seal has failed on two separate occasions causing shock oil to spill all over the catalytic converter posing a huge risk for fire. On both failure instances the motorcycle was being transported on a motorcycle specific hitch rack on the back of my pickup truck. The first shock seal failure occurred when I was transporting the motorcycle to my local dealer for service and the temperature was 16 degrees Fahrenheit during transport. The second shock seal failure occurred when I was transporting the motorcycle to Moab for a riding trip and the temperature dropped down to -6 degrees Fahrenheit during transport. KTM completed the first repair under warranty, which only …

NHTSA complaint 11498129, quoted in part. Filed by an owner and not verified by NHTSA or by us.

The engine’s intake crank lobe (left side) and it’s follower wore unexpectedly to a point that the engine is unusable without inspection and replacement of internal parts. All manufacturer’s service instructions were strictly adhered to and the motorcycle (and original engine) has little more than 10,500 miles on it. Engine can break down completely if operated in its current state and leave the vehicle’s operator in a position of potential harm, especially during off-highway use, which this vehicle is designed for. Vehicle is available for inspection upon request. (Pictures of internal engine damage are attached.) Dealer currently has vehicle; states they will not be able to independently …

NHTSA complaint 11481716, quoted in part. Filed by an owner and not verified by NHTSA or by us.

* Severe camshaft lobe and follower wear at 17,500 miles with very loud valve knock. I have photos of the wear, and the motorcycle is currently at the dealer for work. And yes, it is available for inspection. *Valve clearance check is due @ 18,600 miles. I checked my valves at 17,500 due to a long upcoming trip. Since the valve follower on the intake of cylinder #1 inboard was worn down severely, this could've caused catastrophic engine failure while on the road and possibly caused a sever accident. *The dealer has witnessed the problem and have serviced other similar model KTM bikes for the same issue. *The bad components have been inspected by the KTM authorized dealer. *The only warning …

NHTSA complaint 11475257, quoted in part. Filed by an owner and not verified by NHTSA or by us.