2020 KTM 1290 Super Duke R

The shifting mechanism components became loose, and it hindered me from shifting up - it would upshift with difficulty, then it would go from 1st gear to neutral, making for a very dangerous experience. It quickly degraded and I could not shift out of 1st gear at all.

NHTSA ID

11429340

Incident

Aug 16, 2021

GEAR SHIFTER HITS THE KICK STAND IF USER MAKES THE WRONG ADJUSTMENTS. USER CAN HAVE ACCIDENT IF THEY DON'T NOTICE THEY MOVED THE SHIFTER WHEN BIKE HAS KICK STAND DOWN.

NHTSA ID

11416391

Incident

May 12, 2021

Mileage

1,700 mi

THIS FAULT HAS OCCURRED TWICE WITHIN 220 MILES (2 WEEKS). WHILE RIDING THE MOTORCYCLE AND ENTERING A CORNER (IN MOTION), THE DASH SHOWED THE ALERT OF "MTC FAILURE". THIS FAILURE NOT ONLY CAUSED THE BIKE TO BECOME UNSETTLED/UNSTABLE, BUT UPON TURNING THE THROTTLE TO ACCELERATE OUT OF THE CORNER, I DISCOVERED THAT IT COMPLETELY STOPPED ALL PROPULSION TO THE REAR WHEEL. THE MTC FAILURE STOPS THE POWER DELIVERY TO THE BACK WHEEL ALTOGETHER, MAKING THE BIKE UNSTABLE AND UNABLE TO BE CONTROLLED THROUGH ACCELERATION (THE VERY THING THAT NEEDED FOR STABILITY ON A TWO WHEEL VEHICLE). I WAS ABLE TO PULL IN THE CLUTCH AND COAST THROUGH THE TURN, PULLING OFF THE ROAD ONCE THROUGH THE CORNER, BUT THE PROBLEM WAS BEYOND DANGEROUS NONETHELESS. HAVING SPOKEN WITH KTM AND HAD MY BIKE TO THE DEALERSHIP, I WAS INFORMED THAT THE MTC FAILURE AND BEHAVIOR OF THE MOTORCYCLE FROM THAT FAILURE WAS NOT THE RESULT OF AN ENGINE MALFUNCTION, BUT EXHAUST SERVO CABLES BEING OUT OF ADJUSTMENT. WHILE THE DANGER OF THE BIKES BEHAVIOR AND LOSS OF PROPULSION IS PROBLEMATIC IN ITSELF, THE GREATER ISSUE IS THE CAUSE OF THAT FAILURE COMING FROM COMPLETELY UNRELATED ISSUES. THE EXHAUST SERVO CAUSED THIS FAILURE ON MY MOTORCYCLE TWO TIMES NOW IN LESS THAN TWO WEEKS (220 MILES), BUT I HAVE BEEN INFORMED THAT THIS SAME FAILURE HAS BEEN CAUSED BY AS LITTLE AS A LOW BATTERY. HAVING SPOKEN WITH KTM A NUMBER OF TIMES AND CONTINUING TO SPEAK WITH THEM REGARDING THIS ISSUE, THEY HAVE NO PERMANENT SOLUTION TO THIS PROBLEM. NOT ONLY THAT, THEY HAVE NO PLANS OR IDEA HOW TO PREVENT THIS PROBLEM FROM HAPPENING IN THE FUTURE. THIS ISSUE NEEDS TO BE ADDRESSED AND RECTIFIED IMMEDIATELY, AS IT IS ONLY A MATTER OF TIME BEFORE SOMEONE IS KILLED.

NHTSA ID

11395746

Incident

Jan 24, 2021

Mileage

220 mi

SOFTWARE UPDATE OF THE RACE ON SYSTEM In the course of continuous product improvement and further development, the locking behavior of the RaceOn fuel tank cap on the above-mentioned models has been modified to prevent occasional damage. For this purpose, the time between switching off the ignition and the automatic locking of the fuel tank cap was increased from 60 seconds to 120 seconds. KTM therefore recommends updating the software of the RaceOn lock system.

During continuous product development, the exhaust flap control on the above-mentioned Super Duke models was improved. Performing the update prevents a possible malfunction of the exhaust flap and error messages. On affected 2020, 2021 and 2022 Super Duke models the following updates must be performed: •Install a new V-clamp D=70.1 (#61705058200) on the exhaust (see Fig.1). An additional anti-twist device on the improved clamp prevents possible damage to the radiator. •Install a new header gasket 54 mm (#61705005105) on the exhaust (see Fig.1). •Install the new repair kit (#A62405031044) for the exhaust flap control (see Fig. 2). •Install the latest software file. •Use action code 00 for this update. On affected 2023 Super Duke models the following update must be performed: •Install the latest software file. Note: Model year 2023 Super Duke’s already have the new V-clamp D=70.1, header gasket 54 mm and repair kit installed therefore these parts do not need to be replaced and updated on the 2023 Super Duke models. Only the latest software file needs to be installed on 2023 Super Duke models. •Use action code 01 for this update.

KTM North America, Inc. has determined that a defect which relates to motor vehicle safety exists with certain model year 2020, 2021 and 2022 Super Duke R motorcycles. The recall pertains to a potential electrical short circuit failure if the main wiring harness becomes damaged. Therefore the wiring harness on affected motorcycles must first be inspected to verify if the wiring harness is currently routed to the improved wiring harness standards along with being equipped with the wiring harness protection parts. Motorcycles that have incorrectly routed wiring and that are missing the wiring harness protection parts can potentially experience damage in certain frame contact areas which could cause the wire to chafe or melt in the area of damage which could cause the engine to stall. If a short circuit occurs there is a possibility it could lead to injury and/or damage to property.

As a result of our active market monitoring and constant product improvement processes, we have determined that the items listed below on the 2021 1290 SUPER DUKE R should be inspected and updated in order to ensure the best functionality. 1. It is possible that the cables for the exhaust flap rest on the brake line for the rear brake. 2. Under frequent use, the screw connection on the housing of the spring preload handwheel may become loose. The instructions for points 1 and 2 are described below and on the following pages in detail. The deviations are not necessarily present on all vehicles; however, inspection of all vehicles is necessary.

As a result of our active market monitoring and constant product improvement processes, we have determined that the items listed below on the 2020 1290 SUPER DUKE R should be inspected and updated in order to ensure the best functionality. 1. The cables for the exhaust flap may rest on the lock washer of the rear brake reservoir. 2. It is possible that the cables for the exhaust flap rest on the brake line for the rear brake. 3. The screw connection between the front header and the center silencer can become loose under extreme conditions. 4. Under frequent use, the screw connection on the housing of the spring preload handwheel may become loose. 5. It is possible that an error message for the exhaust valve control unit may appear because the triggering threshold is too low. This can trigger emergency mode in certain cases. The instructions for points 1-5 are described below and on the following pages in detail. The deviations are not necessarily present on all vehicles; however, inspection of all vehicles is necessary.

KTM North America, Inc. has determined that a defect which relates to motor vehicle safety exists with certain 2020 1290 SUPER DUKE R motorcycles pertaining to a possibility of damage to the wiring harness in the area of the tail end lower part on the lower subframe due to differences in the assembly process and an incorrect routing of the wiring harness. The main wiring harness must therefore be checked in three places for possible damage. Also the tail end lower part must be removed and modified to do this repair. On affected motorcycles there is a possibility of a short circuit if the wiring is damaged. If damage to the wiring harness exists, during operation it is possible that the engine can stop running if the wiring is damaged. If a short circuit happens there is a possibility it could lead to injury and/or damage to property.