2019 KTM 790 Adventure R

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 ID

11581180

Incident

Apr 1, 2023

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 ID

11448739

Incident

Oct 23, 2021

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 issue.

NHTSA ID

11445681

Incident

Jul 3, 2019

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 THINK THE PROBLEM IS VERY DANGEROUS AND COULD RESULT IN RIDERS BEING KILLED.

NHTSA ID

11383590

Incident

Dec 15, 2020

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 ID

11382801

Incident

Dec 9, 2020

Mileage

10,000 mi

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 ID

11382783

Incident

Aug 24, 2019

Mileage

2,000 mi

ALL THREE BRAKE ROTORS (2 FRONT, 1 REAR) ARE COMING LOOSE FROM THEIR SUPPORT POINTS WITH THE VEHICLE HAVING JUST OVER 4,000 MILES ON IT. THERE IS NO WAY TO TIGHTEN THE ROTORS. OTHER RIDERS HAVE REPORTED CATASTROPHIC BRAKING FAILURES AS A RESULT. A VIDEO OF THE LOOSE ROTORS IS AVAILABLE HERE: HTTPS://PHOTOS.APP.GOO.GL/WH9RTBWQKG9T6TYN9

NHTSA ID

11372614

Incident

Oct 28, 2020

Mileage

4,060 mi

WARPED FRONT ROTORS CAUSE STRONG PULSING WHEN FRONT BRAKE APPLIED WHICH IS DESTABILIZING WHEN ON CURVY MOUNTAIN ROADS OR AT HIGHWAY SPEEDS AND SUDDEN BRAKING REQUIRED. FRONT ROTORS WARPED WITH 1200 MILES ON THE ODOMETER AND KTM REFUSED TO REPLACE UNDER WARRANTY SAYING THIS IS A "WEAR ITEM". ROTOR THICKNESS IS WEAR BUT WARPING IS NOT WEAR, ESPECIALLY ON A NEW BIKE. HAVING DONE MORE RESEARCH ONLINE SINCE MY FIRST ATTEMPT TO GET ROTORS REPLACED LAST YEAR, I SEE IT HAS AFFECTED NUMEROUS OTHER OWNERS, SOME OF WHICH HAVE SUCCESSFULLY HAD ROTORS REPLACED UNDER WARRANTY OTHERS NOT. I BROUGHT INTO DEALER AGAIN LAST MONTH TO SEE IF THEY WOULD REPLACE BUT AGAIN WAS REFUSED. NOT SURE WHY SOME DEALERS / OWNERS HAVE BEEN SUCCESSFUL GETTING WARRANTY DONE BUT SEEM LIKE A KNOWN ISSUE TO KTM AND SHOULD BE RECALL. THANKS FOR YOUR ATTENTION TO THE MATTER

NHTSA ID

11331598

Incident

Jul 31, 2019

Mileage

1,200 mi

KTM will also retroactively examine warranty or goodwill applications if customers of affected models have already had repairs carried out at their own expense by an authorized KTM dealer in the past due to damaged camshafts or finger followers. If the conditions explained in the communication with the authorized KTM dealer network are met, subsequent goodwill may be considered. Note: All relevant invoices and a credit signed by the customer must be attached to the application. The invoice date must be specified as the repair and fault date, and the affected camshaft must be specified as the component causing the fault.

Even though complaints have been reported about the camshafts on the 790 Duke/Adventure MY 2018- 2020 models, examinations of the allegedly defective camshafts have shown that a large proportion of these camshafts are in order. In these cases, it is not a question of wear, but usually only of discoloration or running marks that have formed on the running surface of the cams or on the bearing points of the shafts. To avoid further unnecessary repairs and to counteract any inquiries, the following procedure has been defined:

On affected motorcycles there is a possibility that the preload force of the return spring is too low and does not meet the specified tolerance. This could result in the brake piston not being returned to its original position which in rare cases can impair the function of the front brake. To ensure the highest level of safety, performance, reliability and customer satisfaction, it is necessary to replace the front brake master cylinder piston return spring on all affected motorcycles.

For the 2019 and 2020 790 ADVENTURE and 790 ADVENTURE R models, KTM has enabled the ability to purchase and install the Quickshifter+ technical accessory software extension again using only the XC_2 diagnostic tool. On certain 2020 790 ADVENTURE R RALLY models, it is possible that the Cruise Control and the Quickshifter+ features are not activated as delivered from production. Please do not purchase the Cruise Control and do not purchase the Quickshifter+ for this model as the software purchases are not refundable. It is necessary to activate these two features during PDI and before customer delivery. This can be done by using the XC_2 diagnostic tool in the Technical Accessories menu, select the software icon, click Update, click Activate.

This bulletin supersedes KTB2012 dated April 15, 2020 because the 2020 890 DUKE R software installation errors have been resolved. KTM North America, Inc. has identified a technical problem using the XC_2 tool when attempting to purchase and install some of the Technical Accessories Software Extensions for the above-mentioned model motorcycles.

KTM North America, Inc. has identified a technical problem using the XC_2 tool when attempting to purchase and install some of the Technical Accessories Software Extensions for the above-mentioned model motorcycles.