2021 KTM 790 Adventure R Problems

The valve train of my bike failed and left me stranded in the woods. There were no signs or warnings beforehand. After further research online, I found that this issue has been happening quite a bit. Luckily it happened to me while my bike was parked. The issue is the valve train is wearing out prematurely and causing the bikes to run poorly or not run at all. My bike has 13,000 miles on it and other bikes have had more or less miles when this issue occurred. I've worked on several motorcycles with three times the miles and never had an issue with the valve trains being chewed up like this current issue. This issue could possibly cause the bike to stop running while it is being driven at whatever speed. A bike suddenly stalling out in traffic isn't the safest scenario for a motorcycle rider. Especially if they're riding at interstate speeds. If you search online, you'll see others with this issue and it's much worse than mine. There are numerous YouTube videos and even a dedicated Facebook page about this issue. I do not have Facebook but I have attached a link with this description. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I have checked the cam shafts condition at only 3900 miles since there are a lot of people with the same motorcycle mentioning this issue and there is an unsuspected wear starting to happen. Motorcycle always ran on recommended Motorex oil and air filter was maintained as it should be.

Motorcycle hard/impossible to start. Excessive valve wear. Currently unrideable due to mechanical problems. Motorcycle stalled at intersection of busy highway, would not start creating hazard of being hit in the intersection and while pushing it to side of road. Mechanic inspected vehicle, found excessive wear to valvetrain causing engine power loss and stalls. States that it appears to be a manufacturing defect in the intake system allowing dirt ingestion leading to excessive irreparable valve wear.

Motorcycle does not start properly when cold. Takes several tries to start. Once started it dies several times and must be restarted. Once running, it idles very rough for several minutes.

I recently discovered that the brake light does not activate when applying the front brake lever. I became aware of the issue only after noticing that the motorcycle’s cruise control system would no longer engage. Upon researching the cruise control malfunction, I found numerous reports from owners indicating that failed front or rear brake pressure switches were the root cause. In almost all cases, the faulty brake pressure switch prevented the brake light from functioning properly. Online searches reveal widespread owner reports across multiple model years describing identical failures related to defective brake pressure switches. These failures impact both brake light operation and cruise control functionality. The safety implications are extremely serious. Motorcyclists may unknowingly operate their motorcycles without functioning brake lights, significantly increasing the risk of rear-end collisions. Owners may be completely unaware their brake lights are not functioning. In my case, I only discovered the defect because the cruise control stopped working. Had that not occurred, I may have continued riding without realizing my brake light system had failed. I also found reports indicating that other owners filed complaints with NHTSA and were subsequently contacted regarding dealership repairs facilitated through KTM. This suggests the issue may already be known within the manufacturer and regulatory system. Given the repeated reports across multiple KTM models and years, I respectfully request that NHTSA investigate this defect and issue a safety recall . Brake light failure caused by defective brake pressure switches presents a substantial and potentially life-threatening safety hazard to motorcycle operators and surrounding traffic. Good faith repairs by KTM should be mandated for all owners.

I have had three separate incidences of the either the front or rear brake sensor switch failing which requires replacement. It causes the brake light to not function. I do have one of the three switches for inspection. It has been confirmed by a mechanic. As it is out of warrantee there has been no manufacturer inspection. There is no indication that it is not working other than cruise control will not turn on.

Good day to whoever is reading! I've recently discovered that my brake light does not turn on on my bike no matter what brake i use front or rear. Only way it works if i push brake really hard, like way beyond regular or emergency braking. I've found similar issues online and people pointing on faulty brake sensors. They are located under the gas tank. It requires good amount of skill and time to replace them. But i did and my brake lights returned, but during a test ride i'm loosing my rear brake COMPLETELY. I take everything apart again and find out that rear brake sensor is leaking. Turned out it needed one more turn really really hard turn, so hard i thought ABS module which they connect to is not going to endure it. I guess it could happen to front brake as well. And the brakes were fine my initial test ride around a corner. In theory i could lose both brakes on my way to work next day if i did not test ride enough. It is not just unacceptably hard to fix such a simple and crucial thing like a brake lights which go out without a warning but there is also a chance to lose both brakes in a middle of a ride. What component or system failed or malfunctioned, and is it available for inspection upon request? Brake lights, yes How was your safety or the safety of others put at risk? Not safe Has the problem been reproduced or confirmed by a dealer or independent service center? Unknown Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? No Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? No warning

Brake light no longer activates upon applying normal pressure to front brake lever. Brake light activation requires greater than normal front brake lever pressure/input in order to activate the light. This issue causes a safety concern with traffic when the motorcycle brake light does not activate appropriately when stopping. This issue is consistent/repetitive and is believed to be caused by a faulty brake light switch on the front brake circuit. KTM appears to have updated/superseded part numbers relating to the faulty part in question.

I recently discovered that the brake light does not activate when applying the front brake lever. I became aware of the issue only after noticing that the motorcycle’s cruise control system would no longer engage. Upon researching the cruise control malfunction, I found numerous reports from owners indicating that failed front or rear brake pressure switches were the root cause. In almost all cases, the faulty brake pressure switch prevented the brake light from functioning properly. Online searches reveal widespread owner reports across multiple model years describing identical failures related to defective brake pressure switches. These failures impact both brake light operation and cruise control functionality. The safety implications are extremely serious. Motorcyclists may unknowingly operate their motorcycles without functioning brake lights, significantly increasing the risk of rear-end collisions. Owners may be completely unaware their brake lights are not functioning. In my case, I only discovered the defect because the cruise control stopped working. Had that not occurred, I may have continued riding without realizing my brake light system had failed. I also found reports indicating that other owners filed complaints with NHTSA and were subsequently contacted regarding dealership repairs facilitated through KTM. This suggests the issue may already be known within the manufacturer and regulatory system. Given the repeated reports across multiple KTM models and years, I respectfully request that NHTSA investigate this defect and issue a safety recall . Brake light failure caused by defective brake pressure switches presents a substantial and potentially life-threatening safety hazard to motorcycle operators and surrounding traffic. Good faith repairs by KTM should be mandated for all owners.

Starting immediately after the mandatory 600 mile service check by an authorized KTM dealer, this vehicle started experiencing prolonged cold start failures. It went from starting 100% of the time after three or less start attempts to requiring approximately ten failed start attempts before starting and running. Until 10/20/21, this motorcycle has always been fueled with either 93 octane gasoline with 10% alcohol or 90 octane fuel with no alcohol (only 2-3 times) as recommended by the manufacturer. On 10/20/21, I filled the nearly empty fuel tank with 87 octane, 10% alcohol. On the next overnight cold-soak starting attempt, and every cold start following, the vehicle started immediately on the first start attempt and settled immediately into a normal fast idle until warmed-up. This vehicle was purchased new with 0 miles on June 11, 2021. It received it's 600 mile manufacturer-required service at approximately 680 miles in September, 2021. It currently has, as of 10/24/2021, approximately 1300 miles on the odometer.

Motorcycle hard/impossible to start. Excessive valve wear. Currently unrideable due to mechanical problems. Motorcycle stalled at intersection of busy highway, would not start creating hazard of being hit in the intersection and while pushing it to side of road. Mechanic inspected vehicle, found excessive wear to valvetrain causing engine power loss and stalls. States that it appears to be a manufacturing defect in the intake system allowing dirt ingestion leading to excessive irreparable valve wear.

When running the motorcycle on the manufacturer-recommended 91+ (premium) octane fuel, the engine can take up to 5 or 6 tries (over the course of a few minutes) to start when it's sat overnight. When the engine eventually does start it runs very rough on only one (of two) cylinder. During this rough starting there is an overpowering smell of raw/un-ignighted fuel coming from the exhaust pipe. There seems to be some kind of issue with the fueling or ignition timing that prevents the engine from running properly on 91+ octane fuel. Switching to a slightly lower 89 (mid-grade) octane fuel mostly, but not completely, seems to fix the issue. However this fuel is not rocommended by the manufacturer due to the high compression ratio and I'm worried that it might cause damage in the long term. The bike was taken to the KTM dealer who performed a reset of the factory ECU; however, this did not help the issue at all. Reading online, I've found dozens of people with other 2021 KTM 890 Adventure motorcycles experiencing the same issues e.g. no start, hard starting, running on one cylinder, etc. Running on only one cylinder and sometimes dying is a major safety issue.

I recently discovered that the brake light does not activate when applying the front brake lever. I became aware of the issue only after noticing that the motorcycle’s cruise control system would no longer engage. Upon researching the cruise control malfunction, I found numerous reports from owners indicating that failed front or rear brake pressure switches were the root cause. In almost all cases, the faulty brake pressure switch prevented the brake light from functioning properly. Online searches reveal widespread owner reports across multiple model years describing identical failures related to defective brake pressure switches. These failures impact both brake light operation and cruise control functionality. The safety implications are extremely serious. Motorcyclists may unknowingly operate their motorcycles without functioning brake lights, significantly increasing the risk of rear-end collisions. Owners may be completely unaware their brake lights are not functioning. In my case, I only discovered the defect because the cruise control stopped working. Had that not occurred, I may have continued riding without realizing my brake light system had failed. I also found reports indicating that other owners filed complaints with NHTSA and were subsequently contacted regarding dealership repairs facilitated through KTM. This suggests the issue may already be known within the manufacturer and regulatory system. Given the repeated reports across multiple KTM models and years, I respectfully request that NHTSA investigate this defect and issue a safety recall . Brake light failure caused by defective brake pressure switches presents a substantial and potentially life-threatening safety hazard to motorcycle operators and surrounding traffic. Good faith repairs by KTM should be mandated for all owners.

Tire size 90/90-21 front tire inflated with Motorcycle manufacturers recommended psi without warning it instantly deflats. I had this happen twice with the same tire. Once deflated it causes the tire to debead off the rim while riding and renders the motorcycle nearly uncontrollable. Especially dangerous in a curve or turn. My riding skill kept me upright. Yes my safety was at risk. Many riders would have crashed. and likely have but have no explanation as to why. I started a thread on two Facebook groups and one Forum that are related to my motorcycle Make and model. Many owners wrote of their experiences. with the same manufacturer of the tire. The tire is marked Tubeless but I would recommend running it with a tube. Something is wrong with either the tire or the KTM OEM wheel. It's going to kill someone. No Joke!