2019 KTM 790 Adventure

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 bag of taken out parts along with cams ,clutch plates in a bag. I asked KTM North America in writing of my denial of my "goodwill Scheme " that they were providing for this motor but was told "sorry" we cannot give you that. -No prior warning -Noise was present at time of pulling off to shoulder of highway -Breather tube was melted from heat from intake cam -No asked answers were given at time (what was valve clearance,where would the dust come from)- There is actually a bulletin informing KTM techs to seal up the motor in 5 places when they service the motorcycle, mine was not sealed, no answers on that either.

NHTSA ID

11627611

Incident

Sep 7, 2024

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

NHTSA ID

11591382

Incident

May 26, 2024

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 ID

11495399

Incident

Sep 5, 2022

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 miles or so and is currently working.

NHTSA ID

11480069

Incident

Jun 2, 2022

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 ID

11448395

Incident

Mar 1, 2021

Mileage

2,382 mi

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 THE REQUIRED STOPPING DISTANCE. THIS CONDITION IS INDICATIVE OF WARPED BRAKE ROTORS OR MALALIGNED WHEEL HUBS. THE DEALER SERVICE TECHNITION RODE THE MOTORCYCLE AND EXPERIENCED THE SAME CONDITION AS I. NEXT, HE MEAURED THE FRONT BRAKE ROTORS AND DETERMINED THEY WERE SEVERELY WARPED. HE FILED A WARRANTY CLAIM WITH THE MANUFACTURER (KTM) AND THE CLAIM WAS DENIED. I CONTACTED KTM CUSTOMER SERVICE DEPARTMENT 3 TIMES AND EACH TIME WAS INFORMED THEY WOULD NOT HONOR THE WARRANTY BECAUSE THEY CLAIM BRAKE ROTORS ARE "WEAR ITEMS". I EXPLAINED TO KTM THAT I HAVE RIDDEN MOTORCYCLES FOR 40 YEARS AND HAVE NEVER HAD A ROTOR WARP OR WEAR OUT WITHIN 3K MILES, INDEED MY 2017 BMW F800 GS BRAKES WORK PERFECTLY AND IT STILL HAS THE ORIGINAL ROTORS AND BRAKE PADS WITH 18,000 MILES ON THEM. WHEN ROTORS "WEAR" THEY BECOME CONSISTENLY THINNER AROUND THE ENTIRE CIRCUMFERENCE OF THE CONTACT SURFACE WITH THE BRAKE PAD, NOT AT RANDOM POINTS ON THE ROTOR SURFACE.

NHTSA ID

11384998

Incident

Mar 10, 2020

Mileage

3,000 mi

OIL LEAK AT COUNTER SHAFT SEAL, REPAIRED BY KTM SAFETY RECALL ON REAR BRAKES DASH GOES' BLANK WHILE RIDING, STEERING DAMPENER FAILED WATER PUMP LEAKED THE CLUTCH FAILED ( SLIPPING ) KTM DECLINED TO REPAIR THIS, I TOOK IT UPON MYSELF AND FOUND A BROKEN CLUTCH PLATE. THE FRONT BRAKES EXPERIENCED A PULSATING SENSATION WHILE BRAKING, THIS GRADUALLY GOT WORSE OVER TIME, KTM REPLACE THE FRONT WHEEL AND ONE BRAKE ROTOR THE FRONT BRAKES EXPERIENCED INCONSISTENT FREE PLAY IN THE LEVER, THIS CAUSED THE FRONT BRAKE REACTION TIMING TO BE DIFFERENT EVERY TIME, KTM DECLINED TO REPAIR THIS, WE HAD THE DEALER BLEAD THE BRAKES AT OUR EXPENSE, THIS SEEMED TO HELP THE REAR BRAKES WHERE NOT FULLY RELEASING CAUSING DRAG AND THE BRAKES TO GET HOT, THIS ALSO DAMAGED THE RIVETS THAT HOLD THE ROTOR TOGETHER AND CAUSED THEM TO WEAR ON THE CALIPER MOUNT, KTM DECLINED TO REPAIR THIS BUT DID SUPPLY NEW BRAKE CALIPER MOUNT AND ROTOR, BUT NOT LABOR.

NHTSA ID

11382803

Incident

Dec 9, 2020

Mileage

6,000 mi

FRONT BRAKE LEVER INCONSISTENT, THEN FRONT BRAKE BEGAN APPLYING ITSELF FORCING UNWANTED REDUCTION OF SPEED DURING HIGHWAY USE AND OVERHEATING OF FRONT BRAKE. THE ONLY WAY TO GET BRAKE TO RELEASE WAS TO PULL BRAKE LEVER VERY HARD AND SUDDENLY MULTIPLE TIMES TO FORCE ENGAGEMENT OF ANTI-LOCK SYSTEM, AT WHICH POINT THE BRAKES WOULD RELEASE.

NHTSA ID

11378689

Incident

Oct 6, 2020

Mileage

17,000 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.