AMHERST, Ohio – KTM North America, Inc., has informed the National Highway Traffic Safety Administration (NHTSA) it has begun a recall of certain 2019-2020 model year KTM 790 Adventure and KTM 790 Adventure R motorcycles due to a potential front-brake issue.

This is the second brake-related recall for 2019-2020 KTM 790 Adventure/Adventure R motorcycles in as many years. The 2020 recall concerned a rear-brake issue, while this one is a potential front-brake defect.

According to NHTSA Part 573 Safety Recall Report 21V-304  in the most recent case, there is a possibility the piston return spring on the front master cylinder of the affected motorcycles might be defective which could, “ . . . in rare cases, impair the braking function.”

According to KTB2106 KTM TECHNICAL BULLETIN – USA, “As a result, this may increase the stopping distance which could cause injury to the rider or others and/or damage to property.”

The bulletin describes the problem, “The cause of the defect is due to the preload force of the originally equipped return spring being too low. To remedy this defect, a stronger return spring must be installed on all affected motorcycles.”

The original parts were provided by J.Juan

Related post:
KTM Recalls Certain 790 Adventure Motorcycles

The repair is replacement of the return spring on all recalled motorcycles, including any in unsold units in dealer inventory (which cannot be sold until the repairs are made).

The recall covers 3,707 total motorcycles. According to NHTSA there have been 79 complaints about a braking issue worldwide.

KTM dealers were informed of the recall, which will be performed at KTM’s expense, beginning April 28th. Owners will be contacted about the recall beginning May 21st.

Last year KTM agreed to recall certain 2019 and 2020 KTM 790 Adventure and KTM 790 Adventure R motorcycles which might suffer from rear-brake failure due to brake-hose overheating. In that case, 3,164 motorcycles were covered by the recall.