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ADV NewsKTM Issues New Recall on 790 Adventure Models for Brake Issues

KTM Issues New Recall on 790 Adventure Models for Brake Issues

Front brake issues trigger recall on multiple KTM 790 Adventure models.

Published on 05.10.2021

KTM has issued a safety recall on certain 790 Adventure/R and Rally bikes for a faulty front brake master cylinder. A total of 3,707 bikes are affected by the recall filed with the National Highway Traffic Safety Administration. This recall follows a separate one issued last year on 790 Adventure models for a rear brake failure.


According to this new defect report, the master cylinder piston return spring may be too weak to return the brake piston to its original position, reducing the functionality of the front brake. The recall was triggered after KTM received 79 reports regarding front brake issues on 790 Adventure models worldwide, prompting an investigation into the components supplied by J.Juan SA. Testing determined that the cause of the failure is due to the preload force of the originally equipped return spring being too low.

What Can Happen

A master cylinder piston with a return spring that does not meet the specified tolerance, will reduce the overall braking system’s effectiveness on the bike. This can increase the distance required to stop as well as the risk of a crash. 

KTM790 Adventure2019-2020
KTM790 Adventure R2019-2020
KTM790 Adventure R Rally2020

How To Get it Fixed

Owners of affected models are instructed to call their local authorized KTM Dealer as soon as possible to have the repair for recall KTM2106 performed. To remedy this defect, dealers will replace the front brake master cylinder piston return spring with a stronger and larger one free of charge. KTM states that the repair will take approximately 35 minutes however, it may be necessary to leave your motorcycle with the dealer for a longer period of time depending on their work schedule. 

According to the official NHTSA filing, owner notification letters are expected to be mailed by KTM North America on May 21, 2021. You can also contact KTM customer service at 1-888-985-6090 or check your VIN to see if you are affected by the recall at

Author: ADV Pulse Staff

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KTM Issues New Recall on 790 Adventure Models for Brake Issues - ADVENTURE & OVERLAND MOTORCYCLE TRAVEL
May 10, 2021 11:01 am

[…] post KTM Issues New Recall on 790 Adventure Models for Brake Issues appeared first on ADV […]

May 11, 2021 10:06 am

Disappointing for a top dollar brand. I’ve read about so many recalls that are quite serious. Get it together Orange.

Robbie Johnson
Robbie Johnson
May 12, 2021 1:50 pm

As one of the 79 people with this documented issue, it’s about f*#^ing time. My 790 was in the shop for most of the two winters since I got it in 2019 while they tried to figure out a fix. No mention of a recall after my warranty ran out and I had to spend my own time/money on it… if it wasn’t such a fun bike I would’ve sold it a long time ago because of this repeated issue

May 14, 2021 9:08 pm

KTM should also have a recall for faulty brake switches that leave the brake light on (which also keeps the Cruise Control from working if equipped). Is that not a safety issue? I had to have them replaced on my 2020 R as well as a leaking CS seal.

May 17, 2021 11:15 am

Both KTM and BMW seem to have mastered the art of multiple recalls and crappy brake issues. I’ve got a 2019 BWM S1000 XR, which is now on its 3rd recall for brake issues, including leaking pistons – yes, really – on both front brake callipers. The bike is currently not useable while BMW await parts, so I’m really chuffed I spent near on 18k for my XR. My mate’s got a pretty high mileage Yamaha Tracer 900, which has had zero issues since new. He took the piss when I said I was getting the XR and to ‘look forward to recall ownership’ – how right he was…..

June 2, 2021 9:11 am

Guess I got a Diamond as my 790 has almost 25k on it with Zero issues. Well, I have had to put on several sets of tires and new chain and sprockets. Would think KTM could just give me the spring and I could do it myself.

Gary Keith Lyons
Gary Keith Lyons
September 11, 2022 5:47 am

My bike was diagnosed with warped rotors by the dealership. They filed a warranty claim, which KTM denied saying rotors are wear items not covered by warranty. I was told the cause was most likely riding the brake unintentionally.
If the return spring was weak would that be cause for cooking the rotors and cause warping. ? If so should the warped rotors be replaced under warranty?


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