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ADV NewsKTM Issues Recall On 790 Adventure Models In US

KTM Issues Recall On 790 Adventure Models In US

 New recall issued for 790 Adventure rear brake performance issues.

Published on 04.10.2020

KTM has issued a recall on certain 790 Adventure and 790 Adventure R models for an issue with the rear brake system. A total of 3,164 bikes are affected by the recall issued through the National Highway Traffic Safety Administration.


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According to the defect report, insufficient heat transfer between the rear brake hose and the metal fitting that mounts to the rear brake caliper may cause the brake line to overheat. For affected units, there is a possibility that the rear brake system may fail under heavy use.

What Can Happen

A failure of the rear brake system will obviously reduce the overall braking system’s effectiveness on the bike. As a result, braking can only be performed with the front brake which may increase stopping distance, increasing the risk of a serious accident.

MakeModelYear
KTM790 Adventure2019-2020
KTM790 Adventure R2019-2020

How To Get it Fixed

A new rear brake line, with a longer metal fitting, has been developed to improve heat transfer. To remedy the braking issue, it is necessary to replace the brake line that leads from the rear brake caliper to the ABS modulator. Also during the repair it is necessary to replace the round head Torx screw on the rear brake lever with a new screw. KTM will notify owners, and dealers will install the recommended parts, free of charge.

The recall is expected to begin June 1, 2020. Owners may contact KTM customer service at 1-888-985-6090. KTM’s number for this recall is TB2011. Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or check your VIN for recalls at www.nhtsa.gov.

Author: ADV Pulse Staff
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7 thoughts on “KTM Issues Recall On 790 Adventure Models In US

  1. Just CONFIRMS my thoughts about weather KTM tested their new models before releasing them out to the public.——– What is the problem? 1. Rubbish hose 2. Small Rotor? —Non Vented brake Rotor 3 Small Pads running on LARGE Dia Rotor 3 Caliper has poor cooling 4 poor Braking material on the pads? ——– To test a new bike you also need to try it out with new riders They are Qualified to find any weak area in any bike!

  2. This failure happened to .e on a trip in Baja, I had the pleasure of riding 8 days off road with no rear brake, KTM declined to cover the repair initially, fortunately I had a video of of it melting, and that helped me to vet it warrantied

    • Kirk, could you please post this video somewhere, or at least describe what actually is melting?
      Currently there is a hot discussion in the European KTM Forum going on about what actually happens when the brake line overheats.
      Thanks & regards, Olaf

  3. Kirk, could you please post this video somewhere, or at least describe what actually is melting?
    Currently there is a hot discussion in the European KTM Forum going on about what actually happens when the brake line overheats.
    Thanks & regards, Olaf

  4. I own 2 350 EXC/Fs that have a number of minor issues “like the funky gas cap” a true POS that I don’t understand how it ever made it to the public. Same for the right rear blinker in direct line of hot exhaust. I could list others but I just bought a 790R and hope to enjoy it. I’ve owned Honda’s and Kawasaki’s both dirt and street bikes and have never been disappointed with either Japanese brand.

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