2021 KTM 790 Adventure R problems

VEHICLE SPEED CONTROL

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.

NHTSA complaint #11737074 — an unverified report by a vehicle owner.

ELECTRICAL SYSTEM

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.

NHTSA complaint #11737074 — an unverified report by a vehicle owner.

SERVICE BRAKES

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.

NHTSA complaint #11737074 — an unverified report by a vehicle owner.

ENGINE

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)

NHTSA complaint #11678897 — an unverified report by a vehicle owner.

SERVICE BRAKES

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.

NHTSA complaint #11667944 — an unverified report by a vehicle owner.

EXTERIOR LIGHTING

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

NHTSA complaint #11613634 — an unverified report by a vehicle owner.

SERVICE BRAKES

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

NHTSA complaint #11613634 — an unverified report by a vehicle owner.

EXTERIOR LIGHTING

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.

NHTSA complaint #11612747 — an unverified report by a vehicle owner.

SERVICE BRAKES

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.

NHTSA complaint #11612747 — an unverified report by a vehicle owner.

ENGINE

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.

NHTSA complaint #11581257 — an unverified report by a vehicle owner.

ENGINE

Difficult cold start ups. When the bike is cold or has been sitting for 1-2 weeks and I start it up intermittently the bike has problems starting up and running. Will stall out and need to attempt to restart it several times before it will run. Appears to be running on a single cylinder for 30-45 seconds when it does finally start up then will run as normal. This does not occur when the motorcycle is already warm. Concerned about possible mechanical damage from running on a single cylinder which could be dangerous on a motorcycle and result in injury.

NHTSA complaint #11523231 — an unverified report by a vehicle owner.

TIRES:BEAD

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!

NHTSA complaint #11494485 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

1) The vehicle TFT display containing important data such as speed etc.. blacks out on occasion. The vehicle itself is still functional but with the display blacked out the operator has no speed information, or information about the vehicle such as fuel levels and ABS control. KTM has been made aware of the issue as it has affected multiple users worldwide. 2) The indicator/blinker control switch does not engage the blinkers when pushing the switch to the left. In right hand drive markets this a particular hazard. Again, the issue is common across the 790/890 Adventure and Duke models.

NHTSA complaint #11450634 — an unverified report by a vehicle owner.

EXTERIOR LIGHTING

1) The vehicle TFT display containing important data such as speed etc.. blacks out on occasion. The vehicle itself is still functional but with the display blacked out the operator has no speed information, or information about the vehicle such as fuel levels and ABS control. KTM has been made aware of the issue as it has affected multiple users worldwide. 2) The indicator/blinker control switch does not engage the blinkers when pushing the switch to the left. In right hand drive markets this a particular hazard. Again, the issue is common across the 790/890 Adventure and Duke models.

NHTSA complaint #11450634 — an unverified report by a vehicle owner.

POWER TRAIN

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.

NHTSA complaint #11449741 — an unverified report by a vehicle owner.

ENGINE

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.

NHTSA complaint #11449741 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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.

NHTSA complaint #11449741 — an unverified report by a vehicle owner.

UNKNOWN OR OTHER

The motorcycle's instrument cluster (TFT Display) often becomes obscured by internal condensation (fogging), sometimes remaining obscured for extended periods of time (i.e., 30 minutes). When this occurs, it is impossible to see critical operation/safety information such vehicle speed, traction, and ABS settings. It is also impossible to operate the menu to control these same settings. The resulting conditions make vehicle operation unsafe--especially when fogging occurs while operating the vehicle. Based on extensive forum searches, this issue is a design flaw that is well-known, but largely unaddressed by the manufacturer (KTM). Many owners of the same vehicle model experience this safety issue. My local dealership has "warrantied" (replaced) one display for this condensation issue, but refuses to further remedy the issue, even though the replacement display has the same problem.

NHTSA complaint #11448515 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

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.

NHTSA complaint #11446703 — an unverified report by a vehicle owner.

ENGINE

The motorcycle is having a cold start issue. When starting after 24hours, the motorcycle will not start right away or will only start on one of two cylinders. After roughly 60 seconds the second cylinder starts up.

NHTSA complaint #11446509 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

The motorcycle is having a cold start issue. When starting after 24hours, the motorcycle will not start right away or will only start on one of two cylinders. After roughly 60 seconds the second cylinder starts up.

NHTSA complaint #11446509 — an unverified report by a vehicle owner.

ENGINE

When I start the bike, it sounds like the engine is only running on one cylinder and misfiring. It runs 'rough' like this for about 30 -60 seconds and the revs are sitting between 1000-1300 instead of the normal 1300-1500rpm range. You can smell fuel while this is happening. It then 'pops' and the engine runs fine after that. I live in the Netherlands, but wanted to register the issue here as well for investigation.

NHTSA complaint #11445537 — an unverified report by a vehicle owner.

ENGINE

When engin is cold for more then 8 hours. Engin will start only on 1 cylinder (right), for +/- 1 minute (1000 +/- rpm), after, you will heard internal explosion, and left cylinder will start (1600 +/- rpm) . and dropping at 1400 for normal idle. With an strong gazoline smells after start-up, after 2 3 minutes smeel is gone Please note that I live in Canada Quebec

NHTSA complaint #11445599 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

When I start the bike, it sounds like the engine is only running on one cylinder and misfiring. It runs 'rough' like this for about 30 -60 seconds and the revs are sitting between 1000-1300 instead of the normal 1300-1500rpm range. You can smell fuel while this is happening. It then 'pops' and the engine runs fine after that. I live in the Netherlands, but wanted to register the issue here as well for investigation.

NHTSA complaint #11445537 — an unverified report by a vehicle owner.

FUEL/PROPULSION SYSTEM

If the bike has been sitting overnight, then the first start of the day is difficult. It does not want to start and takes a few tries. When it does start it is on only 1 cylinder...this goes back to normal once it warms up after a minute or so. This began @700 miles. This problem goes away immediately if you use 89 octane fuel. I have just stayed with 89 but other owners have reported after going back to the fuel KTM recommends 91 octane or higher, the problem comes back.

NHTSA complaint #11445550 — an unverified report by a vehicle owner.