KTB2211 Wiring Harness Damage May Cause Engine Stall – 2020-2022 KTM 1290 Super Duke R & Super Duke R EVO Motorcycles

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December 6, 2022 NHTSA CAMPAIGN NUMBER: 22V900000

Wiring Harness Damage May Cause Engine Stall

An engine stall can increase the risk of a crash.

 

NHTSA Campaign Number: 22V900

Manufacturer KTM North America, Inc.

Components ELECTRICAL SYSTEM

Potential Number of Units Affected 1,040

 

Summary

KTM North America, Inc. (KTM) is recalling all 2020-2022 1290 Super Duke R and Super Duke R EVO motorcycles. The main wiring harness may be misrouted or missing parts, which can cause wiring harness damage and result in an electrical short-circuit or engine stall.

 

Remedy

Dealers will inspect and repair the main wiring harness installation, as necessary, free of charge. Owner notification letters were mailed January 26, 2023. Owners may contact KTM customer service at 1-888-985-6090. KTM’s number for this recall is KTB2211.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check for KTM Recalls

 


IMPROVEMENTS TO THE MAIN WIRING HARNESS
(Inspection and repair if needed)

AFFECTED MODELS:

2020 1290 SUPER DUKE R
2021 1290 SUPER DUKE R
2022 1290 SUPER DUKE R EVO

RESTRICTIONS: AFFECTED MODELS ARE LINKED BY VIN IN KTM DEALER.NET

 

INITIAL INFORMATION:

KTM North America, Inc. has determined that a defect which relates to motor vehicle safety exists with certain model year 2020, 2021 and 2022 Super Duke R motorcycles. The recall pertains to a potential electrical short circuit failure if the main wiring harness becomes damaged. Therefore the wiring harness on affected motorcycles must first be inspected to verify if the wiring harness is currently routed to the improved wiring harness standards along with being equipped with the wiring harness protection parts. Motorcycles that have incorrectly routed wiring and that are missing the wiring harness protection parts can potentially experience damage in certain frame contact areas which could cause the wire to chafe or melt in the area of damage which could cause the engine to stall. If a short circuit occurs there is a possibility it could lead to injury and/or damage to property.

It is possible that motorcycles linked to this recall already have the correct wiring harness routing and wiring protection parts installed from production. If during your inspection you find the motorcycle to have the correct wiring routing along with the wiring harness protection parts then you only need to take pictures of the wiring harness routing and protection parts to attach to the TI claim to document that the motorcycle meets the improved wiring routing and protection standards.

If during your inspection of the wiring harness you find that the wiring routing does not meet the improved wiring harness standard and are missing the wiring harness protection parts then you must update the motorcycle wiring harness routing and also install the wiring harness protection parts according to the photos and short videos.

There are three inspection and repair procedures that must be performed on three specific areas of the motorcycle.

The three specific inspection procedures will be explained on the following pages with instructions and photos. Also attached to the Notification posting in Dealer.net are three short video clips that explain the inspection and repair process to help with understanding the inspection and repair procedures. It is advised that you watch the three videos before performing the procedures that are explained on the following pages.

KTM is notifying all registered owners of the motorcycles by mail. A copy of the customer letter is included in this bulletin. The customer should take the letter along with the affected motorcycle to an authorized KTM Dealer to have their wiring harness inspected for correct routing and to verify the installation of the wiring harness protection parts.

Dealers must inspect and perform the wiring harness updates if necessary on all affected model motorcycles in their inventory prior to any customer delivery. Any of the affected model motorcycles received directly from KTM North America, Inc. require the wiring harness to be inspected and repaired if necessary prior to customer delivery. Affected motorcycles acquired through dealer transfers or trades must be remedied and checked in KTM Dealer.net to ensure and document that the repair has been performed.

Motorcycles that are affected must not be sold or operated until the inspection and if needed repair procedure has been performed as described in this bulletin. It is a violation of KTM North America, Inc. policy for an authorized KTM dealer to deliver any affected motorcycles to customers before the procedure in this bulletin has been performed.

KTM must report to the federal government on a regular basis how many motorcycles have been repaired during this campaign. Be sure to submit your warranty request for reimbursement on every motorcycle repaired to ensure accurate compliance numbers.

 

PROCEDURE FOR REPAIR:

We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here. It is assumed that the repair work will be performed by a fully trained mechanic who has completed training or has a corresponding qualification. In the event of uncertainty, the most recent repair manual must be consulted.

In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not always necessary to disassemble the component to perform the activity in question. Please follow the instructions in the text.

 

Inspection procedure general information

The wiring harness must be inspected in Area A, Area B and Area C as shown in the photos and Table 1 below.  There may be components on this vehicle from this TI already installed at the factory which is why an inspection of Area A, Area B and Area C is required first.

 

Note: Each area (A, B and C) that is inspected has a before and after photo shown on the following pages to show the difference between a motorcycle that has incorrect wiring routing compared to a motorcycle that has correct wiring routing and wiring protection parts.

The before photo with a red X displays an example of a motorcycle that has incorrect wiring routing and does not have the wiring harness protection parts installed. Motorcycles that have areas that look like the before photo in each area must have the wiring harness routed to the improved wiring harness standards along with having the wiring harness protection parts installed according to the “after” photos and videos.

The after photo with a green checkmark displays an example of a motorcycle that has the correct wiring harness routing that is routed to the improved wiring harness standards along with being equipped with the wiring harness protection parts. Motorcycles that have areas that look like the after photo meet the approved standard and do not require repair. Make sure pictures are taken of each inspected area and that the checklist is completed so it can be attached to the TI claim that you will submit.

 

Inspection and repair procedure for Area A (cable tie with foot section)

1. Remove the left side fairing in accordance with the repair manual to access Area A and Area B.

2. During work, take photos according to the attached checklist.

3. Photograph the current position of the cable gland on areas A1 described below from the same angle and distance as in this TI and attach to the warranty claim.

4. Inspect wiring harness at position A1 for damage to underside and photograph from same distance and angle as shown in this TI and attach to warranty claim.

5. If damages to the wiring harness are determined, repairs must be approved by the Dealer Services Department. A special warranty claim must be used for this. Include the number of this TI (TI_11_2009785) in the warranty claim.

6. Check the correct wiring harness routing to ensure it is routed to the improved wiring harness standards along with being equipped with the wiring harness protection parts as shown in photo A2.

7. If the wiring harness is routed correctly and the wiring harness protection parts are installed as shown in photo A2 then the motorcycle meets the improved wiring harness standards and no further repair is required. Just make sure that you have taken the required photos and have completed the checklist so you can attach them to the claim.

 

8. If the Battery support is missing the cable tie with foot section you must update this area by installing the cable tie with foot section wiring harness protection parts as shown in photo A2. Following is the part number to order and install: (p.n. 0330000520000) – Cable tie with foot section

9. Check the positioning of the wiring harness for contact-free mounting, only the cable tie with foot section, cable tie guide and the frame cover are permissible as contact points.

10. Photograph the final positioning of cable tie with foot section, cable tie guide and frame cover from same distance and angle as shown in this TI, and attach to warranty claim

Note: Insufficient photo documentation and an incomplete checklist as described above can lead to   rejection of a warranty claim.

 

Area A1 (Before): If the Battery support looks like this and is missing the cable tie with foot section it must be updated to look like A2.
(Take photo for claim)

Area A2 (After): If the Battery support is missing the cable tie with foot section you must update this area by installing the cable tie with foot section wiring harness protection parts. Install the cable tie with foot section as shown here in photo A2. If needed order and install (0330000520000) – Cable tie with foot section.
(Take photo for claim)

Note: Watch the video as well

 

Inspection and repair procedure for Area B (cable tie guide)

1. With the left side fairing already removed inspect the main wiring harness in Area B.

2. During work, take photos according to the attached checklist.

3. Photograph the current position of the cable gland on areas B1 described below from the same angle and distance as in this TI and attach to the warranty claim.

4. Inspect the wiring harness at position B1 for damage to contact point to rear frame and photograph from same distance and angle as shown in this TI and attach to warranty claim.

5. If damages to the wiring harness are determined, repairs must be approved by the Dealer Services Department. A special warranty claim must be used for this. Include the number of this TI (TI_11_2009785) in the warranty claim.

6. Check the correct wiring harness routing to ensure it is routed to the improved wiring harness standards along with being equipped with the wiring harness protection parts.

7. If the wiring harness is routed correctly and the wiring harness protection parts are installed as shown in photo B2 then the motorcycle meets the improved wiring harness standards and no further repair is required. Just make sure that you have taken the required photos and have completed the checklist so you can attach them to the claim.

8. If the cable tie guide with cable tie is missing you must update this area by installing the cable tie guide with cable tie protection parts as shown in photo B2. Following are the part numbers to order and install: (p.n. 60311046050) – Cable tie guide and (p.n. 44011076140) – Cable tie 140/2.5 mm black

9. Check the positioning of the wiring harness for contact-free mounting, only the cable tie with foot section, cable tie guide and the frame cover are permissible as contact points.

10. Photograph the final positioning of cable tie with foot section, cable tie guide and frame cover from same distance and angle as shown in this TI, and attach to warranty claim.

Note: Insufficient photo documentation and an incomplete checklist as described above can lead to   rejection of a warranty claim.

 

Area B: Inspect the main wiring harness behind side cover in the location indicated in this photo B.

 

Area B1 (Before): If the main wiring harness looks like this and is missing the cable tie guide with cable tie it must be updated to look like photo B2.
(Take photo for claim)

Area B2 (After): If the cable tie guide with cable tie is missing you must update this area by installing the cable tie guide with cable tie protection parts.
Install the cable tie guide with cable tie as shown here in photo B2.
If needed order and install the following parts:
(60311046050) – Cable tie guide
(44011076140) – Cable tie 140/2.5 mm black
(Take photo for claim)

Note: Watch the video as well

 

Inspection and repair procedure for Area C (frame cover)

1. With the left side fairing already removed inspect the main wiring harness in Area C.

2. During work, take photos according to the attached checklist.

3. Photograph the current position of the cable gland on areas C1 described below from the same angle and distance as in this TI and attach to the warranty claim.

4. Inspect wiring harness at position C1 for damage to frame tab and photograph from same distance and angle as shown in this TI and attach to warranty claim.

5. If damages to the wiring harness are determined, repairs must be approved by the Dealer Services Department. A special warranty claim must be used for this. Include the number of this TI (TI_11_2009785) in the warranty claim.

6. Check if the frame tab frame cover is missing or installed as shown in photo C1 and C2.

7. If the frame tab cover is missing you must order it and install it as shown in photo C2. The part number for the frame cover is 61703083000

8. Check the positioning of the wiring harness for contact-free mounting, only the cable tie with foot section, cable tie guide and the frame cover are permissible as contact points.

9. Photograph the final positioning of cable tie with foot section, cable tie guide and frame cover from same distance and angle as shown in this TI, and attach to warranty claim.

Note: Insufficient photo documentation and an incomplete checklist as described above can lead to rejection of a warranty claim.

 

Area C: Inspect the wiring harness for damage at the indicated location.
(Take photo for claim)

 

Area C1 (Before): If the frame tab looks like this without the frame cover it must be updated to look like C2.
(Take photo for claim)

 

Area C2 (After): If the frame cover is missing you must update this area by installing the frame cover as shown here in photo C2. If needed order and install (p.n. 61703083000) – Frame cover
(Take photo for claim)

Note: Watch the video as well

 

PARTS ORDERING:
Area A: 1 QTY. 0330000520000 – Cable tie with foot section (if needed)
Area B: 1 QTY. 60311046050 – Cable tie guide (if needed)
1 QTY. 44011076140 – Cable tie 140/2.5 mm black (if needed)
Area C: 1 QTY. 61703083000 – Frame cover (if needed)

 

VEHICLE LOCK INFORMATION:

Unsold motorcycles that are linked to this recall are locked in the vehicle history. The vehicle lock prevents the motorcycle from being retailed to a customer before the recall is performed. In order to unlock the vehicle, you must perform the recall and then submit a TI claim. After the TI claim is submitted it will be possible to unlock and retail the motorcycle.

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Chronology :

In March 2022, a warranty report in France is received regarding a melted wiring harness

April – September 2022, KTM Austria Customer Service continues market monitoring of warranty and customer service claims

September 16, 2022, KTM HQ determined a recall should be issued

 


3 Affected Products

Vehicle

MAKE MODEL YEAR
KTM 1290 SUPER DUKE R 2020-2022

 


8 Associated Documents

Defect Notice 573 Report

RCLRPT-22V900-1515.PDF 213.831KB

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Safety Bulletin

RCSB-22V900-1369.pdf 894.568KB

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Recall Acknowledgement

RCAK-22V900-8450.pdf 645.875KB

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KTM Dealers US List

RMISC-22V900-9068.pdf 321.186KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-22V900-7964.pdf 270.778KB

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Recall Quarterly Report #1, 2023-1

RCLQRT-22V900-5980.PDF 211.141KB

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Recall 573 Report – May 17, 2023

RCLRPT-22V900-1976.PDF 213.88KB

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Recall Quarterly Report #2, 2023-2

RCLQRT-22V900-4956.PDF 211.24KB

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=22V900&docType=RCL

 


 

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