2019-2020 KTM Motorcycles KTM2106 Replacement Of The Piston Return Spring On The Front Brake Master Cylinder

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April 30, 2021 NHTSA CAMPAIGN NUMBER: 21V304000

Weak Front Brake Return Spring May Reduce Braking

A front brake with reduced functionality may increase the distance required to stop as well as the risk of a crash or injury.

NHTSA Campaign Number: 21V304

Manufacturer KTM North America, Inc.

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 3,707

Summary

KTM North America, Inc. (KTM) is recalling certain 2019-2020 KTM 790 Adventure and 790 Adventure R, and 2020 KTM 790 Adventure R Rally motorcycles. The front brake 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.

Remedy

Dealers will replace the return spring, free of charge. Owner notification letters were mailed May 21, 2021. Owners may contact KTM customer service at 1-888-985-6090. KTM’s number for this recall is KTM2106.

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.safercar.gov.

Check for KTM Recalls

KTB2106 KTM TECHNICAL BULLETIN – USA

APRIL 20, 2021

RECALL: THIS MODIFICATION HAS TOP PRIORITY AND MUST BE PERFORMED IMMEDIATELY TO ENSURE CUSTOMER SAFETY

REPLACEMENT OF THE PISTON RETURN SPRING ON THE FRONT BRAKE MASTER CYLINDER

AFFECTED MODELS:

2019 790 ADVENTURE and 790 ADVENTURE R

2020 790 ADVENTURE, 790 ADVENTURE R and 790 ADVENTURE R RALLY

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 2019 and 2020 motorcycles listed above pertaining to the front brake master cylinder piston return spring. On affected motorcycles there is a possibility that the preload force of the return spring is too low and does not meet the specified tolerance. This could result in the brake piston not being returned to its original position which in rare cases can impair the function of the front brake. To ensure the highest level of safety, performance, reliability and customer satisfaction, it is necessary to replace the front brake master cylinder piston return spring on all affected motorcycles.

If the function of the front brake is impaired due to the return spring not returning the brake piston to its original position this may reduce the braking systems effectiveness. As a result, this may increase the stopping distance which could cause injury to the rider or others and/or damage to property.

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.

Fig. 1 – Spring location

Fig. 2 – Original versus New spring

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 the front brake master cylinder piston return spring replaced.

This recall must only be performed by trained technicians with proper equipment. Dealers should take every reasonable action to make sure the customer does not try to repair or perform the recall on their vehicle. Doing so is a violation of Federal law. Dealers are to properly record the repair of the recall, report and return parts to KTM.

Dealers must replace the front brake master cylinder piston return spring 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 replacement of the front brake master cylinder piston return spring 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 front brake master cylinder piston return spring is replaced as described in this bulletin. It is a violation of KTM North America, Inc. policy for an authorized KTM dealer to deliver any affected units 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 inspected and repaired during this campaign. Be sure to submit your warranty request for reimbursement on every unit repaired to ensure accurate compliance numbers.

PROCEDURE FOR REPAIR:

(Please reference the repair manual for more detailed instructions on the removal and installation of parts)

Avoid contact between brake fluid and painted parts. Brake fluid attacks paint!

Small amounts of brake fluid may leak out, therefore protect surrounding surfaces with proper protective covering to prevent damage.

Immediately wash off brake fluid residues or stains with water.

1. Loosen the right handguard and turn it downwards and cover painted body panels with proper protective covering to prevent damage from brake fluid.

2. Move the brake reservoir to a horizontal position with a corresponding handlebar position.

3. Remove the front brake lever and diaphragm (Fig. 3 – a).

4. Remove the reservoir cover and diaphragm (Fig. 3 – b).

5. Extract the brake fluid and pry out the screen (Fig. 4 – c).

6. Push the piston slightly in by hand and pull out the locking pin. A pair of needle nose pliers is suitable for pulling out the locking pin. Let the piston slide out slowly. (Fig. 4 – d).

7. Remove the return spring. (Fig. 4 – e).

8. Install the new return spring and carefully push in the piston.

9. Insert the locking pin and reinstall the screen.

10. Mount the diaphragm and front brake lever. Install the new plastic plug from the kit into the lever bolt.

11. Fill brake fluid in the reservoir up to the mark (DOT 4/DOT 5.1).

12. Gently actuate the brake lever several times until no more air bubbles rise through the screen and a firm brake pressure is felt.

13. Check the level in the reservoir and mount the cover and diaphragm.

14. Tighten the handguard, perform a function control and test ride.

15. Cut the original spring in half with a pair of side cutters. Attach a photo of the original spring to the claim for crediting. Then dispose of the destroyed original spring.

Table 1 – Screw connections and torques

Component	Screw	Torque	Remark
Bolt, front brake lever	M6	5 Nm
Nut, front brake lever	M6	10 Nm
Screw, reservoir	M4	3 Nm
Screw, handguard	M8	25 Nm

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.

PARTS ORDERING:

Please order the following for each affected motorcycle:

1 QTY. 63713009044 – Rep. kit for front master cylinder spring

WARRANTY INPUT INFORMATION:

This Technical Bulletin only affects certain VIN numbers! Please check the VIN by performing a Motorcycle History search in KTM Dealer.net to determine if it’s affected. If the motorcycle is affected, you will see a link to the bulletin and its repair status in the history results. KTM North America will not warranty units whose VIN numbers are not linked as this bulletin does not apply to them. It is the responsibility of the dealer to determine if the unit requires this update by checking the vehicle history and understanding the instructions provided by this bulletin.

Please note that when entering a warranty claim on an affected model, you must perform a vehicle history search, expand the Technical information window and click the orange arrow on the right side of the corresponding bulletin message.

You can now choose the TI Number from the list. The TI number for this procedure is according to the repairs performed and listed in the warranty claim input information; click Continue with selected action code. The Warranty Claim is automatically entered for you, including parts & labor. You must enter additional information in the required fields marked with an asterisk “*” before submitting the claim to KTM. The flat rate time for this repair is based on the action performed and provided in minutes.

Warranty type:

TI warranty

Assembly group:

13 – Front brake

Damage code:

900 – Failure identification by manufacturer

Damage-causing component:

63513001033 – Front master cylinder, complete

Action code, parts, working time:

Replacement of return spring

Action code:

13_1870664_00

Working time:

35 minutes

Parts:

1 QTY. 63713009044 – Rep. kit for front master cylinder spring

1 QTY. GA06 – brake fluid 0.1 l

Are stock items affected:

IMPORTANT SAFETY RECALL NOTICE

NHTSA Recall No. xxxVxxx

4/xx/2021

Affected VIN: «Vin»
«PdiFirstName» «PdiLastName»
«PdiAddress1»
«PdiCity», «PdiProvince» «PdiPostalCode»

RE: Affected models:

2019 790 ADVENTURE and 790 ADVENTURE R

2020 790 ADVENTURE, 790 ADVENTURE R and 790 ADVENTURE R RALLY

Dear KTM Customer,

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

KTM North America, Inc. has decided that a defect which relates to motor vehicle safety exists in the model year 2019 and 2020 model motorcycles listed above. It is necessary to have the front brake master cylinder piston return spring replaced on all affected motorcycles. This work must be performed by an authorized KTM Dealer and will be free of charge.

On affected motorcycles there is a possibility that the preload force of the return spring is too low and does not meet the specified tolerance. This could result in the brake piston not being returned to its original position which in rare cases can impair the function of the front brake. If the function of the front brake is impaired due to the return spring not returning the brake piston to its original position this may reduce the braking systems effectiveness. As a result, this may increase the stopping distance which could cause injury to the rider or others and/or damage to property.

Please contact your authorized KTM Dealer (log onto www.ktm.com for a complete dealer listing) as soon as possible to arrange having your front brake master cylinder piston return spring replaced. It is suggested that you call your local authorized KTM Dealer to make an appointment to have the recall repair performed. The procedure 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. Please present a copy of this letter along with your motorcycle to your local authorized KTM dealer. There will be no charge for this service.

If you have any questions related to the content of this letter, please contact KTM North America, Inc. Customer Relations at (888) 985-6090 for assistance. Furthermore, if for any reason KTM is unable to remedy the situation without charge, or within a reasonable amount of time, you may write the Administrator, National Highway Traffic Safety Administration, 1200

New Jersey Avenue, S.E., Washington, DC 20590 or call 1-888-327-4236 (TTY: 1-800-424-9153); or go to https://www.safercar.gov

If you have sold, traded or no longer own this motorcycle, it is important for the safety of the current owner that you inform KTM North America, Inc., of current ownership or unknown ownership status by returning the second page of this letter in the enclosed self-addressed prepaid postage envelope.

We apologize for any inconvenience and want to assure you that our commitment together with all KTM Dealers is to provide you with the highest level of service, support and customer satisfaction.

Best Regards,
Dealer Services Department
KTM North America, Inc.

IMPORTANT SAFETY RECALL NOTICE

NHTSA Recall No. 21V304

5/21/2021

Affected VIN: «Vin»
«PdiFirstName» «PdiLastName»
«PdiAddress1»
«PdiCity», «PdiProvince» «PdiPostalCode»

RE: Affected models:
2019 790 ADVENTURE and 790 ADVENTURE R
2020 790 ADVENTURE, 790 ADVENTURE R and 790 ADVENTURE R RALLY

Dear KTM Customer,

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. KTM North America, Inc. has decided that a defect which relates to motor vehicle safety exists in the model year 2019 and 2020 model motorcycles listed above. It is necessary to have the front brake master cylinder piston return spring replaced on all affected motorcycles. This work must be performed by an authorized KTM Dealer and will be free of charge.

On affected motorcycles there is a possibility that the preload force of the return spring is too low and does not meet the specified tolerance. This could result in the brake piston not being returned to its original position which can impair the function of the front brake. If the function of the front brake is impaired due to the return spring not returning the brake piston to its original position this may reduce the braking systems effectiveness. As a result, this may increase the stopping distance required, which could cause a crash or injury to the rider or others and/or damage to property.

If you have already paid for a repair related to this concern before the date of this letter, you may be eligible for reimbursement. Please contact KTM Customer Relations at (888) 985-6090 for more information.

We apologize for any inconvenience and want to assure you that our commitment together with all KTM Dealers is to provide you with the highest level of service, support and customer satisfaction.

Best Regards,
Dealer Services Department
KTM North America, Inc.

5 Affected Products

Vehicles

MAKE	MODEL	YEAR

KTM	790 ADVENTURE	2019-2020
KTM	790 ADVENTURE R	2019-2020
KTM	790 ADVENTURE R RALLY	2020

9 Associated Documents

Recall 573 Report – AMENDMENT 2

RCLRPT-21V304-2373.PDF 214.495KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V304-4407.pdf 392.182KB

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Recall 573 Report – Amendment 1

RCLRPT-21V304-7858.PDF 214.373KB

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Miscellaneous Document – KTM Dealer List

RMISC-21V304-2757.pdf 311.507KB

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Defect Notice 573 Report

RCLRPT-21V304-5198.PDF 214.367KB

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Manufacturer Notices(to Dealers,etc) – KTB2106 KTM TECHNICAL BULLETIN – USA APRIL 20, 2021

RCMN-21V304-9024.pdf 295.337KB

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Recall Acknowledgement

RCAK-21V304-4097.pdf 646.46KB

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Recall Quarterly Report #3, 2021-4

RCLQRT-21V304-6691.PDF 211.331KB

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Recall Quarterly Report #1, 2021-2

RCLQRT-21V304-0703.PDF 211.146KB

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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=21V304&docType=RCL

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Summary

Remedy

Notes

RECALL: THIS MODIFICATION HAS TOP PRIORITY AND MUST BE PERFORMED IMMEDIATELY TO ENSURE CUSTOMER SAFETY

REPLACEMENT OF THE PISTON RETURN SPRING ON THE FRONT BRAKE MASTER CYLINDER

Latest Recalls Documents

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