2018-2020 KTM Motorcycles KTB2112 Inoperable Clutch

October 12, 2021 NHTSA CAMPAIGN NUMBER: 21V792000

Inoperable Clutch

An inoperable clutch increases the risk of a crash.

 

NHTSA Campaign Number: 21V792

Manufacturer KTM North America, Inc.

Components POWER TRAIN

Potential Number of Units Affected 8,398

 

Summary

KTM North America, Inc. (KTM) is recalling certain 2018-2020 690 Enduro R, Vitpilen 701, 701 Enduro, 701 Supermoto, 2019-2020 690 SMC R, Svartpilen, 2018-2019 690 Duke, and 2020 701 Enduro LR motorcycles. The bellow-style gasket on the clutch slave cylinder may have been damaged during manufacturing, which could cause the clutch to become inoperable and not disengage when the clutch lever is pulled in.

 

Remedy

Dealers will inspect the clutch slave cylinder and replace it if necessary, free of charge. Owner notification letters are expected to be mailed December 3, 2021. Owners may contact KTM customer service at 1-888-985-6090. KTM’s numbers for this recall are KTB2112 and HTB2110.

 

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

 


KTB2112 KTM TECHNICAL BULLETIN – USA

OCTOBER 1, 2021

 

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

 

CLUTCH SLAVE CYLINDER INSPECTION AND REPLACEMENT IF NEEDED

 

AFFECTED MODELS: 

  • 690 Duke and 690 Enduro R
  • 690 Duke, 690 Enduro R and 690 SMC R 2020 690 Enduro R and 690 SMC R

 

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  2018, 2019 and 2020 motorcycles listed above pertaining to the clutch slave cylinder. On affected motorcycles there is a possibility that the bellow style gasket can be damaged caused by deviations during assembly.  Damage to the bellow gasket may affect the function of the clutch slave cylinder. This could result in the rider noticing a change in shifting behavior and the clutch becoming inoperable to the point where the clutch will not disengage when the clutch lever is pulled in.  To ensure the highest level of safety, performance, reliability and customer satisfaction, it is necessary to replace the clutch slave cylinder on all affected motorcycles that have a bellow style gasket clutch slave cylinder mounted (Fig. 1).

If the function of the clutch slave cylinder is impaired due to the bellow gasket being damaged this may prevent the rider from shifting the motorcycle in a normal manner due to the clutch becoming inoperable and may make it difficult to operate the motorcycle or difficult to stop or start which could cause injury to the rider or others and/or damage to property. For example, when motorcycle is in gear it will not start in the way the rider is used to or the motorcycle will not start if the transmission is not in neutral.

The cause of the defect is due to design of the originally mounted clutch slave cylinder that has a bellow style gasket that can be damaged.  To remedy this defect, a new clutch slave cylinder without the bellow style gasket must be installed on all affected motorcycles (Fig. 2).

Fig. 1 – Version with bellow style gasket

(p.n. 79432061144)

 

Fig. 2 – New version without bellow style gasket

(p.n. 76132061044)

 

Some motorcycles might already have the new version clutch slave cylinder mounted from a customer replacement. Therefore it is first necessary to inspect the clutch slave cylinder to determine which version is installed.  If the bellow style gasket clutch slave cylinder is mounted it must be replaced by the new version (p.n. 76132061044). If the new version is already mounted then you must reinstall the new style slave cylinder using a new gasket and o-ring on the slave cylinder and a new lock washer for the front sprocket to seal and remount the components properly.

 

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 clutch slave cylinder 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 clutch slave cylinder 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 clutch slave cylinder 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 clutch slave cylinder 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)

  • 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. Remove the front sprocket cover and front sprocket nut according to the repair manual.

2. Pull off the front sprocket together with the chain and allow to hang downward.

3. Take off the clutch slave cylinder together with the seal according to the repair manual.

4. Inspect the clutch slave cylinder version.

 

Version with bellows, exchange necessary > point 5 (action code 01) Version without bellows, no exchange necessary > point 6 (action code 00)

 

5. Loosen the clutch line and fit to the new clutch slave cylinder (76132061044).

6. Mount the clutch slave cylinder with a new seal and a new O-ring according to the repair manual and bleed in the case of a replacement.

7. Mount the front sprocket together with the chain, the front sprocket nut with new lock washer and the front sprocket cover according to the repair manual.  Check the system for leaks, perform a function test and take a test ride.

 

Table 1 – Screw connections and torques

Component Screw Torque Remark
Clutch line M6 6 Nm
Front sprocket nut M20 100 Nm Loctite 243
Front sprocket cover, screws M8

M6

25 Nm

10 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. 76132061044 – CLUTCH SLAVE CYL. DOT CPL. 27MM (order if the slave cylinder needs replaced due to the motorcycle having a bellow style gasket slave cylinder mounted)

1 QTY. 51033031000 – Lock washer (order for each affected motorcycle that has the inspection or replacement)

1 QTY. 59032065100 – Gasket (order for each affected motorcycle that has the inspection or replacement)

1 QTY. 0770300015 – O-ring (order for each affected motorcycle that has the inspection or replacement)

 

Replaced clutch slave cylinders must be returned to the KTM Warranty Department at 1119 Milan Ave. Amherst, OH 44001. Warranty Claims will only be processed after the replaced parts have been received. Parts must be tagged and include a copy of the claim.

 

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.

 

REIMBURSEMENT FOR CUSTOMERS THAT ALREADY PAID FOR THE REPAIR:

If a customer has already paid for a repair related to this concern before the date of this bulletin, the customer  may be eligible for reimbursement.  Please contact Dealer Services for more information regarding reimbursement for this type of situation.

 

Warranty type:
TI warranty
Assembly group: 
32 – Clutch
Damage code: 
900 – Failure identification by manufacturer
Damage-causing component:
79432061144 – Clutch slave cylinder
Action code, parts, working time:
Inspection of clutch slave cylinder

Action code: 32_1948775_00
Working time: 30 minutes
Parts: 1 QTY. 51033031000 – Lock washer
1 QTY. 59032065100 – Gasket
1 QTY. 0770300015 – O-ring

 

Replacement of clutch slave cylinder

Action code: 32_1948775_01
Working time: 40 minutes
Parts: 1 QTY. 76132061044 – Clutch slave cylinder
1 QTY. 51033031000 – Lock washer
1 QTY. 59032065100 – Gasket
1 QTY. 0770300015 – O-ring
1 QTY. GA06 – brake fluid 0,1l

 

Are stock items affected:
YES  Please send the clutch slave cylinders 79432061144 via RMA back to the Spare Parts Center.

 


IMPORTANT SAFETY RECALL NOTICE 

NHTSA Recall No. xxxVxxx 

 

10/xx/2021

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

 

RE: Affected models: 

  • 690 Duke and 690 Enduro R
  • 690 Duke, 690 Enduro R and 690 SMC R
  • 690 Enduro R and 690 SMC R

 

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 2018, 2019 and 2020 model motorcycles listed above.  It is necessary to have the clutch slave cylinder inspected and 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 bellow style gasket on the clutch slave cylinder can be damaged caused by deviations during assembly.  Damage to the bellow gasket may affect the function of the clutch slave cylinder. This could result in the rider noticing a change in shifting behavior and the clutch becoming inoperable to the point where the clutch will not disengage when the clutch lever is pulled in.  To ensure the highest level of safety, performance, reliability and customer satisfaction, it is necessary to replace the clutch slave cylinder on all affected motorcycles that have a bellow style gasket clutch slave cylinder mounted.

 

If the function of the clutch slave cylinder is impaired due to the bellow gasket being damaged this may prevent the rider from shifting the motorcycle in a normal manner due to the clutch becoming inoperable and may make it difficult to operate the motorcycle or difficult to stop or start which could cause injury to the rider or others and/or damage to property. For example, when motorcycle is in gear it will not start in the way the rider is used to or the motorcycle will not start if the transmission is not in neutral.

 

The cause of the defect is due to design of the originally mounted clutch slave cylinder that has a bellow style gasket that can be damaged.  To remedy this defect, a new clutch slave cylinder without the bellow style gasket must be installed on all affected motorcycles.

 

If you are unable to transport your motorcycle to your nearest KTM dealer, please contact KTM North America, Inc. Customer Relations at (888) 985-6090 to make arrangements for the transportation and repair of your motorcycle. The transportation and repair will be conducted with no cost to you.

 

Please contact your authorized KTM Dealer (log onto www.ktm.com for a complete dealer listing) as soon as possible to arrange having your clutch slave cylinder inspected and 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 40 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 http://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.

 


19 Affected Products

Vehicles

MAKE MODEL YEAR
HUSQVARNA 701 ENDURO LR 2020
HUSQVARNA 701 SUPERMOTO 2018-2020
HUSQVARNA ENDURO 2018-2020
HUSQVARNA SVARTPILEN 701 2019-2020
HUSQVARNA VITPILEN 701 2018-2020
KTM 690 DUKE 2018-2019
KTM 690 ENDURO R 2018-2020
KTM 690 SMC R 2019-2020

 


2 Associated Documents

Defect Notice 573 Report

RCLRPT-21V792-9285.PDF 216.488KB

RCLRPT-21V792-9285

 


Recall Acknowledgement

RCAK-21V792-5728.pdf 747.153KB

RCAK-21V792-5728

 


Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V792&docType=RCL

 


 

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