NHTSA ID Number: 10190960
Manufacturer Communication Number: KTB2104
TSB/Document Date: 2021-04-26
Summary
KTM
North America, Inc. has determined that a defect which relates to motor vehicle safety exists with certain 2020 1290 SUPER DUKE R motorcycles pertaining to a possibility of damage to the wiring harness in the area of the tail end lower part on the lower subframe due to differences in the assembly process and an incorrect routing of the wiring harness. The main wiring harness must therefore be checked in three places for possible damage. Also the tail end lower part must be removed and modified to do this repair. On affected motorcycles there is a possibility of a short circuit if the wiring is damaged. If damage to the wiring harness exists, during operation it is possible that the engine can stop running if the wiring is damaged. If a short circuit happens there is a possibility it could lead to injury and/or damage to property.
KTB2104 KTM TECHNICAL BULLETIN - USA
FEBRUARY 19, 2021
RECALL: THIS MODIFICATION HAS TOP PRIORITY
AND MUST BE PERFORMED IMMEDIATELY TO
ENSURE CUSTOMER SAFETY
INSPECTION AND REPAIR OF THE MAIN WIRING
HARNESS AND MODIFICATON OF THE TAIL END
LOWER PART
AFFECTED MODEL:
2020 1290 SUPER DUKE R
RESTRICTIONS: AFFECTED MODELS ARE LINKED BY VIN IN KTM
DEALER.NET
To ensure the highest level of safety, performance, reliability and customer satisfaction, it is necessary to have
the wiring harness located in the rear part of the motorcycle inspected for damage and repaired as necessary.
A piece of the body work called the “tail end lower part” must also be modified by cutting out a section of it to
improve the wiring routing. During the repair it will also be necessary to add two new additional pieces of wiring
protection and cable ties to prevent damage to the wiring.
It is necessary to inspect and rework the wiring harness and perform one of the three following possible wiring
repairs in addition to the tail end lower part modification which must be performed on every affected motorcycle.
1. Wiring repair possibility #1: If there is no damage or mild damage (Fig. 4) to the wiring insulation
tape as explained on page 9 then you must perform the steps shown on page 9. Use the Action code
ending in 00 when submitting the claim.
2. Wiring repair possibility #2: If there is damage to the wiring for the voltage regulator (Fig. 5.) which
is located in Area A (Fig. 2) then the wire can be replaced. If the voltage regulator wire is damaged
and needs replaced you will need to follow the instructions on page 10 and Annex 2 from the repair
manual which is attached to the Dealer.net notification. Use the Action code ending in 01 when
submitting the claim.
3. Wiring repair possibility #3: If the wiring insulation on the main wiring harness is damaged in Area
B and/or Area C (Fig. 2, 3 & 6) then you must replace the main wiring harness and perform the steps
shown on page 11. Use the Action code ending in 02 when submitting the claim.
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
1
DEALER SERVICES DEPARTMENT © 2021 KTM North America, Inc. – All rights reserved
INITIAL INFORMATION:
KTM North America, Inc. has determined that a defect which relates to motor vehicle safety exists with certain
2020 1290 SUPER DUKE R motorcycles pertaining to a possibility of damage to the wiring harness in the area
of the tail end lower part on the lower subframe due to differences in the assembly process and an incorrect
routing of the wiring harness. The main wiring harness must therefore be checked in three places for possible
damage. Also the tail end lower part must be removed and modified to do this repair. On affected motorcycles
there is a possibility of a short circuit if the wiring is damaged. If damage to the wiring harness exists, during
operation it is possible that the engine can stop running if the wiring is damaged. If a short circuit happens
there is a possibility it could lead to injury and/or damage to property.
KTB2104 KTM TECHNICAL BULLETIN - USA
FEBRUARY 19, 2021
KTM is notifying all registered owners of affected 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 and tail end lower part modified.
This recall must only be performed by trained technicians with proper equipment. Dealers are not to
send out parts to customers and 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 inspect and repair the wiring harness and modify the tail end lower part on all affected motorcycles
in their inventory prior to any customer delivery. Any affected 2020 1290 SUPER DUKE R models received
directly from KTM North America, Inc. require the repair to be performed prior to customer delivery. Affected
units 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 repair 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 units to customers before the procedure in this bulletin has been performed.
DEALER SERVICES DEPARTMENT © 2021 KTM North America, Inc. – All rights reserved
KTM must report to the federal government on a regular basis how many units 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.
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
2
KTB2104 KTM TECHNICAL BULLETIN - USA
FEBRUARY 19, 2021
PROCEDURE FOR REPAIR:
On the following pages you will find the repair instructions for the three wiring repair possibilities.
Be aware that all three repair possibilities will require you to inspect the wiring of the motorcycle at the zoomed
in locations shown below in Figure 1, 2 and 3.
B
C
A
Fig 2. - Zoom of Area A and B
Fig 3. - Zoom of Area C
Table 1 - Wiring locations to inspect and repair. Decide what action to take depending on the wires condition.
Area
Possible action
codes
Description
Wire OK
Wire
Not OK
A
Wiring harness from main wiring harness to voltage regulator
00
01/02
B
Main wiring harness in the diagnostics connector area
00
02
C
Main wiring harness in the seat lock area
00
02
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
3
DEALER SERVICES DEPARTMENT © 2021 KTM North America, Inc. – All rights reserved
Fig 1. - Overview
KTB2104 KTM TECHNICAL BULLETIN - USA
FEBRUARY 19, 2021
Table 2 - Types of possible wiring damage. Perform the repair that relates to the condition of the wiring.
Action code
Damage pattern
00
- No wear or Mild wear to the black electrical insulation tape (Fig. 4).
- No damage to the wire.
01
- Wire insulation from the voltage regulator ground down copper visible (Fig. 5).
- Damage less than 1 cm.
02
- Wire insulation melted, destroyed or cracked by more than 1 cm in any one area (Fig.
6).
- Damage extends into the main wiring harness.
- More than three wires damaged.
Fig. 4 - Mild or no Damage (follow code 00)
Fig. 5 - Copper visible (follow code 01)
Fig. 6 - Severe Damage (follow code 02)
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
4
DEALER SERVICES DEPARTMENT © 2021 KTM North America, Inc. – All rights reserved
Repairs at level action code 02 must be approved by Dealer Services
KTB2104 KTM TECHNICAL BULLETIN - USA
FEBRUARY 19, 2021
Rear bodywork modification (tail end lower part)
(Please reference the repair manual for more detailed instructions on the removal and installation of parts)
All three wiring repair possibilities require the rear bodywork to be modified in conjunction with the wiring
inspection and repair. Also all affected motorcycles must have the new cable protection and edge protection
installed. It will also be necessary to secure the wiring harness in certain locations with additional cable ties
(see Fig. 11 for cable tie securing and positioning).
Follow steps 1 through 9 below and Figures 7 through 9 for instructions on how to modify the rear bodywork.
Photos must be taken for documenting in the warranty claim.
Table 3 – Torque specifications
Component
Screw
Torque
Remark
Screws, passenger foot peg bracket
M8
25 Nm
Medium strength thread lock
(e.g. Loctite® 243™)
Screws, subframe metal flange
M8
25 Nm
Medium strength thread lock
(e.g. Loctite® 243™)
Screws, subframe
M8
28 Nm
Medium strength thread lock
(e.g. Loctite® 243™)
Screws, license plate holder
M6
10 Nm
Screw, battery terminal
M6
4.5 Nm
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
5
DEALER SERVICES DEPARTMENT © 2021 KTM North America, Inc. – All rights reserved
1. Remove the tail end lower part as per the repair manual Annex 1.
Note: Annex 1 is an additional attachment that is available for download in the Dealer.net notification.
2. Check the main wiring harness for signs of rubbing, damaged or melted wires. See Figures 1 to 6 and
Table 1 and Table 2 for further details.
3. Place the tail end lower part on a suitable underlay.
4. Mark bores and cut lines as shown in Fig. 7 B = 15 mm C = 45 mm.
5. To avoid scratches, cover the surrounding area with adhesive tape.
6. Drill a hole at the marked point using a 10 mm drill bit. A = 10 mm (Fig. 7).
7. Use a hand saw to saw laterally into the indicated section until it is completely cut out (Fig. 7 & 8).
8. Deburr and round off the edges of the cut section and remove the adhesive tape.
9. Place the plastic part (61708019025) on the rib of the inner side of the tail end lower part and mount
the edge protection (76003095074) as shown (Fig. 9).
KTB2104 KTM TECHNICAL BULLETIN - USA
FEBRUARY 19, 2021
Before
With section
cut out
After
Fig. 8 - Piece of tail end lower part completely cut out
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
6
DEALER SERVICES DEPARTMENT © 2021 KTM North America, Inc. – All rights reserved
Fig. 7
As described in steps 4 through 8 on page 5 - Cut out the area shown in A, B and C
Bore position on the tail end lower part B = 15 mm C = 45 mm
KTB2104 KTM TECHNICAL BULLETIN - USA
FEBRUARY 19, 2021
p.n. 61708019025
p.n. 76003095074
Fig. 10 - Main wiring harness area to be checked
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
38429 Innovation Court // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
7
DEALER SERVICES DEPARTMENT © 2021 KTM North America, Inc. – All rights reserved
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