KTM Recalls

2024–2026 KTM 390 DUKE, 390 ENDURO R, 390 SMC R, 390 ADVENTURE R and X

Due to a software issue in the vehicle’s Engine Control Unit (ECU), the engine may stall at low RPM resulting in a sudden loss of motive power whilst riding.

2023–2025 KTM 390 Duke and 990 Duke

Due to a manufacturing defect, the fuel tank cap seal may crack. If this occurs, fuel may leak and in the presence of an external ignition source could result in a vehicle fire.

2023 KTM 890 ADVENTURE R ASEAN

The front brake master cylinder seals may swell and affect the front brake application resulting in a reduction or loss in braking performance.

2019–2022 KTM 1290 SUPER DUKE R (2020-2022) 1290 SUPER DUKE R EVO, 1290 SUPER DUKE RR

Due to the wiring harness routing at production, it may result in rubbing or chaffing of the wiring harness at frame contact points. As a result, the wiring harness may become damaged over time. If this occurs, it may result in a vehicle fire.

2017 KTM X-Bow

The front axle housing may not meet manufacturing specifications and may crack. If this occurs it may result in a loss of vehicle control.

2017–2020 KTM 690 Enduro R / 690 SMC R 690 Enduro R Model Year 2018 - 2020, 690 SMC R Model Year 2019 - 2020

A clutch slave cylinder manufactured with a bellow style gasket may be damaged during assembly. Damage could result in the clutch failing to disengage preventing the rider from being able to change gears.

2020–2021 KTM 1290 SUPER ADVENTURE Adventure R, Adventure S

The plastic plug of the drainage hose from the activated carbon filter source may melt, forming an ignition source. As fuel may leak out from the drainage hose and result in a fire.

2019–2021 KTM 790 ADVENTURE

The preload force of the return spring located in the front brake cylinder may not meet specifications. This can result in the brake piston not being returned to its original position, which can impair the function of the front brake and result in a loss of brake performance.

2020–2021 KTM 1290 SUPER DUKE R

The rear section of the wiring harness may have been routed incorrectly during assembly. This may have damaged the wiring harness.

2019–2020 KTM 790 ADVENTURE

Due to a possible material failure of the rear brake line as a result of overheating , the rear brake system can fail.

2015–2019 KTM 1290 SUPER ADVENTURE

An error occurred in the moulding process of the fuel tank. There may be a fuel leakage at the lower fitting insert for the fuel tank fairing in the seat area.

0 KTM 690 DUKE / R

The system comprising of the fuel tank, fuel tank filler neck and fuel tank filler neck gasket may leak and fuel may escape.

2015–2018 KTM 1290, SUPER DUKE GT

The piston component material made of PPS (polyphenylene sulphide) located in handbrake master cylinder (front brake), may crack.

2017 KTM 125 & 390 DUKE

1. The current Head Light Control Unit (HLU) software may cause the LED headlight to reboot while in operation. 2. The instrument dashboard may lose information or not display all information.

2016–2017 KTM 1290 SUPER DUKE GT

Fuel hoses on specific motorcycle VINs may be faulty, which could cause a fuel leak.

2012–2016 KTM 690 DUKE/DUKE R

Contact may occur between the wiring harness and the ABS modulator due to deviations in the assembly process. This will only occur if the wiring harness is frayed and in contact with the ABS modulator, and the brake line is electrically conductive. This may cause a conductive brake line to overheat and ultimately melt, which can result in failure of a brake system circuit.

2013–2016 KTM 1190 ADV/ADV R & 1290 S/ADV

In isolated cases contact may occur between the wiring harness and the ABS modulator due to deviations in the assembly process. This will only happen if the wiring harness is frayed and in contact with the ABS modulator, and the brake line is electrically conductive. This may cause a conductive brake line to overheat and ultimately melt, which can result in failure of a brake system circuit.

2016 KTM EXC, EXC-F & EXC-F SIX DAYS

Certain batches have hand brake cylinders with defective machining. This can lead to early wear of the sealing cup in the hand brake cylinder, thus leading to impaired braking performance.

2016 KTM 250 SXF Factory Edition & 250 SXF

Quality deviations in the production process of the connecting rod may result in early failure and fracturing of the conrod under certain load conditions. This issue is identified to a specific vin range of 250 SXF Factory Edition vehicles in Australia.

2015–2016 KTM SUPER ADVENTURE

There may be an oil leak at the plug connection, and software for the semi active shock requires updating.

2015 KTM 125, 150, 250 SX & 250, 350, 450 SX-F

Due to variations in the spoke manufacturing process, some spokes on the front wheel may exhibit quality deviations. Depending on where they are fitted in the wheel, care and spoke tension, it is possible that individual spokes may break while riding. This can overload the remaining intact spokes and consequently break them.

2014–2015 KTM KTM Sportmotorcycle

Deviations in the manufacturing process of the moulded fuel hoses can cause problems including uncontrolled fuel leakage at the bends or at the ends.

2015 KTM KTM Sportmotorcycle

Deviations in the manufacturing process of the supplier of the M12 aluminium fuel pump nut can result in insufficient sealing and cause uncontrolled fuel leakage on affected motorcycles.

2011–2015 KTM KTM Sportmotorcycle.

In certain cases there may be problems with the tank breather in individual cases.

2013–2015 KTM 1290 Super Duke

Due to deviations in the manufacturing process, the internal overflow pipe in some fuel tanks may not be completely enclosed by plastic. This may lead to a fuel leak.

2014–2015 KTM 690 ENDURO, SMC R

KTM discovered that the rear ABS brake line of the 690 ENDURO R and 690 SMC R models of model year 2015 have possibly been damaged while mounting the spring band clamps of the engine ventilation tube. Even without this pre-existing defect, subsequent damage caused by vibrations at the contact point as well as a sudden braking pressure loss, with resultant total failure of the rear brake, cannot be excluded.

2014–2015 KTM 690 SMC R

It was determined that in some cases the spacers of the 690 ENDURO R where installed on the front wheel of the 690 SMC R. These spacers are 4.4mm shorter and the resulting play can cause the wheel to move axially on the front wheel spindle.

2014 KTM 125SX, 150SX, 250SXF, 350SXF, 450SXF, 250XCF, 350XCF, 450XCF

Due to a change in production process, the threaded connection between the piston rod and screw cap may not be sufficiently tight. If the piston rod detaches from the screw cap, this will result in damage to the inside of the fork and it may seize.

2013–2014 KTM 690 ENDURO R & 690 SMC 4

During routine production checks, KTM discovered that the tool for tightening the foot brake levers on the foot rest brackets was not set correctly.

2012–2013 KTM FULLSIZE

Due to a production fault on the upper part of the throttle grip housing, the throttle cable wire may slide out of the deflection roller and become wedged between the deflection roller and the housing. This blocks the throttle slide and results in an uncontrollable riding situation.

2011–2012 KTM 350EXCF,450EXC,500EXC,350 FREERIDE,250XCF,350EXCF,350XCF,450EXC,450XCF

Due to a production error, certain fuel hoses may leak fuel at the hose bends or ends.

2007–2012 KTM 990 Super Duke R

There have been reports of breakage of the steering damper clamp on 3 vehicles in other markets.

2008–2012 KTM 300 EXC

Due to an incorrect heat treatment process, the inner tubes for the front forks may crack.

2006–2007 KTM Sport motorcycle—Retrofit

On affected models, during use the 1/4 turn filler cap may leak from the sealing area of the filler cap and fuel tank.

0 KTM 990 ADVENTURE

Water leaking into the ABS switch in the cockpit can lead to the malfunction of the switch and in some cases to a failure of the speed indicator.

0 KTM Various

Cracking on the clamp area of the lower triple clamp.