2020 KTM 790 Adventure R

KTB2011 – Rear Brake Line And Rear Brake Lever Screw Replacement – 2019-2020 KTM 790 Adventure & 790 Adventure R Motorcycles

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April 6, 2020 NHTSA CAMPAIGN NUMBER: 20V198000

Rear Brakes May Fail

If the rear brake system fails, there would be reduced braking ability, increasing the risk of a crash or injury.

 

NHTSA Campaign Number: 20V198

Manufacturer KTMeBay North America, Inc.

Components SERVICE BRAKES, HYDRAULIC

Potential Number of Units Affected 3,164

 

Summary

KTMeBay North America, Inc. (KTMeBay) is recalling certain 2019-2020 790 Adventure and 790 Adventure R motorcycles. The rear brake hoseeBay may overheat, causing the rear brake system to fail.

 

Remedy

KTMeBay will notify owners, and dealers will install a new rear brake line, free of charge. The recall began April 28, 2020. Owners may contact KTMeBay customer service at 1-888-985-6090. KTMeBay’s number for this recall is TB2011.

 

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

 

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

 

REAR BRAKE LINE AND REAR BRAKE LEVEReBay SCREW REPLACEMENT

 

AFFECTED MODELS: 

2019 790 ADVENTURE and 790 ADVENTURE R

2020 790 ADVENTURE and 790 ADVENTURE R

 

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

 

INITIAL INFORMATION: 

KTMeBay North America, Inc. has determined that a defect which relates to motor vehicle safety exists with certain 2019 and 2020 790 ADVENTURE and 790 ADVENTURE R motorcycles pertaining to a possible material deviation of the rear brake line. On affected units there is a possibility that the rear brake system may fail under extreme conditions.  To ensure the highest level of safety, performance, reliability and customer satisfaction, it is necessary to replace the brake line that leads from the rear brake caliper to the ABSeBay modulator.  Also during the repair it is necessary to replace the round head Torx screw on the rear brake levereBay with a new screw.

If the rear brake system fails this may reduce the braking systems effectiveness.  As a result, braking can only be performed with the front brake which may increase stopping distance which could cause injury or death to the rider or others and/or damage to property.

The cause of the defect is due to insufficient heat transfer between the hose and the metal fitting that mounts to the rear brake caliper (see Figure 1). The material deviation could lead to a failure of the rear brake system.  To remedy this defect, a new rear brake line with a longer metal fitting has been developed to improve heat transfer (see Figure 2). The new rear brake line along with new copper sealing rings must be installed on all affected motorcycles.

KTMeBay 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 KTMeBay Dealer to have their rear brake line and foot brake levereBay screw replaced. 

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 replace the rear brake line along with new copper sealings rings that leads from the rear brake caliper to the ABSeBay modulator and must also replace the rear brake levereBay screw on all affected motorcycles in their inventory prior to any customer delivery. Any affected 2019 and 2020 790 ADVENTURE and 790 ADVENTURE R models received directly from KTMeBay 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 KTMeBay 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 KTMeBay North America, Inc. policy for an authorized KTMeBay Dealer to deliver any affected units to customers before the procedure in this bulletin has been performed.

KTMeBay 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.

 

PROCEDURE FOR REPAIR – Rear brake line:

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

 

Info: Avoid contact between brake fluideBay and painted parts. Brake fluideBay attacks paint!

 

  1. Remove the engine guard, seat, side fairing, rear fairing, fuel tank and any other attachments according to the repair manual.
  2. We recommend marking the ventilation hoses on the tank insert to clearly distinguish between them to prevent them from being mixed up during disassembly and assembly (see Figure 3 on the next page).
  3. Drain the rear brake line.
  4. Exchange the rear brake line along with the four copper sealing rings (see Figure 4 on the next page).
  5. Make sure the metal fitting ends of the new brake hoseeBay are fitted to the proper connections to ensure proper installation. The long fitting mounts to the rear brake caliper. The short fitting mounts to the ABSeBay modulator.
  6. Bleed the rear brake system using a pneumatic or vacuum type brake bleeding device.

Follow the instructions in the Owner’s Manual of the bleeding device.

  1. Check the brake system for leaks.
  2. Assemble the vehicle. Torques and further specifications can be found in the repair manual and on page 4 of this bulletin.
  3. Perform a test ride with function check. Check the brake system again for leaks.

 

Mark the ventilation hoses on the tank insert to clearly distinguish between them to prevent them from being mixed up during assembly.

 

Make sure the long fitting of the new hose is mounted to the rear caliper.

 

 

PROCEDURE FOR REPAIR – Rear brake levereBay screw 

  1. Also exchange the connecting screw between the foot brake levereBay and the push rod with a new screw (see Figure 5). Use a T30 Torx bit. Tightening torque: 5 Nm

 

Table 1 – Screw connections and torques

PartBolt DimensionTorqueNote
Tank fastener screwM825 Nm
Screw, fuel tank coverM65Nmmedium strength screw lock
Screw, engine guardM6x88Nm
Screw, engine guardM6x1010 Nmmedium strength screw lock
Screw, engine guardM6x128Nm
Screw, engine guard frameM825 Nmmedium strength screw lock
Banjo Bolt brake lineM10x125 Nm
Screw, rear brake pedalM6x205Nm

 

PARTS ORDERING:

Order the following parts for each affected motorcycle.

1 QTY. 63542004100 – Brake line rear

4 QTY. 0603100141 – Copper seal ring DIN7603-10x14x1

1 QTY. 0738060205S – Round head screw ISR M6x20-A2-7

 

 

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 accepted it will be possible to unlock and retail the motorcycle.

 

WARRANTY INPUT INFORMATION:

This Technical Bulletin only affects certain VIN numbers! Please check the VIN by performing a Motorcycle History search in KTMeBay 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. KTMeBay 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 KTMeBay.  The flat rate time for this repair is based on the action performed and provided in minutes.

 

Replaced rear brake lines and rear brake pedal screws both must be returned to the KTMeBay 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.

If you need additional tags or labels please order using the following part numbers:

Warranty Part ID Tag p.n. U6999093

FedEx Prepaid Return Label p.n. U6999094

 

Warranty type:
TI warranty
Component group: 
13 – Rear brake
Failure code: 
900 – Troubleshooting at manufacturer’s site
Failure causing part:
63542004000 – Rear brake line
Campaign code, parts, labor time:  
Action code:       13_1667518_00

Labor time:        85 minutes

Parts:                1 QTY. #63542004100 – Brake line rear 

4 QTY. #0603100141 – Copper seal ring DIN7603-10x14x1

10 QTY. #GA06 – Brake fluideBay 0,1l

1 QTY. #0738060205S – Round head screw ISR M6x20-A2-7

Are stock items affected: YES

 

IMPORTANT SAFETY RECALL NOTICE

x/xx/2020

 

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

 

RE: Affected models: 

2019 790 ADVENTURE and 790 ADVENTURE R
2020 790 ADVENTURE and 790 ADVENTURE R

 

Dear KTMeBay Customer,

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.  KTMeBay North America, Inc. has decided that a defect which relates to motor vehicle safety exists with the motorcycle models and years listed above.  To ensure the highest level of safety, performance, reliability and customer satisfaction, it is necessary to have a new rear brake line installed. This work must be performed by an authorized KTMeBay Dealer and will be free of charge.

On affected models during operation there is a possibility that the rear brake system may fail under extreme conditions.  If the rear brake system fails this may reduce the braking systems effectiveness.  As a result, braking can only be performed with the front brake which may increase stopping distance which could cause injury or death to the rider or others and/or damage to property. Also during the repair it is necessary for the dealer to replace the round head torx screw on the rear brake levereBay with a new screw.

The cause of the defect is due to insufficient heat transfer between the hose and the metal fitting that mounts to the rear brake caliper.  The material deviation could lead to a failure of the rear brake system.  To remedy this defect, a new rear brake line with a longer metal fitting has been developed to improve heat transfer.  The new rear brake line along with new copper sealing rings must be installed on all affected motorcycles.

Please contact your authorized KTMeBay Dealer (log onto www.ktm.com for a complete dealer listing) as soon as possible to arrange having your having your rear brake line replaced. It is suggested that you call your local authorized KTMeBay Dealer to make an appointment to have the recall repair performed. The replacement procedure will take approximately 1.5 hours. 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 KTMeBay dealer. There will be no charge for this service.

If you have any questions related to the content of this letter, please contact KTMeBay North America, Inc. Customer Relations at (888) 985-6090 for assistance. Furthermore, if you believe that KTMeBay North America, Inc. has failed to remedy this defect without charge or is unable to do so within a reasonable time, you may submit a complaint to 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 KTMeBay 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.

Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within 10 days.

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

Best Regards,

Dealer Services Department KTMeBay North America, Inc.

 

IMPORTANT SAFETY RECALL NOTICE

x/xx/2020

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

 

RE: Affected models: 

2019 790 ADVENTURE and 790 ADVENTURE R  2020 790 ADVENTURE and 790 ADVENTURE R

 

Dear KTMeBay Customer,

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.  KTMeBay North America, Inc. has decided that a defect which relates to motor vehicle safety exists with the motorcycle models and years listed above.  To ensure the highest level of safety, performance, reliability and customer satisfaction, it is necessary to have a new rear brake line installed. This work must be performed by an authorized KTMeBay Dealer and will be free of charge.

On affected models during operation there is a possibility that the rear brake system may fail under extreme conditions.  If the rear brake system fails this may reduce the braking systems effectiveness.  As a result, braking can only be performed with the front brake which may increase stopping distance which could cause injury or death to the rider or others and/or damage to property. Also during the repair it is necessary for the dealer to replace the round head torx screw on the rear brake levereBay with a new screw.

The cause of the defect is due to insufficient heat transfer between the hose and the metal fitting that mounts to the rear brake caliper.  The material deviation could lead to a failure of the rear brake system.  To remedy this defect, a new rear brake line with a longer metal fitting has been developed to improve heat transfer.  The new rear brake line along with new copper sealing rings must be installed on all affected motorcycles.

Please contact your authorized KTMeBay Dealer (log onto www.ktm.com for a complete dealer listing) as soon as possible to arrange having your having your rear brake line replaced. It is suggested that you call your local authorized KTMeBay Dealer to make an appointment to have the recall repair performed. The replacement procedure will take approximately 1.5 hours. 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 KTMeBay dealer. There will be no charge for this service.

If you have any questions related to the content of this letter, please contact KTMeBay North America, Inc. Customer Relations at (888) 985-6090 for assistance. Furthermore, if you believe that KTMeBay North America, Inc. has failed to remedy this defect without charge or is unable to do so within a reasonable time, you may submit a complaint to 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 KTMeBay 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.

Federal law requires that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within 10 days.

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

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

4 Affected Products

Vehicles

MAKEMODELYEAR
KTMeBay790 ADVENTURE2019-2020
KTMeBay790 ADVENTURE R2019-2020

 

8 Associated Documents

Remedy Instructions and TSB

RCRIT-20V198-6480.pdf 370.586KB

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Miscellaneous Document – Dealership List

RMISC-20V198-4631.pdf 290.839KB

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Recall Acknowledgement

RCAK-20V198-2987.pdf 245.267KB

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Defect Notice 573 Report

RCLRPT-20V198-4183.PDF 215.516KB

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Recall Quarterly Report #1, 2020-2

RCLQRT-20V198-4362.PDF 211.133KB

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Recall Quarterly Report #3, 2020-4

RCLQRT-20V198-5329.PDF 211.319KB

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Recall Quarterly Report #2, 2020-3

RCLQRT-20V198-8621.PDF 211.23KB

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ISSUED Owner Notification Letter(Part 577)

RCONL-20V198-7089.pdf 122.335KB

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V198&docType=RCL

 

 

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