2021 KTM 790 Adventure R Problems & Complaints

The valve train of my bike failed and left me stranded in the woods. There were no signs or warnings beforehand. After further research online, I found that this issue has been happening quite a bit. Luckily it happened to me while my bike was parked. The issue is the valve train is wearing out prematurely and causing the bikes to run poorly or not run at all. My bike has 13,000 miles on it and other bikes have had more or less miles when this issue occurred. I've worked on several motorcycles with three times the miles and never had an issue with the valve trains being chewed up like this current issue. This issue could possibly cause the bike to stop running while it is being driven at whatever speed. A bike suddenly stalling out in traffic isn't the safest scenario for a motorcycle rider. Especially if they're riding at interstate speeds. If you search online, you'll see others with this issue and it's much worse than mine. There are numerous YouTube videos and even a dedicated Facebook page about this issue. I do not have Facebook but I have attached a link with this description. [XXX] INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

I have checked the cam shafts condition at only 3900 miles since there are a lot of people with the same motorcycle mentioning this issue and there is an unsuspected wear starting to happen. Motorcycle always ran on recommended Motorex oil and air filter was maintained as it should be.

Difficult cold start ups. When the bike is cold or has been sitting for 1-2 weeks and I start it up intermittently the bike has problems starting up and running. Will stall out and need to attempt to restart it several times before it will run. Appears to be running on a single cylinder for 30-45 seconds when it does finally start up then will run as normal. This does not occur when the motorcycle is already warm. Concerned about possible mechanical damage from running on a single cylinder which could be dangerous on a motorcycle and result in injury.

Stalled dozens of times and sudden loss of power when cold

I just wanted to make you aware of my 2021 KTM 890 R VIN # [XXX] 2000 MILES Since new it has had a hard start when cold or sitting overnight. It takes 2 or 3 times to start and keeps stalling I stalls runs rough and even runs on one cylinder for 30 to 60 seconds. Its a 2 cylinder motorcycle. Once running it runs great rest of day. MANY folks are seeing the same condition and KTM is not responding with anything of a solution I have owned many many motorcycles and even 6 KTMS but their lack of attention here is not good. Dealers say it's normal or no problem found. My local dealer said yeah, we have seen it no real fix. The earlier 2019/2020 790 models had hard start issues but this new 2021 890 model is worse, more widespread and more severe— running on one cylinder at start up. I am a master mechanic in the auto industry and understand something is wrong. If ANYONE bought a new car and it took several times to start each morning and it ran rough for a little you would not accept it. Not only is it not great for customer satisfaction but could be hurting the engine and might be an excess EPA emission issue too. Thanks for listening and more info is on the ADV website with lots of potential impacted customers here is a vid-- https://youtu.be/rPwFnlp0oxE [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

Good day to whoever is reading! I've recently discovered that my brake light does not turn on on my bike no matter what brake i use front or rear. Only way it works if i push brake really hard, like way beyond regular or emergency braking. I've found similar issues online and people pointing on faulty brake sensors. They are located under the gas tank. It requires good amount of skill and time to replace them. But i did and my brake lights returned, but during a test ride i'm loosing my rear brake COMPLETELY. I take everything apart again and find out that rear brake sensor is leaking. Turned out it needed one more turn really really hard turn, so hard i thought ABS module which they connect to is not going to endure it. I guess it could happen to front brake as well. And the brakes were fine my initial test ride around a corner. In theory i could lose both brakes on my way to work next day if i did not test ride enough. It is not just unacceptably hard to fix such a simple and crucial thing like a brake lights which go out without a warning but there is also a chance to lose both brakes in a middle of a ride. What component or system failed or malfunctioned, and is it available for inspection upon request? Brake lights, yes How was your safety or the safety of others put at risk? Not safe Has the problem been reproduced or confirmed by a dealer or independent service center? Unknown Has the vehicle or component been inspected by the manufacturer, police, insurance representatives or others? No Were there any warning lamps, messages or other symptoms of the problem prior to the failure, and when did they first appear? No warning

Brake light no longer activates upon applying normal pressure to front brake lever. Brake light activation requires greater than normal front brake lever pressure/input in order to activate the light. This issue causes a safety concern with traffic when the motorcycle brake light does not activate appropriately when stopping. This issue is consistent/repetitive and is believed to be caused by a faulty brake light switch on the front brake circuit. KTM appears to have updated/superseded part numbers relating to the faulty part in question.

The brake lights were not illuminated intermittently and ABS was not engaging intermittently

The motorcycle is having a cold start issue. When starting after 24hours, the motorcycle will not start right away or will only start on one of two cylinders. After roughly 60 seconds the second cylinder starts up.

When engin is cold for more then 8 hours. Engin will start only on 1 cylinder (right), for +/- 1 minute (1000 +/- rpm), after, you will heard internal explosion, and left cylinder will start (1600 +/- rpm) . and dropping at 1400 for normal idle. With an strong gazoline smells after start-up, after 2 3 minutes smeel is gone Please note that I live in Canada Quebec

When I start the bike, it sounds like the engine is only running on one cylinder and misfiring. It runs 'rough' like this for about 30 -60 seconds and the revs are sitting between 1000-1300 instead of the normal 1300-1500rpm range. You can smell fuel while this is happening. It then 'pops' and the engine runs fine after that. I live in the Netherlands, but wanted to register the issue here as well for investigation.

Motorcycle does not start properly when cold. Takes several tries to start. Once started it dies several times and must be restarted. Once running, it idles very rough for several minutes.

If the bike has been sitting overnight, then the first start of the day is difficult. It does not want to start and takes a few tries. When it does start it is on only 1 cylinder...this goes back to normal once it warms up after a minute or so. This began @700 miles. This problem goes away immediately if you use 89 octane fuel. I have just stayed with 89 but other owners have reported after going back to the fuel KTM recommends 91 octane or higher, the problem comes back.

I have had three separate incidences of the either the front or rear brake sensor switch failing which requires replacement. It causes the brake light to not function. I do have one of the three switches for inspection. It has been confirmed by a mechanic. As it is out of warrantee there has been no manufacturer inspection. There is no indication that it is not working other than cruise control will not turn on.

Tire size 90/90-21 front tire inflated with Motorcycle manufacturers recommended psi without warning it instantly deflats. I had this happen twice with the same tire. Once deflated it causes the tire to debead off the rim while riding and renders the motorcycle nearly uncontrollable. Especially dangerous in a curve or turn. My riding skill kept me upright. Yes my safety was at risk. Many riders would have crashed. and likely have but have no explanation as to why. I started a thread on two Facebook groups and one Forum that are related to my motorcycle Make and model. Many owners wrote of their experiences. with the same manufacturer of the tire. The tire is marked Tubeless but I would recommend running it with a tube. Something is wrong with either the tire or the KTM OEM wheel. It's going to kill someone. No Joke!

1) The vehicle TFT display containing important data such as speed etc.. blacks out on occasion. The vehicle itself is still functional but with the display blacked out the operator has no speed information, or information about the vehicle such as fuel levels and ABS control. KTM has been made aware of the issue as it has affected multiple users worldwide. 2) The indicator/blinker control switch does not engage the blinkers when pushing the switch to the left. In right hand drive markets this a particular hazard. Again, the issue is common across the 790/890 Adventure and Duke models.

Motorcycle hard/impossible to start. Excessive valve wear. Currently unrideable due to mechanical problems. Motorcycle stalled at intersection of busy highway, would not start creating hazard of being hit in the intersection and while pushing it to side of road. Mechanic inspected vehicle, found excessive wear to valvetrain causing engine power loss and stalls. States that it appears to be a manufacturing defect in the intake system allowing dirt ingestion leading to excessive irreparable valve wear.

The motorcycle's instrument cluster (TFT Display) often becomes obscured by internal condensation (fogging), sometimes remaining obscured for extended periods of time (i.e., 30 minutes). When this occurs, it is impossible to see critical operation/safety information such vehicle speed, traction, and ABS settings. It is also impossible to operate the menu to control these same settings. The resulting conditions make vehicle operation unsafe--especially when fogging occurs while operating the vehicle. Based on extensive forum searches, this issue is a design flaw that is well-known, but largely unaddressed by the manufacturer (KTM). Many owners of the same vehicle model experience this safety issue. My local dealership has "warrantied" (replaced) one display for this condensation issue, but refuses to further remedy the issue, even though the replacement display has the same problem.

The motorycle has a hard time to start. At times throttle needs to be added to keep the engine from dying out. A modern and fuel injected bike should not need to have the throttle be opened for the bike to start up.

Starting immediately after the mandatory 600 mile service check by an authorized KTM dealer, this vehicle started experiencing prolonged cold start failures. It went from starting 100% of the time after three or less start attempts to requiring approximately ten failed start attempts before starting and running. Until 10/20/21, this motorcycle has always been fueled with either 93 octane gasoline with 10% alcohol or 90 octane fuel with no alcohol (only 2-3 times) as recommended by the manufacturer. On 10/20/21, I filled the nearly empty fuel tank with 87 octane, 10% alcohol. On the next overnight cold-soak starting attempt, and every cold start following, the vehicle started immediately on the first start attempt and settled immediately into a normal fast idle until warmed-up. This vehicle was purchased new with 0 miles on June 11, 2021. It received it's 600 mile manufacturer-required service at approximately 680 miles in September, 2021. It currently has, as of 10/24/2021, approximately 1300 miles on the odometer.

When running the motorcycle on the manufacturer-recommended 91+ (premium) octane fuel, the engine can take up to 5 or 6 tries (over the course of a few minutes) to start when it's sat overnight. When the engine eventually does start it runs very rough on only one (of two) cylinder. During this rough starting there is an overpowering smell of raw/un-ignighted fuel coming from the exhaust pipe. There seems to be some kind of issue with the fueling or ignition timing that prevents the engine from running properly on 91+ octane fuel. Switching to a slightly lower 89 (mid-grade) octane fuel mostly, but not completely, seems to fix the issue. However this fuel is not rocommended by the manufacturer due to the high compression ratio and I'm worried that it might cause damage in the long term. The bike was taken to the KTM dealer who performed a reset of the factory ECU; however, this did not help the issue at all. Reading online, I've found dozens of people with other 2021 KTM 890 Adventure motorcycles experiencing the same issues e.g. no start, hard starting, running on one cylinder, etc. Running on only one cylinder and sometimes dying is a major safety issue.