Recall 21V304 affects 3,707 2019-2020 KTM 790 Adventure motorcycles for a weak front brake master cylinder spring. Repair is free at any franchised KTM dealer.
KTM is recalling 3,707 2019-2020 790 Adventure, 790 Adventure R, and 2020 790 Adventure R Rally motorcycles under recall 21V304 because the front brake master cylinder piston return spring is too weak to return the piston to its original position. The weakened front brake increases stopping distance, and KTM dealers will replace the part free of charge.
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What's wrong?
The front brake master cylinder on the 790 Adventure is the hydraulic pump under your right handlebar. When you squeeze the front brake lever, a piston inside the master cylinder pushes brake fluid down to the caliper at the front wheel, which clamps the pads onto the rotor. A small return spring inside the master cylinder pushes that piston back to its resting position when you let go of the lever, so the brake is ready for the next pull.
On affected KTM 790 Adventure, 790 Adventure R, and 790 Adventure R Rally motorcycles, the preload force of that return spring is below the specified tolerance. The spring is too weak to push the piston fully back to its starting position after you release the lever. Over time, this reduces the functionality of the front brake and, in rare cases, can impair braking.
The warning sign for riders is a front brake lever that feels weak, slow to return, or less responsive than normal.
Who's affected?
Covers three 790 Adventure variants (Adventure, Adventure R, Adventure R Rally) across the 2019 and 2020 model years, all sharing the same front brake master cylinder piston return spring.
| 2019 KTM 790 Adventure | hydraulic brake system |
|---|---|
| 2020 KTM 790 Adventure | hydraulic brake system |
| 2020 KTM 790 Adventure R | hydraulic brake system |
| 2019 KTM 790 Adventure R | hydraulic brake system |
| 2020 KTM 790 Adventure R Rally | hydraulic brake system |
| Units affected | 3,707 |
| Field incidents | NHTSA has logged 79 field incidents to date. |
A matching year and model does not guarantee inclusion. Check your VIN to confirm whether your specific motorcycle is included in this recall.
What's the safety risk?
Reduced front brake function lengthens the distance needed to stop and raises the risk of a crash. Treat any change in braking feel as a reason to stop riding and call the dealer to schedule the return spring replacement. Repair is free at any franchised KTM dealer.
What should I do?
- Check your VIN to confirm your 2019-2020 KTM 790 Adventure, 790 Adventure R, or 790 Adventure R Rally is included in this recall.
- Contact a franchised KTM dealer to schedule the free return-spring replacement that restores full front-brake function.
- Reference recall number 21V304 (KTM recall KTM2106) when you call so the service desk pulls the correct repair order.
- Call KTM customer service at 1-888-985-6090 with questions about the recall or the owner notification letter.
- Ride cautiously until the repair is complete. Increase your following distance and avoid hard front-brake stops, since the weak return spring can lengthen stopping distance.
What happens at the repair
At the dealer, a KTM technician replaces the front brake master cylinder piston return spring on the affected motorcycle. Parts and labor are free under the recall. If you have already paid out of pocket for repairs related to weak front brake return, KTM's standard reimbursement plan covers documented expenses. Bring your receipts to the service desk, or contact KTM customer service before your appointment to confirm what documentation to submit. Reference recall KTM2106 when you call or arrive at the dealer.
| Reimbursement | Reimbursement available |
|---|
Timeline
| April 28, 2021 | Dealer notification began |
|---|---|
| April 30, 2021 | NHTSA published the recall |
| May 21, 2021 | Owner notification mailed |
| May 21, 2021 | Interim owner notification (was planned for this date) |
| July 22, 2022 | Dealer notification ended |
| July 29, 2022 | VIN-searchable in NHTSA's database — Check your VIN to see whether this recall applies to your specific vehicle. |
Frequently asked questions
What is recall 21V304?
Recall 21V304 covers 3,707 2019-2020 KTM 790 Adventure, 790 Adventure R, and 2020 790 Adventure R Rally motorcycles. The front brake master cylinder piston return spring can be too weak to return the piston to its original position, reducing front brake function and increasing stopping distance.
What should I do if my 2019-2020 KTM 790 Adventure is on this recall?
Check your VIN to confirm your specific motorcycle is included in recall 21V304. If it is, contact a franchised KTM dealer to schedule the front brake master cylinder return spring replacement. Reference recall number 21V304 or KTM2106 when you call. The repair is free.
Is the recall repair free?
Yes. Federal recall law requires manufacturers to perform the recall repair at no cost. KTM dealers will replace the front brake master cylinder return spring free of charge regardless of where the motorcycle was originally purchased.
What warning signs should I watch for?
Watch for a front brake that feels weak, requires more lever pressure than usual, or takes longer to stop the motorcycle. Any change in front brake feel or response on a 2019-2020 KTM 790 Adventure, 790 Adventure R, or 790 Adventure R Rally should be treated as a reason to stop riding and contact a KTM dealer.
What if I bought my KTM 790 Adventure used?
The free repair still applies. Federal recall law requires manufacturers to honor the recall regardless of ownership history. If KTM never mailed you a notice, check your VIN to confirm whether your specific motorcycle is included, and reference recall number 21V304 when you call the dealer.
More information
| NHTSA campaign page | nhtsa.gov/vehicle-recalls/21V304000 |
|---|---|
| KTM customer service | 1-888-985-6090 |
| NHTSA recall # | 21V304 |
| NHTSA recall # (full) | 21V304000 |
Source documents
-
Download Quarterly Report (PDF) - Download Recall Document (PDF) (PDF)
- Download Misc. Document (PDF)
- Download Owner Notification Letter (PDF)
- Download Owner Notice (PDF)
- Download Recall Report (PDF)
- Download Recall Acknowledgement (PDF)
This article is generated from NHTSA's primary recall filings and reviewed against the source on May 24, 2026. RecallNotify does not paraphrase NHTSA's consequence language; that text is reproduced as written above. Editorial standards →