KTM Failed cams

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About the KTM Failed cams website

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My Story

I purchased my KTM 790 Adventure R in September 2019. Unfortunately, I’ve had several faults since day one of ownership with mixed support from KTM.

  1. The ABS pressure switch was faulty before collecting the bike, causing the rear brake to always be on. My dealer said the switch would be replaced at the first 600km service, and as a minor, I thought nothing of it.
  2. Around 1,500km, an oil leak was developed at the countershaft oil seal. My dealer replaced this under warranty.
  3. Around 1,500km, the fuel gauge was displaying empty while the tank was full. My dealer replaced the fuel sender under warranty.
  4. Around 3,500km, the rear shock developed a leak. My dealer organised for this repaired under warranty.
  5. Around 3,500km, one of the front break rotors where showing signs of rust beyond what is expected on a 3,500km bike. Warranty denied.
  6. Around 3,500km, a crack in the frame where the headlight mounts was identified. This was eventually replaced under warranty after waiting five months for a new frame and a couple more months for a compliance plate to make the new frame legal.
  7. The fuel pump was blocked, causing the bike to stutter and not run properly. Replaced fuel filter at cost to myself after being advised KTM would reject the claim as “user error, bad fuel,” and “KTM has been good to me for replacing the frame”. The mechanic who replaced the filter later said the filter was blocked with the white tank moulding residue from the manufacturing process, and the residue was floating in the fuel when they replaced the filter.
  8. Rear brake line safety recall
  9. Reported in July 2020 front disc pulsing issues. I had to purchase a front disc and brake pads after being told warping was likely caused by dropping the bike on its side and “KTM have been good to me for replacing the frame”. I agreed to this reluctantly despite reports online of the same issue happening to other owners and KTM replacing the whole wheel due to the hub not being true.
  10. 1000km after replacing the front brake disc, the original braking issues returned, causing unsafe braking at slow speed. After providing evidence of other owners reporting this, having the front wheel replaced under warranty to fix it completely, and threatening ACCC (Australian consumer laws) KTM agreed to replace the entire front wheel. I never had a warping issue again
  11. I had an incident after turning off the ignition, I could hear a humming noise from the fuel tank that sounded like the fuel pump priming despite the bike being turned off. Opening the fuel cap, the tank sucked in air for 20-30 seconds, followed by fuel bubbling up a squirting out of the tank over me and a hot bike. KTM agreed to investigate as part of my threat of ACCC and said they added some heat protection.
  12. Condensation was reported in the headlight. This was minor; however, I reported it as part of the disc warping and fuel boiling issue as I was getting frustrated. KTM replaced the headlight as part of my initial ACCC threats. After getting the frame, break and other niggles fixed, I gave myself 1,000km with the bike, and if it had any more issues, I would cut my losses and sell it. I had no issues, so I kept the bike. It was fault-free until 28,000km, when I performed the 30,000km service 2,000km early. This is where my journey with premature cams began.

In October 2023, at 28,000km, I had an independent, licenced, trusted workshop perform the 30,000km service early, which involved checking the valves.

While collecting the bike, the workshop showed me pictures of severely worn cams. The workshop said they were taking bets if my bike had cam issues before inspecting it, as they had recently seen four other KTM 790 Adventure bikes in their workshop for the 30,000km service with the exact same issue.

The workshop contacted a KTM dealer they have a relationship with and sent the previous bikes with cam issues to, on my behalf so that I could take my bike for a KTM warranty inspection.

The KTM dealer was slow to get back to me for me to take it in. By their own admission, they were avoiding contacting me as they had several other bikes in the workshop, waiting on cams.

After chasing the dealer myself, we agreed on a date for me to take the bike in for inspection. I was advised that as I have been home servicing, I should take invoices and receipts proving the bike has been serviced for KTM to offer warranty support; otherwise, it would be extremely difficult.

A few days after dropping off the bike, and a folder of invoices showing servicing every 5,000 to 7,000km (KTM specify 15,000km), I was told KTM will replace the cams, valves, cylinder head, gasket free of charge as “good will”. I must pay labour and consumable costs such as oil. I was also told they do not have a timeline as they had five other bikes in the shop who had been waiting several months for back ordered parts.

KTM agreing to replace parts is KTM accepting the parts are defective. Under Australian Consumer Law (ACCC) KTM must cover all costs. With this I left my bike at the dealer not knowing when it would be repaired and also opened a complaint with New South Wales Fair Trading.

I would periodically contact the dealer for an update on the parts, but they had no information to provide when they would be available from KTM.

Mid February, after waiting four months, I received a call from my dealer saying they had received my parts. The bike is now ready to collect, and I had to pay for a 30,000km service to cover the costs. This is despite the dealer being contacted by a workshop they have a relationship with who had just done the 30,000km service, and the dealer having the invoice for the 30,000km service they requested as proof of servicing, and the bike rode 100km max since the 30,000km service as I rode it home from the service, then to the KTM dealer only.

I advised the dealer that I have an open case with NSW Fair Trading and have been advised not to collect the bike unless KTM cover all costs as required under Australian Consumer Law. The dealer argued on the phone that this is not the case; me paying labour is standard, and KTM have been generous to me, “good willing” the parts. Despite disagreeing, the dealer ultimately accepted I would not be collecting the bike until my case had been processed by New South Wales Fair Trading.

Twenty-four hours later, after the dealer being told I had been advised not to collect the bike due to an open NSW Fair Trading case unless all costs are covered by KTM, the dealer phoned me up and said, “KTM has agreed to cover all costs; you are free to collect your bike when you like”.

I believe the dealer/KTM acted in bad faith, initially trying it to make out they are doing a favour “we will good the parts, covering costs of parts” and hoping the customer is not aware of Australia Consumer Law to push for all costs to be covered.

In the dealer’s response to NSW Fair Trading, they stated they had replaced the cams free of charge; they also replaced the battery as it was dead; the issue was caused by “lack of timely maintenance”.

KTM was now gaslighting me, trying to shift the blame!

The battery was dead as it had been sat in their workshop for four months without a battery tender.

They claim the issue was caused by a lack of timely maintenance when

As it stands, Jun 2024, I have not ridden the bike since I have collected it. I’ve replaced it with something more reliable. It’s proving hard to sell the bike as buyers become aware of the issues and prices crashed below it’s competitors.

The bike is fantastic to ride when it works, it is best in class.

Regardless, due to the faults and my entire ownership experience, I will not own a KTM again unless the company addresses its after-sales and quality control issues. Even then, it’ll be hard to forgive them and hand over my money.

Cams have been indefinitely back-ordered since the issue first started being reported online by owners in early 2020. KTM, as of Jun 2024 has not publically acknowledged the issue. Owners are still posting failure reports online on models as new as 2023. The 2024 models are to new for any reports to appear. As the issue gets more known, owners are checking cams early before the 30,000km valve check, and the online reports are increasing.