KTM Expands Throttle Recall to Last-Gen RC 390 and 390 Duke

KTM is issuing a recall on the 2022-2023 390 Duke and 2022-2024 RC 390 because of a risk of throttle failure. The recall is technically an expansion of an earlier recall from last September that involved the 2022-2024 390 Adventure, as well as the 2022-2023 Husqvarna Svartpilien 401 and Vitpilen 401.

The new recall affects 4,186 Duke models and 3,788 RC 390 models, for a total of 7,974 motorcycles in the U.S., which are in addition to the 9,070 motorcycles affected by the original recall campaign. That brings the total up to 17,044 motorcycles for the same throttle issue.

According to the recall documentation released by the U.S. National Highway Traffic Safety Administration, moisture can make its way into the electronic throttle, eroding the connections. This may cause the electronic control unit to detect two different voltage values, which triggers the system to set the engine to idle speed.  While opening the throttle again should bring the engine speeds back up, the sudden loss of throttle response poses a safety risk.

The problem was first reported in the second half of 2022, triggering a KTM internal investigation in January 2023. The investigation included root cause analysis and testing with the component supplier, Uno Minda Ltd. of Pune, India, close to where the 390 and 401 models are produced.

In January 2024, Uno Minda implemented a camera-based inspection process to check its print circuit board assembly after it receives a conformal coating designed to protect it from moisture and dust. The next month, Uno Minda added an automatic cleaning step for circuit board production, after the circuit board is wired.

In September 2024, reports started to come in from Canada. In October, Transport Canada, the Canadian equivalent to NHTSA, opened its own investigation. Over the next year, Transport Canada worked with KTM, exchanging data, additional reports, and warranty claim data. After a meeting between KTM headquarters and Transport Canada, KTM decided to initiate a recall, first in Canada and then the U.S. market.

KTM dealers will inspect recalled units and replace the electronic throttle control with a new part that received the additional inspection and cleaning steps introduced by Uno Minda. On March 27, the recall was expanded to include the 390 RC 390 and Duke models.

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