KTB2402

KTB2402 KTM TECHNICAL BULLETIN - USA
FEBRUARY 12, 2024
EXHAUST SYSTEM UPDATE
AFFECTED MODELS:
2020 1290 SUPER DUKE R
2021 1290 SUPER DUKE R
2022 1290 SUPER DUKE R EVO
2023 1290 SUPER DUKE R EVO
RESTRICTIONS: AFFECTED MODELS ARE LINKED BY VIN IN KTM
DEALER.NET
INITIAL INFORMATION:
During continuous product development, the exhaust flap control on the above-mentioned Super Duke models
was improved. Performing the update prevents a possible malfunction of the exhaust flap and error messages.
On affected 2020, 2021 and 2022 Super Duke models the following updates must be performed:

Install a new V-clamp D=70.1 (#61705058200) on the exhaust (see Fig.1). An additional anti-twist
device on the improved clamp prevents possible damage to the radiator.

Install a new header gasket 54 mm (#61705005105) on the exhaust (see Fig.1).

Install the new repair kit (#A62405031044) for the exhaust flap control (see Fig. 2).

Install the latest software file.

Use action code 00 for this update.

Install the latest software file.
Note: Model year 2023 Super Duke’s already have the new V-clamp D=70.1, header gasket 54 mm
and repair kit installed therefore these parts do not need to be replaced and updated on the 2023
Super Duke models. Only the latest software file needs to be installed on 2023 Super Duke models.

Use action code 01 for this update.
Dealers must perform the exhaust system update on all affected motorcycles in their inventory prior to any
customer delivery. Please contact all of your customers who own affected motorcycles to have the exhaust
system update performed as soon as possible.
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
30125 KTM Way // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
1
DEALER SERVICES DEPARTMENT © 2024 KTM North America, Inc. – All rights reserved
On affected 2023 Super Duke models the following update must be performed:
KTB2402 KTM TECHNICAL BULLETIN - USA
FEBRUARY 12, 2024
Fig. 2 – Exhaust flap control
(Heat shield removed)
Fig. 1 – V-clamp D=70.1
with header gasket
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
30125 KTM Way // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
2
DEALER SERVICES DEPARTMENT © 2024 KTM North America, Inc. – All rights reserved
Affected areas on the 2020, 2021 and 2022 Super Duke models:
KTB2402 KTM TECHNICAL BULLETIN - USA
FEBRUARY 12, 2024
PROCEDURE FOR REPAIR:
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop
are not specified here. It is assumed that the repair work will be performed by a fully trained mechanic who has
completed training or has a corresponding qualification. In the event of uncertainty, the most recent repair
manual must be consulted.
In the interest of clarity, some components may be shown disassembled or may not be shown at all. It is not
always necessary to disassemble the component to perform the activity in question. Please follow the
instructions in the text.
Update of the V-clamp D=70.1 (#61705058200):
(For 2020, 2021 and 2022 Super Duke models only)
Fig. 3 – Protecting the radiator
3. Remove the front silencer according to the repair instructions.
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
30125 KTM Way // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
3
DEALER SERVICES DEPARTMENT © 2024 KTM North America, Inc. – All rights reserved
1. Dismantle the rear silencer according to the repair instructions.
2. Protect the cooler against damage with cardboard, see Fig. 3.
KTB2402 KTM TECHNICAL BULLETIN - USA
FEBRUARY 12, 2024
Note: The lambda sensors do not have to be removed, it is sufficient to loosen the pre-silencer, lower it
slightly and support it with a suitable tool (e.g., scissor jack), see Fig. 4.
Fig. 4 – Support for front silencer
DEALER SERVICES DEPARTMENT © 2024 KTM North America, Inc. – All rights reserved
4. Fit the header gasket (#61705005105).
5. Fit the V-clamp D=70.1 (#61705058200) so that the anti-rotation device does not touch the flange of
the lambda sensor, see Fig. 5.
Fig. 5 – Position of V-clamp D=70.1
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
30125 KTM Way // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
4
KTB2402 KTM TECHNICAL BULLETIN - USA
FEBRUARY 12, 2024
6. Tighten the V-clamp D=70.1 (#61705058200) to the specified torque (see Table 1).
7. Install the front silencer and rear silencer according to the repair instructions.
Note: Do not fit the Bowden cables yet.
Table 1
Fitting the exhaust flap control repair kit (#A62405031044):
(For 2020, 2021 and 2022 Super Duke models only)
DEALER SERVICES DEPARTMENT © 2024 KTM North America, Inc. – All rights reserved
1. Remove the exhaust flap locking plate and nut, see Fig. 6 and Fig. 7.
Fig.6 – Locking plate and nut
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
30125 KTM Way // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
5
KTB2402 KTM TECHNICAL BULLETIN - USA
FEBRUARY 12, 2024
Fig.7 – Locking plate and nut removed
Fig.8 – Replacing the torsion spring.
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
30125 KTM Way // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
6
DEALER SERVICES DEPARTMENT © 2024 KTM North America, Inc. – All rights reserved
2. Replace the installed torsion spring of the exhaust flap control with the new torsion spring included in
repair kit #A62405031044, see Fig. 8.
KTB2402 KTM TECHNICAL BULLETIN - USA
FEBRUARY 12, 2024
3. Fit the new lock washer and tighten the nut to the specified torque (Table 2), see Fig. 9.
4. Secure the nut with a lock washer.
5. Check exhaust flap for freedom of movement.
6. Install the exhaust flap control Bowden cables included in repair kit #A62405031044 according to the
repair instructions.
7. Fit the rear silencer according to the repair instructions.
8. Install the latest software file for the exhaust flap control using the XC_2 diagnostic tool and set the
Bowden cable tension of the exhaust flap control according to the repair instructions.
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
30125 KTM Way // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
7
DEALER SERVICES DEPARTMENT © 2024 KTM North America, Inc. – All rights reserved
Fig.9 – Locking plate and nut refitted
KTB2402 KTM TECHNICAL BULLETIN - USA
FEBRUARY 12, 2024
NOTE:
To adjust the cable tension, use only the adjusting screw with a width across flats of 8 mm as shown in Fig. 10.
Fig.10
– Adjusting screw with wrench size 8 mm for cable tension
Table 2
PARTS ORDERING:
Please order the following for each affected motorcycle:
1 QTY. 61705058200 – V-clamp D=70.1
1 QTY. 61705005105 – Header gasket 54 mm
1 QTY. A62405031044 – Repair kit for exhaust valve
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
30125 KTM Way // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
8
DEALER SERVICES DEPARTMENT © 2024 KTM North America, Inc. – All rights reserved
9. Take a photo of the final positioning of the V-clamp with anti-rotation lock and the Bowden cables and
attach it to the warranty claim.
10. Install heat protection.
11. Take a test ride.
12. After the test drive, check the setting of the exhaust flap control again according to the repair
instructions and readjust if necessary.
KTB2402 KTM TECHNICAL BULLETIN - USA
FEBRUARY 12, 2024
WARRANTY INPUT INFORMATION:
This Technical Bulletin only affects certain VIN numbers! Please check the VIN by performing a
Motorcycle History search in KTM 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. KTM North America will not
warranty motorcycles 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 motorcycle requires this update by checking the
vehicle history and understanding the instructions provided by this bulletin.
To submit a TI claim click the orange arrow on the right side of the corresponding technical information message
to start the claim process.
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 KTM. The flat rate
time for this repair is based on the action performed and provided in minutes.
Warranty type:
TI warranty
Component group:
05 – Exhaust system
Failure code:
700 – Series improvement
Failure causing part:
61441070100 Exhaust flap control motor
Improvements to the exhaust system
Action code: 05_2166128_00 (For 2020, 2021 and 2022 Super Duke models only)
Labor time: 60 minutes
Parts:
1 QTY. 61705058200 – V-clamp D=70.1
1 QTY. 61705005105 – Header gasket 54 mm
1 QTY. A62405031044 – Repair kit for exhaust valve
Action code: 05_2166128_01 (For 2023 Super Duke models only)
Labor time: 15 minutes (For the installation of the latest Software file)
Parts:
none
Are stock items affected:
Yes. All #61705058100 V-clamps in your dealer stock must be returned to the spare parts
warehouse and can be invoiced via RMA (return goods request).
COPYRIGHT NOTICE: The user acknowledges that all components of this technical information are KTM’s and/or third parties’ copyright protected
property. Alteration, assignment, distribution and reproduction are forbidden.
LIMITATION OF LIABILITY: The information included in or available through this technical information may include inaccuracies or errors. In no event
shall KTM and/or its suppliers be liable for any damages whatsoever, arising out of or in connection with the use of this technical information. Please
always refer to the KTM owners and repair manuals for proper instructions or contact the KTM Dealer Services Department.
KTM NORTH AMERICA, INC.
30125 KTM Way // Murrieta, CA 92563
1119 Milan Avenue // Amherst, OH 44001
8701 Rue Samuel-Hatt // Chambly, QC J3L-6V4
www.ktm.com
9
DEALER SERVICES DEPARTMENT © 2024 KTM North America, Inc. – All rights reserved
Action code, parts, labor time: