Confirmed: KTM 390 Duke front sprocket being replaced

We’ve occasionally heard reports of incidents where the front sprocket of the KTM 390 Duke has come off, sometimes with serious consequences. Recent reports suggested that KTM has begun to address this issue with dealers being equipped to replace the old front sprocket with a new modified item.

Though no official statement has been released, we can now confirm that sprocket replacements have already begun across dealerships for the 390, with one of ThrillOfDriving.com’s fleet bikes already in service for a free replacement, with others in line.

Our dealer sources have confirmed that there was an issue with the front sprockets which will be rectified free of cost on bikes manufactured before March 2014. Bikes manufactured after this date are unaffected and will not need a replacement.

Update

We’ve just received one of our fleet bikes from service, where they did indeed replace the front sprocket. The problem, in fact, lies in the locking plate that holds the sprocket in place. Prior to March 2014, the plate was a symmetrical design that could be mounted incorrectly, leaving the sprocket free to slide off. The problem does not manifest when the chain is under tension, but as soon as it’s loose, there’s the potential for the sprocket to be dislodged.

The new locking plate is asymmetrical in design and designed to avoid human error in installation. While KTM/Bajaj could well have just replaced the plate, they’re replacing the sprocket as well for good measure.