Showing 405 complaints for KTM
Incident date: Jun 20, 2008
TL*THE CONTACT OWNS A 2005 KTM 950 ADVENTURE. WHILE DRIVING AT NIGHT AT APPROXIMATELY 25 MPH THE WINDSCREEN REFLECTS A GLARE AND MAKES IT DIFFICULT TO SEE. THERE WAS AN OPTICAL DISTORTION MIDWAY OF THE WINDSCREEN. THE MOTORCYCLE WINDSREEN WAS ALSO REPLACED BY THE CONTACT. THE FAILURE MILEAGE WAS 25,000 AND THE CURRENT MILEAGE WAS 27,300. UPDATED 09/10/08. *LJ UPDATED 09/11/08*JB
Incident date: Jun 1, 2008
1.ATV RIDING CHAIN BROKEN DEALER REPLACED 1WEEK. 2.BRAKE CALIPER BROKE 3RD RIDE 2 WEEKS TO GET BRIDGE REPLACED,LOOKED LIKE SAME PART THAT HAD BROKEN. 3.CLUTCH LEAVER ACTUATORBINDS UP CAUSING CLUTCH ENGAGEMENT IMPOSSIBLE HAD TO SHUT ATV OFF TO GET STOPPED.4.PLASTICS MOUNTING TABS BREAKING . BOLT INSERTS STRIPPING OUT ,HAD TO PULL PLASTIC THROUGH BOLTS TO REMOVE.PLASTICS DESTROYED IN PROCESS. 5.T
... HROTTLE NON RESPONSIVE ON INCLINES COMES AND GOES,NOT RELIABLE. 6.REAR WHEEL HUB STRIPPED OUT CAUSING ONE WHEEL TO GRAB THROWING ME OUT OF CONTROL. 7. SEAT TEARING AT KNEE AREA. *TRRead more
Incident date: Jun 1, 2008
1.ATV RIDING CHAIN BROKEN DEALER REPLACED 1WEEK. 2.BRAKE CALIPER BROKE 3RD RIDE 2 WEEKS TO GET BRIDGE REPLACED,LOOKED LIKE SAME PART THAT HAD BROKEN. 3.CLUTCH LEAVER ACTUATORBINDS UP CAUSING CLUTCH ENGAGEMENT IMPOSSIBLE HAD TO SHUT ATV OFF TO GET STOPPED.4.PLASTICS MOUNTING TABS BREAKING . BOLT INSERTS STRIPPING OUT ,HAD TO PULL PLASTIC THROUGH BOLTS TO REMOVE.PLASTICS DESTROYED IN PROCESS. 5.T
... HROTTLE NON RESPONSIVE ON INCLINES COMES AND GOES,NOT RELIABLE. 6.REAR WHEEL HUB STRIPPED OUT CAUSING ONE WHEEL TO GRAB THROWING ME OUT OF CONTROL. 7. SEAT TEARING AT KNEE AREA. *TRRead more
Incident date: Jun 1, 2008
1.ATV RIDING CHAIN BROKEN DEALER REPLACED 1WEEK. 2.BRAKE CALIPER BROKE 3RD RIDE 2 WEEKS TO GET BRIDGE REPLACED,LOOKED LIKE SAME PART THAT HAD BROKEN. 3.CLUTCH LEAVER ACTUATORBINDS UP CAUSING CLUTCH ENGAGEMENT IMPOSSIBLE HAD TO SHUT ATV OFF TO GET STOPPED.4.PLASTICS MOUNTING TABS BREAKING . BOLT INSERTS STRIPPING OUT ,HAD TO PULL PLASTIC THROUGH BOLTS TO REMOVE.PLASTICS DESTROYED IN PROCESS. 5.T
... HROTTLE NON RESPONSIVE ON INCLINES COMES AND GOES,NOT RELIABLE. 6.REAR WHEEL HUB STRIPPED OUT CAUSING ONE WHEEL TO GRAB THROWING ME OUT OF CONTROL. 7. SEAT TEARING AT KNEE AREA. *TRRead more
Incident date: Jun 1, 2008
1.ATV RIDING CHAIN BROKEN DEALER REPLACED 1WEEK. 2.BRAKE CALIPER BROKE 3RD RIDE 2 WEEKS TO GET BRIDGE REPLACED,LOOKED LIKE SAME PART THAT HAD BROKEN. 3.CLUTCH LEAVER ACTUATORBINDS UP CAUSING CLUTCH ENGAGEMENT IMPOSSIBLE HAD TO SHUT ATV OFF TO GET STOPPED.4.PLASTICS MOUNTING TABS BREAKING . BOLT INSERTS STRIPPING OUT ,HAD TO PULL PLASTIC THROUGH BOLTS TO REMOVE.PLASTICS DESTROYED IN PROCESS. 5.T
... HROTTLE NON RESPONSIVE ON INCLINES COMES AND GOES,NOT RELIABLE. 6.REAR WHEEL HUB STRIPPED OUT CAUSING ONE WHEEL TO GRAB THROWING ME OUT OF CONTROL. 7. SEAT TEARING AT KNEE AREA. *TRRead more
Incident date: Jun 1, 2008
1.ATV RIDING CHAIN BROKEN DEALER REPLACED 1WEEK. 2.BRAKE CALIPER BROKE 3RD RIDE 2 WEEKS TO GET BRIDGE REPLACED,LOOKED LIKE SAME PART THAT HAD BROKEN. 3.CLUTCH LEAVER ACTUATORBINDS UP CAUSING CLUTCH ENGAGEMENT IMPOSSIBLE HAD TO SHUT ATV OFF TO GET STOPPED.4.PLASTICS MOUNTING TABS BREAKING . BOLT INSERTS STRIPPING OUT ,HAD TO PULL PLASTIC THROUGH BOLTS TO REMOVE.PLASTICS DESTROYED IN PROCESS. 5.T
... HROTTLE NON RESPONSIVE ON INCLINES COMES AND GOES,NOT RELIABLE. 6.REAR WHEEL HUB STRIPPED OUT CAUSING ONE WHEEL TO GRAB THROWING ME OUT OF CONTROL. 7. SEAT TEARING AT KNEE AREA. *TRRead more
Incident date: Jun 1, 2008
1.ATV RIDING CHAIN BROKEN DEALER REPLACED 1WEEK. 2.BRAKE CALIPER BROKE 3RD RIDE 2 WEEKS TO GET BRIDGE REPLACED,LOOKED LIKE SAME PART THAT HAD BROKEN. 3.CLUTCH LEAVER ACTUATORBINDS UP CAUSING CLUTCH ENGAGEMENT IMPOSSIBLE HAD TO SHUT ATV OFF TO GET STOPPED.4.PLASTICS MOUNTING TABS BREAKING . BOLT INSERTS STRIPPING OUT ,HAD TO PULL PLASTIC THROUGH BOLTS TO REMOVE.PLASTICS DESTROYED IN PROCESS. 5.T
... HROTTLE NON RESPONSIVE ON INCLINES COMES AND GOES,NOT RELIABLE. 6.REAR WHEEL HUB STRIPPED OUT CAUSING ONE WHEEL TO GRAB THROWING ME OUT OF CONTROL. 7. SEAT TEARING AT KNEE AREA. *TRRead more
Incident date: Jun 7, 2008
MOTORCYCLE STALLS WHEN RIDING IT ALOT. *TR
Incident date: Apr 8, 2008
MY NEW 2007 KTM 990 ADVENTURE MOTORCYCLE CONTINUES TO HAVE A SERIOUS SAFETY DEFECT. WHILE RIDING THE MOTORCYCLE THE ENGINE SHUTS OFF WHILE CHANGING GEARS. I AM UNAWARE OF THE ENGINE BEING OFF UNTIL I FEEL THE REAR WHEEL SLIPPING OR SEE THE RED OIL PRESSURE LIGHT. THIS IS UNACCEPTABLE AND HAS BEEN BROUGHT TO KTM BOTH AT THE DEALER AND THROUGH THE KTM NA REP. I HAVE NO ISSUES WITH THE PEOPLE HANDLI
... NG MY BIKE - THEY HAVE BEEN TRYING. I'M SIMPLY NOT WILLING TO DIE OVER IT. THIS ENGINE SHUT DOWN OCCURS AT RANDOM TIMES, BOTH HIGH (FREEWAY) AND LOW SPEEDS. THE ONLY CORRELATION APPEARS TO BE WHEN THE CLUTCH HANDLE IS PULLED IN, AND ENGINE RPM DROPS WHILE CHANGING GEARS. RELEASING THE CLUTCH ON A SHUT DOWN ENGINE RESULTS IN THE REAR WHEEL LOCKING UP AND SLIDING OUT FROM UNDER THE BIKE - UNACCEPTABLE. THIS ISSUE HAPPENED IN THE FIRST HUNDRED MILES OF MY OWNERSHIP AND RANDOMLY UP UNTIL THE 600 MILE SERVICE. KTM DEALER WAS TOLD ABOUT THE SHUTDOWN AND CHECKED THE BIKE OVER. THEY REMAPPED - UPDATED THE FUEL INJECTION AND WERE CONFIDENT THE PROBLEM WAS FIXED. IT IS NOT FIXED! SOME HAVE ATTRIBUTED THE PROBLEM TO BEING A "NEW" BIKE - HOWEVER I HAVE 1454 MILES ON IT AND IT SHUT DOWN ON ME TWICE TODAY AT HIGH SPEED. THIS IS A SERIOUS SAFETY DEFECT AND MUST BE AGGRESSIVELY HANDLED BY KTM. PLEASE HELP ME ACCOMPLISH THAT. I AM AN ADVANCED RIDER AND IT TAKES ALL MY SKILL TO MANAGE A BIKE AT FREEWAY SPEED WITH THE ENGINE SHUT DOWN. I DO NOT WANT SOMEONE TO GET HURT OR KILLED BY THIS DEFECT. *TRRead more
Incident date: Feb 29, 2008
FUEL TANK STARTED LEAKING FUEL IN MY GARAGE AND WHILE MOTORCYCLE WAS IN OPERATION. I RETURNED THE MOTORCYCLE TO THE DEALER FOR REPAIR. THE FUEL TANK WAS REPLACED TWICE (TOTAL OF 3 FUEL TANKS) AND THE BIKE STARTED LEAKING FUEL AGAIN. MY GARAGE FILLS WITH GASOLINE FUMES. I CONTACTED KTM AND REQUESTED A REFUND AND THEY REFUSED. KTM HAS OFFERED TO REPLACE THE FUEL TANK AND INSPECT THE MOTORCYCLE.
... *TRRead more
Incident date: Jun 15, 2007
KTM MOTORCYCLE (DIRT BIKE) RODE 1ST , BROKEN ENGINE, CHAIN, SWINGARM, 2ND TIME SAME, 3RD TIME SAME. *TR
Incident date: Feb 1, 2006
2006 KTM 250 XC-W OFF-ROAD MOTORCYCLE GAS CAP LEAKS. *JB
Incident date: Mar 21, 2006
2006 KTM 300XC GAS CAP LEAKED GASOLINE ON MY LEGS AND DOWN SIDE OF FUEL TANK CONTINUALLY. REPLACED GAS CAP 3 TIMES PRIOR TO NEW RECALL GAS CAP. NEW RECALL GAS CAP LEAKED GASOLINE ON MY LEGS VERY FIRST RIDE AND CONTINUES TO LEAK EVERY TIME THE MOTORCYCLE IS RIDDEN. *TR
Incident date: Jun 28, 2007
KTM 950 SUPERMOTO GAS TANK LEAKS FROM THE LEFT HAND SIDE. GAS IS EVIDENT AT THE BOTTOM OF THE FAIRING AND THE FLOWING OUT OF THE TANK AT A SUFFICIENT RATE TO DRIP AND POOL. MOTORCYCLE WAS IN STORAGE AND NOT DRIVEN FOR SEVERAL MONTHS WHEN LEAKING OCCURRED SO IT IS NOT THE RESULT OF MISUSE OR ABUSE. *TR
Incident date: Mar 20, 2007
LEAKING GAS CAP. *TR
Incident date: Mar 16, 2007
LEAKING GAS CAP ON 2007 KTM 300 XCW. *AK
Incident date: Sep 15, 2004
TL* THE CONTACT OWNS A 2004 KTM950 ADVENTURE. THE CONTACT RECEIVED RECALL #07V065000 TO HAVE THE REAR BRAKING SYSTEM REPLACED. THE DEALER ADVISED THE CONTACT THAT THE PARTS WOULD BE AVAILABLE IN 2 TO 3 WEEKS. THE CONTACT FELT THAT THIS WAS UNACCEPTABLE. THE CURRENT MILEAGE WAS 17,000. *AK UPDATED 04/09/07. *JB
Incident date: Mar 9, 2007
I HAVE A 2007 KTM 300 XCW WITH A LEAKING GAS CAP. I HAVE RETURNED TO THE DEALER AND THEY GAVE ME A SECOND CAP. THIS CAP ORIGINALLY WORKED WELL. AFTER 2 RIDES HOWEVER, THE CAP HAS BECOME SWOLLEN AND DIFFICULT TO INSTALL. ALSO THE LEAK HAS RETURNED. *JB
Incident date: Feb 24, 2007
1) GAS WAS PUT INTO TANK 2) GAS CAP LEAKS GAS WHEN IT SLOSHES AROUND 3) THERE IS NO FIX AVAILABLE FROM THE KTM DEALER. *JB
Incident date: Jul 10, 2006
I PURCHASED A 2006 KTM 450 XC - THE GAS CAP BEGAN TO LEAK APPROXIMATELY 2 MONTHS AFTER PURCHASE. I HAVE SINCE PURCHASED 4 GAS CAPS. EACH ONE HAS CURED THE LEAK PROBLEM FOR APPROXIMATELY 2 MONTHS. AT TIMES THE AMOUNT OF GAS THAT LEAKS CAN BE SIGNIFICANT. *JB
Incident date: Oct 20, 2006
I PURCHASED A NEW 2006 KTM 400EXC JUNE 2006, IN OCTOBER I TRANSPORTED THE MOTORCYCLE IN A TRAILER TO A RIDING AREA, WHEN I ARRIVED IT WAS LEAKING SO BADLY THAT GASOLINE WAS DRIPPING OUT OF THE TRAILER ONTO THE GROUND, THE GAS CAP WAS SO DEFORMED THAT IT WAS NEARLY IMPOSSIBLE TO TAKE OFF AND ON. THE DEALERSHIP TOLD ME THIS IS AN ONGOING PROBLEM AND THEY REPLACED THE CAP WITH AN IDENTICAL DEFECTIVE
... CAP THAT DEFORMED AND LEAKED IN ABOUT 3 MONTHS. THE CAP WAS REPLACED AGAIN. THEY HAVE SINCE MAILED ME A NEW SEAL FOR THE CAP, SAYING THIS IS THE SOLUTION TO ALL OF THE GAS CAP PROBLEMS, BUT MY CAP NEEDS TO BE REPLACED, IT IS DEFORMED AND SWOLLEN AGAIN. HAVING A GAS CAP THAT DOES NOT LAST MORE THAN 3 OR 4 MONTHS AND REGULARLY LEAKS IS NOT ACCEPTABLE, AND KTM IS CONTINUING TO SELL NEW MODELS WITH THE SAME DEFECTIVE DESIGN. *JBRead more
Incident date: Jan 15, 2007
ABOUT TWO MONTHS AFTER I PURCHASED A 2006 KTM 450EXC MOTORCYCLE THE FUEL CAP STARTED TO DEFORM AND WOULD NO LONGER SEAL. FUEL LEAKS PAST THE SEAL ON THE FUEL CAP AND SPILLS ONTO MY LEGS WHILE I RIDE. KTM RECENTLY SENT OUT A NEW SEAL (X-RING), BUT THIS DID NOT SOLVE THE PROBLEM. *JB
Incident date: Sep 21, 2006
FUEL CAP ON MOTORCYCLE LEAKS AND MANUFACTURER REFUSES TO FIX. VERY DANGEROUS AND CAN CAUSE INJURY OR DEATH WHILE RIDING. *JB
Incident date: Nov 29, 2006
LEAKING FUEL CAP ON MOTORCYCLE RESULTING IN FUEL SPILLAGE AT THE LEAST, CATASTROPHIC INJURY DUE TO FIRE AT WORST. *JB
Incident date: Jan 1, 2007
FUEL FILLER CAP LEAKING, REPLACED CAP AND ADDED O-RING, BUT STILL LEAKS. *JB
Incident date: Mar 3, 2007
LEAKING 1/4 TURN GAS CAP ON 2006 KTM 450 EXC MOTORCYCLE THAT I BOUGHT NEW FROM POWERSPORTS EAST IN DELAWARE. KTM APPARENTLY KNOWS ABOUT THE PROBLEM AND RATHER THAN FIX THIS POTENTIALLY DANGEROUS CONDITION, THEY ELECT TO GIVE OUT O-RINGS AS A FIX. THIS DOES NOT FIX THE PROBLEM. THE EFFECTS OF GASOLINE RUNNING OUT OF A PLASTIC GAS TANK AND ONTO A HOT ENGINE DOES NOT SEEM TO BE IN ANY WAY A SAFE S
... ITUATION. I BELIEVE THAT KTM HAS SINCE MODIFIED THE DESIGN OF THIS FAULTY GAS CAP, BUT DOES NOT OFFER THE FIX TO THOSE WHO HAVE PURCHASED EARLIER DESIGNS. *JBRead more
Incident date: Feb 25, 2007
FUEL TANK CAP IS DISTORTED CAUSING GAS TO LEAK OUT EVERYWHERE. *JB
Incident date: Dec 1, 2005
THIS RELATES TO A MANUFACTURING DEFECT DELIVERED BY KTM SPORTMOTORCYCLES NA. ON PRODUCT LINE FOR MODEL YEARS 2006 AND 2007, INCLUDING MY VEHICLE 06 450 EXC, THE 1/4-TURN GAS CAPS HAVE HAZARDOUS AND POTENTIALLY LIFE-THREATENING FAULTS. TO DATE KTM HAS FAILED TO PROPERLY ADDRESS IT. DETAIL OF THE CAP PROBLEMS: - THE CAP HAS 3 LOCKING TABS THAT MATE WITH THE TANK. THE ORIGINAL CAP'S NECK WAS TOO
... LONG, PREVENTING A TIGHT SEAL AND LEAKED BADLY - KTM ISSUED NEW CAPS WITH SHORTER NECKS, TIGHTENING THE SEAL AND TEMPORARILY FIXED THE LEAKING. - THE NEW CAPS LEAKED WITHIN DAYS OR WEEKS OF INSTALLATION. IT WAS DISCOVERED THAT THE CAPS BECAME GROSSLY DISTORTED OVER TIME, LIKE DUE TO INCREASED PRESSURE ON THE CAPS, INTERACTION BETWEEN THE CAP MATERIAL AND THE FUEL, AND POOR DESIGN. THE NEWER CAPS LEAK AS BADLY AS THE ORIGINALS WHEN DISTORTED. - THE CAP VENT TUBES POP OUT RESULTING IN FUEL LEAKING OUT FROM THAT AREA. - CAPS HAVE POPPED OFF IN CRASHES, RESULTING IN RIDERS BEING SOAKED IN FUEL. THE BADLY DISTORTED CAPS WILL NEVER PROVIDE A SECURE CONNECTION TO THE TANK. AFTER 2 LONG YEARS KTM FINALLY RELEASED A '''''PERMANENT''''' FIX, WHICH IS MERELY ANOTHER X-RING. IT IS NOT A FIX AT ALL. MANY RIDERS HAVE INSTALLED THIS NEW X-RING AND STILL LEAK. IN NO WAY DOES IT ADDRESSES THE CAP WARPING AND POP-OFFS OR THE VENT-HOSE POP OFFS, ALL WHICH ARE POTENTIALL LIFE-THREATENING. IT IS INTERESTING TO NOTE THAT KTM OFFICIAL RACES TEAMS FOR OFF-ROAD, MOTOCROSS, AND SUPERMOTO, BOTH ON THE NATIONAL AND WORLD CHAMPIONSHIP CIRCUITS, DO NOT RUN THESE 1/4-TURN GAS CAPS! FINALLY, KTM APPEARS TO BE DONE WITH THIS PROBLEM. SOMEONE IS EVENTUALLY GOING TO GET BURNED OR DIE. HOPEFULLY THE NHTSA WILL TAKE ACTION AND FORCE THE ISSUE. I HAVE MUCH MORE DETAIL AVAILABLE IF NEEDED.Read more
99 injured
Incident date: Dec 1, 2005
THIS RELATES TO A MANUFACTURING DEFECT DELIVERED BY KTM SPORTMOTORCYCLES NA. ON PRODUCT LINE FOR MODEL YEARS 2006 AND 2007, INCLUDING MY VEHICLE 06 450 EXC, THE 1/4-TURN GAS CAPS HAVE HAZARDOUS AND POTENTIALLY LIFE-THREATENING FAULTS. TO DATE KTM HAS FAILED TO PROPERLY ADDRESS IT. DETAIL OF THE CAP PROBLEMS: - THE CAP HAS 3 LOCKING TABS THAT MATE WITH THE TANK. THE ORIGINAL CAP'S NECK WAS TOO
... LONG, PREVENTING A TIGHT SEAL AND LEAKED BADLY - KTM ISSUED NEW CAPS WITH SHORTER NECKS, TIGHTENING THE SEAL AND TEMPORARILY FIXED THE LEAKING. - THE NEW CAPS LEAKED WITHIN DAYS OR WEEKS OF INSTALLATION. IT WAS DISCOVERED THAT THE CAPS BECAME GROSSLY DISTORTED OVER TIME, LIKE DUE TO INCREASED PRESSURE ON THE CAPS, INTERACTION BETWEEN THE CAP MATERIAL AND THE FUEL, AND POOR DESIGN. THE NEWER CAPS LEAK AS BADLY AS THE ORIGINALS WHEN DISTORTED. - THE CAP VENT TUBES POP OUT RESULTING IN FUEL LEAKING OUT FROM THAT AREA. - CAPS HAVE POPPED OFF IN CRASHES, RESULTING IN RIDERS BEING SOAKED IN FUEL. THE BADLY DISTORTED CAPS WILL NEVER PROVIDE A SECURE CONNECTION TO THE TANK. AFTER 2 LONG YEARS KTM FINALLY RELEASED A '''''PERMANENT''''' FIX, WHICH IS MERELY ANOTHER X-RING. IT IS NOT A FIX AT ALL. MANY RIDERS HAVE INSTALLED THIS NEW X-RING AND STILL LEAK. IN NO WAY DOES IT ADDRESSES THE CAP WARPING AND POP-OFFS OR THE VENT-HOSE POP OFFS, ALL WHICH ARE POTENTIALL LIFE-THREATENING. IT IS INTERESTING TO NOTE THAT KTM OFFICIAL RACES TEAMS FOR OFF-ROAD, MOTOCROSS, AND SUPERMOTO, BOTH ON THE NATIONAL AND WORLD CHAMPIONSHIP CIRCUITS, DO NOT RUN THESE 1/4-TURN GAS CAPS! FINALLY, KTM APPEARS TO BE DONE WITH THIS PROBLEM. SOMEONE IS EVENTUALLY GOING TO GET BURNED OR DIE. HOPEFULLY THE NHTSA WILL TAKE ACTION AND FORCE THE ISSUE. I HAVE MUCH MORE DETAIL AVAILABLE IF NEEDED.Read more
99 injured
Incident date: Feb 28, 2007
GAS CAP IS DISTORTED AND IS HARD TO REMOVE AND INSTALL. GAS CAP LEAKS. SEEMS LIKE GAS CAP COULD FALL OFF. PARTS OF THE GAS CAP ARE FALLING APART. *JB
Incident date: Aug 17, 2006
GAS CAP LEAKS GAS. *JB
Incident date: Feb 17, 2007
GAS CAP LEAKS AND CAN BE EASILY DISLODGED IN A CRASH RESULTING IN A POSSIBLE FIRE OR CHEMICAL BURNS TO THE RIDER. *JB
Incident date: Nov 28, 2006
2006 MODEL YEAR OFF ROAD MOTORCYCLE, GAS CAP LEAKS AFTER 2 MONTHS USE. FUEL DRIPPING DOWN THE SIDE OF THE FUEL TANK. CONTACTED DEALER AND WAS REFUSED A WARRANTY REPLACEMENT, BOUGHT A NEW ONE. AFTER SEVERAL MONTHS USE, THIS CAP IS ALSO LEAKING. *JB
Incident date: Nov 23, 2005
I HAVE HAD LEAKING ISSUES WITH THE FUEL CAP ON MY KTM MOTORCYCLE. I BOUGHT THE BIKE NEW IN SEPTEMBER OF 2005. THE GAS CAP STARTED LEAKING ALMOST IMMEDIATELY. KTM SUPPLIED A NEW CAP BUT IT LEAKED SHORTLY AFTER INSTALLATION AS WELL. THE CAP ALSO SWELLED AND BECAME HARD TO REMOVE. I THEN GOT A 3RD CAP THAT I PAID FOR AND IT ALSO LEAKS BUT HAS NOT SWOLLEN. *JB
Incident date: Jan 1, 2007
KTM 1/4 TURN GAS CAPS LEAK AND CAUSE BURNS ON YOUR LEGS AND MAY CAUSE A FIRE! ALSO THE CAP BECOMES DISTORTED AND MAY FALL OFF WHILE RIDING ALLOWING GAS TO FLOW OUT! *NM
Incident date: Jul 7, 2006
ON MY 2006 KTM 525 EXC THE GAS CAP CAME OFF WHILE TRAIL RIDING AND SPILLED GAS ALL OVER ME. THIS WAS NOT DUE TO A CRASH. I WAS SIMPLY RIDING THE MOTORCYCLE OFF ROAD. THIS HAS HAPPENED TWICE WITH THE SAME RESULTS. I HAVE TRIED THE O-RING REPLACEMENT FIX RECOMMENDED BY KTM AND IT WORKED FOR A SHORT TIME AND NOW IT IS LEAKING AND SPRAYING GAS ALL OVER THE BIKE AND RIDER. THIS IS A KNOWN ISSUE AND KT
... M WILL NOT FIX IT. *NMRead more
1 injured
Incident date: Jan 2, 2007
GAS CAP LEAKS AND DISTORTS CAUSING LEAKAGE. MANUFACTURE NEEDS TO REDESIGN GAS TANK. *NM
Incident date: Mar 1, 2007
LEAKING GAS CAP. *NM
1 injured
Incident date: Jan 20, 2007
FUEL CAP LEAKS AND POPS OFF. *NM
Incident date: Nov 7, 2006
I OWN A 2007 KTM 300 XC-W DISTRIBUTED BY KTM NORTH AMERICAN IN CORINTH MS. IT CAME WITH A 'NEW' 1/4 TURN FUEL CAP. THIS CAP HAS A CHRONIC LEAK ISSUE ON MANY BIKES AND WILL EVEN POP OFF OF THE TANK ON OCCASION. I PURCHASED THE RECOMMENDED O RING THAT WAS SUPPOSED TO FIX THE ISSUE BUT IT HAS MADE MINIMAL IMPROVEMENT AT BEST. THIS IS AN EXTREMELY COMMON ISSUE AMONG 2006 KTM MOTORCYCLE OWNERS AND CONT
... INUES INTO THE 07 MODEL YEAR. I FEEL IT'S JUST A MATTER OF TIME UNTIL MYSELF OR SOMEONE IS BADLY HURT OR KILLED BECAUSE OF SPILLED FUEL COMING INTO CONTACT WITH AN IGNITION SOURCE. KTM HAS COME OUT WITH THE CAP RECALL/REPLACEMENT MENTIONED ABOVE IN LATE 05 AND THEY HAVE GIVEN SOME FOLKS A SEAL RING ACCOMPANIED BY A LETTER SAYING THERE WERE WORKING ON A FINAL SOLUTION. HERE IS A LINK TO A SCAN OF THAT SEAL RING DOCUMENT OF 8/24/06 WHERE THEY SAY THEY ARE WORKING ON A PERMANENT FIX: HTTP://216.165.194.66/KTMTALK/PHOTOGALLERY...BERS/X-RING.JPG SO THEY'VE KNOWN ABOUT THIS ISSUE FOR OVER A YEAR. FOR SOME REASON, THEY ARE NOT MAKING THE ABOVE RING/NOTICE AVAILABLE TO MOST OF US. KTM APPEARS TO HAVE AN ALUMINUM CAP BECOMING AVAILABLE THAT MAY FIX THIS ISSUE BUT THEY ARE NOT GIVING IT TO OWNERS OF THESE DEFECTIVE PRODUCTS. THEY ARE TRYING TO CHARGE THE OWNERS FOR THEIR OWN SERIOUS SAFETY ISSUE. I FEEL KTM SHOULD AT THE VERY LEAST GIVE THESE ALUMINUM CAPS TO ALL 06 AND 07 OWNERS. IF THAT IS NOT THE FIX, KTM SHOULD ADDRESS THIS ISSUE IN SOME WAY TO PERMANENTLY FIX IT, AND QUICKLY. *NMRead more
Incident date: Jul 18, 2006
2006 KTM 300XCW MOTORCYCLE PURCHASED JUNE 2006. GAS CAP BEGAN LEAKING WITHIN A COUPLE OF WEEKS. GAS DRAINS FROM AROUND THE BASE OF THE CAP ONTO THE TANK, SEAT, RIDERS LEGS, AND MAY DRIP ONTO THE MOTOR AND EXHAUST. TANKS OPENING IS ALSO DISTORTED. KTM SENT AN X-RING TO FIX THE PROBLEM BUT IT STILL LEAKS JUST AS BADLY AS BEFORE. *NM
Incident date: Sep 1, 2006
I PURCHASED A NEW KTM MOTORCYCLE IN MARCH 2006 FROM A LOCAL DEALER. APPROXIMATELY AUGUST 2006 I NOTICE THE GAS CAP(NEW 1/4 TURN DESIGN) LEAKING WHILE RIDING THE MOTORCYCLE. ONE DAY IN SEPTEMBER WHILE RIDING I FELL OVER AND DROPPED THE MOTORCYCLE AND THE GAS CAP ACTUALLY POPPED OFF THE GAS TANK AND SPILLED GAS ON ME. IT TOOK ME 15 MINUTES TO GET BACK TO MY TRUCK AND WASH THE GAS OFF. IT MADE SEVERA
... L BLOTCHY RED AREAS ON MY LEG WHERE THE GAS HAD SOAKED MY PANTS. I REPORTED THIS ALL TO THE DEALER AND THEY SOLD ME A NEW GAS CAP. THE NEW CAP STARTED LEAKING GAS AFTER ONLY TWO RIDES. I REPORTED THIS TO THE DEALER AND THE KTM NORTH AMERICAN SERVICE REP. KTM AT THIS POINT SUGGESTED AN O-RING SO I BOUGHT ONE FROM THE LOCAL HARDWARE STORE AND PUT IT ON THE GAS CAP. THIS SEEMED TO STOP THE LEAK BUT THEN I NOTICED THE GAS CAP GETTING HARDER AND HARDER TO REMOVE. UPON INSPECTION OF THE CAP IT WAS NOTICEABLY DEFORMED SO I REPORTED THIS TO MY LOCAL KTM DEALER IN OCTOBER 2006. THEY GAVE ME ANOTHER CAP BUT THIS ONE WAS FREE AND THEY GAVE ME A X-RING TO INSTALL ON THE CAP. SINCE THEN, THE NEW CAP HAS ALSO DEFORMED AND NOW THE VENT CHECK BALL HOUSING HAS ALSO COME APART CAUSING THE CHECK BALL TO DROP INTO THE GAS TANK SO NOW GAS SPILLS OUT THE VENT TUBE. I REPORTED ALL OF THIS TO MY DEALER AND THEY SHOWED ME A LETTER FROM KTM WITH NEW X-RINGS ATTACHED STATING THIS WAS THE FIX BUT THEY COULD NOT GIVE IT TO ME AS THEY ONLY HAD A COUPLE AND OFFERED TO SELL ME ANOTHER NEW GAS CAP. I HAVE ALSO CALLED THE KTM NORTH AMERICAN SERVICE REP. AND INFORMED HIM OF ALL OF THESE ISSUES BUT IT DOES NOT SEEM TO BE GETTING ANYWHERE. THEIR X-RING FIX MAY RESOLVE THE GAS LEAK BUT IT DOES NOT RESOLVE THE DEFORMED, POPPING OFF, FALLING APART PROBLEM WITH THEIR DESIGN. *NMRead more
1 injured
Incident date: Jan 28, 2007
GAS CAP LEAKS. I HAVE PERSONALLY SEEN THE SAME DESIGN CAP ON A FRIENDS BIKE FALL OFF AFTER A CRASH, SPILLING GAS ON THE GROUND. *JB
Incident date: Oct 20, 2005
I HAVE A 2006 KTM 300XC-W WHICH HAS LEAKED FUEL FROM THE GAS CAP SINCE IT WAS NEW IN SEPTEMBER OF 2005. THE LEAK FROM THE DEFECTIVE CAP HAS RESULTED IN CHEMICAL BURNS TO MY UPPER THIGH AREA IN ONE PARTICULAR TIP OVER. *JB KTM IS AWARE OF THE FLAW AND HAS ATTEMPTED TO PLACATE THE OWNERS WITH BANDAIDE TYPE FIXES, NONE OF WHICH HAS PERMANENTLY FIXED THE PROBLEM. IT IS JUST A MATTER OF TIME BEFORE
... SOMEONE IS SERIOUSLY INJURED OR KILLED AS A RESULT OF SPILLED GASOLINE ON THEMSELVES OR HOT ENGINE PARTS. I WAS FORCED TO PURCHASE A FUEL TANK THAT HAS A TRADITIONAL SCREW TYPE CAP AT MY OWN EXPENSE IN ORDER TO RIDE THE BIKE WITH OUT WORRY OF PERSONAL INJURY OR DEATH. *JBRead more
1 injured
Incident date: Mar 3, 2006
BIKE PURCHASED 11-05. RIDING BIKE SLOWLY THROUGH WOODS AND FELL OVER. THE FUEL CAP POPPED OFF SPILLING A LARGE PORTION OF FUEL. 3-06 VACATION IN GA, FUEL CAP STARTED LEAKING. FUEL TANK COVERED IN FUEL, UNDERNEATH SEAT AND THE FRAME COVERED IN FUEL. MY LEFT LEG PANTS FUEL SOAKED AFTER EVERY RIDE. COMPLAINED TO DEALER. FINALLY AFTER COMPLAINING TO THE DEALER OWNER ( ABOUT A MONTH LATER) THEY TOOK A
... CAP OF A NEW BIKE AND GAVE IT TO ME. THE OLD CAP WAS TURNED IN TO THEM. IT LASTED A COUPLE OF MONTHS AND THEY GAVE ME ANOTHER CAP, MAYBE IN 8-06. BY OCT 06 FUEL CAP IS AGAIN LEAKING BADLY. THE CAP ALSO IS SWOLLEN AND VERY DIFFICULT TO REMOVE. CALLED SERVICE MANAGER AT DEALER. A WEEK PASSES AND I CALL AGAIN. HE SAYS THIS IS NOT A KTM ISSUE AND THEY WILL NOT GIVE AWAY ANY MORE FUEL CAPS. I THEN CALLED THE OWNER OF THE DEALER AGAIN. WHO IN TURN CALLED KTM. A COUPLE OF WEEKS LATER THEY GAVE ME A NEW CAP THAT WAS MODIFIED WITH A ADDITIONAL O-RING. I ORIGINALLY CALLED IN MY COMPLAINT. THERE WAS NO FOLLOW UP. *JBRead more
Incident date: Feb 24, 2007
I OWN A 2004 KTM 200EXC MOTORCYCLE WITH 2006 GAS TANK. THE 1/4 TURN GAS CAP ON THIS 2006 GAS TANK HAS LEAK MULTIPLE TIMES AROUND THE SEALING SURFACE WHEN THE BIKE WAS LEANED OVER. ALSO, THE GAS CAP HAS BECOME DISTORTED AND SWOLLEN. IT IS DIFFICULT TO INSERT AND REMOVE FROM THE GAS TANK. I PURCHASED A NEW GAS CAP FROM THE DEALER BUT THE GAS CAP IS TOO LOOSE WITHIN THE GAS TANK AND WILL NOT STAY ON.
... I WANT TO FILE A FORMAL COMPLAINT AGAINST KTM ON THE DEFECTIVE GAS CAP AND GAS TANK. THIS IS A SAFETY HAZARD DUE TO POTENTIAL OF FIRE WITH THE GASOLINE AND SKIN IRRITATION FROM GASOLINE CONTACT. *JBRead more
Incident date: Sep 30, 2006
GAS CAP ON MOTORCYCLE POPPED OFF, GASOLINE/CHEMICAL BURN ON LEG. *JB
1 injured
Incident date: Dec 23, 2006
FROM DAY OF PURCHASE, MY 2007 KTM 200 XC MOTORCYCLE HAS BEEN LEAKING GASOLINE FROM THE GAS CAP, AND SPLASHING FUEL INTO MY LAP AND ALL OVER THE BIKE. THIS IS FROM THE 1/4 TURN GAS CAP KTM HAS BEEN SHIPPING ON MODEL YEAR 2006 AND 2007 MOTORCYCLES. PLEASE LOOK AT WWW.KTMTALK.COM IN THE "GENERAL FORUM" FOR AN ENTIRE HISTORY OF OWNER COMPLAINTS. AND ALTHOUGH KTM JUST RECENTLY ATTEMPTED TO FIX THE ISS
... UE BY MAILING NEW O-RINGS, THE GAS CAP AND TANK ARE THE ISSUE, AS THE CAP SWELLS AND ENLARGES THE FILLER HOLE TO THE POINT THAT THE O-RING WILL ONLY WORK FOR A BRIEF PERIOD BEFORE IT BEGINS LEAKING AGAIN. I RECOMMEND A 100% RECALL ON THE KTM GAS TANKS. IF THIS WAS A CAR SPILLING GAS ON OUR LAPS, A RECALL WOULD HAVE ALREADY HAPPENED. *NMRead more
Incident date: Dec 10, 2006
THE GAS CAP ON THE '06 KTM 450 EXC MODEL LEAKS FUEL AFTER THE FIRST FEW MONTHS OF OPERATION. THE VENT GLUE FAILED CAUSING THE FUEL TO SPILL OUT OF THE VENT AREA OF THE CAP. THE FUEL CAP BUILT IN GASKET DOES NOT SEAL PROPERLY AND FUEL LEAKS OUT OF THIS AREA AS WELL. THE CAP IS 1/4 TURN TO CLOSE AND DUE TO SWELLING OF THE TANK AND ENLARGEMENT OF THE TANK CAP RECEPTACLE ENLARGE DUE TO SWELLING WIL
... L POP OFF ON IMPACT. A CRASH OCCURRED IN A ROCKY AREA WITH THE BIKE FALLING AND THE RIDER ON THE GROUND THE CAP POPPED OFF ON IMPACT WITH GAS RELEASED FROM THE TANK ALL OVER THE RIDER AND INTO RIDING BOOT. CHEMICAL BURNS WERE SUSTAINED. IF THE BIKE HAD NOT FALLEN DOWNHILL THE FUEL WOULD HAVE CONTACTED THE HOT ENGINE OR EXHAUST AND IGNITED THE BIKE AND RIDER. KTM HAS SUPPLIED A TEMPORARY FIX OF AN O-RING, BUT HAS NOT BEEN FORTHCOMING FOR A PERMANENT FIX TO THIS LEAKING PROBLEM AND UNSECURED CAP ISSUE FOR 2 YEARS. HUNDREDS OF '06 THROUGH '07 KTM OWNERS EXPERIENCE THIS SAME PROBLEM. IT IS ONLY A MATTER OF TIME BEFORE A DEATH IS REPORTED DUE TO FIRE. *NMRead more
Crash
1 injured
Incident date: Nov 10, 2006
DT*: THE CONTACT STATED THE GAS CAP LEAKED WHEN THE VEHICLE WAS IN MOTION AT ANY SPEED. THE SERVICE DEALER AND MANUFACTURER HAVE NOT BEEN NOTIFIED.