2005 Ducati Monster S2 R

After opening this PE, we met with subject owners, dealers, and Ducati North America personnel.We learned that the subject leakage is limited to the Multistrada line alone and is unrelated to composite fuel tank deformation.Rather it stems from the inability of the original sealing O-ring to conform to the tank's relatively rough sealing surface.Recall 11V-020 provides a new X section O-ring to address the Multistrada issue and with that recall, this PE is closed for the Multistrada.Meanwhile, unlike the Multistrada, the Monster line fails to exhibit a current safety defect trend and, on that basis, this PE is closed for those models as well.

PLASTIC GAS TANK HAS EXPANDED AND WARPED, CAUSING TANK VENTS TO STOP WORKING EFFECTIVELY. GASOLINE NOW LEAKS AND SPRAYS EXTENSIVELY FROM THE TOP OF THE TANK, COVERING THE TANK AND SURROUNDING AREAS WITH GASOLINE. GASOLINE ALSO LEAKS EXTENSIVELY FROM THE OVERFLOW TUBE ONTO MY GARAGE FLOOR. THE EXPANSION HAS ALSO MADE IT VERY DIFFICULT TO ACCESS THE FRONT TANK RELEASE LATCH. I MAINLY OBSERVE THIS WHILE THE MOTORCYCLE IS STATIONARY IN MY GARAGE. THE GASOLINE FUMES ARE ALWAYS PRESENT IN THE GARAGE. WHILE I HAVE NOT OBSERVED IT, I SUSPECT THIS LEAKING AND SPRAYING ALSO HAPPENS WHILE RIDING ON STREETS AND HIGHWAYS. THE CONSTANT PRESENCE OF GASOLINE OUTSIDE THE TANK IS UNSAFE. ON 3-17-17, THE DUCATI DEALER RECOMMENDED THAT I REPLACE THE PLASTIC TANK WITH ANOTHER PLASTIC TANK FOR $1,200. THAT IS NOT AN ADEQUATE SOLUTION. THESE PLASTIC TANKS EXPAND AND WARP OVER TIME. IT'S JUST A MATTER OF TIME BEFORE THE REPLACEMENT TANK EXPANDS AND WARPS.

NHTSA ID

10966646

Incident

Mar 17, 2017

Mileage

8,000 mi

THE PLASTIC FUEL TANK ON THIS AND OTHER DUCATI MOTORCYCLES EXPAND WITH GENERALLY AVAILABLE NORTH AMERICAN GASOLINE, SUCH THAT THE TANK CANNOT BE ATTACHED TO THE FRONT ATTACHMENT AT THE IGNITION KEY AREA, NEAR THE HANDLE BARS. THIS MAKES THE FUEL TANK NOT SECURED TO THE FORWARD PART OF THE MOTORCYCLE. THIS LEAVES ONLY ONE ATTACHMENT, AT THE REAR HINGE, SO IF THE MOTORCYCLE CRASHES OR IS DROPPED THE FORWARD PART OF THE FUEL TANK WILL POP AWAY FROM THE FRAME, PROBABLY LEAKING AND SUSCEPTIBLE TO RUPTURE BEING PLASTIC. DUCATI IS AWARE OF THE PROBLEM AND REPLACED THESE DEFECTIVE TANKS (INCLUDING MINE) PURSUANT TO A CLASS ACTION SETTLEMENT. UNFORTUNATELY DUCATI USED OTHER ALSO DEFECTIVE TANKS (SAME EXPANSION DEFECT WITH NO WARNING OF FUEL NOT TO USE - IF THAT IS THE PROBLEM) TO REPLACE THE ORIGINAL DEFECTIVE EXPANDED TANKS. DUCATI REFUSED MY REQUEST IT RECTIFY THE PROBLEM. MY MOTORCYCLE IS NOW DANGEROUSLY DEFECTIVE, A FIRE HAZARD, NOT SUITABLE FOR USE AND WOULD FAIL A SAFETY INSPECTION MAKING IT UNLAWFUL TO OPERATE ON HAWAII ROADS.

NHTSA ID

10822360

Incident

Jun 1, 2015

Mileage

6,000 mi

AFTER SEVERAL TANK REPLACEMENT BY DUCATI THE PROBLEM PERSISTS. TANK KEEPS SWELLING AND PUTS STRESS ON THE LATCH SO THAT IT CAN'T BE UNLATCH TO GET TO THE BATTERY OR FOR SERVICE . TANK ALSO DOESN'T SIT FIRM ON FRAME AT PIK SWELLING TIME . TANK ALSO LEAKS FUEL AT BOTTOM AROUND SEAL WHILE SWELLING IS AT MAX. FUEL GOES ALL OVER THE ENGINE AND FLOOR .DEALER SALES K 100 FUEL ADDITIVE FOR ETHANOL PROBLEMS SINCE DUCATI PERSIST ON NOT CHANGING TANK FOR A IMPROVED MATERIAL. *TR

NHTSA ID

10676839

Incident

Jan 20, 2015

Mileage

37,000 mi

THE PLASTIC FUEL TANK HAS EXPANDED DUE TO ETHANOL IN THE GASOLINE. IT IS PRESSING ON THE IGNITION SWITCH AND CAN NO LONGER BE MOUNTED OR REMOVED IN THE NORMAL FASHION. *TR

NHTSA ID

10509341

Incident

Apr 23, 2013

PLASTIC FUEL TANK IS SWOLLEN OR WARPED MAKING IT HARD TO LIFT THE TANK FOR SERVICE. ALSO, TANK DOESN'T SIT CORRECTLY ON THE FRAME, THE RUBBER FRAME BUMPERS SEEM TO HAVE MOVED OUTWARD ENOUGH TO NOT SIT FLUSH WITH THE FRAME. THIS SEEMS TO BE AN ONGOING PROBLEM WITH NUMEROUS MODELS IN THE DUCATI LINE WITH PLASTIC FUEL TANKS. *TR

NHTSA ID

10436804

Incident

Nov 22, 2011

I OWN A 2005 DUCATI S2R 800 MOTORCYCLE. MY FUEL TANK HAS EXPANDED BEYOND THE POINT WHERE THE PAINT HAS STARTED TO CRACK AND IT HAS BECOME DIFFICULT TO OPEN THE LATCH TO GET ACCESS TO THE BATTERY AND OTHER COMPONENTS. I HAVE ALREADY HEARD THAT THIS IS NOT AN UNCOMMON ISSUE WITH CERTAIN DUCATI FUEL TANKS. DUCATI HAS REFUSED TO COVER THE TANK DAMAGE AND AFTER SPEAKING WITH THE MECHANIC, HE TOLD ME THAT THE TANK WILL CONTINUE TO EXPAND AND POSSIBLY LEAK MORE GASOLINE AS TIME GOES ON. I DON'T WANT TO IMAGINE WHAT COULD POSSIBLY HAPPEN AS THE TANK CONTINUES TO EXPAND AND GASOLINE CONTINUES TO LEAK. *TR

NHTSA ID

10399456

Incident

Apr 1, 2011

Mileage

5,500 mi

EXPANDING GAS TANK IN 2005 DUCATI MONSTER POSES RISK OF LEAKING FUEL FROM WARPED FUEL PUMP O-RING GASKET. *TR

NHTSA ID

10395964

Incident

Apr 15, 2011

Mileage

5,000 mi

EXPANDING AND DEFORMING PLASTIC TANK. DUCATI USA REPLACED WITH THE SAME KIND OF TANK. *TR

NHTSA ID

10372595

Incident

Nov 10, 2010

Mileage

18,000 mi

Procedure for Assessing Front Fork Oil Leaks. Applicability: All Models. This service repair bulletin informs dealers and service managers of the assessment criteria for identifying front fork-related defects. The purpose is prevent technicians from mistaking oozing oil or assembly grease, for legitimate defects. The bulletin further provides examples and pictures for clarification.

Guided Diagnosis for Front Brake System Bleeding. Applicability: All Models. This Service Bulletin replaces and cancels the previous bulletin SRV-SRB-20-014 published on 4/17/2020. It provides dealers and service managers with needed information to correctly bleed the front brake system of the various Ducati models. This bulletin further refers the reader to an attached diagnosis guide. The referenced guide/annex is available to NHTSA upon request.

Finial Drive Chain Maintenance Precautions. Applicability: All Models and Model Years (except XDiavel). This Service Bulletin replaces and cancels the previous bulletins: SRV-SRB-18-030 published on 05/11/2018, SRV-SRB-19-046 published on 12/31/2019, SRV-SRB-20-050 published on 11/24/2020. It provides dealers and service managers additional final drive chain care to ensure optimum performance and longevity for the chain. this includes cleaning, lubricating, inspecting and tension guidelines.

Procedure for Analysis and Control of Oil and Coolant Leaks from Engine_Rev.01. Applicability: All Models. This service repair bulletin instructs dealers and service managers on authorized procedures for identifying and isolating coolant and engine oil leaks. The use of a prescribed leak trace powder is stressed. This bulletin includes service instructions.

Precautions to Follow During Crankcase Cleaning. Applicability: All Models. This service bulletin informs dealers and service managers about precautions in using abrasive cleaners for engine component sealant, and in particular the crankcase covers. The bulletin further provides cleaning instructions with approved cleaning tools.

Tips and Tricks Revision 7 Summary. Range and motor error codes for the Multistrada; assembly procedure of the brake caliper mounting plate when refitting the rear wheel for the Monster; oil seal install instructions on dry clutch housing for the Panigale; and timing layshift seal removal for a all models.