2005 Ducati Multistrada 1000 S 2005

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.

GAS TANK IS SWELLING DUE TO ETHANOL EXPANSION AND BEGINNING TO PUT BODY OUT OF ALIGNMENT, INHIBIT STEERING AND AFFECT SEATING. *TR

NHTSA ID

10482423

Incident

Oct 10, 2011

Mileage

10,000 mi

MY MOTORCYCLE CAME WITH A POLYAMIDE PA6 GAS TANK WHICH EXPANDED. THE DIMENSIONS OF THE TANK INCREASED UNTIL IT DID NOT SIT CORRECTLY IN THE FRAME, THE HANDLEBAR SWITCH HIT THE TANK WHEN TURNED TO THE RIGHT, THE FRONT SUSPENSION FORK TUBE HIT THE TANK WHEN STEERED TO THE LEFT, AND THE TANK BECAME NEARLY IMPOSSIBLE TO REMOVE FOR ROUTINE MAINTENANCE. IN ADDITION, THE FRONT AND REAR BODYWORK PANELS, WHICH ATTACH TO THE TANK, BEGAN TO BECOME DAMAGED AT THEIR ATTACHMENT POINTS DUE TO THE PRESSURE ON THEM FROM THE EXPANDING TANK. I HAVE NOT SIGNIFICANTLY MODIFIED MY MOTORCYCLE EXCEPT FOR AN AFTERMARKET EXHAUST AND SOME COSMETIC CHANGES. I HAVE MADE NO MODIFICATIONS TO THE FUEL TANK OR FUEL PUMP. I TOOK THE BIKE TO THE DEALER, WHO SUBMITTED A CLAIM TO DUCATI NORTH AMERICA (THE IMPORTER/FACTORY). THE ORIGINAL TANK WAS REPLACED IN 4/2010 UNDER A "GOODWILL PROGRAM". THE DEALER DID NOT MENTION WHETHER THE REPLACEMENT TANK WAS DESIGNED TO CORRECT THE EXPANSION PROBLEM. THE REPLACEMENT TANK BEGAN TO SHOW THE SAME SYMPTOMS OF EXPANSION WITHIN 6 MONTHS; BY 10/2010, THE BODY PARTS WERE AGAIN MISALIGNED AND DANGEROUSLY STRESSED AT THEIR ATTACHMENT POINTS. I AM CONCERNED THAT INTERFERENCE WITH THE STEERING WILL OCCUR AGAIN, AS WITH THE ORIGINAL TANK, OR THAT THE SEAL OF THE FUEL PUMP, WHICH IS SEATED IN THE BOTTOM OF THE TANK, WILL FAIL, DUE TO THE DISTORTION OF THE TANK. ON 2/4/2011, DUCATI NORTH AMERICA RELEASED A RECALL NOTICE THAT REFERENCES NHTSA CAMPAIGN I.D. NUMBER 11V020. THE RECALL LETTER DESCRIBES A PROBLEM WITH FUEL SEEPAGE CAUSED BY FAILURE OF THE SEAL BETWEEN THE FUEL PUMP FLANGE AND THE FUEL TANK. THE CORRECTION OFFERED IS A REPLACEMENT FLANGE TO TANK SEAL WITH AN "X" CROSS-SECTION. I CONTEND THAT THIS TYPE OF GASKET IS A NON-STANDARD FUEL PUMP GASKET, AND IS A DANGEROUS BAND-AID SOLUTION THAT IGNORES THE CAUSE, WHICH IS FUEL TANK EXPANSION. *TR

NHTSA ID

10381718

Incident

Apr 1, 2007

Mileage

600 mi

DUCATI PLASTIC FUEL TANKS EXPANDING AND LEAKING IN THE USA. *TR

NHTSA ID

10367875

Incident

Nov 19, 2010

Mileage

8,000 mi

2005 DUCATI MULTISTRADA FUEL TANK EXPANDED TO SUCH A POINT IT COULD NOT BE REMOVED TO PERFORM THE REQUIRED ENGINE SERVICES. TANK WAS REPLACED 07-09. NEW TANK IS SHOWING SIGNS OF SAME PROBLEM. OTHER OWNERS HAVE EXPERIENCED LEAKING FUEL. IT IS CRITICAL THAT THE FUEL TANK BE REMOVABLE TO MAINTAIN THE ENGINE COMPONENTS. THE DEALER SAYS THAT DUCATI WILL REPLACE THE TANK AGAIN BUT THE QUESTION IS HOW MANY TIMES WILL THEY DO IT AS THE MODEL IS NO LONGER IN PRODUCTION. *TR

NHTSA ID

10360090

Incident

Jul 22, 2009

Mileage

20,000 mi

MY MOTORCYCLE FUEL TANK HAS EXPANDED TO THE POINT THAT GAS IS LEAKING OUT FROM AROUND THE FUEL PUMP. *TR

NHTSA ID

10356876

Incident

Aug 27, 2010

Mileage

27,200 mi

FUEL LEAKING AND PUDDLING UNDER THE BIKE. THE FUEL TANK IS EXPANDING, CAUSING IT TOO LEAK AT THE FUEL PUMP FLANGE. GAS DRIPS ONTO THE BACK TIRE. HOUSE AND GARAGE STINK OF GASOLINE. *TR

NHTSA ID

10356257

Incident

Nov 10, 2009

Mileage

650 mi

FUEL TANK WAS LEAKING NEAR FUEL FILTER OPENING UNDER THE SEAT OF MOTORCYCLE. TANK WAS REPLACED WITH NEW TANK UNDER WARRANTY. OLD TANK HAD BECOME WARPED. REPLACEMENT TANK HAS EVIDENCE OF WARPING, BUT NO LEAK AT THE MOMENT. *TR

NHTSA ID

10355720

Incident

Mar 1, 2008

Mileage

11,000 mi

TL* THE CONTACT OWNS A 2005 DUCATI MULTISTRADA 1000S MOTORCYCLE. THE CONTACT STATED THAT THE FUEL TANK WAS BEGINNING TO DEFORM AND EXPAND DUE TO THE PLASTIC COMPOSITE MATERIAL IT WAS MANUFACTURER FROM. THE CONTACT STATED THAT THE DIMENSIONS OF THE TANK HAD CHANGED AND THE BODY PANELS WERE NOT LINING UP PROPERLY. THE CONTACT WAS CONCERNED THAT THE FUEL TANK WAS ADJACENT TO THE EXHAUST SYSTEM AND OVER THE REAR WHEEL WHICH COULD RESULT IN A FIRE IF THE TANK CONTINUED TO DEFORM. THE VEHICLE WAS NOT INSPECTED OR REPAIRED. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS APPROXIMATELY 11,800 AND THE CURRENT MILEAGE WAS APPROXIMATELY 12,200.

NHTSA ID

10351934

Incident

Jul 29, 2010

Mileage

11,800 mi

Tips & Tricks Revision 05 Summary. Applicability: All Models-Sygic Navigator App software bug for iOS Apple devices

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.

Tips & Tricks Summary Rev. 15 Summary: Applicability: Multistrada. Availability and characteristics of a particular racing exhaust, and possible abnormal play of passenger seat.

Tips & Tricks Summary Rev. 13 Summary: Applicability: Incorrect evaluation of the wear condition of front wheel bearings, and Error C1134 – High DRL temperature (update) for the Multistrada. Melting of coolant distributor due to engine overheating for all models.

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.