2006 KTM 300 XC-W Fuel system Problems

2006 KTM 250 XC-W OFF-ROAD MOTORCYCLE GAS CAP LEAKS. *JB

NHTSA ID

10197777

Incident

Feb 1, 2006

Mileage

20 mi

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

NHTSA ID

10196409

Incident

Mar 21, 2006

Mileage

100 mi

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. *JB

NHTSA ID

10184385

Incident

Oct 20, 2006

Mileage

260 mi

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

NHTSA ID

10184283

Incident

Jul 10, 2006

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

NHTSA ID

10184245

Incident

Jan 15, 2007

Mileage

100 mi

FUEL FILLER CAP LEAKING, REPLACED CAP AND ADDED O-RING, BUT STILL LEAKS. *JB

NHTSA ID

10184171

Incident

Jan 1, 2007

FUEL TANK CAP IS DISTORTED CAUSING GAS TO LEAK OUT EVERYWHERE. *JB

NHTSA ID

10184091

Incident

Feb 25, 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

NHTSA ID

10184059

Incident

Feb 28, 2007

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.

NHTSA ID

10183994

Incident

Dec 1, 2005

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 SEVERAL 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. *NM

NHTSA ID

10183969

Incident

Sep 1, 2006

Mileage

20 mi

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

NHTSA ID

10183968

Incident

Jul 18, 2006

Mileage

200 mi

FUEL CAP LEAKS AND POPS OFF. *NM

NHTSA ID

10183953

Incident

Jan 20, 2007

Mileage

200 mi

LEAKING GAS CAP. *NM

NHTSA ID

10183946

Incident

Mar 1, 2007

Mileage

50 mi

GAS CAP LEAKS AND DISTORTS CAUSING LEAKAGE. MANUFACTURE NEEDS TO REDESIGN GAS TANK. *NM

NHTSA ID

10183934

Incident

Jan 2, 2007

Mileage

100 mi

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 KTM WILL NOT FIX IT. *NM

NHTSA ID

10183925

Incident

Jul 7, 2006

Mileage

260 mi

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

NHTSA ID

10183924

Incident

Jan 1, 2007

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

NHTSA ID

10183918

Incident

Nov 23, 2005

Mileage

10 mi

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

NHTSA ID

10183914

Incident

Nov 28, 2006

Mileage

1,000 mi

GAS CAP LEAKS GAS. *JB

NHTSA ID

10183888

Incident

Aug 17, 2006

GAS CAP LEAKS AND CAN BE EASILY DISLODGED IN A CRASH RESULTING IN A POSSIBLE FIRE OR CHEMICAL BURNS TO THE RIDER. *JB

NHTSA ID

10183887

Incident

Feb 17, 2007

GAS CAP ON MOTORCYCLE POPPED OFF, GASOLINE/CHEMICAL BURN ON LEG. *JB

NHTSA ID

10183855

Incident

Sep 30, 2006

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. *JB

NHTSA ID

10183852

Incident

Feb 24, 2007

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. *JB

NHTSA ID

10183849

Incident

Mar 3, 2006

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

NHTSA ID

10183840

Incident

Jan 28, 2007

Mileage

950 mi

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. *JB

NHTSA ID

10183834

Incident

Oct 20, 2005

Mileage

20 mi