Fuel Tank (structural member) expanded due to faulty vent in fuel cap/plug; breaking off the mounts to the relay/fuse block. Still available for inspection as KTM has no listed recall and vehicle is out of warranty. Tank expanded enough to break the relay/ fuse block mounts, dislodging them and their electrical connections; shorting the battery. Problem was confirmed by KTM mechanic at dealership; verified "other vent paths clear; recommend replacing fuel cap" . Copy of dealer invoice available apon request. Vehicle has been inspected only by mechanic and service manager at KTM dealership. Tank expansion produced excessive panel gaps, Motorcycle seat kept falling off after ride; panel gaps started showing a month after ownership.
- NHTSA ID
- 11577271
- Incident
- Feb 28, 2024