2021 KTM 690 Smc R Problems
Owner-reported complaints filed with NHTSA, grouped by component
Data refreshed
What this page shows
Everything below is an owner-reported complaint submitted to NHTSA about the 2021 KTM 690 Smc R, grouped by the component NHTSA recorded on the report. These are not confirmed defects, and they are not recalls. NHTSA does not verify most reports before publishing them, and a category with more reports in it is not evidence that a part is defective.
Complaints are reports submitted by owners and drivers to NHTSA. They are not verified and do not establish that a defect exists.
Reports by component
Ranked by how many owner reports name each component category
- Fuel system457.1%
- Body & structure228.6%
- Interior & seats114.3%
Percentages are of component mentions. A single complaint can name more than one component, so these do not sum to the total complaint count.
Each component in detail
What the reports in each category say, in the owners' own words
Fuel system
Reports naming fuel storage or delivery — tanks, pumps, lines, injectors and fuel leaks.
From owner reports, verbatim
Description of Defect: I am reporting a severe safety hazard regarding the plastic fuel tank on my 2021 KTM 690. On this specific motorcycle architecture, the plastic fuel tank is a load-bearing, structural component that acts as the rear subframe. The rear passenger footpegs and the entire rear seat assembly mount directly onto this plastic fuel tank structure.The tank has severely warped, expanded, and deformed. This material warping introduces severe structural stress to the factory mounting points, creating a high risk of catastrophic structural breakage while in motion. A failure here puts both the rider and a passenger in immediate physical danger of a crash or separation from the motorcycle.Furthermore, this swelling and warping has caused the fuel filler neck area to become completely non-flush. This prevents the fuel filler cap assembly from sealing correctly against the tank surface, leaving a noticeable gap where fuel sloshes out and seeps past the filler cap during regular operation. This creates a simultaneous, severe fire hazard directly over the hot exhaust. Prior Actions & Context: KTM previously acknowledged manufacturing defects on older models under NHTSA Campaign Number: 17V388000. However, the exact same structural warping, material swelling from ethanol exposure, and sealing failures are actively persisting on my 2021 model. Because this tank functions as the primary structural subframe and carries passenger weight, its deformation poses a critical mechanical and fire hazard. I am requesting that the NHTSA expand its investigation into later-year KTM 690 tank assemblies to mandate a permanent structural remedy from the manufacturer.
The fuel tank has been expanding consistently now for the past few years. It has began to crack the attachment points for the body plastics. I sent pictures and reported this years ago to KTM and they told me it would have to be inspected which they may not cover and even still wouldn’t guarantee it would be replaced/fixed. This puts my safety at risk if I experience a crash or collision since the integrity of the tank is in question and it puts others safety at risk because it could rupture from a fall and cause a fire. There are no warning lamps on, the only symptom has been the swelling worsening over time and stress cracking the plastic fairings surrounding it. It could possibly be putting stress under the back part of the seat also.I have not had it inspected yet by the manufacturer or the police. The problem hasn’t been reproduced to my knowledge at any dealership but I’ve seen that others have had this same issue with the same model of motorcycle.
Too few reports in this category for a page of its own — they appear in the full complaint list.
Body & structure
Reports naming the vehicle structure, frame, body panels, doors, hood and trim.
From owner reports, verbatim
Description of Defect: I am reporting a severe safety hazard regarding the plastic fuel tank on my 2021 KTM 690. On this specific motorcycle architecture, the plastic fuel tank is a load-bearing, structural component that acts as the rear subframe. The rear passenger footpegs and the entire rear seat assembly mount directly onto this plastic fuel tank structure.The tank has severely warped, expanded, and deformed. This material warping introduces severe structural stress to the factory mounting points, creating a high risk of catastrophic structural breakage while in motion. A failure here puts both the rider and a passenger in immediate physical danger of a crash or separation from the motorcycle.Furthermore, this swelling and warping has caused the fuel filler neck area to become completely non-flush. This prevents the fuel filler cap assembly from sealing correctly against the tank surface, leaving a noticeable gap where fuel sloshes out and seeps past the filler cap during regular operation. This creates a simultaneous, severe fire hazard directly over the hot exhaust. Prior Actions & Context: KTM previously acknowledged manufacturing defects on older models under NHTSA Campaign Number: 17V388000. However, the exact same structural warping, material swelling from ethanol exposure, and sealing failures are actively persisting on my 2021 model. Because this tank functions as the primary structural subframe and carries passenger weight, its deformation poses a critical mechanical and fire hazard. I am requesting that the NHTSA expand its investigation into later-year KTM 690 tank assemblies to mandate a permanent structural remedy from the manufacturer.
The fuel tank has been expanding consistently now for the past few years. It has began to crack the attachment points for the body plastics. I sent pictures and reported this years ago to KTM and they told me it would have to be inspected which they may not cover and even still wouldn’t guarantee it would be replaced/fixed. This puts my safety at risk if I experience a crash or collision since the integrity of the tank is in question and it puts others safety at risk because it could rupture from a fall and cause a fire. There are no warning lamps on, the only symptom has been the swelling worsening over time and stress cracking the plastic fairings surrounding it. It could possibly be putting stress under the back part of the seat also.I have not had it inspected yet by the manufacturer or the police. The problem hasn’t been reproduced to my knowledge at any dealership but I’ve seen that others have had this same issue with the same model of motorcycle.
Too few reports in this category for a page of its own — they appear in the full complaint list.
Interior & seats
Reports naming seats, latches, locks, linkages and interior fittings.
From owner reports, verbatim
Description of Defect: I am reporting a severe safety hazard regarding the plastic fuel tank on my 2021 KTM 690. On this specific motorcycle architecture, the plastic fuel tank is a load-bearing, structural component that acts as the rear subframe. The rear passenger footpegs and the entire rear seat assembly mount directly onto this plastic fuel tank structure.The tank has severely warped, expanded, and deformed. This material warping introduces severe structural stress to the factory mounting points, creating a high risk of catastrophic structural breakage while in motion. A failure here puts both the rider and a passenger in immediate physical danger of a crash or separation from the motorcycle.Furthermore, this swelling and warping has caused the fuel filler neck area to become completely non-flush. This prevents the fuel filler cap assembly from sealing correctly against the tank surface, leaving a noticeable gap where fuel sloshes out and seeps past the filler cap during regular operation. This creates a simultaneous, severe fire hazard directly over the hot exhaust. Prior Actions & Context: KTM previously acknowledged manufacturing defects on older models under NHTSA Campaign Number: 17V388000. However, the exact same structural warping, material swelling from ethanol exposure, and sealing failures are actively persisting on my 2021 model. Because this tank functions as the primary structural subframe and carries passenger weight, its deformation poses a critical mechanical and fire hazard. I am requesting that the NHTSA expand its investigation into later-year KTM 690 tank assemblies to mandate a permanent structural remedy from the manufacturer.
Too few reports in this category for a page of its own — they appear in the full complaint list.
Higher-selling and older vehicles accumulate more reports. Counts are not failure rates and are not directly comparable between vehicles that sold in very different numbers.
Elsewhere on this vehicle
Data sources
- NHTSA Office of Defects Investigation — owner-reported complaints and the components recorded on them
Data on this page last refreshed .