2016 KTM 690 DUKE Fuel/propulsion System Problems

FUEL LEAK FROM TOP OF THE FUEL TANK WHEN IN MOTION.

Mileage: 1,500

WHILE RIDING MOTORCYCLE GASOLINE STARTED LEAKING FROM THE TOP OF THE TANK LEAKING DOWN BOTH SIDES OF THE BIKE AND SATURATING MY PANTS WITH GASOLINE AND RUINING THE FINISH OF BIKE. THE CONSUMER STATED THE MOTORCYCLE CONSTANTLY SMELLED OF FUEL, EASILY OVERHEATED, CONSUMES OIL STALLS AT RANDOM, AND SOMETIMES WOULD NOT RESTART FOR LONG PERIODS OF TIME. THE FUEL LEAKAGE CAUSED DAMAGE TO THE FINISHING FRAME, SWINGARM, AND PLASTICS ON THE MOTORCYCLE. THE EXHAUST WOULD TURN RED HOT AND GLOW. FUEL ALSO LEAKED ONTO THE EXHAUST. THE CONSUMER STATED THE MANUFACTURER AND DEALER WERE CONTACTED, BUT DID NOT OFFER ANY ASSISTANCE. UPDATED 10/02/2017*JS

Mileage: 3,500

GAS FUMES LEAKING FROM MOTORCYCLE. GAS TANK MAY BE LEAKING AT TOP FILLER DUE TO WARPING PLASTIC GAS TANK.

TAKATA RECALL TANK LEAKING

FUEL TANK (PLASTIC) IS WARPED AND LEAKS FUEL AND FUEL VAPOR NEAR THE UPPER FLANGE SEAL. TANK WAS REPLACED ONCE BY KTM UNDER WARRANTY WITH THE SAME PLASTIC TANK AS THE ORIGINAL, THE PROBLEM IS LESS BUT PERSISTS, FUEL SMELL IS STILL COMING FROM THE TANK, FUEL VAPOR IS STILL ESCAPING. I KNOW OF TWO OTHER 2016 KTM 690 DUKE MOTORCYCLES WITH THIS SAME EXACT PROBLEM AND I BELIEVE THIS FUEL TANK FAILURE IS DUE TO POOR FUEL TANK DESIGN. THIS IS BOTH A SAFETY ISSUE AND AN ENVIRONMENTAL ISSUE. A RECALL ON THIS FUEL TANK SHOULD BE CONSIDERED.

Mileage: 1,400

GAS TANK LEAKS FROM FILLER CAP. THE DEALER CHANGED IT 3 TIMES. IT STILL LEAKS. I KNOW THREE PEOPLE WHO'S 2016 KTM 690 DUKE LEAKS FUEL FROM THE FILLER CAP.

VEHICLE'S FUEL TANK HAS WARPED AROUND THE FILLER NECK. THIS CAUSES GAS TO LEAK OUT OF THE TOP WHEN FULL. VEHICLE NEEDS TO BE IN MOTION OF THIS TO HAPPEN AS FUEL WILL SLOSH AROUND. FUEL TANK IS MADE OF PLASTIC AND WILL NEED REPLACEMENT TO FIX THE ISSUE. THIS IS A SAFETY HAZZARD.

Mileage: 1,600

THERE IS A DEFORMITY WHERE THE FUEL TANK CONNECTS WITH THE FUEL LID/CAP. IT APPEARS WAVY WHICH DOESN'T ALLOW FOR A PROPER SEAL BETWEEN THE TANK AND LID. WHEN THE TANK IS FULL AND THE MOTORCYCLE IS TILTED SIDE TO SIDE IT SLOSHES THE FUEL AND FUEL LEAKS OUT OF THE TANK. FUEL LEAKS WHEN TURNING ON THE ROADWAY.

Mileage: 700

FLANGE ON FUEL TANK WHERE FILLER CAP ATTACHES IS WARPED ALLOWING FUEL TO RUN OUT INTO ELECTRICAL WIRING BELOW. FUEL LEAKS OUT WHEN MOTORCYCLE IS IN MOTION.

Mileage: 1,000

THE FUEL TANK ON MY 2016 KTM 690 DUKE DOES NOT SEAL AROUND THE FUEL DOOR. GAS CAN SPILL OUT OF THE TOP OF THE TANK, ESPECIALLY WITH A FULL TANK. THE FUEL TANK IS ALSO OPEN TO THE ATMOSPHERE CAUSING VAPOR TO ENTER AN ENCLOSED PARKING GARAGE. THE TANK APPEARS TO BE WARPED AT THE AREA WHERE THE FUEL DOOR IS MOUNTED TO THE TANK. THE GAS SMELL HAS ALWAYS BEEN PRESENT SINCE PURCHASING THE BIKE BUT I DID NOT FIND THE PROBLEM UNTIL 6 MONTHS LATER. THE DEALER WAS NOTIFIED AND THEY SAID TO IMMEDIATELY BRING THE BIKE IN. THERE WERE SEVERAL OTHER BIKES OF THE SAME MODEL YEAR AND MODEL WITH THE SAME PROBLEM AT MY THE DEALER.

Mileage: 3,300

2016 KTM 690 DUKE PLASTIC GAS TANK IS SWELLING AND DEFORMING. THIS IS CAUSING A GAPPING ISSUE WITH THE PLASTICS ON THE BIKE AS WELL AS AROUND THE FUEL DOOR AREA WHICH ALLOWS FUEL AND FUEL VAPOR TO LEAK WHEN THE BIKE IS ROCKED DURING OPERATION OR WHEN THE BIKE IS STATIONARY.

Mileage: 2,000