2018 KTM 690 DUKE — Problems, Recalls & Safety Data

2018 KTM 690 Duke fuel tank shape has warped and the fuel filler neck gasket no longer seals the filler neck to the tank so that fuel spills out the top of the fuel tank. This same issue was addressed for the 2016-2017 model year KTM 690 Duke under NHTSA Campaign Number 17V388000. The result of this fuel leak is a potential fire hazard that could result in injury or death. This problem has not been confirmed by a dealer or independent service center and has not been inspected by the manufacturer, police, insurance representative or others. There were no warning lamps or messages associated with this problem. The main symptom of the problem is a strong fuel smell when near the motorcycle.

The plastic fuel tank has warped at the bottom interface where the fuel pump assembly sits. As a result, fuel leaks between the fuel tank and gasket (which is no longer sealed against a flat surface). The fuel pump assembly sits immediately above the engine. Fuel that leaks will drip onto the engine and may ignite. Fuel ignition presents a significant hazard to the rider. This issue appears to be related to recall campaign number 17V388000, which affects the 2016 and 2017 models. This recall addressed a warping plastic tank that resulted in the fuel filler neck not sealing. My understanding is that there are very little to no material differences between the 2016-2017 and 2018 models, and therefore the problem of a warping plastic tank would be shared among the model years.

Fuel is leaking a steady drop from bottom of fuel tank.

The contact owns a 2018 KTM 690 Duke motorcycle. The contact stated after having ridden the motorcycle approximately 30 MPH and then returning to his residence; after parking the motorcycle, there was an abnormal gasoline odor detected. The contact noticed that gasoline was leaking between the fuel pump and fuel tank at the rear center underside. The gasoline started to form a puddle in the driveway. The contact stated there was no warning light illuminated. The contact had not taken the vehicle to a dealer or independent mechanic. The vehicle was not repaired. The manufacturer had been informed of the failure. The failure mileage was approximately 900.

Gasoline had visibly leaked from the fuel filler cap on the plastic fuel tank. Liquid fuel and fuel vapors are freely exiting the tank. This presents an extreme fire risk. There is an active recall (NHTSA Campaign Number: 17V388000) for 2016-2017 production of the same model. This recall should be expanded to include the 2018 model year. I removed a few parts and inspected the filler neck to tank connection and found visible warpage. A photo is included with this report. I will be contacting a KTM dealer to report this when they are open.