2006 KTM 950 SUPERMOTO — Problems, Recalls & Safety Data

THE FUEL TANK SWELLS IN SIZE SO MUCH THAT IT CANNOT BE REINSTALLED TO THE BIKE USING THE FACTORY MOUNTING BRACKET. IT HAD TO BE MODIFIED, AND NOW I MIGHT HAVE TO DRILL A HOLE FURTHER BACK IN THE FRAME TO FIT MY TANK BACK ON. I KNOW MULTIPLE PEOPLE WITH THE SAME BIKE WHO'S TANKS START TO LEAK AFTER THEY EXPAND LIKE THIS, THAT WORRIES ME. THE TANK ALSO DOES NOT HOLD GASOLINE COMPLETELY INSIDE, AS IS EVIDENT BY THE FACT THAT ANY DECALS ON MY BIKE BUBBLE OFF FROM FUEL ABSORBING INTO THE TANK THEN THE DECAL. I DO NOT KNOW HOW MANY OTHER PEOPLE HAVE REPORTED THIS BUT FOR A SMALL RUN PRODUCTION BIKE, IT SURE DOES HAPPEN ON A LOT OF THEM. IT IS A CONSTANT ISSUE IN THE LOCAL SHOP AND ON THE INTERNET MESSAGE BOARDS. *TR

THE FUEL TANK HAS DEVELOPED A LEAK. THE LEAK APPEARS TO BE A MANUFACTURING DEFECT AND IS COMING FROM A THREADED FITTING. THE TANK WAS NOT MECHANICALLY DAMAGED IN ANY WAY. *TR

FUEL LEAKS FROM TANK WHERE LOW FUEL LEVEL SENSOR IS FASTENED TO TANK. THE SEALING O-RING ON FUEL LEVEL SENSOR DOES NOT CONTACT THE MATING SURFACE ON THE PLASTIC TANK DUE TO A DIP OR LOW SPOT IN THE MATING SUFFICE. *TR

FAILURE OF FUEL TANK RESULTING IN GASOLINE LEAK DUE TO WARPING OF TANK. *TR

FUEL TANK DEFORMED AND LEAKED ABOUT 2 GALLONS OF GASOLINE IN MY CLOSED GARAGE - 2008. KTM NORTH AMERICA INSTRUCTED BIKE BE TAKEN TO DEALERSHIP FOR EVALUATION - ELLICOTT CITY MOTORSPORTS VISUALLY INSPECTED, CALLED KTM/NA WHO INSTRUCTED ME TO "TRY LOCTITE 518 SEALANT". THIS WORKED FOR ABOUT 6 MONTHS, TANK BEGAN TO LEAK AGAIN. CONTACTED MATTO CYCLES IN PA ON ADVICE OF AN INDUSTRY CONTACT - TANK WAS REPLACED BY KTM UNDER GOODWILL WARRANTY EARLY 2009. REPLACEMENT AND HAS JUST BEGUN TO LEAK FROM THREADED FITTING AT LOWER LEFT FRONT AND WILL REQUIRE REPLACEMENT AGAIN. WEB SEARCH INDICATES THIS IS A RELATIVELY COMMON PROBLEM. *TR