NHTSA complaint: 2006 KTM 300 XC-W — EQUIPMENT
THIS RELATES TO A MANUFACTURING DEFECT DELIVERED BY KTM SPORTMOTORCYCLES NA. ON PRODUCT LINE FOR MODEL YEARS 2006 AND 2007, INCLUDING MY VEHICLE 06 450 EXC, THE 1/4-TURN GAS CAPS HAVE HAZARDOUS AND POTENTIALLY LIFE-THREATENING FAULTS. TO DATE KTM HAS FAILED TO PROPERLY ADDRESS IT. DETAIL OF THE CAP PROBLEMS: - THE CAP HAS 3 LOCKING TABS THAT MATE WITH THE TANK. THE ORIGINAL CAP'S NECK WAS TOO LONG, PREVENTING A TIGHT SEAL AND LEAKED BADLY - KTM ISSUED NEW CAPS WITH SHORTER NECKS, TIGHTENING THE SEAL AND TEMPORARILY FIXED THE LEAKING. - THE NEW CAPS LEAKED WITHIN DAYS OR WEEKS OF INSTALLATION. IT WAS DISCOVERED THAT THE CAPS BECAME GROSSLY DISTORTED OVER TIME, LIKE DUE TO INCREASED PRESSURE ON THE CAPS, INTERACTION BETWEEN THE CAP MATERIAL AND THE FUEL, AND POOR DESIGN. THE NEWER CAPS LEAK AS BADLY AS THE ORIGINALS WHEN DISTORTED. - THE CAP VENT TUBES POP OUT RESULTING IN FUEL LEAKING OUT FROM THAT AREA. - CAPS HAVE POPPED OFF IN CRASHES, RESULTING IN RIDERS BEING SOAKED IN FUEL. THE BADLY DISTORTED CAPS WILL NEVER PROVIDE A SECURE CONNECTION TO THE TANK. AFTER 2 LONG YEARS KTM FINALLY RELEASED A '''''PERMANENT''''' FIX, WHICH IS MERELY ANOTHER X-RING. IT IS NOT A FIX AT ALL. MANY RIDERS HAVE INSTALLED THIS NEW X-RING AND STILL LEAK. IN NO WAY DOES IT ADDRESSES THE CAP WARPING AND POP-OFFS OR THE VENT-HOSE POP OFFS, ALL WHICH ARE POTENTIALL LIFE-THREATENING. IT IS INTERESTING TO NOTE THAT KTM OFFICIAL RACES TEAMS FOR OFF-ROAD, MOTOCROSS, AND SUPERMOTO, BOTH ON
National Highway Traffic Safety Administration — Office of Defects Investigation