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KTM 300 Xc-W fuel system problems

36 of the 38 complaints filed about the KTM 300 Xc-W are about the fuel system — 95% of everything owners reported. The worst model year for it is 2006.

36

Complaints

95%

Share of all complaints

1

Crashes

0

Fires

Fuel & Propulsion complaints by model year

2006 300 Xc-W 28 77.8%

Median failure at 100 miles

2007 300 Xc-W 8 22.2%

Median failure at 52 miles

What owners said

2006 KTM 300 Xc-W at 20 miles Portland, OR

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

2006 KTM 250 XC-W OFF-ROAD MOTORCYCLE GAS CAP LEAKS.

NHTSA complaint #10197777 — an unverified report by a vehicle owner.

2006 KTM 300 Xc-W at 100 miles MT. Shasta, CA

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

2006 KTM 300XC GAS CAP LEAKED GASOLINE ON MY LEGS AND DOWN SIDE OF FUEL TANK CONTINUALLY. REPLACED GAS CAP 3 TIMES PRIOR TO NEW RECALL GAS CAP. NEW RECALL GAS CAP LEAKED GASOLINE ON MY LEGS VERY FIRST RIDE AND CONTINUES TO LEAK EVERY TIME THE MOTORCYCLE IS RIDDEN.

NHTSA complaint #10196409 — an unverified report by a vehicle owner.

2007 KTM 300 Xc-W Andrews, TX

FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY

LEAKING GAS CAP.

NHTSA complaint #10189192 — an unverified report by a vehicle owner.

2007 KTM 300 Xc-W at 10 miles Thornton, CO

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

LEAKING GAS CAP ON 2007 KTM 300 XCW.

NHTSA complaint #10186063 — an unverified report by a vehicle owner.

2007 KTM 300 Xc-W at 125 miles Canterbury, NH

FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY

I HAVE A 2007 KTM 300 XCW WITH A LEAKING GAS CAP. I HAVE RETURNED TO THE DEALER AND THEY GAVE ME A SECOND CAP. THIS CAP ORIGINALLY WORKED WELL. AFTER 2 RIDES HOWEVER, THE CAP HAS BECOME SWOLLEN AND DIFFICULT TO INSTALL. ALSO THE LEAK HAS RETURNED.

NHTSA complaint #10184659 — an unverified report by a vehicle owner.

2007 KTM 300 Xc-W Cotati, CA

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

1) GAS WAS PUT INTO TANK 2) GAS CAP LEAKS GAS WHEN IT SLOSHES AROUND 3) THERE IS NO FIX AVAILABLE FROM THE KTM DEALER.

NHTSA complaint #10184470 — an unverified report by a vehicle owner.

2006 KTM 300 Xc-W ELK Grove, CA

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

I PURCHASED A 2006 KTM 450 XC - THE GAS CAP BEGAN TO LEAK APPROXIMATELY 2 MONTHS AFTER PURCHASE. I HAVE SINCE PURCHASED 4 GAS CAPS. EACH ONE HAS CURED THE LEAK PROBLEM FOR APPROXIMATELY 2 MONTHS. AT TIMES THE AMOUNT OF GAS THAT LEAKS CAN BE SIGNIFICANT.

NHTSA complaint #10184283 — an unverified report by a vehicle owner.

2006 KTM 300 Xc-W at 260 miles Portland, OR

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

I PURCHASED A NEW 2006 KTM 400EXC JUNE 2006, IN OCTOBER I TRANSPORTED THE MOTORCYCLE IN A TRAILER TO A RIDING AREA, WHEN I ARRIVED IT WAS LEAKING SO BADLY THAT GASOLINE WAS DRIPPING OUT OF THE TRAILER ONTO THE GROUND, THE GAS CAP WAS SO DEFORMED THAT IT WAS NEARLY IMPOSSIBLE TO TAKE OFF AND ON. THE DEALERSHIP TOLD ME THIS IS AN ONGOING PROBLEM AND THEY REPLACED THE CAP WITH AN IDENTICAL DEFECTIVE CAP THAT DEFORMED AND LEAKED IN ABOUT 3 MONTHS. THE CAP WAS REPLACED AGAIN. THEY HAVE SINCE MAILED ME A NEW SEAL FOR THE CAP, SAYING THIS IS THE SOLUTION TO ALL OF THE GAS CAP PROBLEMS, BUT MY CAP NEEDS TO BE REPLACED, IT IS DEFORMED AND SWOLLEN AGAIN. HAVING A GAS CAP THAT DOES NOT LAST MORE THAN 3 OR 4 MONTHS AND REGULARLY LEAKS IS NOT ACCEPTABLE, AND KTM IS CONTINUING TO SELL NEW MODELS WITH THE SAME DEFECTIVE DESIGN.

NHTSA complaint #10184385 — an unverified report by a vehicle owner.

2006 KTM 300 Xc-W at 100 miles Farmington, NM

FUEL SYSTEM, OTHER:STORAGE:TANK ASSEMBLY

ABOUT TWO MONTHS AFTER I PURCHASED A 2006 KTM 450EXC MOTORCYCLE THE FUEL CAP STARTED TO DEFORM AND WOULD NO LONGER SEAL. FUEL LEAKS PAST THE SEAL ON THE FUEL CAP AND SPILLS ONTO MY LEGS WHILE I RIDE. KTM RECENTLY SENT OUT A NEW SEAL (X-RING), BUT THIS DID NOT SOLVE THE PROBLEM.

NHTSA complaint #10184245 — an unverified report by a vehicle owner.

2007 KTM 300 Xc-W at 52 miles Mount Pleasant, SC

FUEL SYSTEM, GASOLINE

FUEL CAP ON MOTORCYCLE LEAKS AND MANUFACTURER REFUSES TO FIX. VERY DANGEROUS AND CAN CAUSE INJURY OR DEATH WHILE RIDING.

NHTSA complaint #10184276 — an unverified report by a vehicle owner.

2006 KTM 300 Xc-W Green Cove Springs, FL

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

FUEL FILLER CAP LEAKING, REPLACED CAP AND ADDED O-RING, BUT STILL LEAKS.

NHTSA complaint #10184171 — an unverified report by a vehicle owner.

2007 KTM 300 Xc-W Waynesville, NC

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

LEAKING FUEL CAP ON MOTORCYCLE RESULTING IN FUEL SPILLAGE AT THE LEAST, CATASTROPHIC INJURY DUE TO FIRE AT WORST.

NHTSA complaint #10184170 — an unverified report by a vehicle owner.

2006 KTM 300 Xc-W Greeley, CO

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

FUEL TANK CAP IS DISTORTED CAUSING GAS TO LEAK OUT EVERYWHERE.

NHTSA complaint #10184091 — an unverified report by a vehicle owner.

2007 KTM 300 Xc-W Owings, MD

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

LEAKING 1/4 TURN GAS CAP ON 2006 KTM 450 EXC MOTORCYCLE THAT I BOUGHT NEW FROM POWERSPORTS EAST IN DELAWARE. KTM APPARENTLY KNOWS ABOUT THE PROBLEM AND RATHER THAN FIX THIS POTENTIALLY DANGEROUS CONDITION, THEY ELECT TO GIVE OUT O-RINGS AS A FIX. THIS DOES NOT FIX THE PROBLEM. THE EFFECTS OF GASOLINE RUNNING OUT OF A PLASTIC GAS TANK AND ONTO A HOT ENGINE DOES NOT SEEM TO BE IN ANY WAY A SAFE SITUATION. I BELIEVE THAT KTM HAS SINCE MODIFIED THE DESIGN OF THIS FAULTY GAS CAP, BUT DOES NOT OFFER THE FIX TO THOSE WHO HAVE PURCHASED EARLIER DESIGNS.

NHTSA complaint #10184089 — an unverified report by a vehicle owner.

2006 KTM 300 Xc-W Greenfield, MA 99 injured

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY:FILLER PIPE AND CAP

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 THE NATIONAL AND WORLD CHAMPIONSHIP CIRCUITS, DO NOT RUN THESE 1/4-TURN GAS CAPS! FINALLY, KTM APPEARS TO BE DONE WITH THIS PROBLEM. SOMEONE IS EVENTUALLY GOING TO GET BURNED OR DIE. HOPEFULLY THE NHTSA WILL TAKE ACTION AND FORCE THE ISSUE. I HAVE MUCH MORE DETAIL AVAILABLE IF NEEDED.

NHTSA complaint #10183994 — an unverified report by a vehicle owner.

2006 KTM 300 Xc-W Harrisburg, PA

FUEL SYSTEM, GASOLINE

GAS CAP IS DISTORTED AND IS HARD TO REMOVE AND INSTALL. GAS CAP LEAKS. SEEMS LIKE GAS CAP COULD FALL OFF. PARTS OF THE GAS CAP ARE FALLING APART.

NHTSA complaint #10184059 — an unverified report by a vehicle owner.

2006 KTM 300 Xc-W Pocatello, ID

FUEL SYSTEM, OTHER:STORAGE

GAS CAP LEAKS GAS.

NHTSA complaint #10183888 — an unverified report by a vehicle owner.

2006 KTM 300 Xc-W Taylorsville, UT

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

GAS CAP LEAKS AND CAN BE EASILY DISLODGED IN A CRASH RESULTING IN A POSSIBLE FIRE OR CHEMICAL BURNS TO THE RIDER.

NHTSA complaint #10183887 — an unverified report by a vehicle owner.

2006 KTM 300 Xc-W at 1,000 miles Boise, ID

FUEL SYSTEM, GASOLINE:STORAGE:TANK ASSEMBLY

2006 MODEL YEAR OFF ROAD MOTORCYCLE, GAS CAP LEAKS AFTER 2 MONTHS USE. FUEL DRIPPING DOWN THE SIDE OF THE FUEL TANK. CONTACTED DEALER AND WAS REFUSED A WARRANTY REPLACEMENT, BOUGHT A NEW ONE. AFTER SEVERAL MONTHS USE, THIS CAP IS ALSO LEAKING.

NHTSA complaint #10183914 — an unverified report by a vehicle owner.

2006 KTM 300 Xc-W at 10 miles Rogers, AR

FUEL SYSTEM, DIESEL:STORAGE:TANK ASSEMBLY

I HAVE HAD LEAKING ISSUES WITH THE FUEL CAP ON MY KTM MOTORCYCLE. I BOUGHT THE BIKE NEW IN SEPTEMBER OF 2005. THE GAS CAP STARTED LEAKING ALMOST IMMEDIATELY. KTM SUPPLIED A NEW CAP BUT IT LEAKED SHORTLY AFTER INSTALLATION AS WELL. THE CAP ALSO SWELLED AND BECAME HARD TO REMOVE. I THEN GOT A 3RD CAP THAT I PAID FOR AND IT ALSO LEAKS BUT HAS NOT SWOLLEN.

NHTSA complaint #10183918 — an unverified report by a vehicle owner.