A spike years after the car went on sale usually means a part wearing
out on schedule across the whole fleet — the kind of pattern no single
owner can see from inside their own car.
Nov 2016peak 6Jun 2017
Recalls on the 2016 KTM 690 Duke
A complaint is one owner's allegation. A recall is the point at which
the manufacturer or a regulator agreed the defect is real and dangerous
enough to fix for free — however old the car is.
Canada — Transport Canada
Canada runs its own recall programme, and its campaigns do not
always mirror the American ones.
Recall 201762416 units in Canada
Fuel System
On certain motorcycles, during operation or while sitting still, it is possible that fuel can seep or leak out of the fuel filler cap area of the fuel tank. Fuel leakage, in the presence of an ignition source, could result in a fire causing injury and/or property damage. Correction: Dealers will replace the fuel tank filler neck insert with one that has an improved seal along with a new seal for the fuel level sensor. Note: In the interim, owners are advised to stop riding their motorcycle until the defect has been repaired. Note: This is an expansion of recall 2017-219.
Recall 2017219109 units in Canada
Fuel System
On certain motorcycles, during operation or while sitting still, it is possible that fuel can seep or leak out of the fuel filler cap area of the fuel tank. Fuel leakage, in the presence of an ignition source, could result in a fire causing injury and/or property damage. Correction: Dealers will replace the fuel tank filler neck insert with one that has an improved seal along with a new seal for the fuel level sensor. Note: In the interim, owners are advised to stop riding their motorcycle until the defect has been repaired
Recall 2017084359 units in Canada
Brakes
On certain motorcycles, an electrical connection can be created via the brake line between the anti-lock brake (ABS) modulator and vehicle ground. If the wiring harness is frayed and contacts the ABS modulator, there is a potential for the brake line to conduct electricity, causing overheating and ultimately melting the brake line. This can result in failure of the brake system circuit, increasing the risk of a crash causing injury and/or damage to property. Correction: Dealers will inspect the wiring harness and re-position the wiring harness for the engine control unit. Additionally, dealers will add and attach a ground cable to the ABS modulator and mount it to the motorcycle’s frame. Note: This is an expansion of recall 2016-610.
In the owners' own words, exactly as filed with NHTSA.
at 1,500 milesBaden, PA
FUEL/PROPULSION SYSTEM
FUEL LEAK FROM TOP OF THE FUEL TANK WHEN IN MOTION.
NHTSA complaint #11000969 — an unverified report by a vehicle owner.
at 3,500 milesVancouver, WA
ENGINE AND ENGINE COOLING:EXHAUST SYSTEM
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
NHTSA complaint #10991855 — an unverified report by a vehicle owner.
at 3,500 milesVancouver, WA
STRUCTURE:BODY
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
NHTSA complaint #10991855 — an unverified report by a vehicle owner.
at 3,500 milesVancouver, WA
FUEL/PROPULSION SYSTEM
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
NHTSA complaint #10991855 — an unverified report by a vehicle owner.
LOS Altos Hills, CA
FUEL/PROPULSION SYSTEM
GAS FUMES LEAKING FROM MOTORCYCLE. GAS TANK MAY BE LEAKING AT TOP FILLER DUE TO WARPING PLASTIC GAS TANK.
NHTSA complaint #10979241 — an unverified report by a vehicle owner.
SAN Diego, CA
FUEL/PROPULSION SYSTEM
TAKATA RECALL TANK LEAKING
NHTSA complaint #10969572 — an unverified report by a vehicle owner.
at 1,400 milesLakeside, CA
FUEL/PROPULSION SYSTEM
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.
NHTSA complaint #10969018 — an unverified report by a vehicle owner.
Spring Valley, CA
FUEL/PROPULSION SYSTEM
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.
NHTSA complaint #10968573 — an unverified report by a vehicle owner.
at 1,600 milesWilkes Barre, PA
FUEL/PROPULSION SYSTEM
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.
NHTSA complaint #10966292 — an unverified report by a vehicle owner.
at 700 milesVacaville, CA
STRUCTURE:BODY
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.
NHTSA complaint #10966146 — an unverified report by a vehicle owner.
at 700 milesVacaville, CA
FUEL/PROPULSION SYSTEM
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.
NHTSA complaint #10966146 — an unverified report by a vehicle owner.
at 1,000 milesMesa, AZ
FUEL/PROPULSION SYSTEM
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.
NHTSA complaint #10957303 — an unverified report by a vehicle owner.
at 3,300 milesSAN Mateo, CA
FUEL/PROPULSION SYSTEM
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.
NHTSA complaint #10957132 — an unverified report by a vehicle owner.
at 2,000 milesRedondo Beach, CA
FUEL/PROPULSION SYSTEM
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.
NHTSA complaint #10926320 — an unverified report by a vehicle owner.