32 of the
39 complaints filed about the KTM 690 Duke
are about the fuel system —
82% of everything owners reported.
The worst model year for it is 2016.
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.
NHTSA complaint #11716411 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11542302 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11474900 — an unverified report by a vehicle owner.
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.
NHTSA complaint #11441170 — an unverified report by a vehicle owner.
FUEL TANKS WARP AROUND FUEL FILLER NECK AND CAUSE FUEL TO LEAK OVER HOT ENGINE. HAD RECALL DONE AT DEALER TO REPLACE FUEL-FILLER NECK GASKET UNDER RECALL, WHICH WORSENED LEAK. KTM THEN PROVIDED A WHOLE REPLACEMENT FUEL TANK, WHICH CONTINUES TO LEAK. BIKE HAS BEEN SITTING FOR OVER A YEAR NOW - KTM HAS NOT RELEASED A PROPER SOLUTION TO FIX THIS ISSUE THAT MOST 2016+ KTM 690 DUKE OWNERS HAVE BEEN CONSTANTLY DEALING WITH.
NHTSA complaint #11426734 — an unverified report by a vehicle owner.
Fuel Leaks from filler neck when accelerating after filling the tank. Also, water enters the tank from rain, or washing the motorcycle. Bike ran perfectly before the rainy season started here in FL. After two weeks of commuting in the rain every day the bike barely runs, and when it does, it's unrideable. As it stalls randomly and can take some time to start it back up again. Drain the tank, put fresh gas in it, and it is good to go for another week till it starts the same process over again. Warped tank under filler.
NHTSA complaint #11423851 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2015 KTM 690 DUKE. THE CONTACT STATED WHILE REFUELING THE MOTORCYCLE WITH MORE THAN A HALF TANK OF GASOLINE IN THE FUEL TANK, FUEL WOULD SPILL FROM THE TANK. THE VEHICLE WAS TAKEN TO SHELBY'S POWERSPORTS (1444 COMMERCE AVE, THE BRONX, NY 10461, (718) 828-8599) WHERE IT WAS DIAGNOSED WITH NEEDING THE FUEL TANK TO BE REPLACED. THE VEHICLE HAD NOT BEEN REPAIRED AS OF YET. UPON INVESTIGATION, THE CONTACT ASSOCIATED THE FAILURE WITH NHTSA CAMPAIGN NUMBER: 17V388000 (FUEL SYSTEM, GASOLINE) HOWEVER, THE VIN WAS NOT INCLUDED. THE MANUFACTURER HAD NOT BEEN INFORMED OF THE FAILURE. THE FAILURE MILEAGE WAS APPROXIMATELY 1,800.*DT CONSUMER STATED DEALER AGREED TO REPLACE THE DEFECTIVE PART AT NO COST.*JB*DT CONSUMER WOULD LIKE TO DISMISS THE COMPLAINT.
NHTSA complaint #11390535 — an unverified report by a vehicle owner.
THE PLASTIC GAS TANK HAS WARPED CAUSING LEAKS BOTH ON THE BOTTOM OF THE TANK WHERE THE FUEL PUMP ATTACHES AND ON THE TOP OF THE TANK WHERE THE FILLER NECK IS ATTACHED. THE LEAK FROM THE FUEL PUMP AREA OCCURS BOTH WHEN THE BIKE IS RIDDEN AND STATIONARY, THE LEAK FROM THE FILLER AREA OCCURS WHEN THE BIKE IS RIDDEN AND GAS SLOSHES TO THE TOP OF THE TANK.
NHTSA complaint #11366885 — an unverified report by a vehicle owner.
2015 KTM DUKE 690 IS LEAKING GAS FROM THE GAS CAP NOT SEALING PROPERLY. CURRENT RECALL IS FOR 2016 MODELS AND NEWER. HAVE REPLACED THE FUEL TANK ONCE UNDER WARRANTY, ISSUE STILL PERSIST. GAS COMES OUT UNDER HARD ACCELERATION AND BRAKING AFTER FILLING UP GAS TANK.
NHTSA complaint #11291633 — an unverified report by a vehicle owner.
TL* THE CONTACT OWNS A 2017 KTM 690 DUKE. THE CONTACT STATED THAT THERE WAS A FUEL LEAK ON THE MOTORCYCLE THAT TRAVELED TO THE MOTOR. THE CONTACT SPOKE WITH SCOTT POWERSPORTS, INC. (1675 PA-309, COOPERSBURG, PA 18036, 610-282-4800) AND WAS INFORMED OF NHTSA CAMPAIGN NUMBER: 17V388000 (FUEL SYSTEM, GASOLINE); HOWEVER, THE RECALL DID NOT APPLY TO THE BOTTOM PORTION OF THE FUEL TANK, ONLY THE TOP PORTION. THE MOTORCYCLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT CONTACTED. THE FAILURE MILEAGE WAS 5,300.
NHTSA complaint #11242908 — an unverified report by a vehicle owner.
WHILE RIDING THE MOTORCYCLE TO COMMUTE TO WORK ON CITY STREETS, I COULD SMELL GASOLINE. WHEN STOPPED AT A REDLIGHT, I LOOKED AT THE TOP OF THE TANK AND GAS WAS COMING OUT OF THE TOP OF THE TANK FROM AROUND THE CAP MOUNT/SEAL IS BOLTED TO THE TANK. THIS TANK IS A REPLACEMENT THAT KTM PUT ON ABOUT A YEAR AGO AFTER HAVING THIS SAME ISSUE BEFORE. I KNOW KTM PUT OUT A RECALL ON LATER MODELS, 2015 AND LATER I THINK, THAT WERE HAVING THE SAME PROBLEM, BUT I DON'T BELIEVE MY REPLACEMENT TANK FROM KTM IS ONE OF THE CORRECTED TANKS. NOW, I'M ON MY 2ND TANK WITH THE SAME PROBLEM OF GASOLINE COMING FROM THE TOP OF IT AND SPILLING ONTO THE MOTOR. ANY HELP IS GREATLY APPRECIATED..
NHTSA complaint #11090325 — an unverified report by a vehicle owner.
THERE IS A MANUFACTURE DEFECT CAUSING THE PLASTIC GAS TANK TO SWELL, CRACK AND BECOMING FLEXIBLE TO THE TOUCH DUE TO THE PRESSURE AND GASSES FROM THE FUEL. THE RESULT OF THE GAS TANK SWELLING, IT WILL SPRAY GAS ONTO THE BIKE AND THE RIDER WHILE IN MOTION DUE TO IT NOT SEALING PROPERLY AROUND THE FLANGE. THIS IS A REOCCURRING ISSUE WITH NO FIX TO THE PROBLEM. I PURCHASED MY 2014 KTM 690 DUKE NEW ON JANUARY 1, 2017. I HAD THE TANK REPLACED BY THE LOCAL KTM DEALER (TJ CYCLES IN AUSTIN, TEXAS) IN FEBRUARY AND THE ISSUE HAS OCCURRED AGAIN. THERE ARE MULTIPLE FORUMS ABOUT THIS ISSUE REGARDING OTHER 690 DUKE OWNERS GOING THROUGH THE SAME PROBLEM WITH NO PERMANENT RESOLUTION IN SIGHT.
NHTSA complaint #11031924 — an unverified report by a vehicle owner.
FUEL TANK LEAKS FUEL AT THE FUEL FILLER NECK, BETWEEN THE TANK AND THE GAS TANK CAP, PAST THE GASKET. THE TOP OF THE TANK (PLASTIC) IS WARPED, AND THE GASKET DOES NOT SEAL. FUEL LEAKS DOWN ONTO ENGINE POTENTIALLY CREATING A FIRE THAT WOULD CONSUME THE BIKE, THE RIDER AND ANY OBJECTS AROUND IT.
NHTSA complaint #11023629 — an unverified report by a vehicle owner.
THE FUEL TANK LEAKS FROM THE GAS CAP. ALSO, THIS IS NOT MY FIRST KTM, WHICH HAS HAD A LEAKING GAS CAP. IT'S MY 3RD ONE. THIS ISSUE IS VERY WELL-DOCUMENTED ON THE FORUMS AS WELL AS ON YOUTUBE. GASOLINE POURS RIGHT OUT OF THE GAS CAP ESPECIALLY WHEN IT IS FULL OR WHEN ACCELERATING OR DECELERATING BRISKLY. I AM FAIRLY CERTAIN THIS IS AN ISSUE TO DO WITH THE HIGH ETHANOL CONTENT PRESENT IN ALL U.S. GAS. THE STANDARD FUEL IS E10, WHICH MEANS 90% GASOLINE AND 10% ETHANOL. THERE HAS ALREADY BEEN A CLASS ACTION LAWSUIT AGAINST DUCATI IN THE PAST FOR THIS ISSUE ALTHOUGH IT HAS CROPPED WITH OTHER MANUFACTURERS. THE ISSUE ARISES FROM A REACTION WITH ETHANOL IN PLASTIC TANKS. IT IS NOT AN ISSUE WITH METAL TANKS. MOST MANUFACTURERS HAVE FIXED THE ISSUE OR STOPPED USING THE PLASTIC. HOWEVER, KTM REMAINS A MAJOR PROBLEM AS SEEN ABOVE. EVEN THE NEWEST 2016 AND 2017 MODELS HAVE THE SAME ISSUES, WHICH ARE AGAIN DOCUMENTED IN THE FORUMS. IT IS UNACCEPTABLE AND DANGEROUS. *TT
NHTSA complaint #11001844 — an unverified report by a vehicle owner.