2006 Ktm 300 XC-W

TL*THE CONTACT OWNS A 2006 FREEWAY 150 ZC SCOOTER (NA). WHEN THE CONTACT PURCHASED THE VEHICLE, SHE NOTICED THAT IT HAD MINOR ELECTRICAL ISSUES THAT PROGRESSIVELY WORSENED OVER TIME. WHILE DRIVING 15 MPH, THE VEHICLE STALLED WITHOUT WARNING. SHE TOOK THE VEHICLE TO THE REPAIR SHOP, BUT THE FAILURE COULD NOT BE DUPLICATED. THE CONTACT ALSO NOTICED THAT THE SPEEDOMETER AND ODOMETER ON THE INSTRUMENT CONTROL PANEL WERE INOPERATIVE AND DISPLAYED INACCURATE READINGS. SHE CALLED THE MANUFACTURER TO HAVE A SUBJECT MATTER EXPERT INSPECT THE VEHICLE, BUT HAS NOT YET RECEIVED A RESPONSE. THE FAILURE MILEAGE WAS 150 AND CURRENT MILEAGE WAS 400. UPDATED 10/16/08. *LJ UPDATED 10/17/08. *JB

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. *JB

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.