IllustrationFUEL CAP LEAKS AND POPS OFF. *NM
2006 Ktm 300 XC-W
Owner reports · Recalls · Investigations
Limited comparison data
There is not enough comparable history to draw a useful model-year comparison.
About this comparison →How this year compares
Owner complaints by model year
Compare all 300 XC-W years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
Limited mileage data: 17 of 29 reports include usable mileage. There isn’t enough coverage to show a useful chart.
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Fuel System, Gasoline. Review the 25 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Electrical System. Review the 1 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Equipment. Review the 1 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
1 crash reports0 fire reports7 injury reports
Fuel System, Gasoline complaints
25 reportsLEAKING GAS CAP. *NM
GAS CAP LEAKS AND DISTORTS CAUSING LEAKAGE. MANUFACTURE NEEDS TO REDESIGN GAS TANK. *NM
ON MY 2006 KTM 525 EXC THE GAS CAP CAME OFF WHILE TRAIL RIDING AND SPILLED GAS ALL OVER ME. THIS WAS NOT DUE TO A CRASH. I WAS SIMPLY RIDING THE MOTORCYCLE OFF ROAD. THIS HAS HAPPENED TWICE WITH THE SAME RESULTS. I HAVE TRIED THE O-RING REPLACEMENT FIX RECOMMENDED BY KTM AND IT WORKED FOR A SHORT TIME AND NOW IT IS LEAKING AND …
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ON MY 2006 KTM 525 EXC THE GAS CAP CAME OFF WHILE TRAIL RIDING AND SPILLED GAS ALL OVER ME. THIS WAS NOT DUE TO A CRASH. I WAS SIMPLY RIDING THE MOTORCYCLE OFF ROAD. THIS HAS HAPPENED TWICE WITH THE SAME RESULTS. I HAVE TRIED THE O-RING REPLACEMENT FIX RECOMMENDED BY KTM AND IT WORKED FOR A SHORT TIME AND NOW IT IS LEAKING AND SPRAYING GAS ALL OVER THE BIKE AND RIDER. THIS IS A KNOWN ISSUE AND KTM WILL NOT FIX IT. *NM
KTM 1/4 TURN GAS CAPS LEAK AND CAUSE BURNS ON YOUR LEGS AND MAY CAUSE A FIRE! ALSO THE CAP BECOMES DISTORTED AND MAY FALL OFF WHILE RIDING ALLOWING GAS TO FLOW OUT! *NM
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. *JB
GAS CAP LEAKS AND CAN BE EASILY DISLODGED IN A CRASH RESULTING IN A POSSIBLE FIRE OR CHEMICAL BURNS TO THE RIDER. *JB
GAS CAP ON MOTORCYCLE POPPED OFF, GASOLINE/CHEMICAL BURN ON LEG. *JB
I OWN A 2004 KTM 200EXC MOTORCYCLE WITH 2006 GAS TANK. THE 1/4 TURN GAS CAP ON THIS 2006 GAS TANK HAS LEAK MULTIPLE TIMES AROUND THE SEALING SURFACE WHEN THE BIKE WAS LEANED OVER. ALSO, THE GAS CAP HAS BECOME DISTORTED AND SWOLLEN. IT IS DIFFICULT TO INSERT AND REMOVE FROM THE GAS TANK. I PURCHASED A NEW GAS CAP FROM THE DEALER …
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I OWN A 2004 KTM 200EXC MOTORCYCLE WITH 2006 GAS TANK. THE 1/4 TURN GAS CAP ON THIS 2006 GAS TANK HAS LEAK MULTIPLE TIMES AROUND THE SEALING SURFACE WHEN THE BIKE WAS LEANED OVER. ALSO, THE GAS CAP HAS BECOME DISTORTED AND SWOLLEN. IT IS DIFFICULT TO INSERT AND REMOVE FROM THE GAS TANK. I PURCHASED A NEW GAS CAP FROM THE DEALER BUT THE GAS CAP IS TOO LOOSE WITHIN THE GAS TANK AND WILL NOT STAY ON. I WANT TO FILE A FORMAL COMPLAINT AGAINST KTM ON THE DEFECTIVE GAS CAP AND GAS TANK. THIS IS A SAFETY HAZARD DUE TO POTENTIAL OF FIRE WITH THE GASOLINE AND SKIN IRRITATION FROM GASOLINE CONTACT. *JB
BIKE PURCHASED 11-05. RIDING BIKE SLOWLY THROUGH WOODS AND FELL OVER. THE FUEL CAP POPPED OFF SPILLING A LARGE PORTION OF FUEL. 3-06 VACATION IN GA, FUEL CAP STARTED LEAKING. FUEL TANK COVERED IN FUEL, UNDERNEATH SEAT AND THE FRAME COVERED IN FUEL. MY LEFT LEG PANTS FUEL SOAKED AFTER EVERY RIDE. COMPLAINED TO DEALER. FINALLY AFT…
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BIKE PURCHASED 11-05. RIDING BIKE SLOWLY THROUGH WOODS AND FELL OVER. THE FUEL CAP POPPED OFF SPILLING A LARGE PORTION OF FUEL. 3-06 VACATION IN GA, FUEL CAP STARTED LEAKING. FUEL TANK COVERED IN FUEL, UNDERNEATH SEAT AND THE FRAME COVERED IN FUEL. MY LEFT LEG PANTS FUEL SOAKED AFTER EVERY RIDE. COMPLAINED TO DEALER. FINALLY AFTER COMPLAINING TO THE DEALER OWNER ( ABOUT A MONTH LATER) THEY TOOK A CAP OF A NEW BIKE AND GAVE IT TO ME. THE OLD CAP WAS TURNED IN TO THEM. IT LASTED A COUPLE OF MONTHS AND THEY GAVE ME ANOTHER CAP, MAYBE IN 8-06. BY OCT 06 FUEL CAP IS AGAIN LEAKING BADLY. THE CAP ALSO IS SWOLLEN AND VERY DIFFICULT TO REMOVE. CALLED SERVICE MANAGER AT DEALER. A WEEK PASSES AND I CALL AGAIN. HE SAYS THIS IS NOT A KTM ISSUE AND THEY WILL NOT GIVE AWAY ANY MORE FUEL CAPS. I THEN CALLED THE OWNER OF THE DEALER AGAIN. WHO IN TURN CALLED KTM. A COUPLE OF WEEKS LATER THEY GAVE ME A NEW CAP THAT WAS MODIFIED WITH A ADDITIONAL O-RING. I ORIGINALLY CALLED IN MY COMPLAINT. THERE WAS NO FOLLOW UP. *JB
Official recalls
0No recalls in this snapshot.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
0No exact-year investigations in this snapshot.