2006 Ktm 300 XC-W

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 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

I HAVE A 2006 KTM 300XC-W WHICH HAS LEAKED FUEL FROM THE GAS CAP SINCE IT WAS NEW IN SEPTEMBER OF 2005. THE LEAK FROM THE DEFECTIVE CAP HAS RESULTED IN CHEMICAL BURNS TO MY UPPER THIGH AREA IN ONE PARTICULAR TIP OVER. *JB KTM IS AWARE OF THE FLAW AND HAS ATTEMPTED TO PLACATE THE OWNERS WITH BANDAIDE TYPE FIXES, NONE OF WHICH HAS PERMANENTLY FIXED THE PROBLEM. IT IS JUST A MATTER OF TIME BEFORE SOMEONE IS SERIOUSLY INJURED OR KILLED AS A RESULT OF SPILLED GASOLINE ON THEMSELVES OR HOT ENGINE PARTS. I WAS FORCED TO PURCHASE A FUEL TANK THAT HAS A TRADITIONAL SCREW TYPE CAP AT MY OWN EXPENSE IN ORDER TO RIDE THE BIKE WITH OUT WORRY OF PERSONAL INJURY OR DEATH. *JB

FROM DAY OF PURCHASE, MY 2007 KTM 200 XC MOTORCYCLE HAS BEEN LEAKING GASOLINE FROM THE GAS CAP, AND SPLASHING FUEL INTO MY LAP AND ALL OVER THE BIKE. THIS IS FROM THE 1/4 TURN GAS CAP KTM HAS BEEN SHIPPING ON MODEL YEAR 2006 AND 2007 MOTORCYCLES. PLEASE LOOK AT WWW.KTMTALK.COM IN THE "GENERAL FORUM" FOR AN ENTIRE HISTORY OF OWNER COMPLAINTS. AND ALTHOUGH KTM JUST RECENTLY ATTEMPTED TO FIX THE ISSUE BY MAILING NEW O-RINGS, THE GAS CAP AND TANK ARE THE ISSUE, AS THE CAP SWELLS AND ENLARGES THE FILLER HOLE TO THE POINT THAT THE O-RING WILL ONLY WORK FOR A BRIEF PERIOD BEFORE IT BEGINS LEAKING AGAIN. I RECOMMEND A 100% RECALL ON THE KTM GAS TANKS. IF THIS WAS A CAR SPILLING GAS ON OUR LAPS, A RECALL WOULD HAVE ALREADY HAPPENED. *NM

THE GAS CAP ON THE '06 KTM 450 EXC MODEL LEAKS FUEL AFTER THE FIRST FEW MONTHS OF OPERATION. THE VENT GLUE FAILED CAUSING THE FUEL TO SPILL OUT OF THE VENT AREA OF THE CAP. THE FUEL CAP BUILT IN GASKET DOES NOT SEAL PROPERLY AND FUEL LEAKS OUT OF THIS AREA AS WELL. THE CAP IS 1/4 TURN TO CLOSE AND DUE TO SWELLING OF THE TANK AND ENLARGEMENT OF THE TANK CAP RECEPTACLE ENLARGE DUE TO SWELLING WILL POP OFF ON IMPACT. A CRASH OCCURRED IN A ROCKY AREA WITH THE BIKE FALLING AND THE RIDER ON THE GROUND THE CAP POPPED OFF ON IMPACT WITH GAS RELEASED FROM THE TANK ALL OVER THE RIDER AND INTO RIDING BOOT. CHEMICAL BURNS WERE SUSTAINED. IF THE BIKE HAD NOT FALLEN DOWNHILL THE FUEL WOULD HAVE CONTACTED THE HOT ENGINE OR EXHAUST AND IGNITED THE BIKE AND RIDER. KTM HAS SUPPLIED A TEMPORARY FIX OF AN O-RING, BUT HAS NOT BEEN FORTHCOMING FOR A PERMANENT FIX TO THIS LEAKING PROBLEM AND UNSECURED CAP ISSUE FOR 2 YEARS. HUNDREDS OF '06 THROUGH '07 KTM OWNERS EXPERIENCE THIS SAME PROBLEM. IT IS ONLY A MATTER OF TIME BEFORE A DEATH IS REPORTED DUE TO FIRE. *NM