2006 ktm 300xc gas cap leaked gasoline on my legs and down side of fuel tank continually. Replaced gas cap 3 times prior to new recall gas cap. New recall gas cap leaked gasoline on my legs very first ride and continues to leak every time the motorcycle is ridden.
2006 Ktm 300 XC-W: fuel leak
10 of the 29 complaints about the 2006 Ktm 300 XC-W describe fuel leak.
- owner complaints
- 10
- of this car's complaints
- 34%
- typical mileage
- 50
- recalls
- 0
Is there a fix? No recall or service bulletin covers this area of the car yet.
Fuel leak by model year
- 20075
- 200610
What owners say
About two months after I purchased a 2006 ktm 450exc motorcycle the fuel cap started to deform and would no longer seal. Fuel leaks past the seal on the fuel cap and spills onto my legs while I ride. Ktm recently sent out a new seal (x-ring), but this did not solve the problem.
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 federal safety agency will take action and force the issue. I have much more detail available if needed.
Gas cap leaks gas.
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.
Leaking gas cap.
I purchased a new ktm motorcycle in march 2006 from a local dealer. Approximately august 2006 I notice the gas cap(new 1/4 turn design) leaking while riding the motorcycle. One day in september while riding I fell over and dropped the motorcycle and the gas cap actually popped off the gas tank and spilled gas on me. It took me 15 minutes to get back to my truck and wash the gas off. It made several blotchy red areas on my leg where the gas had soaked my pants. I reported this all to the dealer and they sold me a new gas cap. The new cap started leaking gas after only two rides. I reported this to the dealer and the ktm north american service rep. Ktm at this point suggested an o-ring so I bought one from the local hardware store and put it on the gas cap. This seemed to stop the leak but then I noticed the gas cap getting harder and harder to remove. Upon inspection of the cap it was noticeably deformed so I reported this to my local ktm dealer in october 2006. They gave me another cap but this one was free and they gave me a x-ring to install on the cap. Since then, the new cap has also deformed and now the vent check ball housing has also come apart causing the check ball to drop into the gas tank so now gas spills out the vent tube. I reported all of this to my dealer and they showed me a letter from ktm with new x-rings attached stating this was the fix but they could not give it to me as they only had a couple and offered to sell me another new gas cap. I have also called the ktm north american service rep. And informed him of all of these issues but it does not seem to be getting anywhere. Their x-ring fix may resolve the gas leak but it does not resolve the deformed, popping off, falling apart problem with their design.
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.
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.
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.
Related recalls
No recalls on record for this model year.
Questions about the 2006 Ktm 300 XC-W fuel leak
Is fuel leak a common problem on the 2006 Ktm 300 XC-W?
10 of 29 owner complaints about the 2006 Ktm 300 XC-W (34%) mention fuel leak. The model year with the most reports is 2006.
Is there a recall or service bulletin for this on the 2006 Ktm 300 XC-W?
There is no recall or service bulletin for this area of the car on record.
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