KTM has announced a global recall for several 2024 models. A defective fuel cap seal can lead to fuel leakage and a fire hazard. In the US alone, 5,488 motorcycles are affected; worldwide that number is much higher.
The recall rolled out in Mattinghofen concerns no fewer than 5 different models: the Husqvarna Svartpilen 401, Vitpilen 401, and the KTM 390 Duke, 990 Duke, plus the 250 Duke, not delivered in Europe. In the US alone, there are 5,488 engines that may be equipped with the defective seal.
The cause of the recall is a defective rubber seal in the fuel cap supplied by Minda Corporation. Material deviations can cause small cracks in the seal, causing fuel to escape during use. This entails risks of fire, injury or property damage. KTM emphasizes that no incidents or injuries have been reported to date.
Remarkably, the documents released by the NHTSA in the US about the recall show that the supplier had already discovered deviations in March 2023, but that they were not found during production for a long time, nor were there any reports from the market.
Only after a year and a half, in September 2024, was a broken oil seal discovered on a test engine at KTM AG R&D, after which KTM requested supplier Minda to investigate the matter further. It is noteworthy that KTM already established on March 18, 2025 that there was a defect and that a recall was necessary, but has only now initiated this.
The affected engines were produced between October 30, 2023 and March 22, 2024, depending on the model. Owners are urged to take their motorcycle to an authorized dealer, where the seal ring will be replaced free of charge. The replacement seal has an improved design and manufacturing process.
– Thanks for information from Motorfreaks.