KTM 690 Enduro — Recalls, Reliability, Specs & VIN Decoder

The fuel tank expanded after only 1 year of operation, 3600 miles. The fuel tank has expanded to the point of resting on the exhaust and stretching the rear fender plastics apart. I submitted it for warranty repair 6/2/2025 and KTM has approved the repair but not provided a new replacement and the vehicle and been disabled due to this issue for a year now and they has zero solutions or compensation for a defective fuel tank.

The rear body fairings/panels do not correctly assemble together on this motorcycle, which leaves unintended gaps between the panels and insecure connections to each other and to the motorcycle. It seems that interference with the gas tank is preventing correct assembly.

- Motorcycle gas tank developed a leak near where it bolts onto the frame while riding. KTM dealership did an inspection while they had bike from Aug 24 2024- April 3 2025. KTM determined itself not at fault and I had to pay $1,990.18 out of pocket for replacement. KTM kept faulty gas tank. -Gas tank leak is very dangerous to the rider as well as others because fuel is VERY flammable. Luckily no fire, was stranded 2 hours away from home where I waited for fuel to fully empty on the floor before towing home. -KTM owners on online forums have experienced same leak on this model bike, KTM dealerships should have documentation on multiple reports of faulty gas tanks. -No warnings before failure, tank leaked on Feb 22,2024

This is to support complaint 11721551 - please see pdf with additional information to support the complaint.

I am experiencing gas tank swelling, and am concerned about expansion/cracks in the tank. I’ve submitted three claims after taking the motorcycle in for review. KTM has ignored my concerns, as they will not reply. No diagnostics were complete, but I personally verified proper fuel line vents were not obstructed. Case numbers with KTM include CS0680873, CS0677844, and CS0646742. This gas tank is part of the rear subframe, so it is also a structural part. The plastics that were installed showed obvious signs of deformation at thru holes for bolt placement. I suspect improper thread loading on the thread insert for the tank that could leak to cracking and a thermal event (fire).

CONTINENTAL TIRE COMPANY is not complying with the recall of their TKC80 front tire that came on my 2022 KTM 690 Enduro R VIN# [XXX] INFORMATION Redacted PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6).

I was informed that my motorcycle was affected by the CTA recall. I spoke with my local KTM dealer I bought my bike from that came with the tkc80 tires installed. They were unaware of how to proceed and said to call Continental tire directly. I did so, and the woman on the phone instructed me to buy replacement tires, and that the cost of the tires and installation would be reimbursed. I followed up by ordering replacement tires, getting them installed at my local KTM dealer, filling out the reimbursement form as requested by CTA and mailing it to them in October of 2023. Since then I have been emailed by CTA telling me the following: "Per the recall survey completed, these tires do not meet that requirement. Your tires production period is in 2017. The production period of the affected tires does not start in 2017. Due to this, we are unable to proceed because these tires are not under recall." I was not asked to fill out this 'recall survey' prior to ordering replacement tires and getting them installed. I explained this to CTA and they have just kept repeating that they will not proceed. The NHTSA website still shows my vin as affected and that the recall has not been completed. I simply want to be reimbursed for the replacement tires ($275.16) I was told to order and installation fee ($60) I was told would be reimbursed. This is for both front and rear TKC80 tires 120/90-18 90/90-21

The contact owns a 2019 KTM 690 Enduro R equipped with Continental tires. The contact received notification of the NHTSA Campaign Number: 22V588000 (Tires). The contact stated that while riding at an undisclosed speed, the beads that holds the tire on the rim detached from the tire. The motorcycle was taken to the dealer where it was diagnosed that both tires needed to be replaced. The motorcycle was not repaired. The manufacturer was notified of the failure and the contact was informed that he needed additional information from the dealer, but no further assistance was provided. The failure mileage was approximately 400.

The rear body fairings/panels do not correctly assemble together on this motorcycle, which leaves unintended gaps between the panels and insecure connections to each other and to the motorcycle. It seems that interference with the gas tank is preventing correct assembly.

Seems as if the gas tank has expanded and caused the rear fender plastics to pop out of the clips and can see fender body gaps larger than before.

****note - this is a dirt bike, not a highway vehicle.**** tl* the contact owns a 2014 ktm 350 motorcycle. The contact stated that the engine shut off at approximately 50 mph without warning. The vehicle was taken to an unknown dealer, located in denver, colorado, where the stator and the pulse generator were replaced. The manufacturer was made aware of the failure by an unspecified email without a response. The vehicle was not repaired. The failure mileage was approximately 2,000. ## vin passed ## 2014 ktm 350 ##

On august 9, 2014 at 2:00 pm while riding the ktm 690 enduro r ,i "[xxx]" stopped for lunch after riding the motorcycle for two hours. I looked over the motorcycle and saw engine oil pooling from left side of the motor. I looked closer and saw that the engine oil was leaking and pooling into the motorcycle's engine cover for the stator and also leaking down into and pooling in the skid plate in front of the rear tire. After cleaning the oil off i rode the motorcycle home i had more engine oil in those same areas. I did not ride the motorcycle after that. I contacted the motorcycle dealer ,starr city motorsports of roanoke va and scheduled a time for them to repair the leak on 8/13/2014.they replaced the stator gasket, after wait after waiting eight hours they gave the motorcycle back. When riding the bike back to load it in my truck i noticed the repair did not fix the issue. I still had motor oil leaking from the left side pooling on the engine cover. The mechanic reinspected the motorcycle and saw the oil was leaking from the base gasket of the cylinder. The motorcycle is still currently in their shop for repairs awaiting parts. I purchased the bike from starr city motorsports on august 6, 2014 brand new. Information redacted pursuant to the freedom of information act (foia), 5 u.s.c. 552(b)(6). *tr

The emergency off switch, has shown in the owners manual, does not turn off a running engine. The switch stops the engine from cranking/starting only. Not sure if this is a defect or just a design change and the owners manual was not updated. I owned an older version of this bike and it worked as described.

The contact owns a 2021 KTM 690 Enduro-R Motorcycle. The contact stated that the gas tank cover had developed gaps between them. The contact inspected the fuel tank and discovered that the fuel tank was swollen and had expanded, causing the fuel tank covers to develop gaps. The contact stated that the failure was caused by the ethanol fuel used to operate the motorcycle and was concerned that the fuel tank might eventually develop cracks, causing a fuel leak. The vehicle was not yet repaired. The local dealer was notified of the failure. The manufacturer was not contacted. The failure mileage was 820.

The contact owns a 2021 KTM 690 Enduro-R Motorcycle. The contact stated that the gas tank cover had developed gaps between them. The contact inspected the fuel tank and discovered that the fuel tank was swollen and had expanded, causing the fuel tank covers to develop gaps. The contact stated that the failure was caused by the ethanol fuel used to operate the motorcycle and was concerned that the fuel tank might eventually develop cracks, causing a fuel leak. The vehicle was not yet repaired. The local dealer was notified of the failure. The manufacturer was not contacted. The failure mileage was 820.

Tl* the contact owns a 2015 ktm 690 enduro r. While pulling into the driveway at 5 mph, the rear brake bolt detached from the vehicle. The contact fell to the ground, but was uninjured. The manufacturer was not notified. The approximate failure mileage was 13. ...updated 11/01/16 *bf *cn