Fuel Leak Risk Prompts Recall of Thousands of KTM and Husqvarna Motorcycles

KTM North America, Inc., in conjunction with Husqvarna Mobility, is initiating a safety recall affecting nearly 5,500 of its 2024 model year motorcycles due to a potential fuel leak. The defect lies with the fuel filler cap seal, which, if compromised, could lead to fuel leakage, increasing the risk of fire, injury, or property damage. The National Highway Traffic Safety Administration (NHTSA) has assigned this recall the number 25V740.

The recall encompasses several models, including the 2024 KTM 990 DUKE, 2024 KTM 390 DUKE, 2024 KTM 250 DUKE, 2024 Husqvarna Vitpilen 401, and 2024 Husqvarna Svartpilen 401. These motorcycles were manufactured between October 30, 2023, and April 11, 2024, with the exception of the Husqvarna models, which were produced from January 25, 2024, to March 22, 2024. The total number of potentially affected motorcycles is 5,488, with an estimated 1% of these units exhibiting the defect.

The issue stems from material deviations in the fuel filler cap seal, supplied by MINDA CORPORATION LIMITED. These deviations can result in small cracks forming on the seal, potentially allowing fuel to escape. While no warning signs are anticipated, the risk of a fuel leak necessitates this recall. The fuel filler cap itself is not affected, only the seal. The affected part number for the seal is A60707008066.

KTM North America, Inc. first became aware of potential issues on March 19, 2023, when the supplier, MINDA, observed cracked sealing during laboratory testing, although the condition was not present on production motorcycles at that time. Further testing by MINDA on March 11, 2024, confirmed cracked sealing, prompting KTM to request quality improvements. The problem was later identified on two KTM AG research and development vehicles in September 2024. By March 18, 2025, KTM determined a defect existed, necessitating the recall for the fuel cap seal. To date, no accidents or injuries have been reported in connection with this defect.

Owners of the affected KTM and Husqvarna motorcycles will be notified by mail and advised to bring their units to an authorized dealer for repair. The remedy involves replacing the fuel filler cap gasket with an improved version that features new design specifications and production processes. This replacement will be performed at no cost to the customer. Dealers will also inspect and replace the fuel filler caps on any affected vehicles in their inventory.

For customers who may have already replaced the fuel filler cap themselves, reimbursement is available. These customers are encouraged to contact KTM or Husqvarna Mobility Customer Relations for further information. Dealers will be notified of the recall via Dealernet, an online communication portal, with consumer notification letters to follow. VINs will become searchable at a later date. Owners are advised not to drive the motorcycles and to park them outside due to the potential fire risk associated with a fuel leak.

Article by Mel Anara, based upon information from KTM North America, Inc.

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