KTM North America recently filed a voluntary safety recall report with the US National Highway Traffic Safety Administration (NHTSA) regarding a specific defect with a fuel cap gasket that was used in a specific range of multiple models of bikes. I know that's a lot of information for one sentence, so read on and we'll break it down for you.
According to KTM's records, multiple 2024 KTM and Husqvarna models may be affected, since they all used the same batch of fuel caps from a supplier that were later found to have defective gaskets. Those records go on to state, approximately 5,488 total bikes across all models may be affected. This represents around 1% of the population.
All affected units were produced in the latter months of 2023 or the beginning months of 2024, and the breakdown is as follows.
| Make and Model | Affected Production Dates | Number of Bikes Potentially Involved |
| 2024 KTM 990 Duke | October 30, 2023 through April 11, 2024 | 494 |
| 2024 KTM 390 Duke | October 30, 2023 through April 11, 2024 | 2,125 |
| 2024 KTM 250 Duke | October 30, 2023 through April 11, 2024 | 1,113 |
| 2024 Husqvarna Vitpilen 401 | January 25, 2024 through March 22, 2024 | 550 |
| 2024 Husqvarna Svartpilen 401 | January 25, 2024 through March 22, 2024 | 1,206 |
What's the issue? On affected bikes, the seal on the fuel filler cap may develop small cracks, causing it to no longer seal properly. This could, in turn, lead to unintended fuel leaks from the fuel filler cap, which could increase the risk of fire, injury, and/or a crash.
Per KTM's supplied chronology of the issue, the part supplier that initially provided this part, Minda, first noticed and reported potential cracks in March 2023 while administering standard testing. However, since the firm could not replicate the issue, and since it was not seen in any production bikes, they simply made a note of it and took no further action at that time.
It wasn't until September 2024 that KTM notes finding the issue present on one of its R&D vehicles. It's then that KTM requested Minda to do additional testing. Finally, in March 2025, KTM established that a defect did exist within production motorcycles, and began to issue a recall. As KTM sells its motorcycles in multiple markets, recall reports and procedures are frequently issued in different geographic locations at different times. Per KTM, so far no accidents or injuries related to this issue have been reported.
If you are located in a market outside the US, and you have any of the affected year/make/model bikes in your possession, you may wish to check with your country's recall authority to see if a similar recall exists in your region.
In the US, KTM North America planned to notify its dealer network on November 5, 2025 about this recall. Additionally, the company says that it plans to notify registered owners of affected units on December 15, 2025.
Owners may contact KTM North America's customer service hotline at 1-888-985-6090. Additionally, owners may contact the NHTSA Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-888-275-9171) or go to www.nhtsa.gov. The NHTSA recall number for this issue is 25V740.
