KTM recalls

For affected machines it has been determined that engine vibrations may cause the side stand spring on forged side stands to break.

Fix: Replacement of the side stand spring and fit a rubber protector

5 vehicles · built 17 Jul 2025 to 17 Jul 2025

For affected machines it has been determined that engine vibrations may cause the side stand spring on forged side stands to break.

Fix: Replacement of the side stand spring and fit a rubber protector

29 vehicles · built 24 Jun 2025 to 30 Jun 2025

For affected machines it has been determined that engine vibrations may cause the side stand spring on forged side stands to break.

Fix: Replacement of the side stand spring and fit a rubber protector

1 vehicles · built 30 Jun 2025 to 30 Jun 2025

For certain machines there is an increased risk of stalling at low revs for where loss of power cannot be ruled out.

Fix: Software update to the engine control unit (ECU).

305 vehicles · built 1 Dec 2023 to 25 Aug 2025

For certain machines there is an increased risk of stalling at low revs for where loss of power cannot be ruled out.

Fix: Software update to the engine control unit (ECU).

38 vehicles · built 5 Aug 2025 to 26 Sep 2025

For certain machines there is an increased risk of stalling at low revs for where loss of power cannot be ruled out.

Fix: Software update to the engine control unit (ECU).

128 vehicles · built 17 Jul 2025 to 11 Nov 2025

For certain machines there is an increased risk of stalling at low revs for where loss of power cannot be ruled out.

Fix: Software update to the engine control unit (ECU).

112 vehicles · built 24 Jun 2025 to 29 Oct 2025

For certain machines there is an increased risk of stalling at low revs for where loss of power cannot be ruled out.

Fix: Software update to the engine control unit (ECU).

108 vehicles · built 30 Jun 2025 to 1 Oct 2025

On affected vehicles the fuel filler cap seal may crack leading to a possible fuel leak.

Fix: Affected vehicles will have the fuel filler cap seal replaced.

1,045 vehicles · built 20 Dec 2023 to 16 Aug 2024

On affected vehicles the fuel filler cap seal may crack leading to a possible fuel leak.

Fix: Affected vehicles will have the fuel filler cap seal replaced.

247 vehicles · built 1 Dec 2023 to 18 Jul 2024

On affected vehicles the fuel filler cap seal may crack leading to a possible fuel leak.

Fix: Affected vehicles will have the fuel filler cap seal replaced.

334 vehicles · built 4 Dec 2023 to 28 Jun 2024

The clutch slave cylinder seal may have been damaged during the manufacturing process.

Fix: Check and replace clutch slave cylinder if necessary.

6 vehicles · built 29 Jan 2022 to 29 Jan 2022

As a result of continual product development the routing of the main wiring harness has been improved on the affected models.

Fix: To avoid areas of chafing on the main wiring harness specific parts must be retrofitted.

1,312 vehicles · built 28 Apr 2021 to 23 Jul 2021

As a result of continual product development the routing of the main wiring harness has been improved on the affected models.

Fix: To avoid areas of chafing on the main wiring harness specific parts must be retrofitted.

1,312 vehicles · built 11 Dec 2019 to 5 Apr 2022

As a result of continual product development the routing of the main wiring harness has been improved on the affected models.

Fix: To avoid areas of chafing on the main wiring harness specific parts must be retrofitted.

1,312 vehicles · built 18 Oct 2021 to 3 May 2022

The anticipated endurance of the connecting rod cannot be ensured.

Fix: Conduct a replacement of the CDI control unit with a reduced max RPM limiter.�

259 vehicles · built 3 Mar 2021 to 24 Jan 2022

The anticipated endurance of the connecting rod cannot be ensured.

Fix: Conduct a replacement of the CDI control unit with a reduced max RPM limiter.�

259 vehicles · built 3 Mar 2021 to 24 Jan 2022

Damage to the seal caused by deviations in assembly may impair the function of the clutch slave cylinder.

Fix: Inspect the slave cylinder and check which part version is fitted to the motorcycle. Replace the unit if the affected part version is fitted.

811 vehicles · built 19 Sep 2017 to 12 Sep 2020

Damage to the seal caused by deviations in assembly may impair the function of the clutch slave cylinder.

Fix: Inspect the slave cylinder and check which part version is fitted to the motorcycle. Replace the unit if the affected part version is fitted.

811 vehicles · built 19 Sep 2017 to 12 Aug 2020

Damage to the seal caused by deviations in assembly may impair the function of the clutch slave cylinder.

Fix: Inspect the slave cylinder and check which part version is fitted to the motorcycle. Replace the unit if the affected part version is fitted.

811 vehicles · built 19 Sep 2017 to 12 Aug 2020

The plug of the activated charcoal canister drainage hose can be damaged by heat from the exhaust system.

Fix: The existing plug must be replaced by the new aluminum version.

428 vehicles · built 18 Jan 2021 to 28 May 2021

A defective shift drum may have been installed.

Fix: The shift drum must be replaced on all affected motorcycles.

55 vehicles · built 7 Jul 2020 to 3 Nov 2020

The preload force of the piston return-spring in the front master cylinder may in individual cases lie outside the specified tolerance.

Fix: Replace the piston return-spring with a longer and harder spring.

902 vehicles · built 11 Jan 2019 to 20 May 2020

The preload force of the piston return-spring in the front master cylinder may in individual cases lie outside the specified tolerance.

Fix: Replace the piston return-spring with a longer and harder spring.

902 vehicles · built 11 Jan 2019 to 20 May 2020

The preload force of the piston return-spring in the front master cylinder may in individual cases lie outside the specified tolerance.

Fix: Replace the piston return-spring with a longer and harder spring.

902 vehicles · built 11 Jan 2019 to 20 May 2020

Cracks can cause the handlebar clamp to break off together with the mounted clip-on handlebars.

Fix: The handlebar mounts and clip-on handlebars must be replaced on all vehicles.

1 vehicles · built 22 Jun 2017 to 22 Jun 2017

The potential for damage to the wiring harness.

Fix: Carry out a rework to the tail end lower part and inspect the wiring harness for damage and repair where necessary.

359 vehicles · built 11 Dec 2019 to 12 Oct 2020

A defective drive chain may have been installed.

Fix: Replacement of the drive chain.

39 vehicles · built 2 Nov 2020 to 25 Nov 2020

A defective drive chain may have been installed.

Fix: Replacement of the drive chain.

22 vehicles · built 26 Nov 2020 to 18 Dec 2020

A defective drive chain may have been installed.

Fix: Replacement of the drive chain.

22 vehicles · built 26 Nov 2020 to 18 Dec 2020

A defective drive chain may have been installed.

Fix: Replacement of the drive chain.

22 vehicles · built 26 Nov 2020 to 18 Dec 2020

A defective drive chain may have been installed.

Fix: Replacement of the drive chain.

39 vehicles · built 2 Nov 2020 to 25 Nov 2020

A defective drive chain may have been installed.

Fix: Replacement of the drive chain.

22 vehicles · built 26 Nov 2020 to 18 Dec 2020

A defective drive chain may have been installed.

Fix: Replacement of the drive chain.

39 vehicles · built 2 Nov 2020 to 25 Nov 2020

A defective drive chain may have been installed.

Fix: Replacement of the drive chain.

22 vehicles · built 26 Nov 2020 to 18 Dec 2020

A defective drive chain may have been installed.

Fix: Replacement of the drive chain.

22 vehicles · built 26 Nov 2020 to 18 Dec 2020

The battery vent valve may be missing on some vehicles.

Fix: Check and install the vent or replace the battery as necessary.

3 vehicles · built 26 Jul 2020 to 21 Sep 2020

A possible material nonconformity of the rear brake line

Fix: Replace the brake line leading from the rear brake caliper to the ABS modulator.

474 vehicles · built 11 Jan 2019 to 9 Oct 2019

A possible material nonconformity of the rear brake line

Fix: Replace the brake line leading from the rear brake caliper to the ABS modulator.

474 vehicles · built 11 Jan 2019 to 9 Oct 2019

There may be fuel leakage at the lower fitting insert of the fuel tank fairing.

Fix: Check for leaks replace tank if leak evidenced.If no leak evident fit a retrofit kit to prevent leaks occurring in the area.

339 vehicles · built 27 Nov 2014 to 27 Sep 2016

Nonconformities occurred in the production process of the rear fuel tank.

Fix: The rear fuel tanks need to be replaced on the vehicles affected

6 vehicles · built 27 Sep 2018 to 2 Oct 2018

The carburettor covers may have been fitted incorrectly

Fix: Check and repair carburettor if required.

27 vehicles · built 17 Apr 2018 to 28 Aug 2018

Due to a deviation in the manufacturing process the fuel tank filler nozzle may leak. A modified version has been developed.

Fix: On affected machines replace the fuel tank filler neck and gasdket. The fule level sensor must alsio be replaced.

458 vehicles · built 22 Sep 2015 to 29 Jan 2018

Due to a deviation in the manufacturing process the fuel tank filler nozzle may leak. A modified version has been developed.

Fix: On affected machines replace the fuel tank filler neck and gasdket. The fule level sensor must alsio be replaced.

458 vehicles · built 22 Sep 2015 to 29 Jan 2018

Because of a manufacturing fault the floating piston in the front brake master cylinder may crack under high stress conditions typical of track use frequent ABS interventions or if a machine is dropped. This could reduce the efficiency of the front brake.

Fix: On affected machines replace the floating piston in the front brake master cylinder with a modified version

1,938 vehicles · built 24 Mar 2015 to 14 Jun 2017

Because of a manufacturing fault the floating piston in the front brake master cylinder may crack under high stress conditions typical of track use frequent ABS interventions or if a machine is dropped. This could reduce the efficiency of the front brake.

Fix: On affected machines replace the floating piston in the front brake master cylinder with a modified version

1,938 vehicles · built 19 Mar 2015 to 19 Dec 2017

Because of a manufacturing fault the floating piston in the front brake master cylinder may crack under high stress conditions typical of track use frequent ABS interventions or if a machine is dropped. This could reduce the efficiency of the front brake.

Fix: On affected machines replace the floating piston in the front brake master cylinder with a modified version

1,938 vehicles · built 19 Mar 2015 to 19 Dec 2017

Because of a manufacturing fault the floating piston in the front brake master cylinder may crack under high stress conditions typical of track use frequent ABS interventions or if a machine is dropped. This could reduce the efficiency of the front brake.

Fix: On affected machines replace the floating piston in the front brake master cylinder with a modified version

1,938 vehicles · built 19 Mar 2015 to 19 Dec 2017

Because of a manufacturing fault the floating piston in the front brake master cylinder may crack under high stress conditions typical of track use frequent ABS interventions or if a machine is dropped. This could reduce the efficiency of the front brake.

Fix: On affected machines replace the floating piston in the front brake master cylinder with a modified version

1,938 vehicles · built 19 Mar 2015 to 19 Dec 2017

Under certain conditions the headlight control unit may reboot which can affect the headlight operation

Fix: On affected machines update headlight control unit software.

475 vehicles · built 9 Mar 2017 to 24 Apr 2017

The drive chain connecting link is not manufactured to specification which can lead to premature failure of the connecting link possible consequential damage and loss of drive.

Fix: Recall the machines that are likely affected and replace the drive chain connecting link.

1 vehicles · built 8 Feb 2017 to 8 Feb 2017

It has been identified that a fuel hose may not have been produced to specification. This can cause a fuel leak which is not rectified could in the worst case scenario result in a fire.

Fix: Recall all affected machines to replace the affected fuel hose.

147 vehicles · built 3 May 2016 to 22 Nov 2016

Contact may occur between the wiring harness and the ABS modulator. An electrical connection may be created via the brake line between the ABS modulator and the vehicle ground. For this to occur the wiring harness must be frayed and must be in contact with the ABS modulator and the brake line must be electrically conductive. A conductive brake line can overheat and ultimately melt which can result in failure of a brake system circuit.

Fix: On affected machines screw ground wire onto the ABS modulator and fasten ground wire on the frame. Check the wiring harness for visible damage around the ABS modulator (chafing damaged coating exposed wires etc.) and repair as necessary. Check routing of the entire wiring harness around the ABS modulator and secure to frame.

979 vehicles · built 7 Nov 2011 to 25 May 2016

Contact may occur between the wiring harness and the ABS modulator. An electrical connection may be created via the brake line between the ABS modulator and the vehicle ground. For this to occur the wiring harness must be frayed and must be in contact with the ABS modulator and the brake line must be electrically conductive. A conductive brake line can overheat and ultimately melt which can result in failure of a brake system circuit.

Fix: Recall the machines that are likely to be affected to check and where necessary correct the routing of the wiring harness. If a wiring harness has been damaged the correct level of repair will be applied after advice is sought from the manufacturer.

1,527 vehicles · built 15 Jan 2013 to 27 Apr 2016

Contact may occur between the wiring harness and the ABS modulator. An electrical connection may be created via the brake line between the ABS modulator and the vehicle ground. For this to occur the wiring harness must be frayed and must be in contact with the ABS modulator and the brake line must be electrically conductive. A conductive brake line can overheat and ultimately melt which can result in failure of a brake system circuit.

Fix: Recall the machines that are likely to be affected to check and where necessary correct the routing of the wiring harness. If a wiring harness has been damaged the correct level of repair will be applied after advice is sought from the manufacturer.

1,527 vehicles · built 15 Jan 2013 to 27 Apr 2016

Anomalies in the manufacturing process have resulted in certain batches of hand brake cylinders with defective machining. This can lead to early wear of the sealing cup in the hand brake cylinder thus leading to impaired braking performance.

Fix: Recall the machines that are likely to be affected and check the batch number of the hand brake cylinder. If the batch number appears on the affected list replace the hand brake cylinder.

439 vehicles · built 7 Jun 2016 to 4 Jul 2016

Anomalies in the manufacturing process have resulted in certain batches of hand brake cylinders with defective machining. This can lead to early wear of the sealing cup in the hand brake cylinder thus leading to impaired braking performance.

Fix: Recall the machines that are likely to be affected and check the batch number of the hand brake cylinder. If the batch number appears on the affected list replace the hand brake cylinder.

439 vehicles · built 7 Jun 2016 to 4 Jul 2016

Anomalies in the manufacturing process have resulted in certain batches of hand brake cylinders with defective machining. This can lead to early wear of the sealing cup in the hand brake cylinder thus leading to impaired braking performance.

Fix: Recall the machines that are likely to be affected and check the batch number of the hand brake cylinder. If the batch number appears on the affected list replace the hand brake cylinder.

439 vehicles · built 7 Jun 2016 to 4 Jul 2016

Anomalies in the manufacturing process have resulted in certain batches of hand brake cylinders with defective machining. This can lead to early wear of the sealing cup in the hand brake cylinder thus leading to impaired braking performance.

Fix: Recall the machines that are likely to be affected and check the batch number of the hand brake cylinder. If the batch number appears on the affected list replace the hand brake cylinder.

439 vehicles · built 7 Jun 2016 to 4 Jul 2016

Anomalies in the manufacturing process have resulted in certain batches of hand brake cylinders with defective machining. This can lead to early wear of the sealing cup in the hand brake cylinder thus leading to impaired braking performance.

Fix: Recall the machines that are likely to be affected and check the batch number of the hand brake cylinder. If the batch number appears on the affected list replace the hand brake cylinder.

439 vehicles · built 7 Jun 2016 to 4 Jul 2016

Anomalies in the manufacturing process have resulted in certain batches of hand brake cylinders with defective machining. This can lead to early wear of the sealing cup in the hand brake cylinder thus leading to impaired braking performance.

Fix: Recall the machines that are likely to be affected and check the batch number of the hand brake cylinder. If the batch number appears on the affected list replace the hand brake cylinder.

439 vehicles · built 7 Jun 2016 to 4 Jul 2016

The connecting rod may fail in early life under certain load conditions. The machines in question are designed to be used off road and as such power request is a factor in the control of the machine. If a connecting rod failure occurs in this type machine the rider may be exposed to significant risk.

Fix: Recall the machines that are likely to be affected and replace the complete crankshaft.

151 vehicles · built 20 Jan 2016 to 19 Feb 2016

It is possible there is a leak of hydraulic fluid at the plug of the semi-active shock absorber. A loss of hydraulic fluid can lead to a negative affect of the performance of the shock absorber handling of the machine and damage to the interior of the shock absorber.

Fix: Recall the machines that are likely to be affected and check for fluid leakage from the plug of the semi-active shock absorber. If there is visible leakage the shock absorber will be changed for a new unit and mounted with the original preload adjuster. If there is no leakage the original shock absorber can remain in please. In all cases check the software and update as necessary.

199 vehicles · built 26 Nov 2014 to 1 Dec 2015

Due to variations in the spoke manufacturing process some spokes on the front wheel may exhibit quality deviations. Depending on where they are fitted in the wheel care and spoke tension it is possible that individual spokes may break while riding. This can overload the remaining intact spokes and consequently cause them to break which can affected the stability of the machine.

Fix: Recall the machines that are likely to be affected and replace the spokes that are fitted to the front wheel.

655 vehicles · built 30 Apr 2015 to 18 Sep 2015

Due to variations in the spoke manufacturing process some spokes on the front wheel may exhibit quality deviations. Depending on where they are fitted in the wheel care and spoke tension it is possible that individual spokes may break while riding. This can overload the remaining intact spokes and consequently cause them to break which can affected the stability of the machine.

Fix: Recall the machines that are likely to be affected and replace the spokes that are fitted to the front wheel.

655 vehicles · built 30 Apr 2015 to 18 Sep 2015

It is possible fuel may escape through the fuel tank breather during extreme riding situations.

Fix: On affected machines fit upgrade breather valve.

596 vehicles · built 8 Mar 2012 to 25 Jun 2015

The moulded fuel hoses may not be to specification which can lead to fuel leakage. The fuel leakage can cause damage or in the worst case scenario fire.

Fix: Recall the machines that are likely to be affected and replace the fuel hoses.

166 vehicles · built 30 Jun 2015 to 9 Jul 2015

The M12 aluminium fuel pump nut may not be to specification. This can lead to insufficient sealing allowing fuel to leak. In extreme cases the leaking fuel can cause damage or fire.

Fix: Recall the machines that are likely to be affected and replace the M12 aluminium fuel pump nut. Where necessary the seal will also be replaced.

165 vehicles · built 29 Jul 2015 to 1 Sep 2015

The M12 aluminium fuel pump nut may not be to specification. This can lead to insufficient sealing allowing fuel to leak. In extreme cases the leaking fuel can cause damage or fire.

Fix: Recall the machines that are likely to be affected and replace the M12 aluminium fuel pump nut. Where necessary the seal will also be replaced.

165 vehicles · built 29 Jul 2015 to 1 Sep 2015

The M12 aluminium fuel pump nut may not be to specification. This can lead to insufficient sealing allowing fuel to leak. In extreme cases the leaking fuel can cause damage or fire.

Fix: Recall the machines that are likely to be affected and replace the M12 aluminium fuel pump nut. Where necessary the seal will also be replaced.

165 vehicles · built 29 Jul 2015 to 1 Sep 2015

The internal overflow pipe in some fuel tanks may not be completely enclosed by plastic. This overflow pipe is secured on the inside of the tank by two threaded inserts. Fuel can penetrate the threaded inserts which can lead to fuel leaking in small quantities.

Fix: Recall the machines that are likely to be affected and check the type of tank. If the tank is of the latest pattern no further action is necessary. If the tank is old pattern and if there is any sign of leakage at the threaded inserts a new tank must be fitted. If the tank is old pattern and has no leakage seals will be fitted to the threaded inserts.

248 vehicles · built 20 Sep 2013 to 4 Jul 2014

A clip to hold the engine breather pipe may have been fitted facing the wrong way and could be in contact with the rear brake. In this scenario the brake pipe could be damaged to the extent it will eventually leak and cause a loss of pressure to the rear brake.

Fix: Recall the machines that are likely to be affected to inspect the position of the engine breather pipe clip. Where the clip is facing the wrong way the brake pipe will be replaced and the clip put in the correct position.

64 vehicles · built 21 Nov 2014 to 24 Feb 2015

The front wheel spacer/s may be of the incorrect size. The resultant play will allow the wheel to move on the axle which in turn can cause damage to the brake discs fork tubes and ABS sensor. The brake calliper piston could be pushed back sufficiently to cause total failure of the front brakes.

Fix: Recall the machines that are likely to be affected and check for visible or measureable play between the axle clamp spacer and hub. If the incorrect spacer/s has been fitted they will be replaced with the correct spacers. Any resultant damage will be rectified.

188 vehicles · built 20 Dec 2013 to 3 Mar 2015

The forks may not have been correctly assembled which could lead to initially knocking and the damping in the affected strut decreasing. If the condition is allowed to progress the inside of the fork will be damaged and the fork may seize.

Fix: Recall the machines that are likely to be affected and remove the fork cap. Check the locking nut for correct torque and tighten if necessary.

475 vehicles · built 16 Jun 2014 to 10 Oct 2014

The forks may not have been correctly assembled which could lead to initially knocking and the damping in the affected strut decreasing. If the condition is allowed to progress the inside of the fork will be damaged and the fork may seize.

Fix: Recall the machines that are likely to be affected and remove the fork cap. Check the locking nut for correct torque and tighten if necessary.

475 vehicles · built 16 Jun 2014 to 10 Oct 2014

The forks may not have been correctly assembled which could lead to initially knocking and the damping in the affected strut decreasing. If the condition is allowed to progress the inside of the fork will be damaged and the fork may seize.

Fix: Recall the machines that are likely to be affected and remove the fork cap. Check the locking nut for correct torque and tighten if necessary.

475 vehicles · built 16 Jun 2014 to 10 Oct 2014

The forks may not have been correctly assembled which could lead to initially knocking and the damping in the affected strut decreasing. If the condition is allowed to progress the inside of the fork will be damaged and the fork may seize.

Fix: Recall the machines that are likely to be affected and remove the fork cap. Check the locking nut for correct torque and tighten if necessary.

475 vehicles · built 16 Jun 2014 to 10 Oct 2014

It is possible that the foot brake lever mounting screws have been tightened to an incorrect torque. If ignored the lever may come loose on its mounting and start to feel loose and if continued to be ignored it is possible for the bolt to fall out of the lever mounting causing the loss of rear brake.

Fix: Recall the machines that are likely to be affected and re torque the bolt with new locking agent applied.

99 vehicles · built 20 Dec 2013 to 9 Apr 2014

Due to a production fault on the upper part of the throttle grip housing the throttle cable wire may slide out of the deflection roller and become wedged between the deflection roller and the housing. This blocks the throttle slide and may result in an uncontrollable riding situation.

Fix: Recall the vehicles that are likely to be affected to replace the upper part of the hand throttle control housing the deflector roller and bronze bushing.

1,468 vehicles

Due to a production fault on the upper part of the throttle grip housing the throttle cable wire may slide out of the deflection roller and become wedged between the deflection roller and the housing. This blocks the throttle slide and may result in an uncontrollable riding situation.

Fix: Recall the vehicles that are likely to be affected to replace the upper part of the hand throttle control housing the deflector roller and bronze bushing.

1,468 vehicles

Fuel may leak onto hot engine/exhaust components because of pin-prick holes that can develop in the pre-formed fuel pipes. In the worst cases this could lead to fire.

Fix: Recall the machines that are likely to be affected to replace the preformed fuel hoses.

253 vehicles

Fuel may leak onto hot engine/exhaust components because of pin-prick holes that can develop in the pre-formed fuel pipes. In the worst cases this could lead to fire.

Fix: Recall the machines that are likely to be affected to replace the preformed fuel hoses.

253 vehicles

Fuel may leak onto hot engine/exhaust components because of pin-prick holes that can develop in the pre-formed fuel pipes. In the worst cases this could lead to fire.

Fix: Recall the machines that are likely to be affected to replace the preformed fuel hoses.

253 vehicles

Fuel may leak onto hot engine/exhaust components because of pin-prick holes that can develop in the pre-formed fuel pipes. In the worst cases this could lead to fire.

Fix: Recall the machines that are likely to be affected to replace the preformed fuel hoses.

253 vehicles

Fuel may leak onto hot engine/exhaust components because of pin-prick holes that can develop in the pre-formed fuel pipes. In the worst cases this could lead to fire.

Fix: Recall the machines that are likely to be affected to replace the preformed fuel hoses.

253 vehicles

It is possible that the bolts that secure the two halves of the front wheel brake caliper have not been torqued to the correct specification. This could in extreme circumstances result in a loss of brake fluid and subsequent reduction of brake pressure which could lead to a reduction in braking performance.

Fix: Recall all affected machines to check and if required tighten the bolts to the correct torque specification.

132 vehicles · built 14 Apr 2011 to 21 Jul 2011

The suspension inner forks may crack and lose fluid as a result of the metal being brittle. Should this occur the suspension will not operate correctly.

Fix: Recall the machines that are likely to be affected to replace both the fork legs.

54 vehicles

The suspension inner forks may crack and lose fluid as a result of the metal being brittle. Should this occur the suspension will not operate correctly.

Fix: Recall the machines that are likely to be affected to replace both the fork legs.

54 vehicles

The suspension inner forks may crack and lose fluid as a result of the metal being brittle. Should this occur the suspension will not operate correctly.

Fix: Recall the machines that are likely to be affected to replace both the fork legs.

54 vehicles

The rear brake calliper support bracket may fracture and the calliper can become insecure.

Fix: Recall affected machines and replace calliper mounting with revised type.

59 vehicles · built 1 Nov 2007 to 31 Jul 2008

There is a possibility that the main actuating piston in the front brake master cylinder may not return to its fully returned position.

Fix: Recall affected machines and replace piston return spring.

59 vehicles · built 1 Nov 2007 to 31 Jul 2008

The rear brake calliper support bracket may fracture and the calliper can become insecure.

Fix: Recall affected machines and replace calliper mounting with revised type.

59 vehicles · built 1 Nov 2007 to 31 Jul 2008

There is a possibility that the main actuating piston in the front brake master cylinder may not return to its fully returned position.

Fix: Recall affected machines and replace piston return spring.

59 vehicles · built 1 Nov 2007 to 31 Jul 2008

Under certain circumstances it is possible that if the customers do not properly secure the fuel cap or if it is knocked by the rider's body during off road use then the fuel tank cap may leak and allow fuel to leak over the rider and engine.

Fix: To overcome this issue the manufacturer is to recall the likely affected machines to fit a new design of self locking fuel cap.

2,004 vehicles · built 1 Aug 2005 to 30 Apr 2007

Under certain circumstances it is possible that if the customers do not properly secure the fuel cap or if it is knocked by the rider's body during off road use then the fuel tank cap may leak and allow fuel to leak over the rider and engine.

Fix: To overcome this issue the manufacturer is to recall the likely affected machines to fit a new design of self locking fuel cap.

2,004 vehicles · built 1 Aug 2005 to 30 Apr 2007

The steering damper bracket may fail which could result the steering being locked and loss of directional control.

Fix: Recall the machines that are likely to be affected to remove the steering damper.

65 vehicles · built 1 Apr 2007 to 31 May 2007

It is possible for the chain guide to become dislodged by the drive chain whilst the machine is in motion which could result in the rider loosing control.

Fix: Recalled machines will have the securing bolt removed the threads cleaned and have Loctite 243 applied to them. The bolt will then be re-fitted and tightened to a torque of 6 Nm.

245 vehicles · built 1 Nov 2006 to 31 May 2007

It is possible for the chain guide to become dislodged by the drive chain whilst the machine is in motion which could result in the rider loosing control.

Fix: Recalled machines will have the securing bolt removed the threads cleaned and have Loctite 243 applied to them. The bolt will then be re-fitted and tightened to a torque of 6 Nm.

245 vehicles · built 1 Nov 2006 to 31 May 2007

It has been identified that under certain riding conditions vibrations transmitted from the chassis to the rear brake hydraulic lines can create a phenomenon whereby gas is released from the brake fluid which can then collect in pockets in the brake lines. Any pockets of gas within the hydraulic circuit of the rear brake will significantly reduce the effectiveness of the system and in extreme cases will render the rear brake inoperative.

Fix: Recalled machines will have the original rear brake lines removed and replaced with superseded items that are designed to follow a different routing from the master cylinder to the rear brake caliper via the ABS modulator.

377 vehicles · built 1 Dec 2005 to 31 Jan 2007

The friction material of the brake pad may become de-bonded which would lead to greater than expected stopping distances.

Fix: Recall the vehicles that are likely to be affected to replace the brake pads.

66 vehicles · built 1 Nov 2005 to 28 Feb 2006

It is possible for water to ingress into the ABS brake system override switch and warning light causing a failure of the switch and warning lamp. This will lead to the ABS system not working and the rider being unaware of the situation. The brakes will function but without the facility of ABS.

Fix: Recall the machines that are likely to be affected to replace the original ABS system override switch with a modified item.

174 vehicles · built 1 Dec 2005 to 31 May 2006

The forces produced during heavy braking can in extreme circumstances cause spokes to break. This may result in a puncture and rapid deflation of the tyre which would seriously affect the steering of the machine.

Fix: Recall the likely to be affected machines and replace the front wheel with a new specification front wheel.

119 vehicles · built 13 Dec 2000 to 30 Jan 2003

The possibility exists that a one way valve within the engine breather system may stick. Should this occur there is the possibility that the crankcases could pressurise which may result in oil seals failing allowing oil to escape from the engine. there is also the possibility that some oil could make its way onto the road wheels and tyres.

Fix: Recalled machines will have the crankcase breather valve reworked to a new specification.

177 vehicles · built 1 Apr 2005 to 31 May 2005

Possible cracking of fork tube lower triple clamp during manufacturer. Failure in use may cause partial or total loss of steering stability.

Fix: All machines fitted with triple clamps within the affected range will be initially checked and if necessary new quality assured triple clamps will be fitted.

800 vehicles

Due to the use of poor quality material the rear axle may crack if the securing nuts are overtightened.

Fix: Fit a quality assured replacement axle.

124 vehicles