KTM EXC recalls

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.

• EXC-F: 439 vehicles · built 7 Jun 2016 to 4 Jul 2016
• EXC: 439 vehicles · built 7 Jun 2016 to 4 Jul 2016

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 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.

• EXC: 475 vehicles · built 16 Jun 2014 to 10 Oct 2014
• EXC-F: 475 vehicles · built 16 Jun 2014 to 10 Oct 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

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

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

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