KTM Global Recall: 2024 Duke 125, 250, 390 & 990 Over Fuel Cap Seal

KTM has announced a global recall for the 2024 Duke 125, 250, 390, and 990 models, citing a potential issue with the fuel tank cap seal that could lead to fuel leakage.

Why the Recall?

According to KTM’s internal quality checks, some of the fuel filler-cap seals used in these 2024 Duke bikes may not meet the company’s durability standards. Due to material deviations, micro-cracks could develop, allowing fuel to seep out around the tank cap area over time. KTM is proactively replacing the faulty component free of cost at authorized service centers.

Customers are being contacted individually via letters and are asked to visit an authorized KTM dealer to get the seal replaced. Owners can also check whether their bike is affected by entering their VIN on the “Service” section of KTM’s website. Transport Canada also confirms the recall, highlighting the risk: a cracked seal could lead to fuel leaks, which in turn could create a fire risk.

The Scope

• Models affected: 2024 KTM Duke 125, 250, 390, and 990.
• Markets: Global — the recall is valid in all markets.
• Remedy: Free replacement of the fuel cap gasket by authorized KTM dealers.
• Notification: Owners are being individually informed by KTM.

Potential Risk

If not addressed, the cracked seal could allow fuel leakage. Besides being a wastage issue, this leakage poses a safety risk, as spilled fuel near the cap area can be a fire hazard.

What Owners Should Do

1. Check whether your Duke’s VIN is part of the recall by visiting KTM’s official “Service” page.
2. If your bike is affected, book an appointment with an authorized KTM service center for the seal replacement.
3. Confirm that the repair will be done free of charge — KTM has stated there will be no cost to the owner.

This recall underlines KTM’s emphasis on safety and quality, even for its high-performance street fighters. If you own one of these Duke models, it’s important to act promptly and get the issue rectified — not just for peace of mind, but for your safety.