2016 Ktm 690 Duke problems, complaints & recalls
Most-reported problem areas: Fuel/Propulsion System (9) · Structure:body (2)
🧭 Reliability snapshot
Compared against other Ktm 690 Duke model years — complaint volume vs the model's median year, recalls and severity. How we score →
Safety recalls (1)
Fuel System, Gasoline:storage:tank Assembly:filler Pipe And Cap 2017-06-20 · campaign 17V388000 · 1,029 vehicles
Defect: KTM North America, Inc. (KTM) is recalling certain 2016-2017 KTM 690 Duke motorcycles. The affected motorcycles may leak fuel from filler cap area of the fuel tank.
Risk: A fuel leak increases the risk of fire or injury to the rider.
Fix: The recall began January 2, 2018. Customers may contact KTM customer service at 1-888-985-6090.
Service bulletins (1)
Technical service bulletins are repair instructions manufacturers send dealers for known issues. Unlike recalls, the fix is not automatically free — but naming the bulletin at the service desk can save diagnosis time and support goodwill repairs.
Equipment 2020-11-17 · KTB2025 · Service Bulletin/Repair Instructions
updated software is available for the 2016 and 2017 690 duke. the new software versions contain improvements brightness in night mode, remaining fuel distance, âabs & mtc errorâ caused by low voltage during starting.
What owners report
2017-06-24 · Fuel/Propulsion System · 1,500 mi“fuel leak from top of the fuel tank when in motion.…”
2017-05-26 · Structure:body · 3,500 mi“while riding motorcycle gasoline started leaking from the top of the tank leaking down both sides of the bike and saturating my pants with gasoline and ruining the finish of bike. the consumer stated the motorcycle constantly smelled of fuel, easily overheated, consumes oil stalls at random, and sometimes would not restart for long periods of ti…”
2017-04-19 · Fuel/Propulsion System“gas fumes leaking from motorcycle. gas tank may be leaking at top filler due to warping plastic gas tank.…”
2017-03-28 · Fuel/Propulsion System · 1,400 mi“fuel tank (plastic) is warped and leaks fuel and fuel vapor near the upper flange seal. tank was replaced once by ktm under warranty with the same plastic tank as the original, the problem is less but persists, fuel smell is still coming from the tank, fuel vapor is still escaping. i know of two other 2016 ktm 690 duke motorcycles with this same…”
2017-03-26 · Fuel/Propulsion System“gas tank leaks from filler cap. the dealer changed it 3 times. it still leaks. i know three people who's 2016 ktm 690 duke leaks fuel from the filler cap.…”
2017-03-16 · Fuel/Propulsion System · 1,600 mi“vehicle's fuel tank has warped around the filler neck. this causes gas to leak out of the top when full. vehicle needs to be in motion of this to happen as fuel will slosh around. fuel tank is made of plastic and will need replacement to fix the issue. this is a safety hazzard.…”
2017-03-15 · Structure:body · 700 mi“there is a deformity where the fuel tank connects with the fuel lid/cap. it appears wavy which doesn't allow for a proper seal between the tank and lid. when the tank is full and the motorcycle is tilted side to side it sloshes the fuel and fuel leaks out of the tank. fuel leaks when turning on the roadway.…”
2017-02-27 · Fuel/Propulsion System · 1,000 mi“flange on fuel tank where filler cap attaches is warped allowing fuel to run out into electrical wiring below. fuel leaks out when motorcycle is in motion.…”
2017-02-26 · Fuel/Propulsion System · 3,300 mi“the fuel tank on my 2016 ktm 690 duke does not seal around the fuel door. gas can spill out of the top of the tank, especially with a full tank. the fuel tank is also open to the atmosphere causing vapor to enter an enclosed parking garage. the tank appears to be warped at the area where the fuel door is mounted to the tank. the gas smell has alwa…”
2016-11-15 · Fuel/Propulsion System · 2,000 mi“2016 ktm 690 duke plastic gas tank is swelling and deforming. this is causing a gapping issue with the plastics on the bike as well as around the fuel door area which allows fuel and fuel vapor to leak when the bike is rocked during operation or when the bike is stationary.…”
Excerpts of consumer complaints filed with NHTSA, lightly truncated. They are owner statements, not verified findings.