Fuel tank has swollen over time, causing body panels to no longer fit properly, fuel tank is under the seat and is a structural component of the motorcycles frame by design, my concern is that the tank is in very close proximity to exhaust system and is now considerably closer to exhaust from swelling, which concerns me that it could continue to swell and cause a fire when it contacts exhaust, also side panels on rear of bike are starting to break mounting points and im concerned may come off the bike on the highway and cause an accident. This is a very common issue in the US due to the plastic they used and our ethanol blended fuel, KTM is aware of the issue and will not recall, as this is not a problem overseas where non ethanol fuel is common. This issue is well documented on enthusiast groups online. This has been an issue for me since 2023 and has progressively gotten worse every season. This issue started by around 200 miles and is significantly worse now as it has 1100 miles on it currently. Issue was brought to service departments attention while under factory warranty and I was told its normal and won't get any worse, it is now to the point I am concerned about riding the motorcycle.

Source: NHTSA complaint ODI #11721210 · view all complaints for this vehicle at nhtsa.gov