Perhaps this is old news to you all... it's dated May 2009. I was particularly interested as I have one of the GS' with suspect fork tubes.


KTM Recalls 2009 Off-Road Motorcycles: Front Fork Failure

May 8, 2009; KTM Recalls 2009 Off-Road Motorcycles: Front Fork Failure - THE FOLLOWING PRODUCT SAFETY RECALL WAS VOLUNTARILY CONDUCTED BY THE FIRM IN COOPERATION WITH THE CPSC. CONSUMERS SHOULD STOP USING THE PRODUCT IMMEDIATELY UNLESS OTHERWISE INSTRUCTED.

PRODUCT INVOLVED: OFF-ROAD MOTORCYCLES

UNITS: ABOUT 550

MANUFACTURER: KTM NORTH AMERICA INC., OF AMHERST, OHIO
HAZARD: THE FRONT FORK INNER TUBE ON THE OFF-ROAD MOTORCYCLES CAN CRACK AND SEPARATE FROM THE FORK AXLE, POSING A RISK OF INJURY OR DEATH TO THE OPERATOR.

INCIDENTS/INJURIES: NONE REPORTED. THIS RECALL IS BEING CONDUCTED TO PREVENT POSSIBLE INJURIES.

DESCRIPTION: THIS RECALL INVOLVES MODEL YEAR 2009 KTM OFF-ROAD MOTORCYCLES. THE MODEL NAME AND KTM™ LOGO ARE LOCATED ON THE RIGHT AND LEFT SHROUDS. THE FOLLOWING MODELS ARE INCLUDED IN THIS RECALL:

MODEL NAME DESCRIPTION
125SX ORANGE / BLACK
150SX ORANGE / BLACK
250XC-W ORANGE / BLACK
300XC-W ORANGE / BLACK

SOLD BY: KTM DEALERS NATIONWIDE FROM DECEMBER 2008 THROUGH APRIL 2009 FOR BETWEEN $6,000 AND $8,000.

MANUFACTURED IN: AUSTRIA

REMEDY: CONSUMERS SHOULD IMMEDIATELY STOP USING THESE VEHICLES AND CONTACT THEIR LOCAL KTM DEALER TO SCHEDULE A FREE REPAIR. REGISTERED OWNERS THE RECALLED OFF-ROAD MOTORCYCLES ARE BEING SENT A DIRECT NOTICE.

CONSUMER CONTACT: FOR ADDITIONAL INFORMATION, CONTACT KTM TOLL-FREE AT (888) 985-6090 BETWEEN 8 A.M. AND 5 P.M. ET MONDAY THROUGH FRIDAY, OR VISIT THE FIRM’S WEB SITE AT KTM.com - Ready to Race - KTM-Sportmotorcycle AG

We have been manufacturing motor vehicles for over 100 years, You would have thought that each new model would be an improvement on the old version. Yet still they make basic engineering mistakes.
I blame the bean counters, because as soon as they find something that does not fail under warranty they always seem to cost reduce its replacement.

Some design flaws that come to mind :=
bodyshell flanges pointing upwards so they leak. no one figured water flows downhill. (BMC)
making it necessary to remove the rear axle and suspension to change the hand brake shoes. (JAGUAR)
having to remove crankshaft to repair a sprag clutch. (YAMAHAHA)
ignition key remote fails (or ABS) rendering bike useless (BMW)
replacement light bulb does not work until dealer resets computer (SAAB)

My local dealer had 2 of these to do.
550 units worldwide is a pretty small amount of units once distributed. At least it they made a compulsory recall, I wouldn't complain about a brand new set of forks