Ameer Randolph
KTM motorcycle owners have reported issues with fuel tanks, including surface cracks, blisters, ripples, and swelling, which have been attributed to ethanol additives in the fuel. While some KTM models, like the RC8, have plastic fuel tanks, others, like the 2020 KTM 1290 Super Duke R, feature steel tanks. The use of ethanol fuel, particularly E10, has been a topic of discussion among KTM owners, with some recommending ethanol-free options or fuel stabilizers to prevent potential damage to the fuel system and engine performance. The KTM dealership also advises the use of non-ethanol gas in their Powersports products. However, opinions vary, and some owners have experienced no issues with using ethanol-blend fuels in their KTMs.
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What You'll Learn
KTM fuel tank materials
KTM motorcycle owners and users have been concerned about the effects of ethanol on their fuel tanks. Some have reported issues with their KTM fuel tanks, such as cracking and swelling, which have been attributed to ethanol additives in the fuel. KTM dealers have recommended using fuel without ethanol or adding a fuel stabilizer to prevent these issues.
The KTM Superduke R fuel tanks are made of nylon-based resin fiber, specifically Polymide-6 (PA-6). This material is different from the typical High-Density Polyethylene (HDPE) used in other fuel tanks. While PA-6 is a strong and durable material, some users have experienced issues with their KTM fuel tanks, which they believe are caused by ethanol in the fuel.
Ethanol has been known to cause problems in fuel tanks, especially those made of fiberglass, where it can lead to delamination. Modern plastic fuel tanks, like the ones found in KTM motorcycles, are generally considered to be more resistant to ethanol. However, some KTM owners have still experienced issues with their plastic fuel tanks, such as cracking and swelling, which they attribute to ethanol in the fuel.
To avoid potential damage to KTM fuel tanks, some owners choose to use ethanol-free fuel or fuel with a lower ethanol content. For example, some owners use 91 or 93 octane fuel with less than 10% ethanol, which is recommended in the user manuals of certain KTM motorcycle models. Additionally, using a fuel stabilizer is suggested when the motorcycle is not in use for extended periods.
While the nylon-based resin fiber used in KTM Superduke R fuel tanks is a durable material, the effects of ethanol on these tanks are still a concern for some owners. The preference is to use non-ethanol fuel or fuel with a lower ethanol content to prevent potential issues, especially in areas where non-ethanol fuel is readily available.
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Ethanol's impact on KTM fuel atomization
KTM motorcycle owners have reported issues with fuel tanks and ethanol-based fuel. Some have experienced swelling, blisters, ripples, and surface cracks on their tanks, which KTM has attributed to ethanol additives in the fuel. KTM has advised that customers use non-ethanol gas in all their Powersports products.
Ethanol has been known to impact fuel atomization and burn rate, which can cause issues in certain conditions. Ethanol absorbs moisture, which can lead to problems with the fuel system as the moisture collects in the tank and other parts. This can affect the burn rate of the fuel and cause issues with the engine.
Some KTM owners have opted to use non-ethanol fuel or add a fuel stabilizer to prevent issues. Others have chosen to use higher octane fuel, such as 95 or 98 octane, which often does not contain ethanol. However, this fuel can be more expensive and may not be readily available in all areas.
The impact of ethanol on KTM fuel atomization can vary depending on the specific model and its fuel tank material. KTM motorcycles with plastic fuel tanks, such as the RC8 and some 690 models, seem to be more susceptible to damage from ethanol-based fuel. The Super Duke R, on the other hand, has a nylon-based resin fiber fuel tank, and it is unclear how ethanol fuel affects this material.
To minimize the impact of ethanol on KTM fuel atomization, it is recommended to use non-ethanol fuel or fuel with a low ethanol content, such as 10% or less. Using a fuel stabilizer can also help prevent issues, especially when the motorcycle is not in use for extended periods.
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KTM engine damage from ethanol
KTM motorcycle owners have reported various issues with the use of ethanol in their vehicles. While some claim that ethanol causes no issues in their plastic fuel tanks, others have experienced tank surface cracks, swelling, blisters, and ripples. KTM acknowledged that ethanol additives could cause tank surface cracks, but stated they would not replace the tank for cosmetic reasons. To address this issue, KTM recommended using fuel without ethanol or adding a fuel stabilizer.
Ethanol can also affect the engine's performance and fuel system. It changes fuel atomization and burn rate, which can be a slight issue under certain conditions. Ethanol absorbs moisture, leading to problems with the moisture-laden fuel's burn rate and the fuel system once the moisture collects in the tank and other components. Some KTM owners have opted to use non-ethanol fuel or add fuel stabilizers to prevent these issues.
The recommended fuel type for KTM motorcycles varies depending on the model and region. In the United States, the owner's manual for the RC 390 recommends using 91 octane fuel with 10% or less ethanol. However, some owners prefer to use ethanol-free fuel, believing it to be better for motorcycle engines. In Europe, vehicles must be able to run on a minimum of 10% ethanol, and KTM motorcycles from the same factory in India are sold in the US and Europe.
While some KTM owners have experienced issues with ethanol, others have not reported any problems. Some owners use 95 or 98 octane fuel with 5% ethanol without encountering any significant issues. It is worth noting that the problems caused by ethanol may depend on the specific model, the materials used in the fuel tank, and the riding conditions.
To summarize, KTM motorcycle owners have reported mixed experiences with ethanol fuel. While some have encountered issues with their fuel tanks and engines, others have not noticed any problems. KTM has acknowledged that ethanol can cause cosmetic tank cracks and recommends using non-ethanol fuel or fuel stabilizers. The choice between ethanol and non-ethanol fuel depends on various factors, including the specific KTM model, regional fuel standards, and personal preferences.
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KTM fuel tank swelling
KTM motorcycle owners have reported issues with fuel tank swelling, which has been attributed to the use of ethanol in gasoline. In online forums, KTM owners have shared their experiences with fuel tank swelling and offered advice on preventing and managing the issue.
One owner of a KTM 690 reported a "blown fuel tank" and advised that "avoiding ethanol should be the priority" for those with plastic fuel tanks. This is supported by another KTM owner who stated that their dealer recommended using non-ethanol fuel or adding a fuel stabilizer to prevent tank surface cracks caused by ethanol additives.
The issue of fuel tank swelling appears to be more prevalent in certain KTM models with plastic tanks, such as the RC8 and Superduke R. The Superduke R's fuel tanks are made of a nylon-based resin fiber, specifically Polymide-6 (PA-6). KTM owners have also reported similar fuel tank issues with other motorcycle brands, including Ducati, Aprilia, and KLR650.
While some owners have successfully used ethanol-containing gasoline in their KTMs without issues, others have opted for non-ethanol fuels or fuel stabilizers as a preventive measure. Some KTM owners have expressed concerns about the limited availability of non-ethanol fuels in certain regions, impacting their ability to avoid potential tank issues associated with ethanol.
To summarize, KTM fuel tank swelling has been a concern for some owners, particularly those with plastic fuel tanks. The issue has been linked to the use of ethanol in gasoline, and owners have shared their experiences, advice, and concerns in online forums. While there are mixed reports of ethanol causing issues, many KTM owners prioritize using non-ethanol fuels or fuel stabilizers to prevent potential tank swelling and other related problems.
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KTM fuel tank cracks
KTM fuel tanks are prone to cracking, and ethanol additives in the fuel have been identified as a potential cause. KTM has acknowledged this issue, with some dealers offering to replace affected tanks. However, KTM has also stated that they will no longer replace tanks solely for cosmetic reasons. Owners of KTM motorcycles have reported surface cracks on their fuel tanks, especially on the RC8 and RC8R models.
The cracking of KTM fuel tanks due to ethanol additives is a significant concern for riders. Ethanol has been known to cause issues with fuel atomization and burn rate, and it has a tendency to absorb moisture, leading to problems with the fuel system. While some riders opt for non-ethanol fuel or add fuel stabilizers to mitigate these issues, others have reported success with coating their tanks with Caswell, a product that has been effective in preventing tank swelling and warping caused by ethanol.
In addition to ethanol, other factors have been implicated in KTM fuel tank cracks. One notable factor is the charcoal canister found on street bikes, which can become clogged due to overfilling or fuel leakage when the bike is leaned over. This results in the build-up of gases and subsequent expansion of the fuel tank, leading to cracks. Some riders have addressed this issue by removing the charcoal canisters and re-routing the vent lines.
To address KTM fuel tank cracks, several repair options have been suggested by members of motorcycle forums. One option is to use a plastic repair kit, such as the one offered by Rocky Mountain ATV. Another option is plastic welding, which has been praised for its effectiveness in repairing cracked fuel tanks. Some riders have successfully performed plastic welding using a soldering iron and a piece of liquefied plastic, resulting in a barely noticeable repair after sanding and polishing.
While KTM has offered support by replacing affected fuel tanks, the issue of cracks caused by ethanol additives and other factors remains a concern for riders. To prevent and address this problem, riders have explored various solutions, including the use of non-ethanol fuel, fuel stabilizers, tank coatings, and repairs through plastic welding or repair kits.
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Frequently asked questions
KTM fuel tanks are made of nylon-based resin fiber, or Polymide-6 (PA-6). While ethanol does not damage the fuel tank, it can cause issues with the fuel system. Some KTM owners have reported problems with their fuel tanks, such as cracking, which they attribute to ethanol additives in the gas.
Ethanol can change fuel atomization and burn rate, and its affinity for absorbing moisture can lead to problems with the burn rate and fuel system. It is recommended to use non-ethanol fuel or add a fuel stabilizer to prevent these issues.
Yes, some KTM owners recommend using a fuel stabilizer or additives such as StarTron to prevent ethanol issues. Others suggest mixing leaded Cam2 with non-ethanol premium fuel to raise the octane level and improve engine performance. It is important to note that leaded fuel should not be used in vehicles with catalytic converters or oxygen sensors.
