KTM - Burnt bike due to faulty service part

This all started when I first noticed a crack in my tank of my KTM *** ADVENTURE during a routine wash. I complained to KTM on the same day and discussed it further with Shantanu Service Cluster manager for Gujarat. He asked to keep it quiet and asked me to share photos and do not jerry repair my cracked tank, as he will get it replaced in warranty as it is a manufacturing fault KTM knows about. And Resolution is provided to customer as and when problem appears. I myself asked in my biking group about such issue and shared my bike photos, this is when I got to know there are many people with exact same issue arising. All the bikes are of February.**** manufacturing Date.

After few delays my Tank was finally replaced on *nd januray,****. Shantanu (Service clusterManager) who ordered the replacements as service center had no idea whats parts to order and how to replace these are the words of the service center manager (I have call recording) was on leave during that time and had gone on a trip. I rode my bike with a cracked tank for which i had used industrial tape to temporary fix the crack from Bhavnagar to Ahmedabad almost ***kms to get replacement. when I reached the service centre Gallops KTM at C.G Road, I asked them to fix the crack. the replacement tank was brought in front of me to which I pointed out that the new tank wasn't in pristine condition and was already deteriorating. I had also asked them to change all the O-rings and use torque wrench to fix the tank for which I got a reply sir please sit we will do proper work. the biggest problem I saw at Service Centre was that an untrained worker was working on my bike under the supervision of a trained worker who would come intrust the service guy and then go away. the replacement parts were also missing many items for which those items were removed from old tank and jerry fitted on my new tank such as side rubber padding which were fitted using double sided tape for which I paid extra **rs in cash without any bill, O-rings from the old tank. Which was confirmed when I wasn't billed for them while I was billed for every other small thing such as some **Rs odd for fitting a side mirror. The service engineer also had jerry resolved the tank cracking problem by putting * rubber insert instead of standard * on the chassis mounting point on his own thought.

The same day I had also bought AUX lights Gold runway **x which cost *****rs and were fitted inside service centre by me and electrical fitting for the same was done by the Head Service engineer at service centre. All the tools used were from the service centre.

the *st red flag that I found out something was wrong with my tank was when I was getting refiled after getting my service the spring lock of my tank cap wasn't working and had to be manually forced closed for which I contacted Gajand from the service centre and was assured it isn’t a problem. and I rode back to Bhavnagar the same day.


Now coming to what happened on *th January,****. I had gone for some personal work in Kausamba. I had left Bhavnagar in morning *-*:**am reached Vadodara. And did my last refuel at Vadodara bypass reliance petrol pump. then after which I continued to ride to kausamba, complete my work there and started to ride back to my home Bhavnagar at around **:** am. before leaving I had to call the supplier of the AUX light Vimal Lights in Ahmedabad, as my mounting of the right light had lost the threads due to which I had unconnected the light and kept it in my bag which was clipped on the rear seat. the owner of Vimal light told me that he will be sending me the aluminium mount replacement by next day in Bhavnagar. then after which I started my journey back towards Bhavnagar. At around * am I took a halt at tea point on Surat Vadodara highway. which is around **-**kms before Vadodara’s bridge. I talked to my friends that I would be reaching back home safely by * pm. I freshened up there, drank * teas. and started to ride back at around *:** pm, then I took a small halt at a petrol pump to relive myself, got air filled in my tyres and left. No refuelling here because the petrol pump wasn't a HP or reliance. I try to keep my petrol filling constant from these * companies only. this was around **-** kms before my accident.

Coming to the main events. My bike was on low fuel for some time now. I had driven around *** kms since I last fuelled at reliance. I was entering at the GSFC bridge on the highway heading towards Anand. I was riding in the left most lane at around **kmph speed when I saw a Tata Ace driving in the centre lane ahead of me. As the distance was closing in, at the very last moment the driver of the chota hathi took a left suddenly and braked. I tried to outmanoeuvre it but I had a minor side by side impact with the truck. My right-side stock crash bar of the bike had just touched the left side of chota Hathi near its rear wheel fender and suddenly I saw a ball of fire rising from my tank to my eye level. at that moment I suddenly jumped of the bike on the right side and my bike fell on the left edge of the road, burning viciously. as soon as I got up off the road my *st task was to check myself and I saw my jacket had caught fire. I was trying to remove it but couldn't find the zipper in heat of the moment and decided to remove it over my head. I removed my gloves, removed my helmet and then removed my jacket my face and hand `were burnt at this point but couldn't feel the burn. the Tata ace driver had stopped some few *** meters ahead I begged people around to catch the guy but * guy on motorcycle went up to him they chatted and then both ran away.
Then I tried to remove my bag which was clipped on to my bike on the rear seat but till I try the bike was engulfed in flames and everything was burning. I was begging people to call *** and after ** minutes of trying * person called the ambulance. I was sitting on the side of road, blacking out in front of my eyes, wasn't unconscious when I felt someone trying and succeeded to steal watch off my wrist. I shouted and someone tried to help me. that's when ambulance arrived and I was put in the ambulance and few people have caught few thief’s who tried to steal my few remaining items left on the road. I was finally given back my helmet and my camel water bag. my watch had been stollen off my hand and not sure of other items. my phone and all the items in bag had burnt by then.
I was taken to government hospital at around * pm when I was given *st aid till my parents arrived from Bhavnagar at around ** pm. then after which I was hospitalised in Vadodara & Bhavnagar for total of ** days. Diagnosed with *rd degree burns on my left hand. *nd degree flash burns on my face and dead blood accumulated in my right bicep which was caused because of me jumping off the bike.
My injuries are so severe that I am medically denied to go out under sun For face * months, for hand till full recovery estimated time * year.

After the incident I contacted KTM regarding this to find out the cause of fire. but started deflecting the question plainly blaming my minor crash as the cause of fire. but the true cause of fire is the leaking petrol tank as replacement wasn't done properly. Also I am not the only person with the broken tank issue. I have collectedover ** people with exact same issue sitting in the confiment of my home and the number is much larger at the india level.

A *rd party analysis of my case was also conducted by an Airforce Crash Investigator Retired Wing Commander Rakesh Singh who also pointed out that the ignition for fire spark was caused by metal rubbing with each other when I had a minor crash, but the fuel source for the fire was the leaking air fuel mixture from the tank, which may be due to O-ring failure or screw overtightening which created a minor extra gap where fuel would leak very slowly and accumulate under the tank due to cold ambient temperature. which resulted in the fire ball I saw soon after the crash rising from the tank to my eye level.

KTM has been denying me any conntact with senior staff +denying liablity and also trying to intimidate me with the fear of filing a legalaction against me.

List of Items lost:
Item Cost Opportunity Cost
Bike ****** ****** (Due to service and parts replacement)
Insurance *****
RTO *****
Loan *****
Phone ***** *****
Gopro ***** *****
Gopro accessories ***** *****
Power bank x* **** ****
Charger adaptor ****
Cables **** ****
Riding Jacket *****
Riding Pant *****
Gloves ****
Helmet ****
Earphones ****
Bluetooth receiver ****
Tpms **** ****
Bike Accessories *****
Aux Lights *****
Hard cash *****
Gshock Watch **** ****
Other wearables ****
Bag ****
Shoes ****

Medical Expenses ****** & counting uncountable
Mental & Physical Pain Unmeasurable
ID Proofs x*
Bank Cards & Wallet