2006 Ducati Sport Classic Problems

What owners report

Nearly every sampled complaint for this model year concerns the plastic fuel tank, which owners report swelling and warping so that it no longer sits in its frame brackets. Reports often appear within the first few thousand miles, and many owners describe repeat replacement tanks deforming in the same way. A smaller number of complaints cover electrical faults, fuel line and pump fittings, and steering interference from the swollen tank.

1. 1
   Fuel system

   Fuel tank swelling and spreading off its mounts

   • 69 complaints (92%)
   • median 4,000 mi at 4.2 yrs old (61 state mileage)
   • filed 2008–2013

   Owners describe the plastic tank growing wider over time until the front mounting points no longer engage the brackets on the frame, leaving only the single rear bolt holding it. Many say the tank can be lifted at the front or rocked side to side while riding, and some report surface blisters, dimples, and paint bubbling. Complaints frequently mention that the dealer replaced the tank under warranty, sometimes more than once, with an identical part, and owners expect the same deformation to return. Most reports arrive between roughly 300 and 8,000 miles, often within a year or two of ownership, and several owners link the swelling to warm weather and ethanol-blended fuel.

   What to check: With the bike cold, try to lift the front of the tank and rock it side to side; it should sit firmly in both front brackets with no play. Ask whether the tank has ever been replaced and inspect the top surface for blisters, dimples, or bubbling paint.

   2 excerpts from owner complaints in NHTSA records

   “The plastic fuel tank on my 2006 Ducati paul smart 1000 motorcycle is spreading in width, so that it no longer sits securely on the mounts that attach it to the vehicle. The top of the fuel tank is also becoming dimpled, was smooth when new. I suspect it may the polymer used in the fuel tank reacting badly with the ethanol we have in USA gasoline.”

   NHTSA complaint #10261345, filed 2009-03, 4,000 miles

   “The gas tank has started to deform and does not mount properly to the motorcycle. This is the second time that this has occurred and was replaced at no cost by the Ducati dealer. This second tank the dealer is giving me a bit of hesitation and wants to shim the tank. I believe shimming will not stop the tank from spreading and will eventually be a bigger problem.”

   NHTSA complaint #10279819, filed 2009-08, 15,000 miles
2. 2
   Body and structure

   Steering and control interference from tank growth

   Mentioned in 7 of 60 sampled complaints

   Several owners report that as the tank widens it contacts the handlebar controls or fairing at full steering lock, and some note the tank rubbing against the frame. Complaints describe this as a change from new, when the bars cleared the tank on both sides, and mention that the tank sliding backward and forward affects balance in corners. In these reports the dealer either acknowledged the fitment problem or offered to shim the brackets rather than replace the part. Reported from a few hundred miles up to about 12,000 miles, typically after the tank has visibly spread.

   What to check: Turn the bars fully left and right and check for any contact between the controls, levers, or fairing and the tank, and look for rub marks on the tank sides and frame.

   2 excerpts from owner complaints in NHTSA records

   “Fuel tank on motorcycle has expanded and buckled. It is no longer being held in place by the pucks at the front of the tank. It is only held by the single bolt at the rear of the tank and by the front fairing. The front of the tank can be lifted up off the bike. The tank shifts back and forth when riding the bike. My biggest concern is that the tank could shift and throw off my balance under hard cornering, leading to a loss of control. …”

   NHTSA complaint #10349905, filed 2010-08, 2,500 miles

   “The material of the fuel tank on my 2006 Ducati sport 1000 seems unstable over time. The surface shows bubbles (blisters) and dimples and the tank seems to be growing . When new, at full steering lock left or right, none of the controls on the handlebars would hit / touch / interfere with the tank. Now, both sides do. In addition, cracks are developing in the recessed area of the tank where the filler-cap resides. I have brought this issue to the attention of the dealership where I've brought this motorcycle and they acknowledge the problem. …”

   NHTSA complaint #10249574, filed 2008-11, 10,737 miles
3. 3
   Fuel system

   Fuel leaks and weeping at the pump and fittings

   • 13 complaints (17%)
   • median 3,000 mi at 4.3 yrs old (11 state mileage)
   • filed 2008–2011

   A few owners report fuel seeping where the pump housing and fittings attach to the composite tank, without those parts ever being disturbed. Others describe the deformation reaching the pump mounting surface or the petcock seal, and they say they worry about fuel reaching the engine or exhaust below. One owner also describes the tank pulling on the fuel line connector and the engine stopping, and another reports a clogged filter from internal tank condition causing a loss of power. Reported from as little as a few hundred miles up to about 6,000 miles, generally alongside visible tank deformation.

   Recall 07V017000

   What to check: Inspect the pump flange and line fittings on the underside of the tank for staining, dampness, or a fuel smell, and confirm the recall work on the fuel pump hose and filler fasteners was completed by checking with a dealer against the VIN.

   2 excerpts from owner complaints in NHTSA records

   “Fuel tank is bubbling, spreading and will eventually come apart at the fuel pump mounting surface and leak on my headers. Fire and emission hazard, the tank is being replace by Ducati north america, but what will happen 10years form now when I need another tank for my 15,000 dollar motorcycle?”

   NHTSA complaint #10329978, filed 2010-05, 3,000 miles

   “Plastic gas tank has deformed causing it to become unattached from the two front mounts. Only thing holding tank to motorcycle is one bolt in rear. Obvious bulge in top of tank from the deformation. Plastic may crack and allow gas to escape and leak over engine which is directly below the tank.”

   NHTSA complaint #10255847, filed 2009-01, 5,000 miles

Buying note. The fuel tank is the item to examine closely on this model year: check that it still fits its front brackets with no play and ask for its replacement history. Confirm any open recall work was completed, and budget for a new tank if the existing one shows swelling or blistering.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.