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**xBhp** · 06-24-2019, 02:09 PM

Re: Duke 200 coolant mixing with engine oil

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**rohitvasuniya** · 06-28-2019, 09:47 PM

Re: Duke 200 coolant mixing with engine oil

Originally posted by Wolverine 248609 View Post

Hi All,

I have a duke 200 since August 2012. It has over 40k on the odo. In December 2018, while riding on an empty stretch of road, the entire engine oil got emptied on to the road through the lid named "oil filter" on the right side of the bike. Immediately after that the message "low oil pressure" starts flashing on the display. I found it odd as I got it serviced just a month prior to that day at Madhapur service centre.

After leaving it idle at my home for more than 2 months, I had it filled with a non synthetic engine oil from a local mechanic and took it to Madhapur service centre again. He said that as the engine oil was not leaking at that time there was little to be done. I felt relieved and came home.

I used the bike as usual for some more days before I had a pillion rider one night. Again the message "low oil pressure" started flashing on the screen. Again a trip to madhapur service center and got the oil filter lid changed.

Now in April, I took it to Kondapur service center, where they are telling me that the coolant is mixing with the engine oil and if I continue riding it in the current state, the engine may get siezed. To remedy this they are asking me to get the piston, chambers and an oil seal which helps keep out the coolant out of the engine, changed. And the estimate they are giving me for this is 30k.

I love my bike as it had served me reliably for 7 years, and I still like being able to ride it. But, I am doubtful if investing 30k on this old a bike is a wise decision or not.

Can anyone pls suggest on what I can do? Will I be able to get the same repairs done outside of authorized service centres. Any pointers would be highly appreciated.

The problem is burned head gasket bro

**Wolverine 248609** · 06-28-2019, 11:50 PM

Re: Duke 200 coolant mixing with engine oil

Originally posted by rohitvasuniya View Post

The problem is burned head gasket bro

Thanks for the reply bro.
Do you think it will take 30k to fix it?

**kiran2508** · 07-01-2019, 07:28 PM

Re: Duke 200 coolant mixing with engine oil

Originally posted by Wolverine 248609 View Post

Do you think it will take 30k to fix it?

Take it some other KTM service center and get a 2nd opinion, how many kms did you ride without oil the 1st time when all oil got drained?

Even running for less than 5-10kms without oil will damage the piston, crank rod and crank bearings
If the piston, crank are damaged for running without oil then YES, to rebuild the full engine for both bottom and top end(piston cylinder kit, crank rod and bearing, new valves shims and valve seals, timing kit, clutch assembly and another misc parts) it'll cost around 25-30K for 200 depending on labor charges, around 30-35K for 390.

**Wolverine 248609** · 07-01-2019, 08:58 PM

Re: Duke 200 coolant mixing with engine oil

I did drive 5 kms from that point to home. If I do decide to invest 30k now, will it be worth it? Considering the fact the I have more than 40k on the odo.

**kiran2508** · 07-01-2019, 11:06 PM

Re: Duke 200 coolant mixing with engine oil

Originally posted by Wolverine 248609 View Post

I did drive 5 kms from that point to home. If I do decide to invest 30k now, will it be worth it? Considering the fact the I have more than 40k on the odo.

Either way considering the bikes age and kms run, 40-50K kms is the average engine life of D200, a very very well cared engine will go 60-70K kms+.

If you wish to continue to keep the bike for another 3-4 years, then it'll be good to rebuild with all genuine parts without skipping a step it'll last another 50K kms. Even if you are saving ₹5-8K don't get it done outside anywhere else apart from KTM service center.

Also it really might not cost full 30K atall, mechanics tend to quote the maximum possible estimate because they won't really know how bad the problem is and they quote the worst case scenario price assuming everything has to be changed.

You can check and reuse most of the old components which are good condition and get it done within ₹10-15K. As long you don't see blue smoke, reducing oil within 500-1000kms, loss of power or wired sounds from engine most 60-70% parts will be fine.

So start with
1. Disassemble the head check for valve cover gasket and head gasket condition, valve and valve seal, shims condition, timing chain, oil pressure sensor. This all has to be replaced mandatory if engine head is removed, check for faulty oil pressure sensor first before doing anything else, it might be as silly as that a bad sensor.
2. Remove the head and check for damage or scratches on piston and cylinder walls. Based on the condition, you can only replace the piston rings separately or entire piston assembly or entire kit including both cylinder and piston.
3. Check crank rod and bearing, if there is no play and wobble then you save nearly 50% of the money here, close to 6-8K
4. Clutch is good to replace during a rebuild, if its in good condition you can save 20% of money here aswell. Around 3K

Conclusion assuming the worst case it'll cost ₹25-30K, if labor charges are 20% of parts.
Best case minimum cost with a half rebuild it'll cost you ₹10-12K.
Lucky case it might be as simple as bad sensor or bad head gaskets and bad valve seal or bad oil pump seal and rest all components are fine, then it'll cost you not more than ₹3-4K.

All the best.

**Wolverine 248609** · 07-02-2019, 01:03 PM

Re: Duke 200 coolant mixing with engine oil

Originally posted by kiran2508 View Post

Either way considering the bikes age and kms run, 40-50K kms is the average engine life of D200, a very very well cared engine will go 60-70K kms+.

If you wish to continue to keep the bike for another 3-4 years, then it'll be good to rebuild with all genuine parts without skipping a step it'll last another 50K kms. Even if you are saving ₹5-8K don't get it done outside anywhere else apart from KTM service center.

Also it really might not cost full 30K atall, mechanics tend to quote the maximum possible estimate because they won't really know how bad the problem is and they quote the worst case scenario price assuming everything has to be changed.

You can check and reuse most of the old components which are good condition and get it done within ₹10-15K. As long you don't see blue smoke, reducing oil within 500-1000kms, loss of power or wired sounds from engine most 60-70% parts will be fine.

So start with
1. Disassemble the head check for valve cover gasket and head gasket condition, valve and valve seal, shims condition, timing chain, oil pressure sensor. This all has to be replaced mandatory if engine head is removed, check for faulty oil pressure sensor first before doing anything else, it might be as silly as that a bad sensor.
2. Remove the head and check for damage or scratches on piston and cylinder walls. Based on the condition, you can only replace the piston rings separately or entire piston assembly or entire kit including both cylinder and piston.
3. Check crank rod and bearing, if there is no play and wobble then you save nearly 50% of the money here, close to 6-8K
4. Clutch is good to replace during a rebuild, if its in good condition you can save 20% of money here aswell. Around 3K

Conclusion assuming the worst case it'll cost ₹25-30K, if labor charges are 20% of parts.
Best case minimum cost with a half rebuild it'll cost you ₹10-12K.
Lucky case it might be as simple as bad sensor or bad head gaskets and bad valve seal or bad oil pump seal and rest all components are fine, then it'll cost you not more than ₹3-4K.

All the best.

Thanks for taking out your time and giving me a lengthy explanation. I will take it to another service center soon. Will keep you posted.

Thanks a lot again.

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Duke 200 coolant mixing with engine oil

Duke 200 coolant mixing with engine oil

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