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KTM Duke 200 - Weird Stalling Issue

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  • #1

    KTM Duke 200 - Weird Stalling Issue

    Hello friends,

    I am from Kolkata, and have been facing a weird stalling issue with my Duke 200 (2016 December) since ages, and it has ultimately made the ownership experience pathetic at best.

    Background: The bike had developed a weird rattle, which was diagnosed to be an issue with the head assy by KTM Six Mile, Guwahati (in 2018 I was posted in Guwahati), and the same was replaced under warranty. However, post repair, the bike developed an intermittent stalling problem. It has been more than two years since, but the issue could not be resolved.

    The problem: The bike starts perfectly when cold (even if it is left unused for weeks), idles like a champ, i start riding it, ride for about a hundred metres, and then it would suddenly stall (mostly on releasing the throttle or at low revs). On cranking it back up, it would crank ever so slightly longer than usual and would fire back to life. After that it would run absolutely fine and there would not be any problem. Sometimes after cold starts it would not stall at all, but the throttle response would be a tad dull during the initial few hundred metres and then it would be all good. Again there are times when it would stall the same way, but a single crank does not help. I would crank, the engine would fire up for a second, and again die. It's only after five to six times of cranking that it would start and behave normally. Although the multiple cranking issue does not happen often.

    This stalling issue has proved extremely dangerous amidst traffic a couple of times.

    Apart from the above, it would perform perfectly fine. The bike has been checked by the guys at KTM Six Mile, Guwahati along with their service engineer, but sadly, the problem could not be resolved.

    The problem happens a lot more during winters, but surprisingly, it has happened a couple of times even with a warm engine.

    Last week I went for an oil change and a wash. When I just moved out of the workshop after the job, it stalled and needed five to six times cranking to start.

    Now that the bike is out of warranty, i am not sure what assistance i would receive from KTM. The bike has spent most of its time at the KTM workshop in the name of diagnosis.

    I would really appreciate some help from the experts to get to the roots of the issue myself.

    Note: The throttle body was replaced under warranty months before the head replacement due to a sticky throttle valve spring. Spark plug, ignition coil, all replaced. Injectors and fuel pump have been cleaned by the KTM guys.

    Thanks & Regards,

    Anish
    Tags: cold start, ktm, ktm 200 duke, stall, stalling
  • #2
    Re: KTM Duke 200 - Weird Stalling Issue

    Thread approved.

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    • #3
      Re: KTM Duke 200 - Weird Stalling Issue

      Hey Anish
      It is very sad to hear such repeated issue causing frustration and making our ownership experience okyish, I will recommend you to visit and get checked your bike from very good reputed KTM or equivalent bike mechanic rather than visiting KTM workshop as it might cost lot to you because of dealership mindset.
      As you described I only say the problem with the Spark plug because this happens most when engine temperature is low. But some time problem might be somewhere else
      • Likes 1

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      • #4
        Re: KTM Duke 200 - Weird Stalling Issue

        Hi there..

        I would suggest to
        1. check the battery for a load test and see if its pushing out correct voltage.
        2. Check the spark plug, if im not wrong the gap would be .8mm or 1mm check your manual.
        3. The sparkplug cable rotate and remove, see if there is oxidation build up, if yes either clean or replace rhe cable.
        3. The cable that sits on top of the spark plug should sit with an audible click while installing.

        One other thing is remove the power cable that comes from the fuel tank and reseat it, check for oxidation on the connectors. Happen to me once where vehicle was acting weird and loss of power in some rpms, cleaning,researing this solved the issue for me.
        Dan

        http://www.soundcloud.com/danziie
        http://www.youtube.com/user/dreamgrowls
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        • #5
          Re: KTM Duke 200 - Weird Stalling Issue

          Since you are mentioning bike runs for 100 odd metres before stalling, I'm pretty fixed upon the problem being the fuel pump. Injectors and all were cleaned but you could try this as the injectors plus the fuel lines hold enough fuel to run about 100 metres without pressure build up by the pump, which is same in your case. Again, just my 2 cents.
          • Likes 1

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          • #6
            Re: KTM Duke 200 - Weird Stalling Issue

            Originally posted by Vishal Wagh View Post
            As you described I only say the problem with the Spark plug because this happens most when engine temperature is low. But some time problem might be somewhere else
            Originally posted by dreamgrowls View Post
            Hi there..

            I would suggest to
            1. check the battery for a load test and see if its pushing out correct voltage.
            2. Check the spark plug, if im not wrong the gap would be .8mm or 1mm check your manual.
            3. The sparkplug cable rotate and remove, see if there is oxidation build up, if yes either clean or replace rhe cable.
            3. The cable that sits on top of the spark plug should sit with an audible click while installing.

            One other thing is remove the power cable that comes from the fuel tank and reseat it, check for oxidation on the connectors. Happen to me once where vehicle was acting weird and loss of power in some rpms, cleaning,researing this solved the issue for me.
            Originally posted by tez_padhye View Post
            Since you are mentioning bike runs for 100 odd metres before stalling, I'm pretty fixed upon the problem being the fuel pump. Injectors and all were cleaned but you could try this as the injectors plus the fuel lines hold enough fuel to run about 100 metres without pressure build up by the pump, which is same in your case. Again, just my 2 cents.
            Thank you guys for the response! I forgot to mention that the spark plug along with the lead was replaced before.

            However, considering your inputs, i got them replaced again last week, but it didn't help resolve the issue. On a relatively cool day the bike would still stall, or act slightly weird after about 100 metres and then would act absolutely normally after starting her again.

            I would get the battery load test done, but as per the last test (done six months back) it was dropping to around 10 V during cranking, which is pretty good. This is the battery that came with the bike (December 2016) and is still going strong. But i am having the issue right from the time the cylinder head was replaced (around this time in 2018).

            The SCV guys checked the shim setting and did a compression test last week, and every thing was healthy.

            I am strongly considering the battery and fuel pump suggestions and would ask them to get these checked once again.

            But why is it that the fuel pump would not be able to generate enough fuel pressure at the start, but then become alright after the first 100 metres or so?

            Once again, thank you guys!

            Comment

            • #7
              Re: KTM Duke 200 - Weird Stalling Issue

              Yours question is correct, pump is ok, as same pressure is required from start to end. Please try another battery from another vehicle of same amp rating. SCV guys can easily figure it out.

              ----consecutive posts auto-merged-----

              Also try battery wire mod from General Biking Discussion > The story so far.. My Honda CBR 250R > #102 thread page no.11 .

              As many of the Hondas has this issue and many users claim that it even helped them even ay starting condition also. Follow this thread and share with SCV guys to try this.
              Last edited by Vishal Wagh; 09-17-2020, 01:59 PM.
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              • #8
                Hi guys, sorry for the delayed response. I had to replace the battery, as it had gotten weak. Even then, the problem remains.

                The earthing is in pretty good shape. Apart from the initial stall which happens once in every five rides may be, it runs fine..

                ​​​​​​Very irritating that the we are not being able to get to the problem.
                Last edited by anishbora; 03-21-2021, 01:10 AM.

                Comment

                • #9
                  Faced the exact same issue and it was exactly after head work that they removed for decarbonizing. Initial stalling for some time, no issue after warming up. Bike sat for 3 months with the dealer who had no clue about the issue. They tried swapping almost every part (ECU, wiring kit, sensors, fuel pump, throttle body, etc.), nothing worked and insisted on getting a brand-new cylinder kit. Customer care was involved and it ended in engine sleeving. This happened with a bike that was never redlined till date, properly serviced and idled daily before use. Even after the engine work, issue continued and only part left replacing was the head itself and they replaced with new one and everything solved.

                  So it's better to check the head first.
                  #RetiredRider
                  #KeyboardWarrior
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