Re: KTM 200 Duke

Sorry, didn't notice the reply.

The bike cranked when pressing the start button.

Spark plug was checked and found ok.
And if the spark plug was an issue, then should the bike have started by a push start?

Re: KTM 200 Duke

Everythings going to cost a bit i guess..😅. I will keep udpating the observations. Thank you.

Re: KTM 200 Duke

If you can feel pitting when you slide your finger over the slider, your slider is pitted and yes that's what's causing the fork oil seals to leak. The slider should be pitting free and dust free for the fork seals to stay intact. Any dent or nicks on the slider would mean the fork seals will get damaged as the sealing part of the fork seal is very sensitive, it's universal with all motorcycles. The sliding motion of the slider would ruin the soft innards of the seals which then causes leak. Get the slider replaced.

Cheers!
VJ

Re: KTM 200 Duke

Hey..Thanks man. I adjusted the clutch free play today and gear shifts do feel smoother now....i havent ridden longer after adjusting freeplay..i will post further observations. About throttle body cleaning, it was done when i gave it for service. Actually the svc guy recommended doing it when i said the bike was sitting idle for 11 months. But the thing was they did it by some mechanic outside the authorized svc. . That's what they said to me. The spark plug was not cleaned though i guess. I will check the sparkl plug and go for replacement if neede.
I checked the fork slider as you said. I found a small nick on the slider. I have attached a picture of the same. The nick can be felt only when you rub your nail over it. Will it be this that's causing the oil leak..?
And about the shims, i researched a bit about it and came to know that a lot of svc guys tend to mess up the whole thing. Could anyone suggest the best ktm service centre in ahmedabad, as am currently staying here and also pretty new to this place.

Re: KTM 200 Duke

I think, the basic servicing of your bike has been taken for a toss or not carried right. Starting with your last question, hard gearshifts would probably mean the oil grade is incorrect or not enough oil or improper clutch lever freeplay. Adjust your clutch lever freeplay and see if it helps in smoothening shifts. Secondly, your engine turning off can be due to a gummed up throttle body, which needs an overhauled i.e. throttle body cleaning and spark plug clean/replacement. Since you pressed your spark plug cap, check your spark plug cap so it's not loose and connected firmly to the spark plug lead (wire). A loose spark plug cap/ lead would mean, stuttering and stalling.

Thirdly the metal to metal sliding or knocking sound can be due to improper valve clearances i.e. shims. Check your valve clearances and replace your shims if needed. A worn shim or higher clearance than normal would mean, once the engine is heated, you'd hear "katatatatata, or ticktickticktick" sounds, get them checked.

Fourthly, leaky forks. Either they've not replaced the fork seals, wherein they just clean the seals and install them back, this causes the forks to leak after sometime. If there are scoring on the fork slider (silver part) this would eat the fork seals. Start off by checking the slider for any nicks or hot spots, if all is fine, replace the seal and make sure it's replaced and oil topped up in front of you. 450 ML per leg.

Quite a list to look into, take them one at at time and make sure it's all ticked and inspected. Keep your observations posted.

Hope it helps!

Cheers!
VJ

Re: KTM 200 Duke

Hello guys..i had put up a post somewhere in the
previous pages asking for the things i should do
before using my '11 months sitting idle' duke..thank
you guys to those all who responded..i did all that
was recommended by you guys.

But things are getting rough. There was fork oil
leakage from the left shock. I got the oil seal
replaced and been riding for like 600-700km..and it
has started leaking again. Another major problem
this 'ticking' or 'metal sliding' like sound from left
side of engine after i do some spirited riding for
some 30-40 kms..when the bike is started up it
sound normal but after running for some 30-40 kms,
these sounds appear mostly around 3000-5000 rpm.
I am really confysed what might be the problem..got
to see a lot of threads regarding camshaft chain
tensioner etc..and i dont know much about these
parts in details.

The next problem...is that now when i shift gears,
its feels like a lot of friction is happening like metal
grinding when you shift the gear lever. Sometimes,
gear refuses to engage when goin from three to two
unless you leave the clutch,agin pull in the clutch
and downshift once more..would it be a problem
with the engine oil not being flushed properly? I
seriously doubt the svc guys used an engine flush or
not when they put in new engine oil on my recent
service after the 11 months idle sitting..
Another issue with the bike is, while running it shuts off by itself when the clutch is pulled in or when i release the accelerator and the bike wont start after that. This happened twice now. On pressing the starter i can hear the cranking bt engine just wont start. Once i pressed on the spark plug cap and after a few tries the bike started up reluctantly, sputtering and had to wring the accelerator to get the engine to start up properly..
Please shed some light on these issues guys..

Re: KTM 200 Duke

more details are needed from you..
what do you mean by refuse to start ? does the bike crank up but not start ? do u just hear a click when you thumb the starter? u dont hear anything when you thumb the starter ?

not all 'issues' will be reported by the ecu/diag tools.. but is a good place to start diagnosis, if the common troubleshooting steps don't help.

i doubt it could be due to carbon on valve or piston.. it is normal to have deposits on the valve and piston.

so yeh,
when you thumb the starter and the engine cranks up but doesn't start.. then you need to check if there is a spark at the spark plug.
also clean the ignition coil contacts.
if you hear a click (or maybe not hear it), then it could very well be a weak battery or worn carbon brushes in the starter motor... if indeed there is no clicking, it could be a faulty starter relay.
another possibility is a bad idle control stepper motor.. but this i presume will throw up an error on the diag or have erratic idle.. bike shutting down, am not sure.

Re: KTM 200 Duke

It was not at the KTM ASC.

If the issue comes again then will check at the ASC with diag tool. Thank you!

Re: KTM 200 Duke

Was the mechanic from KTM SVC? Was the bike connected ECU diagnosis tool after the engine stalled in front of him to see any error codes generated?
KTM has a weird system, sometimes even when there is no warning light or check engine light there will some error codes generated in the tool, ECU will have record any past error codes that generated, even if it occurred briefly in the past and might not be present at that time. These fault codes needs to cleared with tool only.

This should give you an idea where to start looking into the issue.

First start with the battery, then look at the clutch position switch attached to the clutch lever, then onto the self starter motor itself(39K kms on stock motor? That's about time overhaul it), stock carbon brushes/armature might be dying, they tend to work on-off randomly while they are in dying state.

Re: KTM 200 Duke

Mechanic checked the spark plug. The cap seems tight to me. And if the cap was loose, will the bike start by push start?

Battery was replaced 7k kms or 7months back. The horn sound appears fine so I guess battery is good.

Bike is 2.5yrs and 39k kms.

Re: KTM 200 Duke

Check the spark plug cap for proper tightness of the cap to the HT lead. Secondly, how old is your battery? A faulty battery too can cause idle stalling with electronics playing gremlins. How old is your bike and how much has it clocked?

Cheers!
VJ

Re: KTM 200 Duke

Twice now by bike has stopped at almost near idling RPM and then it refuses to start by self.

First time it happened couple of weeks ago on the highway, I was going over rumbler strips with clutch lever engaged and then when I tried to accelerate the engine stopped and refused to start. No alarm shown. It then started by a push start and after that the self was working fine.

And second instance was today, and it happened to be in a mechanics hand at the time. He checked the spark plug and it was fine. This time too it had to be push started and now the self works. He suggested that carbon may have formed on the valve or the piston.

The throttle body was cleaned (by disassembling) 4000kms back.

Can SystemG help with this?

Re: KTM 200 Duke

Get LED headlight bulb or you can get yourself Philips Xtremevision 60/55 halogen and get a two LED lamps fixed, this helps with good visibility. Do note, the way the LED lamps are positioned and the watts of the LEDs mean the difference between a good throw and usable beam pattern. Always stick to 5k lumens as they are white with tinges of yellow.

Cheers!
VJ

Re: KTM 200 Duke


You can change the stock headlight 55/60 bulb to Philips Xtreme Vision 55/60 and for parking lights with Philips Ultinon W5W 6700 or Osram 2780CW/2880CW W5W, all of these should improve the lighting by 20-30%

If you are still not satisfied, start looking at a decent quality AUX lights.

Re: KTM 200 Duke

I am thinking to buy ktm duke 200.
But the issue is the bike don't have good headlight. Please suggest any method to increase the power of headlight. As i have to ride daily 1hr at night.