Re: KTM 200 Duke

Yes, even i feel you should live with it. I have experienced same and still there is little bit of sound coming from front brake pads esp if i turn handle, i got it checked in SVC they told me change brake pads but i will change once it is worn out.
Clean rotor frequently and pressure wash near calipers, it will help little bit.
Dusty conditions of India so we cant avoid this kind of problems.

Re: KTM 200 Duke

Live with it if its the front brakes it most probably is from my experience. Or if you have the patience clean the rotor/caliper with a good pressure wash, then take the bike out for a ride and at slow speed (<10kmph) apply the front brake repeatedly a few time (so the front dives a bit).

Re: KTM 200 Duke

If you observe squeaks and repeated brake induced squeals, remove those pads and mildly glaze with them sandpaper, clean the brake calipers with compressed air and install the pads, this trick works for the most part, but for some bikes, the squeal returns after a while. In that case, it's advisable to clean the rotor with petrol to remove any oil residue on the rotor, this also works.

Cheers!
VJ

Re: KTM 200 Duke

Thank you VJ!

I just lubed and cleaned my chain recently - barely 200 kms have passed. I will clean it again this weekend and see how this turns out to be. If it doesn't fix should I get the brake pads replaced or should I just clean it with some sandpaper?

Re: KTM 200 Duke

The sound that you hear is of the friction sound between the pads, drive chain. If you feel that sound is more, lube your motorcycle chain but before that clean your chain off debris and lube your chain, this sound arrest the sound. The other aspect of this sound can be caused by the brake pads, mostly front, since pads are in constant contact with the rotor, new pads can sometimes make a mild high pitched noise when the bike is moved slowly and settles when the bike is on the move.

Bottomline: Clean your chain and lube it thoroughly and see how it fares.

Cheers!
VJ

Re: KTM 200 Duke

Hello team,

Hope you all are fine. I am enjoying my bike to the fullest however I have an issue. When I move my bike forward or backward it makes a annoying sound of chi chi. I don't know how to best explain it however I hope you are able to understand me.

The sound is coming from the front brake side. I am fairly certain of this. It is not coming from engine or likewise because the sound comes even when the bike is turned off and I move it back or front.

Do you know what can be the issue. The sound was less before few months but as months passed it is becoming more and more intense.

Please let me know what can be the cause and if I can fix it myself to avoid the service centre trip.

If the issue is not clear please let me know and I will shoot a video and post it here so you an know more better.

Thank you all!

Re: KTM 200 Duke

13k seems reasonable for a full top end rebuild with new block/piston and valve kit. The 200's parts are pretty economical on the pocket.
iirc the block+piston kit was sub 6k and valves/guides were around 2k for a set of 4. please post a picture of the bill if possible.

as for the run in, i'd say keep it under 6k for the first 1000km and then gradually go up.. a rebuild might not be close to a new engine, so better to err on the safer side.
for the oil change, if you put in the motul with a new filter you could probably skip the oil change at 1000km and do it at around 3000km.

Re: KTM 200 Duke

The cylinder kit is new, it's imperative that you do a run-in procedure. When the vehicle is new, the rings, piston and cylinder should form a perfect seal by running in the motorcycle which is what's recommended by the manufacturer. With new cylinder kit, it's the same process all over, keep the run in RPM at a similar level to what's recommended in the manual and you're good to go.

Cheers!
VJ

Re: KTM 200 Duke

Finally got the bike fixed. First thing they did when I dropped the bike in svc was a compression test, and it was quite low. I asked them to check valve clearance and also to install my old stock exhaust. Got a call from svc 2 days later, they told that valve seating had to be done and the valves & guide also has to replaced .Because the engine oil level was dropping drastically, svc people advised it would be best to replace the bore and piston since the bike was almost 6 years old and had done 40k kms.Final damage 13k₹.Bike runs super smooth now. Earlier it used to sluggish.
Since the bore, piston and valves are new, Should I do a proper run in and change oil in 1000km? So far haven't crossed 6k rpm. What is the rpm limit in run in period?

Re: KTM Duke 200 front disk issues

How much has your motorcycle clocked? Have you replaced your brake pads recently? If not, now is the right time to do. If replaced, inspect the pistons up front, also make sure the piston isn't grabbing or jammed. Worn out pads will cause wheel grabbing and brake noise. Start off with your brake pads and replace if necessary. Keep your observations posted.

Full system Free flow exhaust reduce the calculated backpressure that's required for an engine (I am no thermodynamics expert) but free flow exhaust without calculating the right inlet volume and exhaust gas outlet can over time reduce the life of the engine. In your case, an oil consumption can mean two things, either we have a faulty piston ring set or a leaky valve train, either way oil gets burnt. The former is traceable during cold morning starts, the latter is traceable once the engine is warmed up and revved with blue oil burning smoke coming out of them as opposed to water vapor respectively. I'd suggest you give a try of the aforementioned methods to get a clear picture as to what's exactly wrong. I'd also suggest doing a compression test to rule out faulty rings and or valves. Keep your observations posted.

Cheers!
VJ

Re: KTM 200 Duke

Do you notice smoke from the exhaust ?
The svc folks are plain lazy, same case almost everywhere. It is possible the valves are the issue.. the clearances maybe ok, but what if they aren't sealing properly.
Am surprised they did not ask you to replace the block+piston kit !
Ask them if they can do a compression test. (they'll probably not do it)
At-least remove the spark plug, and check if it is black/has sooty or oily deposits on it. Post a picture here.

Try switching back to the stock exhaust (before going in for any engine repairs) and keep an eye on the oil level for a couple of weeks.

If it still goes down, then either you talk them in to checking/setting the valve clearances to spec.. or replace the valves/guides/springs making sure they are installed properly and in spec. While at it, maybe even just replace only the piston rings (because the oil consumption might be even due to worn rings and oil leaking past them and burning).
The valve related parts (valves, springs etc.) will probably cost you under Rs.2000 iirc and probably another 1000~1500 for labor.

Re: KTM 200 Duke

Hey guys!
I own a 2012 Duke 200 which has done 40,000 Kilometers.I swapped the stock exhaust with IXIL HYPERLOW aftermarket exhaust when the bike had done 21,000 Kilometers.After the swap, I noticed that during long rides my engine oil seems to drop quite fast. In one such long ride where I did close to 800 Kms in a day, with more than 3000km for next service, I found that at the end of the ride there was barely any oil left. And of late I have been toping up oil before the bike hits the 5000 Km service interval.
I want to know if this is because of:

1. The aftermarket exhaust.
2. The valve clearence of the exhaust valves are a bit off

The service center people(Chennai-Both Adayar and Porur) are saying that the valves could have been damaged and all the valves have to be damaged.They are not even ready to check the valve clearences and come to this conclusion.Even if the valve clearence is off they said they dont have the shims and have to replace all the valves. There is no Ticking sound coming from the engine as well.
Any idea on what could be the problem? Should I switch to stock exhaust? Any good mechanics from Chennai (other then SVC)where I can get my bike checked.
Thanks in Advance!

KTM Duke 200 front disk issues

I've been noticing lately that the braking on my motorcycle, the Duke 200, is unprogressive. When I apply the front brakes, the braking force is not linear but instead tends to brake very unprogressively. Looking for a solution to this problem.

Re: KTM 200 Duke

Thank you so much for the Help, Sir! I'll keep an eye on the Coolant level!

Re: KTM 200 Duke

a light buzz, especially on the right foot peg is noticeable if the chain has been adjusted (especially if slack is less).. will go away after a few 100km.

if it continues to stay at min, then probably no issues. you have the option to top if up to between min-max. simply add plain drinking water (it will hardly take 75ml to get it between min-max), if you aren't able to get hold of the coolant.



top up hardly takes less than 100ml, so they might do it for free if you have a good rapport.
Considering your riding/fan on scenario, i would suggest you keep a close eye on the coolant level. if it keep dropping frequently, then it might be an issue. Under normal operation you will notice the coolant level fluctuate a bit up n down between min-max (never goes below min, if you have sufficient coolant)... but if all you are seeing it is going down, then it is a problem.