Re: KTM 200 Duke

Have no idea about your first question.
Oil filter here is 90 INR.
600 INR is unbelievable, suggest you get some 10 filters from punjab for less than a grand and you wouldn't need to buy them for a good few years!!

Re: KTM 200 Duke

That' cheap!! Well i'l get 50 oil filters hahaha.. will distribute some to my friends over here.

Thanks a lot buddy

Re: KTM 200 Duke

What sprocket to go for if someone wants to cruise at greater speeds while keeping rpms low? And how many teeth does the stock Duke has?

Re: KTM 200 Duke

Earlier the rear sprocket was 43T and front 14T and now, the rear is 42T and front 14T; I think. For speed sacrificing the torque, look for a bigger front or smaller rear sprocket; the trick applied on P200NS by altering the final drive ratio to 15:39 i.e. bigger front and smaller rear sprockets.
If you fit the front sprocket of D200 at rear and rear sprocket at front, the speed increases to about 1,180 kmh at 10,000 RPM or about 125 kmh at mere 1,100 RPM but the present maximum torque of 547 Nm at rear sprocket in first gear decreases to a maximum of mere 58 Nm, making it, perhaps, pathetic than this Brazilian super bike.

For both speed and acceleration, consider Duke390 which provides excellent pickup and speed instead of modifying D200.

Re: KTM 200 Duke

Long Post alert : May take a while to read!!

Members here might recall my numerous heating issue related posts. It was like mosquito menace, no matter which repellant, you use, they'll come back after a while.
I had almost learned to live with it, what with the dreaded message flashing everyday. I'd see the message, then feel the fan blowing hot air on my legs and keep on riding waiting for the bars to come down back to the normal region.
I had been complaining to the svc for it but they were least receptive, because this issue won't ever present itself in the svc ever. It was like the ailment refuses to manifest itself in the form of symptoms just when the doctor arrives
Read up a lot on the net and was convinced that the bike was running lean(which leads to higher engine temp), may be due to the fi system(mainly fuel pump/injector) being clogged with fuel dirt which would result in less fuel injected meaning a lean mixture.
I had even gotten the fuel pump pressure checked to rule out lower pressure, but the reading was perfectly normal. Had my spark plug changed fearing a faulty spark might also lead to this condition.
It's all there on this thread!! I had almost given up and had decided to live with it and not loose sleep and simply get the piston block/entire engine block changed whenever the inevitable seizure happens. After all, like all KTM parts, they do not cost a limb!

These were the symptoms/observations :
1) There was never a coolant overspill from the reservoir, which normally happens in these case. I had never seen a green tinge on my radiator cover or anywhere on the bike. May be it'll simply explode one day I thought

2) On the numerous svc visits, the fan would religiously turn on at 96 C and turn off at 89 C. It sometimes took more than 10 minutes to shut down in this process though.(I'll come back to this later)

3) The bike would normally be 1 bar less than the max normal even when riding at 100kmph and very rarely at 2 bar less.

4) Even when the fan turns on and then shuts off, the temp bar would be at the max normal region or 1 bar less and after 1-2 minutes the bike would again start showing "high coolant temperature" and this time the fan would many times won't even start. This led me to believe that the temp sensor had developed a fault or/and the fan motor is faulty or has grown weak.

5) This one is strange: The display would have sudden appearance of 1-2 extra bars as soon as I entered my office parking. I was perplexed and later ascribed it to the parking being a closed area with no wind assistance for the radiator at low speeds of 10kph

6) There were no other/strange noises from the engine when the "high coolant temp" message was displayed or a sudden drop in performance was noticed, though at times I could feel the pickup dropping a bit, may be mental only.

Went to the SVC last weekend after taking an appointment as the issue persisted even after the advised coolant replacement by the KTM engineer.
I had demonstrated this issue to the head mech Rehman when I had my tyres replaced 3 weeks back. This was the one time when I could reproduce the issue. So I had at least confidence that I won't be laughed at when I present my case.


After a bit of testing, we realized that everything was fine with the bike ecu/sensors, since the diagnostic tool showed the fan to kick off at exactly 96C and bring the temp down to 89C. Just that the display would see a sudden spurt in the temp with rapid appearance of temp bars when ever the headlamp was turned on!! and sudden dip when it was turned off.
Rehman it seems had an idea about the problem.He quickly cut the wiring harness to check any loose/torn wires. Logic was that some wiring may be loose and the display(or the ecu module which reads the temp signal and calibrates the bars in the display) was being fed extra voltage from the loose/torn wires carrying the headlamp. Turned out the wires were all right.
He then tightened the bolt which he told me was the earthing point for the electricals (I think the chassis is used as the ground). He then proceeded to tighten some other bigger bolts/nuts which are rarely touched at the svc on a normal service. This would have a more taut chassis meaning a better connected continuous surface for grounding and also less vibrations!!!

And voila, no more "high coolant temperature"

So the issue was basically a false alarm because of loose connection/faulty earthing.

Now that I have the benefit of hindsight, I can say symptom number 5 was because I would turn on the low beam or the pilot lamp on entering the parking lot.
In fact I don't remember encountering this issue in daytime. I'd normally have the high temp message displayed in dusk(when pilot lamp is on) or at night with headlamp on.

Regarding symptom number 2, I'd ascribe the fan keeping on running for 10 minutes to be actually because of coolant performance degradation and the replacement certainly has had benefit. The fan turns off relatively fast.Most internet sources would recommend a coolant change every 12/15 months anyway.

So guys, all the more reason for you to insist on getting the nuts/bolts tightened at the svc preferably with a torque wrench as per the correct torque. A taut chassis is a delight to ride on in any case and all the more important as it's part of the electricals!!

PS :Got my paid service(not sure which number) done and the bike is now delight to ride with new rubbers, oil, filters

Re: KTM 200 Duke

Anyone tried any different chainsets?? The one they give lasts less and is a little costly. CBR 250's chainsets lasts very long. 20-25k+kms. Im on the verge of changing my Duke's chainset.

And [MENTION=48967]Doga[/MENTION] ....Cheers for the issue solved. Its been a pain in your ass since a long time. Anyways this will help us...at least it will be penned down on our service time check list.

Re: KTM 200 Duke


Interesting read Doga, thanks for taking the effort of typing this out.

I have had two back-to-back episodes of my Duke cutting out and refusing to start again. Both of these occurred at the end of a city run where the engine temp was one bar (or is it two?) short of maximum. The engine simply cut out and the bike would not start again. Both the episodes occurred at night, the headlight was switched on. Oddly, there was no error displayed either time.

While attempting a restart, the cranking sound that is normally made was absent, the sound was as if the starter motor was not engaging the engine and sort of spinning by itself.

I needed to park the bike overnight at a friend's place and both the times the bike started after a little coaxing the next morning, presumably after the engine had cooled off.

A call to the mech didn't help as he suspected a coil plate or RR problem. Both the times, the bike started again without a fuss and ran without a hitch. A subsequent visit to the workshop yielded no results. I've got a feeling this is similar to your problem. Could you post pictures and explain where this earthing point and other bolts are located please.

My May 2012 Duke has run only 5000+ km and this weird issue has affected my confidence in the machine. So far, I've never had a bike fail on me ever, especially leaving me clueless and helpless about a possible solution.

Thanks!

Re: KTM 200 Duke

[MENTION=48967]Doga[/MENTION], congrats mate on finally fixing the heating issue... its been for so long...! It definitely helps!!

Re: KTM 200 Duke

Just get regular fuel. You really don't need premium brand for a bike like Duke.

PS : The service at KTM Coimbatore is absolutely epic! I was at Kari for 4 days in December. Crashed my duke twice and both times the service center fixed up my bike in less than half an hour. And it costs lesser than it does in Bangalore as well, for some reason.

Re: KTM 200 Duke

The ground is the point where all the return currents should meet and are supposed to be provided an outlet. In the duke, it's near thee exhaust, where you'd see a black wire bolted with a silver coloured nut/screw to the frame. Will post pics today if I can.
But I doubt your problem is the same as mine. I never had a stalling issue on my bike ever. The bike kept running even after the "high coolant temp" message was flashed.
Actually there was never overheating, just that the display was fooled into believing. Which now that I think means, the ECU does not have any bearing on the fan and may be it's under direct control of the temp sensor signal(The sensor is at the back of the engine and sits surrounded by the coolant pipe). This would explain why the fan turned on at exactly the specified temp and turned off at the recommended temp even when the ECU believed the temp was higher.
Either this or the display calibration is independent of the ECU. Every signal is ok till the time it reaches the display handler, which combines the temp signal with the headlamp signal and hence shows the rider that the temp is higher than it is.

In your case I think, you should get your oil filter changed and try switching to premium fuel or use system G for a period. These stalling issues can sometimes be due to bad quality of fuel or choked fuel filter.
I have been using system G and though it doesn't make a world of difference, it does make the bike tiny bit smoother(may be only in my head!!)

I am confused

Re: KTM 200 Duke

Thanks for the inputs, Doga. My Duke isn't due for service for another ~1000km, but I plan to shift to 300V FS now that I have passed the 5k km mark. There was no issue with the fuel afaik, since I fill all of my vehicles at the same, well known trusted fuel station. The fuel filter was checked and confirmed to be in relatively new, unchoked condition. I shall try adding a fuel additive and see if that helps.

When the trouble occurred, the temperature in my bike's case was never at or near the maximum, the radiator fan kicked in pretty much as it should have and there were no warnings on the console. My best guess is that my issue is with a misbehaving sensor as well, somehow connected with temperature and electrical load. Sustained high speed highway night runs after these engine-cutting-out episodes occurred did not throw up any problems, presumably because the speed helped keep the engine temperature down. I find my bike to be a lot smoother after a sustained full-throttle run.

All in all, I would like to believe that my bike will not fail on me and even if it does, I should be capable of fixing things myself. It is frustrating to be told at night to push the bike to a safe parking spot or load it in a tempo because of what seems to be a relatively minor niggle.

I would like a little more smoothness too and to help things along, I'm going to install the 390 handlebar and bar-end weights, along with the softer 200 NS grips. I dislike the prickly Pulsar grips provided as OE with the Duke. Not nice of Bajaj to sell the Duke with Pulsar grips while providing the 200NS with a newer, better and softer design! The bar-end weights on the 390 are again common with the Pulsar though. However, they are among the heftiest in the market and I hope that their heft will take some of the buzziness away.

Re: KTM 200 Duke

Had 2nd fork oil seal leak today..got it fixed. Apparently KTM is fitting this rubber external rubber seal for better protection. Hope it helps..!!


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Re: KTM 200 Duke

Do post your review on fitting the 390 bar. Actually, I don't feel any vibrations, certainly not even barely annoying, at the handlebars. What I feel is a slight buzz at the footrest(more at the right one) and a fairly pronounced buzz at the right tank flap(where your knee touches the tank). These have lessened a bit after the tightening exercise, but haven't diminished completely.
Also I feel, the feeling of the bike lacking smoothness at high revs is less physical but more aural IMO, because the engine at higher revs, near the redline sounds as if it's starving of fuel and the pistons are screeching against the cylinder walls, may be because the oil has suddenly dried up.
The engine would certainly do better(at least sound better) with a richer map. The stock map is very lean in feel. I have certainly felt the Kiirus map freer revving and smoother.

Hey on another note, I do remember a stalling issue I had, but it was less mysterious in that it was caused due to the side stand sensor malfunctioning. More specifically, the wire which transports the signal from the sensor had worn out because of lube sludge and damages while cleaning the bike etc. The bike would start a bit on pressing the starter but would soon die out. All this while, though the "side stand down" message was flashing on the display.The display would show weird figures for speed in the brief period the engine would be up.
Rehman promptly diagnosed it and the svc sent two guys a day later with a jugaad to bypass the sensor to pick the bike up and the issue was rectified when they fit a new sensor.
One would notice that the sensor was getting slow by noticing the period between the side stand going actually up and the display erasing the side stand down message. This period in my case was gradually lengthening before the sensor malfunctioned. But again I doubt this would apply in your case, since the display is fine and the bike does start later.
Talk with the KTM engineer once

Re: KTM 200 Duke

I actually meant the bike feels a lot smoother at higher revs and the engine noticeably smoothens out for a while afterwards, even while riding at lower revs. I agree that the aural sensation is quite the opposite. Funny though when a Duke goes by it seems quite silent to the bystander.

I would hope the oil isn't drying out at or near the redline! The fuel map that the bike was delivered with was a lot better (and faster) but that went away when they flashed the ECU during one of the early services with a new map that took the bite away and partially castrated the performance.

I wouldn't say there are pronounced vibes in the handlebar, just this prickly feeling and a buzz that is strongly accentuated by the prickly design of the grips. I'm hoping that a change of grips and the addition of bar-end weights results in a smoother ride overall.

Some off-topic stuff:

I'll also look for the rubber dust boots that have been posted above^^ by wallpapers123. I've had a fork oil seal fail on me after the forks were replaced under warranty for a clacking sound that apparently plagued the early lot of bikes.

I've changed the brake pedal to the newer one that incorporates a roller cage; need to change the gear pedal as well.

My bikes are parked in my verandah which is ~3 feet off the ground. There's a slope leading to ground level and a short ride to my gate. I'm used to starting the bike and letting it roll until the gate in neutral, sort of to aid warm-up. However, I find that the Duke has a marked resistance to roll, it slows down noticeably and almost does not coast to the gate. My RX100 and Impulse and even an N650 are happy to roll and actually pick up speed, but the Duke slows. My mech says all Dukes are plagued by this, wheels at both ends do not rotate as freely as they probably should. I've checked out a few other bikes at the workshop and this seems to hold good with them all. Anyone feel this too?

Re: KTM 200 Duke

Duke 200 FMSCI homologation form. http://www.fmsci.co.in/2012/2whomo/K...CI%20final.pdf

I was looking for the gear ratios of duke 200, I was not able to find it on the KTM site or on the manual. Finally got the info from the above link. On the page no 11, it has the gear ratios and the sixth gear is an overdrive. So people looking for a relaxed cruise on the highways can just alter the secondary drive.