Re: KTM 200 Duke

His fuel tank cap has a gap even when locked..which I think is normal. Even my bike has it ..never had a problem of water going into the tank though..


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Re: KTM 200 Duke

Yes I realized that and was editing my response while you posted

Re: KTM 200 Duke

Its going to be long post

Ok!, In my case water doesn't get inside the tank and I clearly understand when a tankful (or even 9/9.5 liters) is done its normal to smell the petrol, whereas in bike no matter the bike is in reserve (tried down till 35km on reserve 'F' mode) or half tank or full, anytime of the day I can smell petrol from the tank lid region.

Took it to svc several times still they couldn't fix it, infact they blamed the tank saying the surface/region where the actual (black colored) tank and the tank lid assembly are connected was uneven/not flat surface (wavy!, thats what it actually looked like) and changed the tank under warranty (which happened because of the number of visits I gave for this issue) but still the problem persists.

Guys I really don't know if any of you have observed the smell emitting from the lid, I did and not on just mine but almost 5-6 dukes at svc and every single one was emiting. Finally guys at svc and a service engineer concluded that it's common on dukes and it doesn't evaporate as much fuel from inside as I should be worried about. And apparently Unconvinced with their reasons and now living with it.

Would ask the fellow dukers here to check if the fuel smell emits from their tank lid region in all situations viz., reserve, 1/4 of tank, 1/2 and so on and post back if possible.

Cheers,
Sarav

Re: KTM 200 Duke

yes the upper lid doesn't need to be watertight but the there are space / gap between lid and tank cap, that's why you can push down a bit

Re: KTM 200 Duke


Ok i m not 100% sure about this but as far as i know fuel tanks are never supposed to be airtight (maybe they can be water tight but not airtight but I don't know how) because if the fuel tank is air tight it would create a lower pressure inside the tank as the fuel gets used. Which would mean the pump has to work extra hard to get fuel which is not at all desirable. thereby all fuel tanks have some sort of air vent to ensure atmospheric pressure inside the fuel tank above the fuel level. It is the same reason why petrol sometimes spill over in case of a fall without any damage to tank or its cap.

The small catchment area around the tank opening and under the fuel cap is for collecting water or any spilled fuel (while fuelling) and letting it out through the small pipe.

Regarding the smell, it is always going to be there and will be more evident in the summers (under the sun) or when refilling (due to splashing of fuel) or during long rides (due to engine heat radiation).

I am no expert but these are my two cents, would love to hear from the experts.

Re: KTM 200 Duke

Can someone plz tell me the current OTR price of the Duke 200 in Mumbai after the reduction in excise duty?

Also is it advisable to buy the Duke 200 now with the launch of RC200 around the corner?, or is it advisable to wait and see how the RC200 fares. Also how will it be priced? Asking in behalf of my brother.

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Re: KTM 200 Duke


Yes you are correct bro.
Normally petrol tanks are not air tight, if they are air tight it may result in dangerous explosion.

For example,
Please be careful while conducting the test.

Take some 2 litre can and pour 200ml of petrol in that can and close the can with the cap tightly, then shake the can for few seconds and open the can. It will release some amount of pressure from the can, more the petrol more the pressure.
Same thing will be happening if the petrol tanks are air tight.

Re: KTM 200 Duke

indeed my friend, air vent should be around the lid.....imagine you parking in open lot, hard rain I bet small pipe can't drain a lot of water on the small catchment area (black area) then water will enter to tank because there are gap /space between cap and lid, it's pity I should cover the bike every rainy day he he he he he come on this is KTM man

anyway thank you for the discussion guys, at least I know every duke like that

I found this at other forum :

Hi, I have a new Duke 200 in Malaysia - two weeks now.

I have investigated the petrol leaking issue - please all Duke riders take note.

In my efforts to ensure my bike is in top condition, I had noticed on various forums that a number of people had experienced petrol overflow, and petrol smell issues. A least one was advised “do not fill the tank so full”.

So, I filled my tank to the top – just below the designed overflow tray – and petrol suddenly was leaking all over the engine. Not just a drop, but a substantial amount. Note – the petrol was not exiting through the designed overflow that takes it down a tube on the left hand side under the tank cover.

As I see this as a major safety issue – petrol leaking onto a potentially hot engine – I have now diagnosed the issue. I removed the tank, then filled the tank to the top. Petrol was pouring from the seal between the tank and the overflow shroud, which means that the petrol then pours around the tank on all sides and then straight down, where the engine is.

I removed the shroud – 3 allen screws – and found that the rubber seal is inadequate, or the compression of the seal between the plastic shroud to the plastic tank by these three screws is inadequate.

I have solved my issue by using an additional sealant (silicone) as well as the rubber gasket. I can now fill the tank to the top with no issue.

Safe riding from Malaysia

so the gap is true, but in my case water pour into tank.....I think I will take sealant too.......

Re: KTM 200 Duke

The factory team does a remap now, its the third one...basically detunes the baby monster.

I got her throttle body cleaned, carried along the ABRO carb and injector cleaner, reduced time it took to service.

Issue resolved.
[MENTION=34367]xzibit[/MENTION] - Engine braking is when decelearating, when u try accelerate on a higher gear she cant take, she will ping...mine used to knock briefly at @8000 rpm.

I guessed it was due to improper mix of fuel, so got the throttle body cleaned, lot of gunk came off, the injector was not misting fuel earlier but throwing spurts.

My FE should improve too

Thanks

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It was knocking...but thats history now : )

Thanks

Re: KTM 200 Duke

Thanks Man. Today after lots of frustration finally I was able to come up with something cheap yet functional . A 15" plain rod and a cloth did the trick .




Just use the tyre hugger bar to pull the bike up and gently sliding the bar as shown with SIDE STAND out. Almost zero effort job . Lifts the bike around an inch easily . I ll get a square base welded to it and give the top a curvy shape for more secure fit . Finally able to lube the chain without moving the bike : ).

Re: KTM 200 Duke

Whats the temp there?

Re: KTM 200 Duke

Mine's eight months old and 8K KMs on it, and I have never had this issue whether it's full tank or quarter tank, not even a whiff of petrol unless I open the cap.

Re: KTM 200 Duke

Karan, I do agree air vent is present on all fuel tanks. You meant smell will always be there in Dukes or on all motorcycles?, because I have checked it on various kind of bikes none of them actually smell petrol except Duke!

I fail to understand as why should the smell always be there at the first place? (ignoring the cases of spillage on to the catchment area while refilling or filling the tank to brim/overfill)

aha2070, Exactly! what you have highlighted is the same that I had witnessed on mine!, the seal between the tank and the overflow shroud was uneven and had patches that looked like fuel been spilled there (not as bad as spilling on the engine) and dried kind of, hence the svc guys replaced the tank but still the tank emits fuel smell.

What is the additional sealant (silicone) you are referring to?where did you get it from? A pic may be helpful...And rubber gasket is the round shaped rubber beneath the overflow shroud, correct?

Can you please elaborate on the usage of rubber gasket and silicone that fixed up the issue.

I'm in Bangalore!, temp is a little hot here now!, but temp really doesn't matter as it is always the same story even in chilling winter ie, fuel smell is always present round the year


Cheers,
Sarav

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Happy for you! but majority (8/10 at svc) of Dukes that I checked on was smelling petrol! (that was in last July/August)

The problem exists for sure!, found by googling though I guess most Dukers ignore/fail to notice the smell of petrol (with bikes having petrol smell issue, ofcourse) may be why it is not posted/discussed in here or in the internet, a lot!

Re: KTM 200 Duke



My tank did leak recently and was changed under warranty. But my bike had done around 25K when it started leaking. The leak was not an overflow from top and then around the tank but was from the bottom of the tank, where there are a few screws and the seepage was from there. The petrol mixed with the rust(in the screws) and became quite sticky by the time it dripped down on the trellis/exhaust.
So this must have been a case of regular wear and tear given the fact that the tank is plastic and metal screws will always eat the plastic threads with time(has happened with my helmet too) , faster than a metallic thread.
Apart from this I have had 2 major leaks, both because of ineptitude of the svc.
First instance was when the fuel filter was changed as part of regular service. The mechanic had managed to tear the rubber hose carrying fuel from the tank to the filter with his plier . I had fuel literally dripping on the engine head/trellis/my shoes. I had done the servicing in the morning and was on my way to ofc when I noticed this on the Powai flyover. had to run to Shreeram Bajaj to change the hoses.This was on a very hot summer day
The second instance was recently, ironically when the tank was replaced , mentioned above for the tank leakage issue.
The mechanic again hadn't tightened the steel clamps on the hoses properly and fuel was leaking. I did a tankful and a substantial amount just leaked out when I pressed the starter.
Actually that's why I don't bother taking the bike for minor niggles to the svc like I used to before. I just thank my Gods for the engine never requiring any fixes,touchwood or else who knows that might lead to may be more leaks/seepages or whatever after the 'fix'

Re: KTM 200 Duke


this silicone sealant....you can get from ace hardware or hardware/tools shop in India you will find it

rubber gasket is the round shapped rubber on the lid, add some sealant just in the front which had gap / space