Re: KTM 200 Duke

Hey guys, I got my Duke 200 on 2nd Nov. I have been enjoying riding it since then. Haven't covered a lot of kms, just under 400 kms till now, but every time I get on my duke, it brings a smile on my face

Anyways, I have already started facing issues as well.
3rd day of my bike, i found the coolant was leaking. (red arrow to the place where it was leaking since i dont know what to call it).
I went to the ASC the very day. Upon inspection, they found a rubber ring in one of the pipes which was carrying the coolant. It was like a washer ( I think). They replaced it and filled the coolant just below the max mark.

2 weeks after this incident, I found the coolant level near min level. I checked for any leakage but was not able to find one. So I again rushed to ASC. I was explained that the engine needs coolant to fill up the air inside the it. They were happy enough to fill up the coolant and I found that explanation kinda justified, I rushed to my office as I was already late.

Yesterday, while washing the bike, I found green spots again in the same area. To my surprise those spots were in pretty liquid state indicating they were still leaking from somewhere. I had no time to go to ASC since.

But I am really disappointed right now. There are heating issues as well, but I have accepted that and I knew about them while I read reviews before buying.
Any suggestions, anything specific which I need to tell the guys at ASC to look into when I visit it in a couple of days.

Re: KTM 200 Duke

You need to tell/Yell and say "FIX IT FOR GOOD"

Anyways like you mentioned you were always prepared for these petty issues which could surface more often. Overheating or heating? This bike heats up a lot during run-in and thats normal. Anything less than 2bars down from max is normal in bumper to bumper.
During your first free service stay at the service center and keep bothering those guys untill all the issues are addressed. Else it will only be a typical "Wash and Polish Service"

Congrats for the ride

Re: KTM 200 Duke

Firstly am going to give you some 'bad' news. The bike you got is from the older lot (pre Sept 2014). The newer ones have a better designed radiator fan and a plastic cover + mud flap over the rear mono shock. The new radiator fan/shroud has been an excellent addition and comparing it with a duke that doesnt have it, it is at least around 30% better in deflecting the heat away from the thighs

Regarding heating 'issue' .. its not an issue but a characteristic of the duke. As long as it doesnt go in to the upper segment, its fine (you will also receive a high coolant temp warning on the console.).
Mine has always been below the two bars in the lower segment no matter how much of stop go traffic it goes thru.

Regarding coolant, I'll tell you my experience:
On taking delivery, the coolant was only a little above 'min' .. and after the first ride to the petrol bunk to get my free tankful and returning to the asc we noticed a few drops of coolant on the fuel tank near the coolant cap area. I just wiped it off and removed and closed the coolant cap(assumed it was a result of splashing after going thru a big pothole)
I left without asking for a top up since i wanted to see how it behaves (i like to experiment a bit)
After two weeks of riding around 250km, i went to the asc to get the chain cleaned/lubed. The coolant level was the same ( just a little above min) but they anyway topped it for me for free (they poured a little more, and it stood at half a cm above the 'max')
Now i was expecting it to over flow/splash.. but to date, a month and 1000km later, there has not been a single spill or reduction in coolant level. I had even done a long ride of 175km before the first service, and it held up well without any overheating and as i mentioned earlier the temp bars were always two notches below on the lower segment (forget the upper segment, mine hasn't reached even the top of the lower segment)

Now coming to your issue, its looks like its leaking from the coolant pump area. Do sit on their heads and get it fixed.

Re: KTM 200 Duke

Guys..

After digesting what [MENTION=16602]s1d[/MENTION] explain, I think I was wrong..
What [MENTION=16602]s1d[/MENTION] explain before about relax riding is right..

I didnt ride my bike on saturday sunday..

Yesterday I start my daily routine ride to work.. I didnt feel strange about the gear to speed ratio anymore.. Everything sounds ok.. Even when I try to speedup above 100kmph..
The same thing happen today..

Is there any other way to makesure clutch plates is Ok without opening the engine cover on the ride side of the bike?



Sent from my GT-I9100G using xBhp Connect mobile app

Re: KTM 200 Duke

I have run into a problem. My duke won't start. Yesterday, I was getting low battery warning intermittently, by evening the starter switch had stopped working. Console lights up fine, no warning. But the check engine light keeps flashing. But after that, there is no response from the starter switch, none at all. The headlights are working fine. What could have gone wrong. Something with the wiring or the electrical system maybe?

My biggest problem is the SVC is 4 hours away. Please help, I do have a local bajaj mechanic who has fixed minor niggles in the past, any ideas?

Re: KTM 200 Duke

Write an email to [email protected] and explain them everything, number of kms you have clocked and name of service you visited and then see the effect.

Cheers
Akshay

Re: KTM 200 Duke


This sounds less like an electrical problem and more like an ecu problem. Were there any signs like excessive knocking, power loss, electrical distress like headlights flickering and random speedo recalibration on a running engine?
Of course your battery might just be at fault. Check it by getting another battery and trying to start the bike. If it works then replace the battery else check all the sensors and replace ecu under warranty.
Btw didn't you get road side assistance from ktm? Give them a call and let them come figure it out.

Re: KTM 200 Duke


Damn, thats exactly what happened before it totally gave up. There was total power loss, very weak throttle response, the rpm when idle were low and the bike sounded different, headlights weren't working, not even the horn. This only happened in the final moments (5km ride) when I was taking it from office to home. Once parked at home, it started acting up then totally stopped working.

There is no SVC where I live, I am at home, nearest svc is 4 hrs away. I am going to talk to them tomorrow, and see if someone from there might be coming to my town in coming days.

I have had battery issues in the past, there would be flickering on the console and it would atleast make a sound when the starter switch is pushed. But this time no response while the console looks fine, apart from the check engine light flashing. Did check with a different battery yesterday and it made no difference.

Is a ECU problem diagnosed with some special equipment? Is the ECU a repairable item? Or has to be replaced, how much does it cost?

Thanks for the help, this thread has been an immense help in the past as well.

Re: KTM 200 Duke



The ecu is not repairable at all. Its only replaceable. If you bike is not under warranty then its gonna cost an arm and a leg and you'll have to wait damn near two months to get it otherwise under warranty its free but you'll still have to wait.

First change the battery with another one (borrow, don't buy) and see. If the problem persists the have you stator coil and rectifier checked as well. Maybe its throwing back power causing a short. (I was a bullet rider so I've seen it all)

I don't want you to take what I say as canon. I am basically speculating at this point coz I can't see your bike but the most likely culprit is the ECU (coz of the check engine warning you mentioned), and second most likel is the battery and stator coil/rectifier.

Re: KTM 200 Duke

I understand, thanks. Bike is not under warranty. Lets see, will try another battery first thing tomorrow, and will post updates if something comes up.

Re: KTM 200 Duke

Btw, the first thing you should be checking are the fuses located under the seat (you also have 3 spare fuses in the box) - replace fuses 1,3,4 with the spares (make sure ratings are correct!)


Do you see any warning message on the console ? If its a low battery voltage (below 10.8V) then a message 'Low battery' will appear on the console. Did you notice any such message ? If it was only the engine check (MIL) light that stays lit up, then its always best to get the SVC check it by connecting their diagnostic tool. There is a connector under the rear seat to which they connect their device and read out any errors that the ecu might have detected.
A new ecu costs around 7k i think.. and from what i have heard from the svc, ecu failures have been very rare.Lets hope you are not one of those unfortunate cases, and its just an electrical issue.

Re: KTM 200 Duke

Hi, I am planning to go for raised front fender for my duke 200. Has anybody tried the one from Hero Impulse? Or do you suggest any aftermarket ones? Any help on fitting appreciated. Thank you.


Sent from my iPhone using Tapatalk

Re: KTM 200 Duke

People have used the ones from cbr..performs well without much vibes.

Alternatively you may want to go for the ktm powerpart replacement thay costs ~2.5k

Sent from my C6602 using xBhp Connect mobile app

Re: KTM 200 Duke

Yes, I will be checking the fuses too, almost forgot about that. Thanks, Actually been really busy since last 2 days and couldn't spare time to properly check the bike, but definitely tomorrow.

Now, the bike is not showing a low battery message, but it was there initially.

Here's the chronological detail of how it happened:

Everything working flawlessly 2 days back, rode it daily last week, got it washed on saturday evening, cleaned and lubed chain, parked securely in garage. Didn't go out on sunday, monday morning started it to go to work. Started in 1st push of the button, but showed "Low battery" warning on console. I disregarded and went to work/ 20 min commute. Shut it off there and started again to see if something was wrong, showed "Low battery" again. Restarted, this time bike wouldn't start up, console was flickering, upon pushing the starter button, console light would go off and a clicking sound would be heard. Actually got it to start after few tries and took to local mechanic (in the evening) who has worked with few dukes in the past and has helped me previously.

He tried jugaad, jump started (? dont know if correct term) with his own battery, after which I rode it and realized that throttle response was suddenly lacking totally, was taking like 5 seconds to go from 3k to 8k rpm in 2nd gear and the sound/rpm sounded way off, horn was very weak, flicking the headlights would lead to console going off while low battery msg was also coming on. Next time I shut it off and tried to start again, there was absolutely no response from the starter button and nothing happened. Now the console lights up fine after turning ignition and killswitch, but can't start the bike with the electric starter. The horn and lights are working but bike wouldn't start.

Also kind of relieved that ECU is ~7k, I was thinking it would be costlier. Hopefully thats the worst scenario and not even worse than that. Feel stupid for not taking proper care of it, wonder if the mechanics jugaad had something to do with it, though probably not since it was getting worse before he even touched it.

Re: KTM 200 Duke

Don't tell them anything about the local mech.. I am not sure that jump starting with a different (was it of same rating?) battery can cause damage to the electricals/ecu..
It's probably the battery or the fuses.
Do check all the fuses and replace any blown ones with the spare (of correct rating)..make sure you remove and reinsert all the fuses. If you find water around/in the fuse box, then remove the fuses and let it dry out in the sun.
If not, get a battery with same rating and check. make sure the connections are secure and that you are not causing any short circuits. Also call the asc mech and ask him where you can find the grounding connections, and check if they are secured correctly.
I did ask them about how much the ecu costs, and i think they said 7k (cant remember exactly )