Re: KTM 200 Duke

Guys, My duke is almost 4 years old and most of the metal bolts are covered in rust. Any suggestions on how to remove the rust?
It's getting almost everywhere

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Re: KTM 200 Duke

I appreciate the car seat suggestion
The exhaust polish work is really fantastic... thumbs up

Re: KTM 200 Duke

Guys I have been having some trouble with my horn set up on my bike.. For some reason the horn started to sound muffled.
Tried changing the horn to a bigger on from minda but I am not sure where to mount it.. Can you give me some idea and relay setup if required?

Re: KTM 200 Duke

It would be better to replace all the rusted bolts... Incase u don't want to change it... Use Autosol.... It removes rust but u have to scrub it a lot.

My Duke is almost 2 yrs old... I have noticed a kind of slight rattling from the bike when i go over potholes... And, i felt the sound comes mostly from the rear portion of bike.

Any suggestions to which is causing the sound...?

Re: KTM 200 Duke

I recently bought a preowned duke200, rode close to 1k km in last one month but today saw some oil leaks at couple of places.


Also noticed this plug is hanging alone with no where to fit in. Anyone has idea what this is about?


The bike still has warranty of around 4 months left. Any suggestions as to why these leaks?

I know am a little noob right now but trying to keep up by reading this entire thread. Meanwhile if someone can help.

Re: KTM 200 Duke

you mean 6 hours non-stop ??? i strongly suggest you take a break every 90-120 min.
the max i can do non stop is around 3~3.5 hours and the stock seat is not an issue.. its just that i need to get off the bike and stretch.. can't blame the seat for it. and among the buddies (with various other bikes) i ride with, there hasn't been anyone who can ride as long as me nonstop
the amount of time you spend on the saddle in most cases is proportional to your riding experience on the particular bike and your fitness/adaptability.
I am someone who is overweight and has also had a spinal compression fracture a few years ago and yet I am able to do long hours on the saddle on the d200. The stock seat i would say isn't bad at all

Re: KTM 200 Duke

Does the 200 have the option of Orange frame and rims?

Re: KTM 200 Duke


It's not non-stop 6 hrs.... I take 5 mins break for every 60 mins.... Till 6 hrs i am fine riding but after that butt sore kicks-in. But, i still keeping riding it.


Warranty is only for the first owner of the bike according to KTM.

The oil stains under the gear rod is because of excessive chain lube. Open the plastic (front sprocket) cover over it and clean with kerosene during chain service.

The stains above the left engine cover is bcz of leaking... U might have to change the gasket and seal it with loctite-> svc guys should do it for u..

I think those plugs are related to headlight unit or horn. Because the 2 black ones there are for gear selector. White one is for stator coil and green one for catalytic converter.

Re: KTM 200 Duke

Thanks for the quick reply. Surprisingly both my headlight & horn are working absolutely fine and this is still hanging around. . Also have started getting 0 for speedo occasionally when riding under 20 & low battery in morning once in a while so i guess will have claim the stator coil replacement also (one of the user said RR can also be an issue in this, can someone tell me what RR stands for). The bike is still in name of first owner, so i guess claiming warranty shud not be a problem in this case. Hopefully the leak should also be covered in warranty (I know i am sounding greedy now).


Just one more question, is battery also covered for 2 years? just in case...

Re: KTM 200 Duke

Thank you [MENTION=61791]Cleaner[/MENTION] I saw that video on you tube it looked promising.. At first I saw a few models costing around 40$ but the master cylinder and the slave didn't look like they would last long. So i am thinking of getting the master cylinder and slave separately from ebay and the hose for the pulsar 220s front brake. I will be trying to put them together myself. Tried to sprocket the bike to achieve a better top end but so far, no luck with it..
I am hoping that I succeed with this mod..

Thought of the magura hymec hydraulic clutch assembly.. many positive reviews on the product but not sure on how to get my hands on it as its costing around 20k Indian rupees. Need to check with few of my buddies a few people have done some modifications to their RD350s. Do we have any other options?

I am thinking of this mod because I am planning on a ride to goa from Chennai this April or May and I don't wanna be stranded with a broken clutch/ throttle cables. So can you also suggest a better way to achieve this? Also is there a way to replace the throttle cable without removing the tank??

Re: KTM 200 Duke

Good for u then.... Don't worry about the hanging plugs...

Better get the stator coil changed under warranty asap before u change the name on RC book.

The speedo 0 is a stator coil problem only. I know it bcz i fixed the same in mine 2 months ago.

Stator has 2 yrs warranty.

Sorry for the bad news Exide battery has only 18 months warranty from date of purchase of bike or 3 yrs from date of manufacture of battery which ever is earlier.

A new Exide/Amaron battery should not cost u more than Rs2700.

R/R stands for the regulator/rectifier setup.

There are ways to check if the problem in your bike is bcz of stator or rectifier or battery... Pm me...i will send u detailed steps. Most of the time it's the stator that gets kaput.... So go ahead and change it in warranty if you don't want to waste time checking... BTW i checked it before changing my stator coil.

Re: KTM 200 Duke

Do you carry your tool kit with you all the time?
Once it happened to me and when I checked it was the tool kit hanging with just one band..

Re: KTM 200 Duke

Guys anyone here knows any easier way to change the clutch and throttle cables without removing the tank? Why is everything so cramped up on the dook :P they have compressed all components to save space and weight and in the end it's very difficult to access the components..

Re: KTM 200 Duke

Yea i have the tool kit always with me and it has 2 bands... Also i keep a cutting plier, insulation tape, bike papers, a piece of cloth and the spiraltech chip for changing 32 patterns of indicators...

Maybe i wil start removing one by one and try to narrow down the rattling culprit


I changed both the wires on my own... And didn't remove the tank... Have patience and do it slowly.... :thumbup:

I felt if we open the headlight unit...things get a bit simpler... But it can be done without removing it too.

Re: KTM 200 Duke

[MENTION=81525]jeshurun99[/MENTION] .. Will it be possible for you to make an instructional video on changing the clutch and throttle cable? Like how you actually did it? I tried google but saw this guy removing the whole tank..
I can't be doing that on a highway if my cables break.. So far they are OK "touchwood"

Why spiraltech?

Well, i am planning on shorting the two positives of the front indicators with a switch and activate all four indicators at once.. with the same indicator switch.. Since these are LEDs I am not sure if they would over load or anything...