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**200Duker1993** · 03-03-2016, 02:23 AM

Re: KTM 200 Duke

Originally posted by jeshurun99 View Post

Hey bro,

Sorry for the late reply.... Duke is 19600+ kms.

I kind of found the culprit.... Firstly see a few pages back i posted a pic of the nut of the chain slider...i tightened it. This reduced the noise to a great extent.

Next was the chain when it is too loose i get that sound.

Sometimes u might have some metal washers which would have fallen under the pillion seat... Try to hit from bottom to isolate the rattling noise...try to lightly beat the tail to check if the noise is from the hollow of tail...

I checked all these and then found the culprits in mine were the nut and chain.

Hello

I am still getting the sound sometimes it's so annoying the whole rear portion rattles I tried zeroing in the portion where the noise is coming from but I wasn't able to din't have time to take it to SVC.

I will follow the steps you have provided. If you can please provide the link to the picture.

I will be going on a ride with pillion this Sunday around 1000KM up and down. Which is the best suspension setting in city as well as for touring ?
Pillion is on slim side (55Kg) I haven't changed the factory set up yet. It will be great if anyone can tell me how to change the suspension setting.

**paradoxr9019** · 03-03-2016, 08:53 AM

Re: KTM 200 Duke

Originally posted by s1d View Post

16t is too big a size and will rob the 200 of its character. though would make highway cruising easier at lower rpms compared to the stock 14t
if the 16t doesn't fit (or you dont like the way the bike behaves), try and get a 15t or better a 41 or 42 rear sprocket.

Exactly S1d ... Totally agreed

Here is my plan..
First I am planning to check the housing and spleen size.
I also learnt that 16t is kinda bigger than I expected..
A 15t is on its way will be trying that too... Hopefully.

Well I actually have a 42t at the rear but I still feel that the bike can be more relaxed at 100 ish speeds.

The back up plan is to get the outer dimensions from the after market 520 pitch sprockets and trace in the spleen dimensions from the stock duke200 if the spleen doesn't match up.
I asked the Irevs guys for a 37t rear but they are charging 4800 + shipping ... So I am planning on trying the odds and if I fail, I might stay stock. Because changing rear sprocket was my first challenge

**paradoxr9019** · 03-03-2016, 09:00 AM

Re: KTM 200 Duke

Originally posted by 200Duker1993 View Post

Hello

I am still getting the sound sometimes it's so annoying the whole rear portion rattles I tried zeroing in the portion where the noise is coming from but I wasn't able to din't have time to take it to SVC.

I will follow the steps you have provided. If you can please provide the link to the picture.

I will be going on a ride with pillion this Sunday around 1000KM up and down. Which is the best suspension setting in city as well as for touring ?
Pillion is on slim side (55Kg) I haven't changed the factory set up yet. It will be great if anyone can tell me how to change the suspension setting.

The stock suspension should suffice

If you wish to change the settings, you would need a screwdriver or a rod and hammer. You would need to hammer your suspension settings .. Literally..

Or you can also avoid the hammering by using the tool that was provided to you with the tool kit... Search at YouTube you might find an instructional video

cheers

**hmunjal** · 03-03-2016, 10:15 AM

Re: KTM 200 Duke

Thanks a lot guys. Will visit SVC today itself.
After resolving this issue, is it advisabel to go on a 400km weekend trip before break in?.(chked internet and got mixed reviews)

**s1d** · 03-03-2016, 10:36 AM

Re: KTM 200 Duke

Originally posted by xplod566 View Post

Yes I am having the same issue.just visit to SVC and ask them to Fix it.its normal on dukes.they have a sealant and will fix it with this .take atleast 4-5 hours to dry the glue

4-5 hours ? where did you come up with such numbers ?
It hardly takes less than an hour for it to set and you can ride normally immediately after the gasket is fixed with the gasket sealant. how do i know? because I have had it attempted to first fix it without sealant and second time with sealant.. the second time has totally eliminated any sign of leakage.
Even otherwise, one can normally go on a 400km tour. I've done even longer runs with the leak and its a non issue. the leak is too tiny and too minimal.

----consecutive posts auto-merged-----

Originally posted by hmunjal View Post

Thanks a lot guys. Will visit SVC today itself.
After resolving this issue, is it advisabel to go on a 400km weekend trip before break in?.(chked internet and got mixed reviews)

you can, but try not to ride above 7500 constantly. you can keep it at around 80kmph with short bursts to 100. fyi, the 200 does exactly 100kmph at 7500rpm in 6th gear

**kundalus** · 03-03-2016, 12:27 PM

Re: KTM 200 Duke

Gave my bike for second paid servicing. The guy suggested me to do engine oil flushing & oil additive each costing 250 odd INR. anyone has tried this before?

Also ended up taking AMC for 3 services @ 1200INR.

**Shourya014** · 03-03-2016, 12:32 PM

Re: Duke 200

Originally posted by s1d View Post

First get the chain adjusted to spec and the gear lever lowered a bit.
Ride another 200 and see.. sometimes its the rider and not the bike at fault

If not , might require changing the gear shift shaft or the 'stopper drum comp'. I've seen this happen on a few ktm's including mine.. when shifting the lever doesn't return to its position and gets stuck at times and needs to be nudged back. the shift shaft and stopper drum comp were replaced under warranty.

What is stopper drum comp..???

**jeshurun99** · 03-03-2016, 02:22 PM

Re: KTM 200 Duke

Originally posted by 200Duker1993 View Post

Hello

I am still getting the sound sometimes it's so annoying the whole rear portion rattles I tried zeroing in the portion where the noise is coming from but I wasn't able to din't have time to take it to SVC.

I will follow the steps you have provided. If you can please provide the link to the picture.

I will be going on a ride with pillion this Sunday around 1000KM up and down. Which is the best suspension setting in city as well as for touring ?
Pillion is on slim side (55Kg) I haven't changed the factory set up yet. It will be great if anyone can tell me how to change the suspension setting.

This was my post....

Originally posted by jeshurun99 View Post

Hey Buddy,

I was doing the chain service the other day and found out the screw of the chain guard was loose. See the pic...i'm referring to this screw.[ATTACH]204758[/ATTACH]

I screwed it back and was a bit shocked to see that there was no Nut behind that screw near the rear shock absorber. Can anyone post a pic of that...? from the opposite side of the pic that is attached above....
I tightened it without the rear nut... the sound has reduced a lot but it has not gone fully.

I didn't have time to remove the tail section...wil report about this later.

Check for other nuts in that area...bcz these are the ones that get loosened on normal wear-n-tear.

I normally tour and ride in city with the stock setting. As far as I know this setting is the best...Not too soft for cornering nor too hard for long rides.

If you want to change the setting get in touch with the nearest SVC... they have a tool with which u can change it easily. And, try not to hammer it. The suspension is a costly part to replace if you spoil it hammering.

----consecutive posts auto-merged-----

Originally posted by kundalus View Post

Gave my bike for second paid servicing. The guy suggested me to do engine oil flushing & oil additive each costing 250 odd INR. anyone has tried this before?

Also ended up taking AMC for 3 services @ 1200INR.

You can flush engine oil using a product from Bosch check in flipkart. It's a blue container.

You can do it once in 1-2yrs...

**kundalus** · 03-03-2016, 03:05 PM

Re: KTM 200 Duke

Originally posted by jeshurun99 View Post

This was my post....

You can flush engine oil using a product from Bosch check in flipkart. It's a blue container.

You can do it once in 1-2yrs...

Okay one more help, does using philips extreme vision void warranty by any chance? Coz my stator coil has gone bad and SVC guy is claiming warranty is void by using this bulb.

**jeshurun99** · 03-03-2016, 03:36 PM

Re: KTM 200 Duke

Originally posted by kundalus View Post

Okay one more help, does using philips extreme vision void warranty by any chance? Coz my stator coil has gone bad and SVC guy is claiming warranty is void by using this bulb.

Technically speaking it does not void the warranty as Extreme vision is of the same rating as stock bulbs. Better change back to original bulbs and pilot lamps and then goto another service centre in your city and get ur stator replaced in warranty. This is a typical behavior of SVC guys to void the warranty be careful.

**Shourya014** · 03-03-2016, 03:52 PM

Re: KTM 200 Duke

Do you know what a stopper drum is...???? And in today i heard a kat kat noise from the engine when lowering the rpm while riding amd it is like giving jhatka and them when i left the throttle and again when i started revving the noise wemt of it is not constant but everytime i ride it is present there.

**s1d** · 03-03-2016, 04:40 PM

Re: KTM 200 Duke

Originally posted by Shourya014 View Post

Do you know what a stopper drum is...???? And in today i heard a kat kat noise from the engine when lowering the rpm while riding amd it is like giving jhatka and them when i left the throttle and again when i started revving the noise wemt of it is not constant but everytime i ride it is present there.

its a part of the shifter mechanism.. its a small piece of metal and costs about Rs.36. See the pictures below, I had the shift shaft also replaced to get rid of the lever getting stuck at every gear shift. this happened to me on day 1 as soon as i took delivery

. no issues since.
Also check out page 133 of the workshop manual : https://drive.google.com/file/d/0B_b...w?pref=2&pli=1

but without riding the bike it's difficult to pinpoint what the issue could be.

**Shourya014** · 03-03-2016, 06:09 PM

Re: KTM 200 Duke

Ayee i had got it changed when my bike was responsing null to gear shift. He told me its gear shift shaft

**s1d** · 03-03-2016, 06:23 PM

Re: KTM 200 Duke

Originally posted by Shourya014 View Post

Ayee i had got it changed when my bike was responsing null to gear shift. He told me its gear shift shaft

good.
i have myself seen a few other folks having this issue and the shift shaft being replaced. it seems to be an issue on few bikes, when the shift shaft on my bike was replaced, they said that they did not find anything wrong with the one which was replaced (some so called area service incharge came and checked the part the next day). i am thinking maybe i should write to bajaj and try to get an explanation.

**RohIIT** · 03-03-2016, 06:59 PM

Re: KTM 200 Duke

Hi , I just saw pic of the gear shifter shaft and would like to pitch in my experience regd it lately.
My uni , done 25k in 8 years suddenly had no gear like effect.
I could either engage gear 1 or 2 , but could engage others by tapping lever back.
So gear lever return spring broke. Which is the one seen in pic near the plate area.
So if you guys are having same issue , just change the spring if available . Entire shaft assy change is not required.
However you will need to drain oil and fill additional oil +200ml i guess if you decide to replace this shaft.

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