2700rs for the O2 sensor!!! did you see the printed mrp on the cover?
400 bucks labor for screwing it in!

I had the speedo sensor replaced today under warranty, damn.. it normally costs 417rs!
My dealer (not ktm) is offering an extended 3yr warranty for 1500rs, I probably should avail that !

Fuel leaks are only two possibilities, either the in line fuel filter tubes are loose, or ill fitted post service or you have a leak in your fuel pump assembly at the bottom. There is a rubber O ring IIRC, at the bottom of the fuel pump assembly, if that is warped or a goner then you have this leak. Start first with the basics such as in line fuel filter, hoses, clamps and then proceed to fuel pump finally if the issue isn't resolved.

Cheers!
VJ

A frnd of mine had jerky ride in lower gears as you have mentioned. Get the fuel pump checked once for the pressure of fuel flow.
He replaced the fuel pump and everything was fine afterwards in his bike.

Thanks a ton for the info guys!

I was facing a similar jerking/stuttering on my motorcycle past 3 weeks, which is 3.4 years and 24K kms old.

I routinely drive at 15 to 20 kph in second gear inside the Tech park that is good 1.5kms which gives sufficient time for engine to warm up in the night.

Following were observations:

When tried to hold steady speeds (ofc with steady throttle) around 15 to 20 kph in second gear (around 2.5k to 3k rpm), bike feels like it is running out of fuel and begins to feel like it is goin to die (jerk/stutter) and with a moderate amount of extra twist of throttle, bike comes to feel normal without any signs of jerk anymore (when rpm reaches a little past 3.5k rpm)

Also was simultaneously getting MIL (engine check light in common terms) blinking on the console, MIL blink pattern was one long and seven short blinks, checked online for blink code and it represented a Lambda (oxygen/o2) sensor malfunction error (Please note it usually takes a cold engine around 3-4 kms to show up MIL code and then it stays on)



Action taken: Took it to my regular svc; Auto service, they read the error readings and confirmed that it is the o2 sensor malfunction error and tried to test the o2 sensor on my bike with a different sensor from another D200 and voila!, no jerking/stutering and no MIL error codes. Mech decided to clean my o2 sensor and give it a try, with my old sensor back on both jerking and MIL code was back. This confirmed my o2 sensor had gone faulty. A new o2 sensor was out of stock, it took 6 days for the stock to arrive. With the new o2 sensor there is no jerking/stuttering at low rpms. Total bill: 2.7k for the new sensor and around 400 bucks as labour.

--
Srvn

Same problem i have,but it doesnt show any MIL.It just stutters the same way yours do.If you hold a steady speed at around 15kmph it starts stuttering .Can it be an O2 sensor fault.If so how is O2 sensor related to stutterig.Clearly my symptoms are same as yours,only difference being i dont see any MIL lights at all.Also after changing O2 sensor any change in mileage?

Guys i m faving a problem where my bike is stalling.. And knocking on low rpms like 3-3.5k nd the acceleration sometimes gives a null response

As I said in the post, it usually takes a cold engine around 3-4 kms of driving to turn on the MIL to blink and then it stays on. Ideally, if there is something wrong w.r.t sensors gone faulty and all, ecu flashes them on the MIL to alert the rider but in your case I'm not sure if it related to o2 sensor. I'd suggest you to take the bike to the svc and read out the ecu for any error readings if any and proceed further, if there's nothing shown on the diagnostic tool (ecu readings) then you might go ahead with fuel pump pressure check.

Additionally, 1.Have you tried changing the fuel station, after you have encountered the jerking/stuttering?

2. Tried cleaning the air filter and run the bike?

If no is the answer, then I would ask you to try above two things and if bike still jerk/stutters then head to svc.

To answer your question about o2 sensor causing jerky behavior, o2/oxygen sensor reads the amount of oxygen present in the exhaust gas in the exhaust system (after combustion stroke) and informs the same to the ecu, so the ecu can determine the optimum amount of fuel needs to be supplied to the engine.

So when o2 sensor becomes faulty, it sends incorrect data or no data to the ecu, which causes ecu to supply excess (rich mixture) fuel (less mileage) or less (lean mixture) fuel (more mileage and more engine heating/wear and tear) and in my case it caused jerk/stuttering in low rpms

No I haven't checked the mileage with the new o2 sensor, I am sure it should have been increased. Hope I was able to help.

--
Srvn

Clogged fuel filter or adulterated fuel could be causing this. Try fuelling from a reputed bunk and check if the issue persists.

By the way, how many kms on the ODO ?

Cheers,
Sanjay

After a short ride I can smell the fuel, checked for leaks but couldn't locate anything .
the fuel quantity drops drastically, but the leaks are nowhere to be found.

when i am parking the bike there is loss of fuel and I don't know how

Any one can help me out .

Fuel leaks are only two possibilities, either the in line fuel filter tubes are loose, or ill fitted post service or you have a leak in your fuel pump assembly at the bottom. There is a rubber O ring IIRC, at the bottom of the fuel pump assembly, if that is warped or a goner then you have this leak. Start first with the basics such as in line fuel filter, hoses, clamps and then proceed to fuel pump finally if the issue isn't resolved.

Cheers!
VJ

Visited the SC to get the leak checked. Had them open the tank in front of me. The tank had two small cracks near the fuel pump. Got the tank replaced under warranty. Cost of a new tank is INR 1700.

Photos attached. My guess is that the mechanic who checked the fuel pump 2 months ago tightened the screws too tight resulting in the cracks. Is it possible? Cannot think of a reason for this to happen.

Visited the SC to get the leak checked. Had them open the tank in front of me. The tank had two small cracks near the fuel pump. Got the tank replaced under warranty. Cost of a new tank is INR 1700.

Photos attached. My guess is that the mechanic who checked the fuel pump 2 months ago tightened the screws too tight resulting in the cracks. Is it possible? Cannot think of a reason for this to happen.

Beautiful, appreciate the pictures. There's a reason why torque specifications are provided, especially the Loctite where required, just so, service personnel don't go overboard with the torque specifications. But do we have a choice? Absolutely none of the mechanics elsewhere follow or go through the torque spec, they either over torque or lower torque the bolts. So, yes if your tank/pump has been removed before then, yes, there is a high probability this might be the reason. Do keep an eye on the upcoming days? Just curious, was this the service center that you gave your bike previously for servicing?

Scary stuff man! I have no doubt that it was the improper fitment/over tightening that caused the damage.
Unfortunately most of these mechanics tend to over tighten bolts. even if they do not want to use a torque wrench, i fail to understand why they can't tighten by feel and use some common sense.
I had the front fender broken near one of the mud flap mounting nut due to their over tightening routine(during one of my complaint about a vibration). They had the audacity to point that out as an accident when i went in with the brake disc issue(which for some reason warped/bent).
I think you should send these pictures to bajaj customer service in an email so that you have the issue documented. This was a potentially very dangerous issue that could have caused a fire and loss of life.