Re: KTM 200 Duke

I wanted to fit radiator guard for my Duke. Was researching for good pieces online and that's when i thought to make a DIY for KTM Duke Radiator Guard.

Total cost of this DIY is less than Rs 100. If you have the rest of the items in-house.

Before:



After:





Let me know if anyone wants the steps to make it.

Re: KTM 200 Duke

Hey I don't know about others but I want to make one like that very badly. Plus rains are about to start gotta keep my radiator fins happy
[MENTION=45051]plexus[/MENTION], do not quote the entire picture set, remove them when quoting. Thanks.

Re: KTM 200 Duke

Hi Buddy,

I know how you feel when the chocolate milkshake [Muddy slush] ends up on the radiator because I stay in Bangalore . And, for me the problem was more bcz i could find 2 bent fins of radiator after my recent long drive.

So, I decided to make it.

The items needed for making it:

1) Annodized Aluminium Mesh [ 12 inches length and 8 inches wide. Tell the shopkeeper for 12 inches and he will give you more than that bcz he will not cut exact size as its a loss for him. I got it for Rs 110 (12' x 30' size) from SP Road, Godown street, Bangalore. There are many designs of different sizes of the diamond structure. Pick the design that you like. Not too small as it might hinder air flow and not too big that stones can enter in. I have so much left in excess that I'm thinking of making the mesh again in different colors KTM Orange maybe .]

2) Axe saw blade or any metal cutter available in-house.

3) Pencil and measuring tape.

4) Spray paint (Matt Black - F1 Spray paint Rs 70). [Omit this if you like the natural aluminium color]

5) Zip ties. [Had this in-house bought it previously on ebay]




Use the pencil and make markings of the size of the radiator guard and cut the Aluminium mesh using the axe saw blade. try to cut it in a way to grind the thickness of the mesh and then bend and break the mesh.

I kept it behind the radiator guard and saw... didn't like the aluminium color so i spray painted it




Once it is dried, Used the Zip ties to mount the aluminium mesh behind the stock radiator guard and removed the excess part of zip tie.
Also once the mesh is mounted bend it on the sides of the radiator guard to prevent any stones from penetrating in through there.




Fix it on the bike and the enjoy riding.

Re: KTM 200 Duke

Appreciate your efforts in making this.
Now coming to the reality (no offense to your effort, do not shoot me!), that mesh is not going to do much.
The stock mudflap that ktm provides does all the job of keeping the muck away from the radiator.
I've ridden quiet a bit on slushy roads and having covered over 21k km now, I can guarantee that there hasn't been the any muck attack on the radiator. The mud flap on the front mud guard and the plastic 'guard' on the radiator do a good job.
the only stuff that sticks in the radiator are those pesky bugs (not many just a couple if one rides early mornings on the highways), which are easy to clean with just a bit of soapy water.

If you do not have the stock mud flap and want something that protects radiator from muck, you have to first find out which part of the radiator is hit the most by muck and put up something like this:

Re: KTM 200 Duke

Ha ha... who am I to shoot you.

Yes you are absolutely right. The radiator guard has no role in protecting the mud from splashing on to it. And, I already have that plastic guard. This mod is good in protecting the radiator from Bug and stone attack.

But on a recent drive i went a bit off-road and that is when i found small pebbles stuck between the fins of radiator. I have no idea how this happened. Also, i found some of the bends at the top part of radiator... I think it was because of a beetle which I hit in high speed. So, I placed the mesh.

And, seriously the ninja's radiator has lots of bent fins. I pity the owner

I hope I don't get any more bent fins... Also, I'm thinking to paint it orange as the black is getting too mixed up with the background. Maybe, orange will pop-out :P

Re: KTM 200 Duke

I still have that problem with my bike. Once it hits low fuel warning, the bike feels underpowered and have some jerky kind of problem which comes when there is no petrol. Even if i twist the throttle, doesn't feel much power. The SVC guys said there is no issue. Did my second service today but still have that issue. Is this related to fuel pump or anything? The bike turns off automatically while riding. But it doesn't happen always

Re: KTM 200 Duke


Ask the SVC guy to take for a spin with you as the pillion so that you can pin point the problem, was the fuel filter changed on second SVC

I haven't faced such kind of issue as of till now

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Changed my D200 charging coil as it was not charging the battery and the screen showed low battery

Thane SVC center charge was 1250rs approx for the coil as 200rs for labor later found out that the bike is under warranty(30000kms or 2 yrs) and should be done at free of cost. they could not refund so they will not charge for for oil in next svc

Re: KTM 200 Duke

Nothing else was changed for second service as I haven't covered much kms

Re: KTM 200 Duke

Took the bike to office and back, covering a distance of 182kms.
Being a citizen of a district town surrounded by villages has its unique experience especially when riding anything but a commuter. Today on my journey of 180 kms, at least 30-35 people signalled me that the light is on, and I kept signalling a like for their gratitude.
Now the experience:
The bike ran beautifully in each gear though I am yet to adjust myself between 2nd & 3rd gear. All other gears are just fine for me.
Felt some vibrations in the handlebar in low rpms, but after 4k it becomes a non-issue.
Didn't get any chances of panic braking, but I felt the braking is good. It was enough to raise the confidence in the time of need.
Rode at around 75-85 kms/h and the temperature bar was never high enough or problematic to me.
And the seat... being an average built person I had adequate space to move my bottom, but the hardness of the seat requires some soft padding. Would check with the seat cover makers if they have any padded cover in stock or could make one.

Re: KTM 200 Duke

Here's the catch. The fins on the Duke 390 are stronger and slightly wider apart when you compare it to the soft aluminum fins on the Ninja, CBR and the Yamaha R3. All can be bent pretty much even by a toddler, provided enough force. Try the Duke's and you'll know it's comparatively thicker and harder to bend the fins. Good job there by KTM.

Beautifully done mod, cheap and effective, looks kinda cool though.

Cheers!
VJ

Re: KTM 200 Duke

So I think it would be better if you used a mesh with slightly smaller dia holes and more importantly, placing the mesh in front of that plastic guard would be better than behind it (Easier to clean and the bugs and stone chips will be stopped well before the fins)

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Yup, the fins hold up pretty well on the ktm's radiator. I've had some incidents of careless water washes, but so far there are hardly 6 bent fins. And i get the bike washed only during the services, and in between services it hardly goes in for a wash (unless its way too mucky after riding in slush).
And the bugs haven't caused much havoc other than wrecking their own lives

Re: KTM 200 Duke

Hi all! Today i order front & rear crash pads from ebay (and a radiator guard). I saw a video on how to install them. I noticed that i have to remove one bolt from the front wheel and apply the one comes with the pads. In the video the guy applied threadlocker liquid on the bolt. My first question is do i need to buy this liquid too or it will be ok without it? Is there any chance that the bolt will be poor quality? How much preasure shall i give to the bolt and is there any chance if something goes wrong with the bolt will make me fall? To be more specific.. this bolt is ctitical to the front wheel stability?
I didnt post the link of the items i bought because i am not sure if its allowed but i will post images when i install them.

Sorry if this questions sounds silly to some people but i want to feel and be safe when i ride

Re: KTM 200 Duke

I get mine serviced in thane near wagle. Found them very coperative. Always helpful but they forget doing couple of things everytime. Even after writing them down in job card. They always insist on engine flushing and i only agree as dont want any issues with warranty.

Re: KTM 200 Duke

The threadlocker liquid is there to prevent the bolts from undoing itself due to vibrations. Not really a necessity, but if you want the threadlocker, you can use a drop on the threads of the bolts on the crash protectors, and screw it in, this way the bolt is secure and gives you peace of mind. There are no torque specification on every crash protectors out there. But as a general rule, make sure you use a good quality wrench, especially if it's an allen key bolt type and torque it in as much as you can to the point where it wouldn't tighten or screw in more. Slight over-torquing is better than an undertorqued nut/bot.

Make sure you don't go overboard and over-tighten, once the threading stops, just apply some extra pressure than normal, once or twice and you're ready to go, do this for all the bolts of the protectors. Don't worry, you won't fall even if those things undo themselves.

Cheers!
VJ

Re: KTM 200 Duke

Do post a link of the product and the installation video. I'd like to see which bolt you are talking about.. is it the axle ?
It's definitely better to use a thread locker (one good and common brand is LOCTITE), but make sure you use only the blue colored one which is a medium strength and used in places where future disassembly will be required and keeps the bolts from loosening out.