Re: KTM 200 Duke

Did you replace the fork oil anytime during your 25k ownership?

I used to change the oil at around 10-11k range on my Honda Twister, oil used to be in pretty bad condition.

Re: KTM 200 Duke

Only the right fork leg oil was changed at around 17k km due to a busted fork oil seal. The oil that was drained out seemed pretty ok to the eye. It did not appear dirty or sticky. They use a pretty thin grade (5W) for the fork oil.
The front holds up very well thanks to those awesome forks.

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yep, the old coolant appeared darker when seen from outside and was easy to spot the level. this motocool almost blends in with the color of the plastic reservoir.

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yep, the old coolant appeared darker when seen from outside and was easy to spot the level. this motocool almost blends in with the color of the plastic reservoir.

Re: KTM 200 Duke

Need some help. Was travelling at around 30 kmph when I came across a pothole. A huge pothole. Had no other option but to go through it so I did, and it was pretty deep. I checked my rims and the forks for any kind of bends or oil leaks, there was none. But the front end still feels a little shaky or wobbly. (can't find the right word)
Basically it feels a little loose. I've come across quite a few front end wobbles after my last accident.
Any idea what I should check ?

Re: KTM 200 Duke

Cone-set.
That's the local term for the steering stem race&bearings.
Another possibility is the rim might also be out of tru i.e. not a perfect circle, but this damage might not be visible to the naked eye.
But first I'd suggest you get the cone-set replaced or the steering stem nuts adjusted.
Get it checked by a mechanic for the cone-set. you can also do a basic test like sit on bike,hold the front brake and try to push/rock the bike forward with your hands on the handlebar and if you notice that there is play (i.e. you feel the handlebar/steering stem move a few mm), it most probably is the cone-set. One can also hold the forks and rock the bike, but since this bike doesnt have a center stand it's difficult to perform this check.

Re: KTM 200 Duke

Apart from what s1d mentioned also chk the wheel bearings at the front. Better to chk at service centre rather than yourself and get expert comments.

Re: KTM 200 Duke

I started my bike today after idle time of 20 days.

The bike started only after cranking approx 15 times. And it started only after I pulled the accelerator while cranking (accelerator pulling was done a couple of times too). I ran the fuel pump a couple of times by using engine kill switch.

After starting, the RPM was 1550. So the Auto choke thing is malfunctioning? (2016 model).

Is this normal for FI bikes?

And the bike was in neutral and side stand up.

In August the bike was idle once for 10 days, but it started at first crank.

Re: KTM 200 Duke

Avoid opening the throttle during a start. It only makes starting difficult.
Prime the fuel pump a couple of times, but use the ignition key instead. Do it 5 times even before you crank it, especially when the bike has sat idle for many days.
Idling at 1550 rpm is normal, that is the auto choke working normally.. the idle will drop down after a few minutes.
It was probably the fuel (old fuel in the filter can gum up over time)
Nothing to worry, just ride the bike as usual and fill up some fresh fuel.
Since you mention you were able to crank the bike 15 times, the battery is probably in good condition. But those 15 cranks might have given the battery a good work out, so just get the voltages checked to see if they are in spec.. Or simply take it out for a 60 minute ride and the battery should be charged back.

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A few days ago, I had mentioned about seeing a new diagnostic tool at the KTM svc. Unfortunately I did not click any pic, but here are some I came across on team-bhp


This tool provides a lot of information including live data.

Re: KTM 200 Duke

Am really out of my wits here with my duke(2013 model) here. In 2014 i met with a accident and my duke's front crashed against a boulder in the middle of the road.
Resultant of which following were changed: Front wheels (rim broke into pieces), Front tyres (it had ripped apart), Chasis ( had a very deep dent and opted to change it out not taking any chances), Handle bar, pillion and rider footpegs, gear and rear brake levers etc.

All these repairs were carried out in the Chennai Adyar SVC and with the help of my friends i got it sent directly to my hometown CBE where i was recovering and had got transferred to because of the fall. Where i had again revisit the SVC every single month to get a lot of issues sorted out and almost after a year only we had found out that there was a big bend in the front fork and and the front wheel axle was adjusted accordingly to hide the fact.(by Adyar SVC guys) And after breaking my head for another year finally four months back i have changed both the front forks and the handle and the cone set and the entire front assembly.(Now its a new bike with a old heart).Even after this the fork that was put on my bike was faulty and didnt function or travel more than 1 mm and the SVC guys asked me to give it a little time which didnt solve the problem
and they replaced the forks with another set which worked better. ( am not able to compare it with any other proper d200s to check it). I had also changed new tyres, whole chain assembly wiht the sprockets and replaced brake pads and all those stuff as it had run 22k kms.


After all this i have gone through i am still not able to ride it at peace. These are the issues i face and would appreciate any kind of help both online and even if offline (coimbatore)
1. Whenever i take a corner the bike is giving a wobble which pushes me in the opposite direction of my lean.
2. In medium speeds of 50 if i take my hands off the handle the bike continues in a straight line as expected. (thats my way of checking the forks bent or not) but if the speed drops to 30 the bike front begins tilting either left or right without any pattern.
3. When i apply the front brakes the front clunks like as if it is separate from the chasis. this is more evident in the slower speeds
4. When leaning in to turn on either side the front seems to turn a little more degrees than i am actually turning and when am counter steering the pain is getting felt in my hands
5.When the bike is in between 5000-6000 rpm there is vibration in the head of the bike which sounds as if the key chain is gettng scratched.

My bike's engine and electronics have never given any issue and i treat my bike with utmost respect both while driving and servicing.I have seen the mechanics from the SVC and also other local bike mechanics too none are able to solve theseI would be very thankful to anyone who could help me in fixing these. i love my bike and don't have the heart to sell it as this is my first own bike.

Thanks.

Re: KTM 200 Duke

Am surprised that considering the damage, they did not replace the forks the first time.
Let me address the second point first, that behavior seems normal.
For the rest of the issues, it is related to the front end.. i.e. fork alignment, triple clamp, cone-set. Some mechanics do not properly install the cone-set and this will cause issues very quickly. Was the triple clamp (lower, also called triple tree) changed after the accident ? The one that looks like an inverted T. If not get this also replaced.
Apart from that have the front end completely removed and put back together with a new cone-set (don't let them replace just the ball bearings) and make sure the race is seated flush in the steering stem (some mechs tap it in and sometimes it isn't aligned correctly). Replace the front axle also.

Also write an email to bajaj customer service/ktm and explain the issue to them and inform them that the svc hasn't been able to get it sorted.

Re: KTM 200 Duke

Yes , they did not replace the forks and i was not there in person to assess the damage and ask them.(my mistake).
And after my recent changes they replaced the triple clamp, cone set, front axle and also the race. and i had to take the bike back to the SVC two three times to get the race aligned in its position and after third time it appeared settled. And didnt give any trouble for the past 4 months. Any person/mechanic who could help check whether the race is seated properly in coimbatore?? Or any DIY to find the same??

Ok i will try and drop a mail with the issue explained but if they again suggest replacing some other part or something then my head is going to burst.

Getting my Duke 200 today.

On my way to the KTM showroom. Excited. Can't define the feeling. Have read a lot of user reviews and totally psyched to get my hands on the 200.

Re: KTM 200 Duke

It's better to get a new cone-set (races & bearings) and make sure its seated and installed correctly the first time with sufficient grease.
Without riding the bike, it would be difficult to pin point further, but fiddling with the race/bearings so many times is not the correct thing to do.

Re: KTM 200 Duke

Ok, Thanks for the inputs let me check this week about changing the coneset , but need to take it upto a differnet SVC this time and try my luck i suppose.

Re: KTM 200 Duke

Yeh, write to ktm and tell them you are not satisfied with the work of the current svc and that they haven't been able to fix the issue. It is their responsibility to fix it right and not charge you repeatedly for the same issue. <<do mention this in your email.

Re: KTM 200 Duke

Hey Guys, my Duke 200 (2015) has completed 12000+ kms now and i will be heading for the 5th Service (2nd Paid) post Dusshera. However, i had some questions -

1. My front Brake pad wear is uneven, i.e. left brake pad has worn to almost nothing while the right brake pad has more than half the life left. I always though brake pad wear was supposed to be even considering their function.
2. I will be getting the chassis replaced under warranty, and the ASC has already ordered the chassis for replacement. How i am supposed to get the new Chassis no. updated in my Reg. Smart Card.
3. My handle feels a bit unstable, i mean when i brake or go over uneven roads it runs to one side and i need to keep it straight manually. This is happening since they loosened the handle/fork on advice of the KTM engineer. I was not present at the time and this was not suggested at all by me, i found the handle fine earlier now, its simply not stable on uneven roads. ASC supervisor says its the bearings/racer and quoted 800 rs for the change.
4. Does resetting the ECU have any benefit after this service?
5. I am getting a constant mileage of 33kmpl which is after 60% State highway and 40 % bumper to bumper traffic. Is this okay?
6. I already got the Fuel injector and Throttle body cleaned at 10000 kms last service but now i doubt if they did it. They charged something around 330 rs as Misc charges and said its done.

I am not able to stay around for the service because, these guys take the bike at 10 AM and will loiter around until you leave. They will work on some other vehicles or roam around but will not work on your bike in your presence. I usually give the bike and return after 2 hours to surprise check but they always somehow complete most of the work. Same issue with Honda SVC for my bro's CBR, the technician simply roamed around as long i was there, and started working the moment i went off to customer lounge.

Looking forward to your advice guys.

Regards,
Vishal