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**s1d** · 10-23-2016, 06:08 PM

Re: KTM 200 Duke

Originally posted by Vishal_G View Post

Thanks for the suggestions Sid. Would definitely look them up.

Upon further checking I found some torx Allen key in my dad's drill set - T27 &T40. T27 was a tiny bit smaller and T40 was quite bigger.

My brake pads are getting worse, the plate and bolt holding them are rusted and I am going for 5th service this Thursday. The asc head keeps on saying the pistons and caliper is fine even though the right side pad is literally new.

Personally, I don't trust them and I really want to stop this rusting which is happening just everywhere.

Just apply a very thing coat of grease on the bolt/clip.
I don't understand the statement in bold. Are you having uneven wear on the pads? i.e. one pad wearing out more than other? If so, it could be one of the piston is stuck, causing all the pressure to be transferred to the other one which in turn in causing one pad to wear out more than other. IIRC we discussed this earlier. The pistons need to be removed cleaned (including the bore in caliper) and put back preferably with new seals and brake fluid. They might also be having a caliper rebuild kit with new pistons/seals.
If you have pics and svc is not helping, shoot an email to ktm and demand an explanation or confirmation that uneven wear is 'normal' (it definitely is not)

**Vishal_G** · 10-23-2016, 06:23 PM

Re: KTM 200 Duke

Yes, you got it right. My svc is close to my place so I have showed them the brake pads but they don't even look at it and say its okay for pads to wear unevenly. And they are saying all you need is a change of brake pads.
Also, my steering is weird and it pulls a bit to the right. While going over uneven roads handle is unstable.

I don't know if the steering is only loose as I am facing this issue ever since they loosened the contest around 6 months ago. It has kept on increasing and now it has become quite a problem

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**s1d** · 10-23-2016, 09:42 PM

Re: KTM 200 Duke

Originally posted by Vishal_G View Post

Yes, you got it right. My svc is close to my place so I have showed them the brake pads but they don't even look at it and say its okay for pads to wear unevenly. And they are saying all you need is a change of brake pads.
Also, my steering is weird and it pulls a bit to the right. While going over uneven roads handle is unstable.

I don't know if the steering is only loose as I am facing this issue ever since they loosened the contest around 6 months ago. It has kept on increasing and now it has become quite a problem

It's clear from the pic that one piston is stuck forcing the fluid to pump the other piston out. Please email ktm as i informed earlier, tell them you want the svc told you and ask them to confirm that in writing!! If you have the patience, you can screw them

As for the steering adjustment, ask them to tighten it.. if that doesn't fix it, then you might have to replace the coneset i.e steering stem ball bearing.
To adjust it, they need to loosen the top nut and then tighten the ring below, then tighten the top nut back again.. Then check the steering if it moves freely (by tilting it on side stand). I had this done last week due to a minor play in cone-set, and now its perfectly alright.. i was in fact expecting a cone-set change (considering my bike is two yrs) but a simple adjustment fixed it.
Btw, you were the one going in for a frame change right? IF so, what happened to that ? Din't they put in a new coneset ?
You seriously need to get behind them and put these complaints in email continuously.

**Vishal_G** · 10-23-2016, 11:35 PM

Re: KTM 200 Duke

Chassis change is supposed to happen but they keep on saying we haven't received it yet. Also, are not doing anything about the suspension. I complained about these things in August.

All they want is to replace everything claiming its a consumable.

I have no idea how will I get the new chassis no updated on the rc book.

**kundalus** · 10-24-2016, 12:42 AM

Re: KTM 200 Duke

Friends need one help, my front tyre has excessive wear on right side. Since its old i am able to make it but rear is new. I am aware of general consensus that these wear is normal but I want confirm if one sided wear is also possible due to suspension issues. Also, I got my right grip changed to 2015 version and now it's giving hell lot of pain. Arm and back both have been in bad shape since a week. And old one 2014 model is not available. Any suggestions of using aftermarket to avoid this pain?

**s1d** · 10-24-2016, 11:10 AM

Re: KTM 200 Duke

Originally posted by kundalus View Post

Friends need one help, my front tyre has excessive wear on right side. Since its old i am able to make it but rear is new. I am aware of general consensus that these wear is normal but I want confirm if one sided wear is also possible due to suspension issues. Also, I got my right grip changed to 2015 version and now it's giving hell lot of pain. Arm and back both have been in bad shape since a week. And old one 2014 model is not available. Any suggestions of using aftermarket to avoid this pain?

excessive wear on one side is not normal on everyday use. a picture of the tire would help understand better.
for the front, you need to make sure the fork and axle is properly aligned, and also the rear wheel alignment by ensuring the chain adjuster blocks (the ones thru which the axle passes) on both sides are at same positions.
Check out the last few pages on the d390 thread where [MENTION=83544]chip94[/MENTION] and myself have discussed fork alignment. you can also check out the workshop manual (google it) as a reference.
now that the tire has uneven wear, you can't undo it.. so get a new tire (and mount it correctly my checking the direction of rotation) and make sure the alignment is correct.

as for the grips, go to a local spares shop and get grip covers that you can slide on to the existing grips. there are different types available like rubber/foam type.. i'd say get a rubber one since the foam might be an issue when wet. These hardly cost 50 bucks a pair and give you a good thick grip to hold on to.

**kundalus** · 10-26-2016, 02:38 AM

Re: KTM 200 Duke

Originally posted by s1d View Post

excessive wear on one side is not normal on everyday use. a picture of the tire would help understand better.
for the front, you need to make sure the fork and axle is properly aligned, and also the rear wheel alignment by ensuring the chain adjuster blocks (the ones thru which the axle passes) on both sides are at same positions.
Check out the last few pages on the d390 thread where [MENTION=83544]chip94[/MENTION] and myself have discussed fork alignment. you can also check out the workshop manual (google it) as a reference.
now that the tire has uneven wear, you can't undo it.. so get a new tire (and mount it correctly my checking the direction of rotation) and make sure the alignment is correct.

as for the grips, go to a local spares shop and get grip covers that you can slide on to the existing grips. there are different types available like rubber/foam type.. i'd say get a rubber one since the foam might be an issue when wet. These hardly cost 50 bucks a pair and give you a good thick grip to hold on to.

Tha ks bro. So here r the pics. I showed the bike at svc. They checked and found everything is ok. Rims are fine. On my request they tried adjusting the handle bar with hand as it seemed bent at one end slightly. Sprocket was fine too, but they did not check alignment even on request. Front forks are fine too. They said Tyre had worn out so I got them changed to ceat ones yesterday. Seems good for after about 150km of riding. My rear also seems to have a little extra wear on right side. I'm suspecting that having pillion since last few dayight have caused. Will keep a check for few days and update if there extra wear on new one.

For hand pain, I think it must be offroading on Mumbai highways since there hardly any road left.

**s1d** · 10-26-2016, 10:27 AM

Re: KTM 200 Duke

Originally posted by kundalus View Post

Tha ks bro. So here r the pics. I showed the bike at svc. They checked and found everything is ok. Rims are fine. On my request they tried adjusting the handle bar with hand as it seemed bent at one end slightly. Sprocket was fine too, but they did not check alignment even on request. Front forks are fine too. They said Tyre had worn out so I got them changed to ceat ones yesterday. Seems good for after about 150km of riding. My rear also seems to have a little extra wear on right side. I'm suspecting that having pillion since last few dayight have caused. Will keep a check for few days and update if there extra wear on new one.

For hand pain, I think it must be offroading on Mumbai highways since there hardly any road left.

Looking at the front tire pic, its clear that your tire was at the end of its like (look at those cracks!) and the wear seems ok, nothing excessive
Good you got it changed !
Maintain right tire pressure

**kundalus** · 10-26-2016, 12:14 PM

Re: KTM 200 Duke

Originally posted by s1d View Post

Looking at the front tire pic, its clear that your tire was at the end of its like (look at those cracks!) and the wear seems ok, nothing excessive
Good you got it changed !
Maintain right tire pressure

Svc guy asked me to keep 26, 28 in front, back as I travel solo most of the times and 28, 32 if with pillion. My new front Tyre is also seeingore exposure on the right side. I tried riding with hands off and there is no swinging. I will get my chain setting and alignment checked now.

**The APPATUCK3R** · 10-26-2016, 04:32 PM

Re: KTM 200 Duke

Originally posted by kundalus View Post

Tha ks bro. So here r the pics. I showed the bike at svc. They checked and found everything is ok. Rims are fine. On my request they tried adjusting the handle bar with hand as it seemed bent at one end slightly. Sprocket was fine too, but they did not check alignment even on request. Front forks are fine too. They said Tyre had worn out so I got them changed to ceat ones yesterday. Seems good for after about 150km of riding. My rear also seems to have a little extra wear on right side. I'm suspecting that having pillion since last few dayight have caused. Will keep a check for few days and update if there extra wear on new one.

For hand pain, I think it must be offroading on Mumbai highways since there hardly any road left.

This is exactly how my front tire was wearing out , the reason behind it was a fork bend. After a crash the SVC guys noticed the bend at the last moment while trying to fix the front wheel so instead of replacing it they just adjusted the front axle and fixed the wheel. So you should definitely check your forks and the entire assembly the issue could be anywhere from handle to the front axle.

For starters,
Check the front axle thats passing through the wheel and the forks. Compare it with another duke and check whether the nut is protruding a little out or not there should be almost a quarter inch gap between the trim of the fork and the axle if its level with the fork (thats how it was for me) then tell them to adjust it in front of you to the right position.
If no such thing make them check the front axle for a bend.

**s1d** · 10-26-2016, 07:09 PM

Re: KTM 200 Duke

Originally posted by kundalus View Post

Svc guy asked me to keep 26, 28 in front, back as I travel solo most of the times and 28, 32 if with pillion. My new front Tyre is also seeingore exposure on the right side. I tried riding with hands off and there is no swinging. I will get my chain setting and alignment checked now.

maybe the road you frequently ride on is causing a uneven wear due to the way it's laid (roads are usually not flat but have a slope). but again a bit on uneven wear on a rounded profile tire could happen, but excessive is not normal.(i couldn't spot any excessive wear in your earlier pics)
As i said earlier, make sure the alignment is correct.
26~28 is fine for the front.
The rear depending on your weight/pillion can be set to 28~32.

i'll post a pic of the front tire on my d200 a little later tonight.. it's done 25k km (i admit i stretched it, it was probably gone by around 22k km). Even though the tread depth was ok at 20k km, i felt that the soft compound nature of the tire and its structure/rounded profile itself dictates that a good time to change the front is around 20-22k km (or lesser depending on riding/braking habits)

**kundalus** · 10-26-2016, 11:44 PM

Re: KTM 200 Duke

Originally posted by The APPATUCK3R View Post

This is exactly how my front tire was wearing out , the reason behind it was a fork bend. After a crash the SVC guys noticed the bend at the last moment while trying to fix the front wheel so instead of replacing it they just adjusted the front axle and fixed the wheel. So you should definitely check your forks and the entire assembly the issue could be anywhere from handle to the front axle.

For starters,
Check the front axle thats passing through the wheel and the forks. Compare it with another duke and check whether the nut is protruding a little out or not there should be almost a quarter inch gap between the trim of the fork and the axle if its level with the fork (thats how it was for me) then tell them to adjust it in front of you to the right position.
If no such thing make them check the front axle for a bend.
[ATTACH]221151[/ATTACH]

Hi! Thanks for sharing this info. In my case I just got my tyre changed day before. And iirc its in proper position coz the tyre was changed in my presence. May b fork bend or alignment could be an issue. I will get it thoroughly checked this weekend or in coming week. Thanks.

Originally posted by s1d View Post

maybe the road you frequently ride on is causing a uneven wear due to the way it's laid (roads are usually not flat but have a slope). but again a bit on uneven wear on a rounded profile tire could happen, but excessive is not normal.(i couldn't spot any excessive wear in your earlier pics)
As i said earlier, make sure the alignment is correct.
26~28 is fine for the front.
The rear depending on your weight/pillion can be set to 28~32.

i'll post a pic of the front tire on my d200 a little later tonight.. it's done 25k km (i admit i stretched it, it was probably gone by around 22k km). Even though the tread depth was ok at 20k km, i felt that the soft compound nature of the tire and its structure/rounded profile itself dictates that a good time to change the front is around 20-22k km (or lesser depending on riding/braking habits)

May b you r right but Im riding same road since 2months now and thus wear is showing up in last week or so. And post the rains the road r in horrible situation. Patches all over them. I think I will have to stop using bike now and travel by train. The roads are in such a condition that I feel am doing a 50km off roading on my 100+ daily commute. Will maintain the pressure for a week and update. Meanwhile will also get fork bend and alignment checked. Thanks, appreciate.

**kundalus** · 10-27-2016, 12:22 AM

Re: KTM 200 Duke

I think my handle is the culprit. [MENTION=16602]s1d[/MENTION] I think on close inspection I am seeing my fork, handle and front Tyre r not in same line. Is it possible in Duke considering it has two forks moving straight out of the handle?

**anishbora** · 10-27-2016, 12:43 AM

Re: KTM 200 Duke

Hello everyone. I am looking forward to buy the Duke 200, and since i did not get much response in the What Bike section, i am posting my queries here.

I happened to meet two Duke 200 owners last week.
Guy 1: very sane rider, doesn't rev up the engine much, takes extremely good care of the bike, rides in city and reports an FE of around 30 kmpl (maximum), and 27 kmpl (worst case).
Guy 2: not that sane of a rider, takes less care of the bike, rides in the same city as well, and reports an FE of "at least" 35 kmpl..
Both said that they used the "tankful to tankful" method to measure the FE. This has left me extremely confused regarding the actual FE of the bike. Duke 200 owners please help!

Also please throw some light on the major service expenses, like engine overhauling, clutch overhauling.

Just curious about something. I have read quite a number of times in this forum, that the engine oil consumption of the Japanese bikes is very less. How does the Duke 200 fare in this regard?

Hope to get some response here.
Thanks in advance!

**kundalus** · 10-27-2016, 12:54 AM

Re: KTM 200 Duke

Originally posted by anishbora View Post

Hello everyone. I am looking forward to buy the Duke 200, and since i did not get much response in the What Bike section, i am posting my queries here.

I happened to meet two Duke 200 owners last week.
Guy 1: very sane rider, doesn't rev up the engine much, takes extremely good care of the bike, rides in city and reports an FE of around 30 kmpl (maximum), and 27 kmpl (worst case).
Guy 2: not that sane of a rider, takes less care of the bike, rides in the same city as well, and reports an FE of "at least" 35 kmpl..
Both said that they used the "tankful to tankful" method to measure the FE. This has left me extremely confused regarding the actual FE of the bike. Duke 200 owners please help!

Also please throw some light on the major service expenses, like engine overhauling, clutch overhauling.

Just curious about something. I have read quite a number of times in this forum, that the engine oil consumption of the Japanese bikes is very less. How does the Duke 200 fare in this regard?

Hope to get some response here.
Thanks in advance!

Well mileage in my city riding experience has been between 30-35 mostly, on highways I have seen 40+. If you ride between 5-6k rpm u will get good mileage. And I feel 35kmpl for a 200cc bike after 2yrs is still good(in my case).

Engine overhauling etc will cost you around 7-8k + labour. Can confirm charges in couple of days if you want. If u buy a new Duke u need to get ur bike serviced at 7.5k km(5k in old models). And oil change at each service. Which is decent enough imo. Service for first two years would mostly be oil + filters. Around 1600 per service.

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KTM 200 Duke

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