Re: KTM 200 Duke

Are there many Dukes out there with the same problem?

They would issue a recall only if multiple vehicles from a batch are affected.

Re: KTM 200 Duke

Stator is a very common issue. Alongside my bike there were two bike with charging issues and I was lucky to have reached first as they had only one of those new covers in stock. I don't think these guys believe in recalls.

Re: KTM 200 Duke

My friend's bike is facing the same battery issue, the battery drain very fast, it starts by pushing but then doesn't normally start and puts this error j.g._17.3 , he gave to KTM for service for change of fuel pump plus , tank, chain. Sprocket, etc came to 14 k, but the battery was got from elsewhere but it was a new battery, any pointers, if this happens again with another n battery it's really frustrating , stator coil was also changed, does he need to change the full wiring to rectify this?

Re: KTM 200 Duke

You never checked the oil levels prior to service? If indeed only 400ml came out, then you might have issues either with an external oil leak, bad valve seals, or a worn block/piston rings. I've seen a rc that had an oil leak of around 400ml but the oil pressure warning did not come on but the level in the sight glass was clearly showing low oil.
Keep an eye on the oil level and for any smoke from the exhaust (especially at rpms > 4000). After a ride, just before you park, on neutral Rev it to 4-6k rpm and observe for any smoke.

Thanks for the update, and what month/year model is your bike? As I mentioned in my earlier post there could have been oil starvation.. But was it due to the case coveror the oil passage itself(blocked) ? Only time will tell.
Never heard of such a change in design of the case cover. Please let us know the month and year you purchased the bike.
yes please, put it in writing to ktm(and also on their fb page for the benefit of others) with the pictures and proof of frequent previous replacements. If not now, it will be useful later on if the issue reoccurs. And hey, 2.3k for the stator and cover seems pretty cheap! That's something I appreciate on the parts pricing from ktm

Re: KTM 200 Duke

Mine is purchased in July '14, must be June mfg model. Even I agree with pricing but I had paid for two stator coils and got first one changed under warranty till now.

The SVC guy told me this can be beacuse of less oil sprinkled on the stator due to old cover design. With this new one it will ensure the oil is sprayed on the coil and will help burning out.

Though there is no assurity on what he is saying is right. I still decided to go for a new cover as 800₹ is still worth trying it out. I also got my entire wiring checked and even RR. They insisted on not to change the RR as it was fine as per their diagnosis and voltage check.

Re: KTM 200 Duke

but still put this in writing via email to ktm. I own a Oct 14 model (manufactured sept2014) i.e.the first lots with the radiator fan shroud and rear mono shock protection bits. I've never had the stator coil issue so far(28k km). I've been on many long rides and ridden constantly for many hrs at a stretch. I have no idea if the cover on mine is the 'newer' one or not. I will check with my svc sometime next week for their opinion on this new/better part. And maybe even I will write to ktm asking for clarification. Once you have many people putting it in writing, there might be a more favorable response from ktm. I've seen my fair share of guys who've had to get the stator replaced included a recent incident involving [MENTION=70615]Ajay Vishwanath[/MENTION] (Ajay bro do u remember how the case looked on you rc? )

Re: KTM 200 Duke

The thing is I bought this bike at 12k odo. It's a pre-owned bike. But I'm close to 35k on odo now and am pretty sane rider with close to 100km riding on weekdays. I did take this bike to couple of tours involving 300kms at a stretch and it is super comfortable. No complaints there except for this stator which went bad for third time in 12months. I'm not sure if previous owner ever got it replaced. I did see oil leak on the wiring that goes into the stator assembly once before it went bad for first time under warranty.

Yeah sure I will write it to them, I preserve all service invoices. Will dig them out and send it as a reference.

Re: KTM 200 Duke


unfortunately, I wasn't there when the stator coil was changed, but the mechanic did tell me that the coil burnt out due to the oil not coming on the coil to cool it down.. mine is a '14 model (actually a '15) but purchased & manufactured on '14, so yeah it's a '14.. has happened to me.. it was actually gradual & slowly.. off late I noticed that my headlights were not as bright as they used to be and eventually died on me one fine day.. poof, new coil & it's fixed, I am guessing that I got the "old" cover..

Re: KTM 200 Duke

Beautiful. Thank you so much for posting this picture. From what I can see from this is they've introduced an oil jet to be sprayed on the stator, beautiful implementation by KTM. Though the stator was already cooled, spray lubricating them should cool them even further. At least they implemented a new design on a proactive method rather than stepping aside. All manufacturers learn, but what makes a product error free is the ironing out of the issues on an active basis. Bajaj has always been stern at rectifying and improving the newer lots.

I would personally recommend all 200 owners to change it to this new improved casing as it helps in cooling and saves your stator in the long run.

Good for you, you didn't seize your engine. Poor filling from the factory, that's all I can speculate at this point in time. Replace the engine oil with the recommended level and keep a tab on the oil consumption if any for a couple of days, this should give you an idea if there is any oil consumption. Also, look for smoke, during early morning, thick two stroke like smoke during cold start ups and after the engine has warmed up. If all is good fore a couple of days, you can be rest assured a poor fill from factory.

Cheers!
VJ

Re: KTM 200 Duke

Yeah I thought the same. I remember giving it to the other SVC for gasket change. They might not have topped it up.it went for a good 2-3k KMS. Today in diagnastics tool they didn't find any issues.
I don't know why but I am in love with the engine.i must say It sustained heavy rough usage. To my surprise the bike feels so smooth now. Only vibes are the ones creeping at 7000 to 9000 Rpm, but I guess it's normal. It's not that harsh. Clearly lose footpegs or something similar on the other side.

Re: KTM 200 Duke

Sorry,was busy with life. Here is the pic i uploaded finally.
The screw where you can see oil coming from had a very small crack, could not detect at first since it was under that screw design.
It is very rare, may be casing had an issue or mechanic's fault.


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

Few basic questions i have,

1. How to determine whether brake pads need replacement? What should be thickness between rotor and the brake pads? That is about my d200 rear brakes and what is cost of rear brake pads?
2. If i move my bike in reverse direction then i hear sound near front brake caliper. Only if my bike is moved in reverse/backward direction. What is it about?
3. Reviews on Tribocor Chain lubes.

TIA

Re: KTM 200 Duke

Thank you for posting the pic, i now understand what happened.
Coming to your questions:
1. Brake pad wear is determined by the amount of pad material left on the pad and not the 'thickness' between rotor and pad. The minimum pad thickness is 1mm. You can check it by peeping from behind the caliper. Download the owners manual and read it, it has pictures for reference. The cost of the rear brake pads is around 200rs.
2. Nothing to worry about. You can get the pads removed and rubbed on some sandpaper and clean the rotor/caliper at your next service. For now just try to clean the rotor with some soapy water.
3. You can use any of those fancy spray cans (tribocor, tvs, rolon, diamond, motul etc..) whatever is easily available to you. But remember to keep the chain lubed at regular intervals 500~700km.

Re: KTM 200 Duke

[MENTION=16602]s1d[/MENTION] [MENTION=39214]B7ACKTHORN[/MENTION] I cranked the bike today morning and there was no black smoke or any sort of smoke coming from the exhaust at all.I think it was the poor oil filling done by the executives last time hence the depletion of the the Engine oil to 400 ml out of 1.5 litres

Re: KTM 200 Duke

Going by your reports, that's a positive. Just try to keep a tab on the oil level for a few more days, and if all set, then I guess you can probably rule out an oil leak or oil burn.

Cheers!
VJ

Re: KTM 200 Duke

Yes.i have been keeping a check on it and so far so good.
Are the modern engines so robust ,specially KTM ones that it can handle so much rough usage even without engine oil ?