Re: KTM 200 Duke

Guys need a quick help. Today while returning home, the clutch pulley near the engine case broke. Thankfully, I was almost home so was able to push it home. Can you guys please advise if the below part can be changed individually and what cost is expected.

Re: KTM 200 Duke

I have experienced a similar thing with my old Pulsar 150 Classic a couple of years ago. IMHO this part may be mass manufactured by Bajaj for all bikes from their stable. I hope they can be used interchangeably with other Bajaj bikes. In my case a roadside mechanic was able to change it, after getting the said part from a shop a few kms far. He charged me 80 bucks, if I can remember correctly, including labour charge which was a few minutes work.

Best of luck!

Re: KTM 200 Duke


iirc it costs around Rs.100~150 and should be a 10min job to replace. That part is called "clutch release lever"

Re: KTM 200 Duke

I was told that they have to open clutch case and change the rod inside will cost 300 for the part and gasket will cost 150. Estimated cost will be 500-700₹

Re: KTM 200 Duke

Yes, the clutch case has to be opened.. but 300 for the part ?! I doubt.. and gasket 150? Geez, i hope the prices haven't shot up.
these guys are known to give over the top estimates.. make sure you get it fixed in your presence and check the mrp on the parts!
maybe with their over priced labor, it might come to around Rs.500 max.. but do check the price label on the part yourself

Here is a similar failure (and a temporary juggad fix to help you ride to svc) and what was discussed: http://www.xbhp.com/talkies/motorcyc...ml#post1222196

Contact this guy and maybe he can let you know what it cost him to replace it.

Re: KTM 200 Duke smouldering and burning up

Hi Everyone,

I have had bought a duke 200 on 27th Jan 2017, and after riding for three months I found a leak in the head gasket seal which may have been caused due to the shitty quality of it or due to another fact that during my 1st service which was done at 350 kms only( as it was already 35 days after buying) more than required engine oil was poured by the svc which I realised after quite sometime, so took it to a svc in Kolkata to get it checked. They check it and ask me to come on a afternoon, keep the bike overnight and take it back the next day as the sealant needs time to set. I take the bike on last friday (19/05/2017) kept the bike overnight and returned the next day on Saturday (20/05/2017) to take delivery of the bike, went to the showroom and found the bike ready and waiting for me. Took the keys happily, looked around the engine a bit, hopped on and left, I was doing moderate speeds, was after 7-8 kms away from the showroom when 2 guys on a scooty overtook me and with horrified looks on their faces yelled at me..Bhaiya aapke engine block se smoke aa rha hai, your bike is burning...I was devastated, somehow got to the side of the road and parked and when I looked down my worst nightmares came true. It was really smouldering, the hot mobil gushing out of the engine head and splashing all over the engine, exhaust pipe, swing arm, rear suspension and thick clouds of smoke emitting from the engine. I was heartbroken and was close to tears to see this. I immediately called up the svc manager about this and he said he come and see it, as I had no KTM orange assist so couldn't demand a flatbed truck. He came about and hour and half later while I was standing under the hot sun worried and sad about their careless work. As the bike cooled down a bit, I took a closer look and realised that they had not put the gasket properly and a part of it was hanging down. He came with another mechanic and they pushed the bike with foot support back to svc, I was dead tired so returned home and went back to svc in the afternoon to find that my bike was again on the bench and they were fixing the gasket again. They had washed the bike off the oil and they had almost completed the work, as I was not going to get the bike delivererd on Saturday and Sunday was closed I returned on Monday morning to take the delivery and enolled for Orange assist too. Took the bike and came back home and after returning home I realised that the golden exhaust pipe is burnt permanatly with hot mobil and its color has turned bad too. Dont know what to expect from a world class company with shitty svc centres. Only KTM's bad service will bring it down. Now I have a 3 month old bike which has burnt bits which was scratchess showroom condition else. One of the many things which I shudder to think is what iof the guys had 'nt warned me then the bike could have got ignited. Really unhappy and sad. Now the burn marks wont go away even with kerosene

Re: KTM 200 Duke smouldering and burning up

Newton, it's a horrendous mistake indeed from the SVC part. I wonder how they realized their mistake of not having to put the gasket in properly earlier. Too much carelessness can only be attributed to such mistake. Any good mechanic with a proper eyesight would definitely inspect the head gasket seating, visually after installing the gasket. At least I can speculate it's either done by some incompetent newbies which are notoriously shelved in Bajaj SVCs. You should probably thank those good samaritans before long you'd have seized your engine.

The fuel spewed from the rocker cover, spewed all over the hot exhaust and that is what the smoke is all about. A few more kilometers and the bike would have drained and you would have probably been on a homestretch.

Now coming to the issue side of exhaust, the exhaust headers can cleaned off the stains using good quality metal polish. For this you'd probably have to remove the header and use good quality metal polish, rebuff it and you can get the old sheen back. You have generic polishes and the one I use is Autosol, you can get them in Amazon, though a little costly, it really works wonders. Mind you, though the stains would be gone, by judicious use of the polish, the original golden color would be gone and you would see a silver aluminum-ish finish, but it's far better than the stain marks on your exhaust.

You can remove the exhaust and get it properly buffed with a metal polish, it works wonders.

P.S. Also as a note you can send a mail to the Bajaj with the photos as to the clumsy job they've done, and the unnecessary chores you had to go through which almost led to an engine seizure. This would mean it doesn't get repeated to you and others.

Cheers!
VJ

Re: KTM 200 Duke

Hey Sid, thanks for the link. Exactly same issue happened with me though the SVC didn't suggest any welding. I won't be at svvc while this is done but my dad will be taking the bike so will ask him to check.

Also, is it possible to bleed brakes ourselves? And which brand or model brake fluid should we use?

Re: KTM 200 Duke smouldering and burning up

Hi Newton, sorry to hear about your experience but can you tell us which SVC in Kolkata was this?

Re: KTM 200 Duke

You can use any commonly available brake fluid (dot4), some options are the stock fluid from svc (comes in a small bottle), Castrol, Bosch that you can buy outside. Always try to get a new sealed bottle and use it (using fluid from a container that has been opened for some time might make the fluid perform suboptimaly since brake fluid is hygroscopic i.e absorbs moisture from air)
I'd say get the stock fluid itself and get it replaced at the svc(make sure they drain out the entire old fluid and some new fluid too, so that you are sure to have 100% fresh fluid). It takes hardly 15min to drain n refill brake fluid.
You can do it yourself too.. But first I'd say observe someone doing it and then attempt it yourself.
Also remember brake fluid is corrosive.. If it spills on painted or other surfaces where it's not supposed to, the immediately wipe it off.. If u let it sit then the paint/surface will be damaged.
@Newton23 that is indeed very shoddy work by the mechanic. Even a trainee will know to check if the gasket was seated properly.. I mean it's basic common sense to do a visual inspection! And this was very obvious to the naked eye!
Please send these pictures and the description of this event as posted here to [email protected] and [email protected] and tell them that you want the exhaust pipe (header) replaced (and also anyother part that was discolored due to the burnt damage.)
If you use a metal Polish to clean the exhaust pipe then it will lose the golden tinge it has and will become clean but have a chrome color to it.
These guys are definitely obliged to replace the part because it was damaged due to their negligence. Do shoot an email with the proof you have and be polite but firm.

These guys probably replaced the gasket without removing the tank and probably couldn't get it aligned due to the restrictive space and then never bothered to check it.
And btw, this gasket is called the valve cover(or head cover) gasket.. It is NOT the head gasket.

You can also file a complaint online here http://callcentermanagement.excellon...plaintKTM.aspx

Re: KTM 200 Duke smouldering and burning up


Hi Vishal, its KTM VIP road svc. According to Google they have the best rating also. I have nothing against them morover the Service manager is friendly enough and good to manually tow it back but then again its someone's fault right that my new bike was almost up in flames

Re: KTM 200 Duke smouldering and burning up

I have always got my bike serviced at VIP road SVC and for everything else as well. They are friendly but casual though I have heard that they are the best in Kolkata.

Do contact Subham Mukherjee , he is the KTM supervisor for east zone. his contact is mentioned in the reception of the SVC.

Re: KTM 200 Duke smouldering and burning up

I agree Vishal, I too have heard that they are the best in Kolkata, moreover whats done is done and there is no functional damage as well. So I don't think they will replace it and moreover next time if any issue or trouble comes up I will have to go back to them only as they r better than the other SVCs. Maybe you can tell me names of some good quality golden/copper heat resistant spray paint

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Thanks for the information and thanks for correcting me for the gasket name too BTW as there is no as functional damage to the header pipe, do you think they will replace it after complaining.

Re: KTM 200 Duke

Awesome it looks. May I know from where did you paint the rims? ktm or garage? from where did you get the duke 390 orange paint?
if anyone else got any idea then please comment.
Thanks.

Re: KTM 200 Duke smouldering and burning up

They should!
Would you buy a new bike if the paint was damaged (with the notion that there is no functional damage?)?

If the exhaust discolored due to normal use (which it will over a period of time) then it is considered normal wear and not covered under warranty (this is explicitly mentioned by ktm.. you may even see a poster at the svc mentioning this). But in your case it was damaged due to negligence and hence they are obliged to replace it. It is up to you if you want to raise the issue and get it replaced.

You can use metal polish such as Brasso (Available at almost any hardware shop) but remember using this will remove the golden tinge (And any other stain) and the exhaust appearance would change to raw stainless steel/chrome shade.
I doubt you can get a similar golden tinge heat resistant paint here in India.. most commonly available heat resistant paints comes in black and silver finish.