Re: KTM 200 Duke

Don't change the throttle body. It could be the idle control stepper motor or the throttle position sensor, both of which are mounted on the Throttle body. I highly suspect the TPS since it works based on varying voltage (As you open and shut the throttle).

You also mentioned low fuel pump pressure, that might also play a part.

Why don't you ask them to connect the diag tool and read out the error code. That will give you a more specific diagnosis. Do not replace anything until you get it checked by their diag tool and see the error code for yourself. Am pretty sure the blink code that you are seeing will definitely trigger a code that can be read out by their diag tool.

Re: KTM 200 Duke



Service Centre Guy called today. Asking to change the wiring harness and throttle body both. Says the bike is old and wires are over there life. Says wiring harness will be Rs 7528, Throttle body Rs 5737 with labour charge extra.

Will see the error code via diag tool myself and then decide what to do. Holding everything for now.

Re: KTM 200 Duke

Wiring does last quite a while, but considering the Duke's tight spaces, fraying and nicks can be a possibility and coupled with the error code, it's imperative to look into it. But, I'd suggest you can insist with the SVC folks to use another fuel pump for the time being and see how the bike behaves. Secondly, get your clutch slack adjusted, poor clutch lever play slack can negatively impact rideability (another member in the Duke 390 forum faced the same stalling issue). Do keep your observations jotted. Best of luck.

Cheers!
VJ

Re: KTM 200 Duke

these svc turds simply want to replace everything, been noticing this trend a lot more these days. all they are bothered about is milking your wallet.. i can't do much but give some advice.. it's your call if you want to go ahead with the replacement. the least you could do is get the diag run.
i highly suspect electrical issue probably due to coil/rr unit/battery or as you said wiring.. wiring can be fixed with a bit of effort instead of replacing the entire loom.

i myself have been pretty pissed with the svc of late, and planning to get myself the diag tool and get any repairs done in future by myself or with the help of a local mech, and getting spares from these turds is another adventure! Am just slowly collecting common spares, and some parts are a swap from the pulsar 200ns like the oil filter, clutch plates iirc which are easier to obtain from local shops.

Re: KTM 200 Duke

Guys, if you are using old D200 then what is your servicing interval? Last time when I visited vikhroli SVC and asked on servicing interval, I was told we can get it done at 7.5k but oil consumption reduces and needs to be refilled a bit in that case. Not sure how true that is. Has anyone recently changed chain-sprocket? Want to know estimated cost after GST. Also any suggestions on battery? Mine shows jg 1.7.4 once in a month and I suspect it is in its end of life.

Re: KTM 200 Duke

On the old d200 i.e. those that came with a 5000km interval, you can safely go upto 7k km or 1yr which ever earlier. This is under normal riding conditions.
If you are someone that rip often and also spend a lot of time in bumper to bumper traffic then i'd suggest you stick to 5000km intervals or 6 months.
There might be a wee bit oil consumption (not more than 100ml max) over a period of 7k km. Just keep an eye on the oil every other day and you should be good to go.. if you notice much more oil consumption, it might be another issue that you might want to look into.

I recently had my d200 serviced at 30k km(3.2yrs) after a gap of 1yr 2 months (though clocked only approx 5700km in the past year), I ride sane 90% of time with occasional ripping. As for the chain sprocket, I was quoted Rs.3000 approx. I keep my chain in decent shape and on inspection i noticed only the front sprocket to be worn beyond useful life, and the rear sprocket and chain were ok.. So I decided to change just the front sprocket (the P220/p180 ug4 sprocket is a direct fit, part no. dv101048) and it cost me 140rs for sprocket and 100rs for labor (@ajay vishwanath on his rc200 and myself on d200 both did this swap). Back to normal now (earlier was giving a annoying tik tik kat kat sound at low speeds under 10kmph). The front sprocket swap will probably save me a few bucks and should be good enough for another 10~15k is my estimate.

For the battery, get the exide battery from a local battery dealer.. will cost you Rs.2000 with exchange of old one. The svc will loot you Rs.2500 or more for the same.

So bottom line for servicing.. it depends on your use. Mostly 2 services a year should suffice assuming you don't clock more than 14k km a year. And make sure the oil,fuel and air filters are replaced every service or 1yr whichever earlier (again if you want to penny pinch, clean the air filter with compressed air and inspect it and reuse if you don't clock many miles). The spark plug will easily last at-least 15k km.. so maybe once a year or depending on the km you clock. The oil i'd say stick to the motul 7100.

And once in two years replace the coolant and brake fluid. i replaced coolant after 2yrs, and brake fluid after 3yrs (both appeared normal when drained out)

Re: KTM 200 Duke

Thanks for this.

Even I'm a sane rider, and I barely take it above 75-80, I'm sure you know Mumbai traffic. My usage is a bit high since it's my daily commute vehicle of close to 100kms everyday on weekdays. Even I'm having the tick tick issue and chain is slightly uneven as it slaps often. Will check the front sprocket tomorrow, haven't taken the effort to open and check it in past few months. After reading your post, I asked the SVC guys and they told me p220 chain sprocket is not sold separately they come as a set. My chain lasts about 15-17k due to pillion riding and the road conditions aren't good for D200 on my route. Though I've been lubing it at regular intervals.

For servicing, I don't mind at 5k, and with my usage I have to service it every 4 months. Just out of curiosity wanted to check if anyone has done it or not. And I prefer not to test new oil. Pretty satisfied with motul. Will check on better locally tomorrow and get it replaced.

Having a thought if it makes sense to use a 4yr old Duke 200 for daily commute. I'm at 45k, have done about 35k in 2 years after purchasing it from previous owner.

Re: KTM 200 Duke

Oh man, that's some serious miles you clock

I've had my bike serviced every 4 months while it was under warranty.. just to keep the warranty intact. For the amount of riding you do, 4~5 months is a safe bet. Stick to the motul 7100.
The front sprocket is available separately. The showroom buggers will try to sell you an entire bike even if your bike has low tire pressure!
Go to a local spares shop and ask for the P220/P180 UG4 front sprocket.. it comes sealed in yellow plastic cover placed inside a blue box (bajaj packing) and the part number is DV101048, mrp is rs.153 iirc.. i got it for rs.140.
Why the thought of if it makes sense? If it aint causing any problems wrt mechanicals or comfort/fuel economy then I don't see why you shouldn't want to use it.. unless maybe you want to retire it from active duty and keep it longer before getting some engine work done.

I recently switched to shell ultra 15w50, and what i notice is that the bike warms up faster.. the fan comes on a bit earlier and does its job and the temp as always remains two segments shy of the lower portion. This is what i noticed the past couple of weeks.. i was expecting the temps to rise slower considering the much cooler weather at this time of the year..no over heating or any issues though.

Re: KTM 200 Duke

Thanks, will figure it first if my front sprocket is the issue or the chain replacement is unavoidable. Also if I change the front sprocket do I need to manually adjust chain tension? Haven't done it before, hence the query.

I'm thinking to change only from a wear and tear perspective. Recently changed the monoshock. Apart from this the front fork leak and chain are regular wear and tear. I've been replacing chain once every 12 months. Either of the fork leaks every 12 months. All this is because of our roads, any other bike would have succumbed to a lot of wear and tear by now.

So from a heavy usage perspective, may be buy a new one. But after riding Duke I don't think it would be easy to adjust to any other bike, so may be 2017- D200[emoji23][emoji23][emoji23]

Re: KTM 200 Duke

So I did my chain cleaning & adjustment today to contain chain slapping. The front sprocket is still good, with normal teeth but I can still hear a bit of hissing sound at low speed. I showed it to SVC yesterday morning, they said no need to replace. It looked in decent shape.

Re: KTM 200 Duke

Hello, anyone here who knows the part number of the screw set that holds the brake lever? Will Pulsar 200's screw work too? TIA

Re: KTM 200 Duke

are you talking about the front brake lever or the rear ? am not sure of either part number.
if its the front, do try the P180/220/200ns screw if you do manage to get one.. local spares shop are a better bet and they usually have an assortment of nuts and bolts (the lever, at least the clutch lever is a direct fit from the pulsar which is what i am using)

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try using the nulon grease spray.. a thin coat once over does wonders.

Re: KTM 200 Duke

Sorry wasn't too clear.yes it is the front brake lever. Will try to shop around. Thanks for your suggestions!

Re: KTM 200 Duke

A peculiar problem and a self inflected one. Couple of years ago got my duke 200 frame stickered with orange color. Over the due course of the years the sticker started peeling off and has taken the black paint of the frame along with it. Now the frame has started to rust in the outer layer. SVC refuses to remove the rust and repaint the frame. What do i do ?

Re: KTM 200 Duke

Get the frame repainted by any trusted and good automobile painting shop.