Re: KTM 200 Duke

Does clutch lever of D200 2015 suits with 2017 model??

Re: KTM 200 Duke

Thanks s1d,
The bike is 6 months old.There is some issue with the relay. Need to get it changed at the svc.

Re: KTM 200 Duke

Direct fit.

Cheers!
VJ

Re: KTM 200 Duke

Finally got the speedometer replaced under warranty, had to wait because they didn't have it in stock [emoji119][emoji119]

Re: KTM 200 Duke

It seems like the number of issues with my 2012 Duke 200 are never ending post 30k kms.

Last year in October, I had a broken output shaft which some how failed and no one at the service center could explain. The engine was opened up and the part was replaced. I said good bye to factory fit as I never had any engine work earlier. I finally got the bike with a ₹6000 bill and a leaky gasket and oil seal, which was replaced almost twice, post that service.

Fast forward to June this year, the head started leaking oil and the valve shims needed replacement. Went to the svc and got the engine opened up again and received a bill of ₹4000. I thought it was done, but no..

Now in August, I found the gearbox to be really hard, so stopped and checked the oil level, and there it was.. Milky-brown colored liquid inside the engine. I checked the coolant tank and it was empty. Coolant has definitely mixed with the oil. Sigh! Another visit to the service but this time I mailed Bajaj about it and immediately received a call from the local svc regarding the email. So they came home and took the bike, I'm still awaiting delivery. I shall post an update about the bike once I receive it.

Bajaj-KTM makes an amazing product but the after-sales service ruin the ownership experience.

Anyone over here has a problem free Duke 200? (Preferable a 2012-13 model)

Re: KTM 200 Duke

It's unfortunate to experience back to back horror episodes. Nonetheless, coming to the recent problem, yes we do have a coolant leak and I hope the motorcycle wasn't ridden much in the same condition prior to prognosis, as it could lead to cylinder scoring and can warrant another piston/cylinder kit replacement. Expensive! The motorcycle does require to be gasketed post any engine work carried on. Little to no use of gasketing solutions would mean, oil leaks, failed oil seals et cetera due to mishandling, yet the chances can go on and on.

Get your hands on the immediate prognosis from the SVC side, regarding the immediate damage that they've observed till now, any cylinder wall, valve train and crank damage. These are critical components and a failed to faulty prognosis of these critical components can lead to more headaches if not observed and checked early on. Keep your feet hot with the SVC and make sure you get a through report on what's getting done and inspected.

Do keep your observations posted.

Cheers!
VJ

Re: KTM 200 Duke

I second that completely. I'm also having a Duke 200 Feb 2012 model and the no. of issues it gave are countless... I have also clocked ~30K kms and let me tell you the items I have replaced till now...

1. Radiator fan 3 times(so inferior quality)
2. Indicator sets 3-4 times (bec the svc guys would tell me that they come in pairs)
3. Rear MRF tyre (It got punctured badly and had to be replaced. This tyre gets punctured very frequently)
4. Clutch plate set
5. Chain set
6. Kill switch circuit
7. Clutch levers
8. Shocker leaks 4-5 times
9. Throttle body (I got it changed around 6 months back and it costed around 7K)
10. My speedometer is dead now. Showing only the immobolizer warning and rest display is completely gone(costs around 8K )
11. My front tyre is also due for replacement

My last 2-3 years experience have been worst wrt the parts quality and durability and also with the expertise of the mechanics. My pickup has gone too low but the mechanics at noida svc says it's absolutely fine. My duke 200 costs me around 15K maintenance every year.


Regards,
Ankur

Re: KTM 200 Duke

A friend has one of em, clocked 70k km iirc.. not faced such repeated issues. Mostly maintained and serviced regularly.
I own a 2014 model, 33k on odo now. Had replaced the following:
gear shift shaft (on delivery day 1 !), gear lever was getting 'stuck' and not popping back to normal position after a shift. No issues since the replacement
Disc rotor - under warranty.
Speedo sensor - under warranty.
fork oil seal - once under warranty and once paid.

Still on stock rear brake pads, chain, battery, stator, clutch plates,

Apart from that no major failures, just regular services and fluid changes. I replaced the coolant at 2yrs (switched to motul motocool) and it is again now two yrs since and will be replacing in a month or two. Most importantly i ride it like a 200cc bike and not like a 600 and rarely does anyone apart from me ride it.

I think your previous repairs, the svc over charged you.. and i agree about the poor levels of service, over priced repairs if the owner isn't knowledgeable or if you leave the bike with them to fix it. Some parts themselves are pretty cheap (Almost similar to say pulsar spares prices), but they loot you in the labor costs (probably since it is a 'premium' bike from bajaj stable)

Re: KTM 200 Duke

Sorry to hear about the issues you're facing with your duke, hope it gets fixed soon. I have a 2013 duke 200, it has done around 56k and engine has never been opened.
Performance is not the same and it needs some work.

Re: KTM 200 Duke

Wow, Duke 200s clocking 56k-70k kms is new to me because most of the owners that I know, sold off their bike at 15k-20k kms because they wanted to upgrade to the 390. Anyway, I've always serviced the bike regularly and was present for every service. The quality of parts isn't top-notch, it's built to a price. I'm okay with that. Yes, I've been overcharged on labour. The October service costed ₹6000 in total, from that ₹4000 was charged for labour. That's crazy, I couldn't get discount over there as they claimed its a standard rate and showed me chart with the prices.

Anyway moving on to today's update: Bike is going to be tested thoroughly by the svc people. They said that I will get the bike today. I've told the service advisor that if I'm not satisfied with the service, I'm going to update bajaj customer care about it (with the reference number that they sent). I'm hoping that I don't have to do it.

Re: KTM 200 Duke

Damn it, I deleted my previous post by mistake while browsing. Anyway I shall update you guys about my bike which was being fixed by the svc people. I received the bike yesterday with a couple of changes which I am going to list below:

1. Gasket Cylinder Head
2. Kit Water Pump Rotor and Seal
3. Gasket Cylinder Block
4. Inugel Expert (Coolant)
5. Grease
6. Oil Filter
7. Motul 20W50 (Engine oil)
8. Clutch Lever(I told them change this as I had issues with my adjustable lever, I shall explain later)

Total = Rs. 2148

I was only charged for parts and not a single rupee on labour. I have been out all day testing the bike, and did not notice any coolant drops, white smoke, milky oil color. So it seems okay for now. I have informed the SVC that I will give my feedback after 1000 kilometers, to which they agreed. I have acknowledged Bajaj Customer Care about my decision.

Coming to my decision of shifting back to the standard non-adjustable clutch lever: well it has been a couple months now that I have been using the new Duke 390's lever. Yes, it is comfortable and convenient to use but... I noticed that even after adjusting the play on the clutch cable and the adjusting the lever itself, the clutch would partially engage when fully pulled in traffic. This would lead to grinding noises from the engine, this sound is not something you want to hear. Hence, even since I discovered it, I was more careful with this lever and finally decided to go back to the standard one. Today, I did not notice any grinding noises, and the lever works fine. My advice to other 2012 model owners is that: stick to the standard one.

Overall, I am happy to have my bike back, hoping I don't face issues anytime soon.

Re: KTM 200 Duke

Please share the price of the new Duke's levers.

Re: KTM 200 Duke

The adjustable level costed me ₹338 while the standard one costs ₹120.

Re: KTM 200 Duke

Ya this was my doubt also regarding to the adjustable clutch lever..when we adjust the lever position i always thought of does the clutch fully engage when we set it closer to us

Re: KTM 200 Duke

That's only the adjustable clutch lever.. the adjustable front brake lever from the 390 is around 1200rs .. i mean just the lever without the yoke/master cylinder!
The normal clutch levers can be swapped with a pulsar 180/220 iirc on the dukes.. i use a pulsars clutch lever (and keep the oem ktm one as spare)

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i haven't tried these adjustable levers, but if you notice the 200's since 2017 (or maybe 2016 not sure) come with a slightly redesigned clutch release lever. take a look at one of my previous post showing the differences.