Hello guys..i had put up a post somewhere in the
previous pages asking for the things i should do
before using my '11 months sitting idle' duke..thank
you guys to those all who responded..i did all that
was recommended by you guys.

But things are getting rough. There was fork oil
leakage from the left shock. I got the oil seal
replaced and been riding for like 600-700km..and it
has started leaking again. Another major problem
this 'ticking' or 'metal sliding' like sound from left
side of engine after i do some spirited riding for
some 30-40 kms..when the bike is started up it
sound normal but after running for some 30-40 kms,
these sounds appear mostly around 3000-5000 rpm.
I am really confysed what might be the problem..got
to see a lot of threads regarding camshaft chain
tensioner etc..and i dont know much about these
parts in details.

The next problem...is that now when i shift gears,
its feels like a lot of friction is happening like metal
grinding when you shift the gear lever. Sometimes,
gear refuses to engage when goin from three to two
unless you leave the clutch,agin pull in the clutch
and downshift once more..would it be a problem
with the engine oil not being flushed properly? I
seriously doubt the svc guys used an engine flush or
not when they put in new engine oil on my recent
service after the 11 months idle sitting..
Another issue with the bike is, while running it shuts off by itself when the clutch is pulled in or when i release the accelerator and the bike wont start after that. This happened twice now. On pressing the starter i can hear the cranking bt engine just wont start. Once i pressed on the spark plug cap and after a few tries the bike started up reluctantly, sputtering and had to wring the accelerator to get the engine to start up properly..
Please shed some light on these issues guys..

I think, the basic servicing of your bike has been taken for a toss or not carried right. Starting with your last question, hard gearshifts would probably mean the oil grade is incorrect or not enough oil or improper clutch lever freeplay. Adjust your clutch lever freeplay and see if it helps in smoothening shifts. Secondly, your engine turning off can be due to a gummed up throttle body, which needs an overhauled i.e. throttle body cleaning and spark plug clean/replacement. Since you pressed your spark plug cap, check your spark plug cap so it's not loose and connected firmly to the spark plug lead (wire). A loose spark plug cap/ lead would mean, stuttering and stalling.

Thirdly the metal to metal sliding or knocking sound can be due to improper valve clearances i.e. shims. Check your valve clearances and replace your shims if needed. A worn shim or higher clearance than normal would mean, once the engine is heated, you'd hear "katatatatata, or ticktickticktick" sounds, get them checked.

Fourthly, leaky forks. Either they've not replaced the fork seals, wherein they just clean the seals and install them back, this causes the forks to leak after sometime. If there are scoring on the fork slider (silver part) this would eat the fork seals. Start off by checking the slider for any nicks or hot spots, if all is fine, replace the seal and make sure it's replaced and oil topped up in front of you. 450 ML per leg.

Quite a list to look into, take them one at at time and make sure it's all ticked and inspected. Keep your observations posted.

Hope it helps!


Cheers!
VJ

Hey..Thanks man. I adjusted the clutch free play today and gear shifts do feel smoother now....i havent ridden longer after adjusting freeplay..i will post further observations. About throttle body cleaning, it was done when i gave it for service. Actually the svc guy recommended doing it when i said the bike was sitting idle for 11 months. But the thing was they did it by some mechanic outside the authorized svc. . That's what they said to me. The spark plug was not cleaned though i guess. I will check the sparkl plug and go for replacement if neede.
I checked the fork slider as you said. I found a small nick on the slider. I have attached a picture of the same. The nick can be felt only when you rub your nail over it. Will it be this that's causing the oil leak..?
And about the shims, i researched a bit about it and came to know that a lot of svc guys tend to mess up the whole thing. Could anyone suggest the best ktm service centre in ahmedabad, as am currently staying here and also pretty new to this place.

If you can feel pitting when you slide your finger over the slider, your slider is pitted and yes that's what's causing the fork oil seals to leak. The slider should be pitting free and dust free for the fork seals to stay intact. Any dent or nicks on the slider would mean the fork seals will get damaged as the sealing part of the fork seal is very sensitive, it's universal with all motorcycles. The sliding motion of the slider would ruin the soft innards of the seals which then causes leak. Get the slider replaced.

Cheers!
VJ

more details are needed from you..
what do you mean by refuse to start ? does the bike crank up but not start ? do u just hear a click when you thumb the starter? u dont hear anything when you thumb the starter ?

not all 'issues' will be reported by the ecu/diag tools.. but is a good place to start diagnosis, if the common troubleshooting steps don't help.

i doubt it could be due to carbon on valve or piston.. it is normal to have deposits on the valve and piston.

so yeh,
when you thumb the starter and the engine cranks up but doesn't start.. then you need to check if there is a spark at the spark plug.
also clean the ignition coil contacts.
if you hear a click (or maybe not hear it), then it could very well be a weak battery or worn carbon brushes in the starter motor... if indeed there is no clicking, it could be a faulty starter relay.
another possibility is a bad idle control stepper motor.. but this i presume will throw up an error on the diag or have erratic idle.. bike shutting down, am not sure.

And if the spark plug was an issue, then should the bike have started by a push start?

Planning to change chain sprocket..
Should i go for stock or any other customs??
Any suggestions for custom sprokets for better performance??

Have a issue with Duke 200 (2014) since past few days. While riding, the bike engine restarts. Initially happened when going from the pot hole or slightly uneven roads on flyovers. In two days it quickly escalated to engine restarts while riding which is concerning since it happens randomly even without potholes. I also noticed the RPMs are abruptly high when clutch is pulled, and once I release it comes back to normal. When kept the bike at idling, the bike switches of for a fraction of second and the oil pressure light blinks unevenly. All this happens without any error in screen. It also randomly showed JG 1.7.4 which is battery issue but got my batter replaced just couple of weeks back.

Haven't been able to visit SVC due to work commitments but if someone can help understand the issue it will help.

Have a issue with Duke 200 (2014) since past few days. While riding, the bike engine restarts. Initially happened when going from the pot hole or slightly uneven roads on flyovers. In two days it quickly escalated to engine restarts while riding which is concerning since it happens randomly even without potholes. I also noticed the RPMs are abruptly high when clutch is pulled, and once I release it comes back to normal. When kept the bike at idling, the bike switches of for a fraction of second and the oil pressure light blinks unevenly. All this happens without any error in screen. It also randomly showed JG 1.7.4 which is battery issue but got my batter replaced just couple of weeks back.

Haven't been able to visit SVC due to work commitments but if someone can help understand the issue it will help.

Two things, check if your battery terminal lugs are secured and fastened properly, a loose connection would mean all sort of trouble. Also, it would be a good idea to check the voltage at the terminals with your engine running at 5k RPM, the measured batt voltage should be around 13.5 to 15V. Keep your observations posted.

Cheers!
VJ

This worked. One of the connector was loose and I can relate to why pothole or uneven road was causing it. Thanks a ton for the quick help... Need one more help. Want to change the Speedo unit. Any idea how much it would cost?

That's great kundalus. The speedo unit costs 5.5k~ approximately. I'd recommend you to check for used ones, you can get it as cheap as 2k.

Cheers!
VJ