Re: KTM 200 Duke

if you recently drained and filled up coolant, it is normal to see a little drop over a couple of days.. top it off and ride.. thereafter there should be nil to negligible drop in coolant levels.
if you are constantly observing coolant drop, there could be a few things causing this:
1. A small leak externally
2. A failed waterpump seal.
3. A failed headgasket.

I suggest you first pay attention to the first two.. look around the hose pipes/radiator area for any leaks. And also take a sample of the coolant from radiator and engine oil and check.
then maybe replace the waterpump and the seals (comes as a kit). Drain and refill fresh coolant and engine oil. Keep an eye on the coolant level and oil condition.

now coming to smoke part.. a tiny leak from a head gasket failure might not cause noticeable smoke. but if the leak is big enough you should be seeing whitish smoke.
if you see bluish smoke, then it is definitely the oil which is getting into the combustion chamber either due to bad valve oil seals or worn piston rings.

Re: KTM 200 Duke

During last month by bike was shutting down (console going off) due to blowing up of Fuse no 8. There was a short circuit (less than 100 Ohms) between the Fuse 8 terminal and the chassis. I had tried disconnecting many sensors and the cable joints but the short still remained. In the end the short would disappear after disconnecting the ECU.

After disconnecting the ECU the resistance between Fuse 8 and chassis would be infinity. But after reconnecting the ECU, there would not be a short circuit, instead I would get a value of 2000 kOhms to 6000 kOhms. At this value the fuse does not blow.

The bike was given to ASC and they found the speed sensor cable was damaged and it was replaced. My coolant level reduction problem was resolved after replacing the water pump seal.

But the fuse 8 blowing up issue has now come up again after 1000kms post ASC repair. The speed sensor cable seems fine visually this time.
Measured the resistance between fuse and chassis and value was near 200 Ohms, hence fuse blowing up.

So I disconnected the ECU, measured resistance between fuse 8 & chassis and value was infinity and then reconnected ECU and resistance was 2kOmhs. So now the fuse 8 is fine.

Can someone please check what is the resistance value between fuse 8 and chassis on their bikes? Measurements were done when the key was OFF. The chassis reference point used by me are the allen bolts of grab handle or the hex bolts of the tail light.

I don’t understand why I get infinity reading with ECU disconnected and then fluctuating readings (sometime 2k and 6k) when ECU is connected. If there is some harness problem (cable core is touching with chassis) then shouldn’t the resistance readings be constant irrespective of ECU connection?

Re: KTM 200 Duke

My speedometer suddenly started during 0kmph while riding. They after a few mins the idling rpm started fluctuating as well.

The last time the speedometer was showing zero kmph the stator was replaced.

But facing the idling RPM fluctuation for the first time. The bike was also not cranking. I'm not near home so won't be able to check battery voltage for a week or so.

Any list of suspected faulty parts for the above faults?

Re: KTM 200 Duke

Like there’s a 99rpm.com for Bajaj, is there a similar site for buying spares online for the KTMs?

Re: KTM 200 Duke

Rpm fluctuating could be coz of throttle body clogging with unwanted materials leading to issue in opening and closing of the valve. If it's showing zero under 20km speed with headlights on then it could be stator coil.

Re: KTM 200 Duke

Does the bike reset, all lights go off and come back while trying cranking?
If yes, then its the RR/Alternator unit. Period.

Get the battery charged outside, put it back and try to start it, if it starts on 1st try. Then its definitely the RR unit.

Re: KTM 200 Duke

Two things, either your stator coil/RR is at fault or your battery is giving up, or a good battery not being charged due to the faulty former two components. A voltage check at the battery terminals will yield the right result. Idling trouble comes down to a couple of things, faulty stepper motor, clogged/fuel filter throttle body and or faulty fuel pump providing poor rail pressure or just simply old and fouled fuel. If your bike has been parked for months, chance are very high your fuel might have rotten causing idling and misfiring. Remove the old fuel and use fresh fuel, and observe if it helps.

Cheers
VJ

Re: KTM 200 Duke

most likely a faulty rr unit. do you see the check engine light flash ? i came across a duke with a similar issue at the svc, it had a blink code (don't remember the code pattern), it was fixed by replacing the rr unit.
bike was not cranking ? maybe the battery is low on charge because the rr unit conked off and did not charge the battery.
worse case, it could be the stator coil again along with the rr unit. Do get it checked at the svc.

Re: KTM 200 Duke

The battery was dead. Replaced it just now. Bike started fine but did not go for a run.

Then increased the RPM and to my surprise the voltage was dropping when increasing RPM. It dropped to 7V! Higher the revs then higher is the voltage drop. Will go crawling to a mechanic tomorrow.

Re: KTM 200 Duke

Yes, exactly what I thought. If the bike was not starting earlier and with a new battery it started just fine indicates ECU, Stator, Ignition coils, Fuel pump are perfectly O.K.

RR unit is not able to put charge back into the battery when its operation and eventually battery voltage drops without battery getting charged when vehicle is running.
Get it replaced and bike should just run fine.

Re: KTM 200 Duke

Checked the stator. It's showing short circuit to ground. Will have it replaced first.

Re: KTM 200 Duke

Ah I see what's happening. So say the bike is running below 5K rpm and once you reach 5K+ rpm the rpm drops to 0 and speed also shoes 0kmph! If you again go below 5K rpm then the rpm and speedo comes back fine normal..

If this is the case, then this is the clear sign of dying stator. Eventually the whole stator fails.

Re: KTM 200 Duke

Has anyone tried installing the mirrors from the newer Dominar? They look great and are damped but apparently they're not a direct fit and require some tinkering. Has anyone done it or seen any thread about it?

Hello folks. Similar problem here.
I have a Duke 200 (2016). My bike has started to shuts off randomly. I noticed this started to happen after I took it out of storage when traffic was allowed during lockdown. The console reboots when this happens. Fuel pump stays quiet however. I installed a new 9Ah battery just a few days back because the old one was 2.5 years old and it died one day. Bike is still doing this randomly, specially when I start the bike start picking up. The engine stalls and console reboots. This does not happen when am riding at normal riding speed (30-60km/hr). Problem is that am not able to recreate the same at service station.
Charger seems to be working. Battery reads 14.2 volts when the engine is running.
Throttle body was cleaned recently but injector was not removed.
Idling is not rough and pretty stable.
No tampering has been done wit the wiring. Its a stock unit without any bells and whistles ever attached.

What should I check? Any input is appreciated.
Thanks and regards...

Check for the wiring and for loose contacts near battery box, fuse box in-out and relay in-out area. Due to fatigue and heat over time, wires contacts do tend to break or rust.

I too had a similar issue where one of the fuel pump relay wires was holding on by a single strand and another wire going out of the fuse was fully broken off, did a proper re-soldering off all wires and sealed with a heat shrink wrap.