This is an alert, and a general inquiry, and also a complaint if you will have it.

The 200 NS was released in the Philippines about November 2014. since that time there have been numerous (some calculate over 60% affected) incidents of coolant mixing with the oil in the crankcase. these cases have been documented by the Naked Wolves group in the Philippines. There has been much speculation as to why the single seal between the water pump impeller shaft and crankcase have repeatedly failed. Kawasaki Bajaj is repairing these instances at no charge but some are getting second third and fourth failures. there has been no recall, no word of advice forthcoming from Kawasaki Bajaj on what the problem is and what might be the reason. there have been ideas ranging from defective seal, to improper installation of the seal to defective spindles and bearings being installed in the Philippine export models. Interestingly to me, there seem to have been no cases of this in the other markets? India or south America. Is this true?

The kawasaki story is that the seals were improperly installed at the factory, but if this were true then why repeated occurrences on the same bike after service center repair? I suspect a deeper problem and unless Bajaj or Kawasaki can resolve this issue I fear the 200 NS will fail in the Philippines. The problem is not going away.
Is it a design flaw? shoddy assembly or purposeful marketing of second quality parts to an export market?
Most liquid cooled motorcycles have two seals between the water pump and the crankcase, when and if the first mechanical seal fails, it serves as a warning to service the seals BEFORE coolant mixes with the oil. In the case of the 200 Ns there is only one seal provided, so if it fails on the road you risk ruining the engine.
since the 200 NS shares the bottom end with the Duke 200, its odd that only the 200 NS exported to the Philippines has this issue.
anyway it is all over the forums and Facebook pages here.

Any incidents in India?

This is an alert, and a general inquiry, and also a complaint if you will have it.

The 200 NS was released in the Philippines about November 2014. since that time there have been numerous (some calculate over 60% affected) incidents of coolant mixing with the oil in the crankcase. these cases have been documented by the Naked Wolves group in the Philippines. There has been much speculation as to why the single seal between the water pump impeller shaft and crankcase have repeatedly failed. Kawasaki Bajaj is repairing these instances at no charge but some are getting second third and fourth failures. there has been no recall, no word of advice forthcoming from Kawasaki Bajaj on what the problem is and what might be the reason. there have been ideas ranging from defective seal, to improper installation of the seal to defective spindles and bearings being installed in the Philippine export models. Interestingly to me, there seem to have been no cases of this in the other markets? India or south America. Is this true?

The kawasaki story is that the seals were improperly installed at the factory, but if this were true then why repeated occurrences on the same bike after service center repair? I suspect a deeper problem and unless Bajaj or Kawasaki can resolve this issue I fear the 200 NS will fail in the Philippines. The problem is not going away.
Is it a design flaw? shoddy assembly or purposeful marketing of second quality parts to an export market?
Most liquid cooled motorcycles have two seals between the water pump and the crankcase, when and if the first mechanical seal fails, it serves as a warning to service the seals BEFORE coolant mixes with the oil. In the case of the 200 Ns there is only one seal provided, so if it fails on the road you risk ruining the engine.
since the 200 NS shares the bottom end with the Duke 200, its odd that only the 200 NS exported to the Philippines has this issue.
anyway it is all over the forums and Facebook pages here.

Any incidents in India?

60% bikes is quite surprising as export vehicles are usually made of superior components in general.

Looks like Bajaj is doing a better job in India than Kawasaki in the Philippines.

]

I don't know if there is only one seal used in Phil, but we in India have two seals on the model here. One inside the RH crankcase and one outside it, on the shaft driving the pump rotor (impeller). The drawing in the spare parts catalogue confirms it. CRANKCASE RH, P.19 and P.20, Part number of the seal is JG 6010 07, Qty is 2.

[ATTACH]181915[/ATTACH]

Bottom mounting of mono-shock lowered by 15mm. The red dot shows original mounting height. The tail end has gone down by around 60mm now (!)
Pros: Increased stability, wife can get on the bike easier
Cons: Ground clearance less by 15mm. Gap between wheel (mudguard) and body has reduced, but has not bottomed out even under worst conditions

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I don't know if there is only one seal used in Phil, but we in India have two seals on the model here. One inside the RH crankcase and one outside it, on the shaft driving the pump rotor (impeller). The drawing in the spare parts catalogue confirms it. CRANKCASE RH, P.19 and P.20, Part number of the seal is JG 6010 07, Qty is 2.

except the bikes are all made in India by BAJAJ aren't they.

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Yes I have the parts manual and saw it, but I missed the fact that there are 2. I was looking more at the service manual, and it is not clearly indicated there that the quantity is two, now it makes me feel better that there are two seals, but I also now realize that Kawasaki/Bajaj here in the Philippines is only replacing the outer seal upon failure which does not solve the problem, they are avoiding the expense of splitting the crankcase to do a proper repair and replacing both seals. sometimes it takes two sets of eyes.

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This is what happens when you leave your bike with svc to change the seals ..

[ATTACH]181924[/ATTACH]

that mechanic stupidly welded a nut at the end of the shaft for no good reason and now i am stuck with jammed sprocket (wont come of the spindle) and chain kit worth 2500 lying around

For now going to keep it like this i am shifting to Bangalore in a few days time will have to get it done from there
If anyone has a quick diy or solution to this would be appreciated

Usually, a small hole is drilled in the crankcase (or a hole is made during casting itself) in the space between the two seals, and this small opening connects the space between the two seals to the outside world (through a channel in the crankcase or water pump housing, depending on the design). This is done in most of the cars and liquid cooled bikes. Advantage is, you can see the coolant drip out from under the crankcase when the coolant seal fails. Plus, it does not mess up the other seal and no chance of mixing with oil. This can be done in our bike too, but unfortunately is not done in production.

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Neatly welded, however. If you remove those two bolts and turn that plate 15 degrees, it (and the sprocket) will come off. Hope the welding has not touched that plate. If it has, :banghead:

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Neatly it looks in photo bro..
The welding has touched the locking plate from 3 places .. Yes i know the plate has to be removed for removing sprocket 🙈🙈

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Hey guys,

My low beam isn't working since yesterday.
Only high beam is working that too I am feeling is too low.

Could anyone tell me what is the exact problem.

If it's a kaput bulb...which would be the best replacement with maximum light some night breaker or smthng I had read somewhere.

Pls help me out guys

Sent from my HTC One_M8

Any help here guys

Sent from my HTC One_M8