Sir, thanks for your reply, radiator fan pic which I posted was second fan which was installed around 6 months back. Fan was quite hot when it was taken out and some rusting was also there on some parts. There are no leaks from hoses and mechanic checked engine oil whether coolant is mixing with it or not but he said everything is fine. Unfortunately I will have to again visit SVC and I will ask him to drain coolant and re-top up it. Today radiator fan which was installed has air flow downwards.

Which month/year is your bike? Did it come with the shroud type fan or naked fan? Try to check the vin to .

Try bleeding the radiator, by flushing it and filling in fresh charge of coolant and then see how it fares.



Check the coolant level, is it high or is it low on the can? Did you hear the fan working before the stall?

Cheers!
VJ

pl make some effort to google based on the horn model and description that i've mentioned.
let me do it for you this time:
Hella Yellow Panther Horn Set: Amazon.in: Car & Motorbike


make sure you get a 4 point relay (not the common 3 point mechanical one which is locally called a cut out) installed if you opt for these horns. both should work but a 4 point electronic one is better and resists water and heat better.

Also the pulsar 220's dual horns can be fitted. my svc said they will do it without cutting any wires and warranty intact.



Please get the oil drained and checked. The expansion tank became empty because the coolant is sucked in to the radiator. now, normal operation will see a slight variation in the level in the expansion tank (because when hot and at a particular pressure the valve in the radiator cap opens and pushes coolant up in to the expansion tank, and on cooling down it is sucked back into the radiator).
since you mention the entire coolant vanishing twice, i strongly suggest you look for leaks and also check the engine oil (a milky white/cloudy appearing oil means the coolant has mixed with the oil).
Can you post a pic of the oil sight glass ?
And which month/year is your bike.. the fan pic that you posted is the open fan unit from pre-sept 2014 models. Post Sept 2014 bikes come with the fan unit that has a shroud that directs some amount of the hot air downwards.. the shroud and fan is one single piece and cannot be separated normally.
I have seen one case where a 2015 duke 200 had its fan replaced with the older model fan
I feel the open design makes heat dissipation better, and the shroud design is more to shield the rider from heat. Though am not sure if quality wise there has been any improvement between the two fans.

----consecutive posts auto-merged-----



Also please take pictures and shoot an email to bajaj customer care explaining your issue politely.

Hi VJ,

Thanks. I will check on this and get back to you. Thanks for your prompt reply. However, is there a check list? I used to traverse the same distance every day in the same kind of traffice before and the bike has never given me a problem. I keep my bike stock than for my KTM Powerpart Orange handguard. Should i be worried about the kind of oil in this bike?

UPDATE : It was coolant entering in engine. They are working will be checking both oil seals & engine block packing. Attaching pic of drained engine oil and oil is only 500kms old. [ATTACH]201220[/ATTACH]

Now you found why it's draining, next puzzle to solve, why's it happening! How they going to seal the leaks!

That's what they are doing, oil is in dark brown color and you can see color of coolant over bubbles. It should have been rectified by yesterday itself.

That's what they are doing, oil is in dark brown color and you can see color of coolant over bubbles. It should have been rectified by yesterday itself.

That's what I have told to them, I am really thinking what will happen after warranty and now I have to pay for engine oil.

Another UPDATE: Just returned from SVC, whole day consumed at SVC, they replaced oil seals ( attached pic of old oil seals ) and have put mineral oil for testing and told me to test it for two days then if all things goes well then FS oil will be filled till then they haven't closed job card also.

Another problem emerged when I left SVC, I have hardly gone around 500 meters I noticed ABS light was on and ABS was not working, I took bike again to SVC they checked fuses but fuse was ok but ABS sensor was gone. [ATTACH]201232[/ATTACH]