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Old 18th September 2012, 11:10   #481
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

Airfoil you are absolutely right. The side stand does get loose. What does not help is crass morons sitting on your bike while it is parked (like the ones at the recent Orange Day I gave a piece of my mind to - twice! So I sincerely hope they read this and realise what we think of them).

Both bolts on my bike were tightened when the chain guide was fitted. Will make sure the link arm is correctly adjusted and pivots lubed.

I don't think its a "sticky" shift issue though. The gear is not slotting if you are a trifle casual (or hurried) about your upshift under acceleration. Noticed one the other day between 2 and 3 as well.
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Old 18th September 2012, 11:32   #482
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

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Originally Posted by ebonho View Post
Congrats bro! Matter of time

Last couple of days been hearing a wierd sound from the front of the bike. Like eletrical static/crackling. Happens on accelerating. Its clearly there if you listen for it. No burning wire smel at all from anywhere. Wonder what it is.
Heard similar sound at particular RPM range & few more have reported the same in the other forum. In my case the sound was from the fuel tank key flap, just hold it firm when & the sound is not heard anymore. Haven't heard it in the last few days even though I have done nothing to get rid of it.

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Don't know if the guys at the SVC did not fit it back after the ECU flashing or it got disldged due to the violent riding off late.
ECU flashing! Any reason given for the ECU to be flashed Doc?


Also have recently noticed when up-shifting at RMP close to 9K the shift doesn't feel smooth, kinda engages with a thud/jerk. Any possible reasons for this?

Last edited by samschenker : 18th September 2012 at 11:36. Reason: added up-shift query.
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Old 18th September 2012, 11:40   #483
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

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Originally Posted by samschenker View Post
Heard similar sound at particular RPM range & few more have reported the same in the other forum. In my case the sound was from the fuel tank key flap, just hold it firm when & the sound is not heard anymore. Haven't heard it in the last few days even though I have done nothing to get rid of it.
This is not the tank key flap. It does not go with finger placed on it. Its clearly coming from within the headlight shroud. Its a crackling sound.

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ECU flashing! Any reason given for the ECU to be flashed Doc?
Sometimes some errors come in, code gets corrupted, like in any software. This was done for all bikes at the recent checkup camp in Pune.

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Also have recently noticed when up-shifting at RMP close to 9K the shift doesn't feel smooth, kinda engages with a thud/jerk. Any possible reasons for this?
Clutch?
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Old 18th September 2012, 12:23   #484
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Default

Quote:
Originally Posted by ebonho

This is not the tank key flap. It does not go with finger placed on it. Its clearly coming from within the headlight shroud. Its a crackling sound.
Can thereby any short circuiting of the headlamp connector wires? Could've become loose while riding over rough patches. Is there headlamp flickering?

Doc any news about Bajaj changing the MID clusters on the newer lot of bikes to prevent water fogging? I told the guys at pbk to inform me when they get the next lot of bikes delivered. Probably some issues resolved by then.

Many folks are asking on this thread about the paddock stand. Rjays has a paddock stand available for 6k iirc. Why not opt for that? Also one of the Dukes on display at pbk was on the paddock stand and it was in the ktm orange color. Wonder why they arent making it available for sale.
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Old 18th September 2012, 12:24   #485
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

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Originally Posted by ebonho View Post
This is not the tank key flap. It does not go with finger placed on it. Its clearly coming from within the headlight shroud. Its a crackling sound.
Interesting do keep us updated on this. Will update here if I find anyone reports the actual problem else where.

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Sometimes some errors come in, code gets corrupted, like in any software. This was done for all bikes at the recent checkup camp in Pune.
By errors you mean the error codes set by the ECU?

Possibility of code corruption is very bleak(IMO close to ZERO possibilities) these software are designed to work much different compared to the ones we use in our computers & if they had re-flashed the software I am sure there was some other reason

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Clutch?
something to do with clutch play?
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Old 18th September 2012, 16:59   #486
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

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Originally Posted by ebonho View Post
I don't think its a "sticky" shift issue though. The gear is not slotting if you are a trifle casual (or hurried) about your upshift under acceleration. Noticed one the other day between 2 and 3 as well.
Agreed, the Duke's gearbox is not as slick as those on the Jap bikes, for example, it is notchy and does tend to get stuck in between gears when one isn't careful. Oiling the pivot does help alleviate this to an extent.
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Old 18th September 2012, 19:07   #487
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

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Originally Posted by Parthasarathig View Post
Doc any news about Bajaj changing the MID clusters on the newer lot of bikes to prevent water fogging? I told the guys at pbk to inform me when they get the next lot of bikes delivered. Probably some issues resolved by then.
No idea yet. I know something is going on as Bajaj are aware of this issue.

Quote:
Many folks are asking on this thread about the paddock stand. Rjays has a paddock stand available for 6k iirc. Why not opt for that? Also one of the Dukes on display at pbk was on the paddock stand and it was in the ktm orange color. Wonder why they arent making it available for sale.
A long time back they did develop and display a fixed stand. No wheels. That neede tow people to lift the rear of the bike and place the swingarm over it. DSG has developed a stand in orange for some 4K last I asked.

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Originally Posted by samschenker View Post
Interesting do keep us updated on this. Will update here if I find anyone reports the actual problem else where.
Thanks man. Would appreciate that!

Quote:
By errors you mean the error codes set by the ECU?
Ya. Not possible? I am a software/tech ignoramus. I am not even on FB.

Quote:
Possibility of code corruption is very bleak(IMO close to ZERO possibilities) these software are designed to work much different compared to the ones we use in our computers & if they had re-flashed the software I am sure there was some other reason
As in making the bikes more docile because of some of the cylinder failures? :( Hope not.

Quote:
something to do with clutch play?
Yup.

Quote:
Originally Posted by airfoil View Post
Agreed, the Duke's gearbox is not as slick as those on the Jap bikes, for example, it is notchy and does tend to get stuck in between gears when one isn't careful. Oiling the pivot does help alleviate this to an extent.
I think its linked to the exact length of the link arm. Have seen detailed instructions on how to adjust that and tolerance ranges. Of course, lube always helps everywhere.
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Old 18th September 2012, 22:54   #488
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Default Weird Noise from Front Sprocket

Hi Guys,

Observation 1 - I am getting weird noises from the front Chain sprocket for last couple of months.
I thought these were normal noises as the chain is open and is sliding over a Chain Slider.

Actually the noise is a tak tak noise which is different from the whining noise of chain sliding over the slider.
This tak tak is audible only at low speeds. As speed increase the whining noise of chain increases subsequently & is much more than the tak tak noise. Hence this tak tak noise is not audible at high speeds.

Last week I got an opportunity to ride 2 other KTMs.
They did not had this tak tak noise. But they did had the constant whining noise.
Hence I was worried & concerned because -
  1. Front Sprocket might be misaligned from the chain travel line
  2. Front Sprocket might be loose internally
  3. Chain might have lubrication problem
  4. O Rings might has some issue and not rotating properly
So today I was relatively free & thought of visiting the SVC.
Observation 2 -

I was told that this noise could be because of dirt in the chain.
The chain was cleaned & lubed 400 kms back (serviced). It was again lubed on the Orange day (about 150 kms back).
Observation 3 -
The noise is much more pronounced when the bike is on ground than on the paddock stand.
Treatment Done -

The chain was cleaned & the noise was not to be heard. But as soon as I reached home, the noise was back & was much more pronounced. I called Sachin & immediately went back to the SVC with Motul Chain Clean & Motul Chain Lube.
Again when the bike was on Paddock stand, the noise was reduced & we cleaned the chain properly, Oiled it & Lubed it again.
Now I was very sure that the noise will not come.
But as soon as I reached home, the noise was back.
Cross Check -

My Flatmate has a Yamaha FZ. His bike's chain is very dirty & he doesn't maintain it. Still it has no Tak Tak noise (although it has that whining noise).

Now the chain is ultra clean as brand new but the issue still persists.

Anyone else facing/ faced this issue?Any recommendations/ solutions?
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Old 19th September 2012, 04:49   #489
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

Quote:
Originally Posted by ebonho View Post
I think its linked to the exact length of the link arm. Have seen detailed instructions on how to adjust that and tolerance ranges. Of course, lube always helps everywhere.
That makes sense. When I refitted the gear linkage, I got the angle wrong at first. The pedal was almost horizontal and it didn't seem right. I hopped on the bike to make sure by feel and realized it needed to be slanting downwards.

Funny thing is, while it was fitted horizontally, I could slot into 1st and back into neutral, but there was no way to get into 2nd or beyond.
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Old 19th September 2012, 12:19   #490
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

Quote:
Originally Posted by Parthasarathig View Post
Many folks are asking on this thread about the paddock stand.
I am using a paddock stand designed for the CBR250 the one which can be found in rksans CBR250 thread here in TBhp, it serves the purpose & is priced much lesser than the Rjays product.


Quote:
Originally Posted by ebonho View Post
Ya. Not possible? I am a software/tech ignoramus. I am not even on FB.
The ECU are designed to store error codes(Diagnostic Trouble Codes) if that is what they cleared then its perfectly fine & is normal.

Quote:
As in making the bikes more docile because of some of the cylinder failures? :( Hope not.
didn't mean that, but IMO chances of code(as in the ECU software) corruption is very very rare.
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Old 19th September 2012, 19:17   #491
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

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Originally Posted by samschenker View Post
I am using a paddock stand designed for the CBR250 the one which can be found in rksans CBR250 thread here in TBhp, it serves the purpose & is priced much lesser than the Rjays product.
Are you talking about the stand mentioned here? How did you get this done? Can you please post pics with the Duke on the stand? And how much was the cost?

Can R15 stand be used for the Duke?

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Originally Posted by rk_sans View Post
Got myself a paddock done by my friend. Basically for rims cleaning, Chain cleaning and chain lubing.
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Old 20th September 2012, 13:07   #492
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

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Originally Posted by samschenker View Post
didn't mean that, but IMO chances of code(as in the ECU software) corruption is very very rare.
But since this is now a gnawing doubt, I will check if its revving all the way to 10500 rpm in each gear now ....

Those who had the diagnostic/reflash done on their bikes at recent service camps could do the same and report back here.

Some updates from my bike washing/riding session yesterday (bike has been caked in mud for the past 3 weeks - no sense in washing her and getting caked in mud again so waited for a dry spell).

There is cracking/peeling of the white coating of the mono shock spring (started at the lower two coils). This in addition to the misting of the MID will be brought to the notice of the Bajaj guys.

After washing, no gear mis-shifts. Maybe I was being careful/attentive. Maybe as airfoil mentioned, the mud/muck getting washed off and the water lubed the pivots. Will anyways get it looked at. Downshifts are super slick as always at high rpm's. At lower trafic rpm's, it helps to blip, otherwise they get a little clunky and the revs also do not match seamlessly.

The fuse box keeps getting dislodged from the metal clip where it is attached under the rear seat. Tak tak noise is from it jumping up and down. The fender hitting the hugger is still there though. Have given up on that.

The "crackling" sound is heard when you decelerate after accelerating as it rolling of the throttle in traffic. It is definitely coming from the small flap over the tank keyhole. Not from the headlight shroud.

Interestingly, keeping finger pressure over the flap (closed) does not make the sound go away. The sound goes away with the flap flipped open. After doing that a few times, the sound has not returned.

The magnet going weak, not holding because of muck - going when bike cleaned?

Some loose allen bolts internally (under the round cap) rattling harmonically?

Last edited by ebonho : 20th September 2012 at 13:10.
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Old 20th September 2012, 13:48   #493
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

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Originally Posted by ebonho View Post
There is cracking/peeling of the white coating of the mono shock spring (started at the lower two coils). This in addition to the misting of the MID will be brought to the notice of the Bajaj guys.
Spoke to Mr. Mayank Bhatt from KTM Service on the above issues (I'm facing both) this morning.

1) MID misting - He said some amount of misting is normal. It is due to the temperature difference inside the MID and the cool air outside (especially during rains). It's just the water vapour in the air within the MID condensing. You notice something similar in watches during rains. He did mention that if it get so bad that you cannot see the display or if it affects your riding, show it to the nearest service centre. (Mine isn't as bad. Was just afraid it would short the electronics. He said it won't unless there is actual water seepage)

2) Paint peeling on Monoshock - They are actively pursuing the issue. They have developed an alternative unit which is being tested by some customers. Apparently, they (Bajaj-KTM) are not satisfied with the result and are relooking at it. He promised to call as soon as they come up with a satisfactory permanent solution.

Hope this helps.
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Old 20th September 2012, 14:02   #494
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

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Originally Posted by NikhilB View Post
Spoke to Mr. Mayank Bhatt from KTM Service on the above issues (I'm facing both) this morning.

1) MID misting - He said some amount of misting is normal. It is due to the temperature difference inside the MID and the cool air outside (especially during rains). It's just the water vapour in the air within the MID condensing. You notice something similar in watches during rains. He did mention that if it get so bad that you cannot see the display or if it affects your riding, show it to the nearest service centre. (Mine isn't as bad. Was just afraid it would short the electronics. He said it won't unless there is actual water seepage)
I was told the same by Brijesh Pandey here during the last checkup camp.

But I frankly do not buy that train of reasoning. Good watches do not mist. Similarly 5000 buck MIDs on international products should NOT mist.

The misting dries off. But now I can see wavy water marks clearly on the INSIDE of the glass/plastic outer cover.

Not acceptable bro. I am definitely not waiting for the entire display to fog over to the point of not being able to read it.

Quote:
2) Paint peeling on Monoshock - They are actively pursuing the issue. They have developed an alternative unit which is being tested by some customers. Apparently, they (Bajaj-KTM) are not satisfied with the result and are relooking at it. He promised to call as soon as they come up with a satisfactory permanent solution.

Hope this helps.
Thanks for this feedback. Will keep track of what they are planning to do. Its largely cosmetic and not functional, but it does look shabby.
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Old 20th September 2012, 14:28   #495
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Default Re: KTM Duke 200 : Baby Duke 222 unites with her new family!

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Originally Posted by ebonho View Post
I was told the same by Brijesh Pandey here during the last checkup camp.

But I frankly do not buy that train of reasoning. Good watches do not mist. Similarly 5000 buck MIDs on international products should NOT mist.

The misting dries off. But now I can see wavy water marks clearly on the INSIDE of the glass/plastic outer cover.

Not acceptable bro. I am definitely not waiting for the entire display to fog over to the point of not being able to read it.
I agree. Ideally, should not happen.

In my case I can only recreate the issue by pouring some water over the MID and then parking the bike under the sun. The condensing in then only visible under the droplets formed on top of the screen. Not a very big deal.

The way I look at it, it is not affecting my riding. If it gets worse, they have promised to replace it (replacement seems to suffer from the same issue).

Additionally, they have promised to call if they do come up with a moisture-proof version

Might as well wait for a permanent solution.
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