ktm duke overheating - radiator fan test & fix

this video shows one cause of engine overheat issue
related to the cooling systm fan .
the oil was checked / colant level was checked / inspection of
engine sound was ok ( no rattle / or unusual noises )
once the reapir was done the heating issue was solved .
ATTENTION !
this video is for learning and education
attempting is at your owne responsability only .
THANKS FOR WATCHING !
Mechanics & DIY

[@linusd3551]

when you tested the connector with the battery, does it matter where minus and plus goes from the battery to the connector?

[@MechanicsDIY]

see min 1:06 2 polarity dose not matter - will show -1 or 1 if the relay switch is dead then it will show 0 . *important : clean the connectore before testing .

[@linusd3551]

@@MechanicsDIY Big thank you.!

[@drpraveenmeena6911]

Same problm i face, but first oil flow in air filter i clean and no selft start the start only bike pushing . What i do?

[@MechanicsDIY]

kzbin.info/www/bejne/gmPSk3dvj72lqdk you can try - at your own risk

[@eloufirjawad]

Thanks man! I, however, have a different issue with the fan. It starts running as usual when the engine heats up, but it doesn't stop. Oddly, the engine doesn't cool down effectively nor does it overheat. Has anyone faced a similar issue after exposure to water? Appreciate any insights or solutions.

[@MechanicsDIY]

the fan kicks in via a thermostat (temp) sensor if the sensor gose bas it might cause issues of this type . if you can use another fan to test it you will know for sure the sensor is on the fan as far as i know and looks like a small black beed of glass with 2 wires coming out of it

[@the390monkey]

same issue have you fixed it?

[@shelbygera8305]

Mate thank you! Just now realised it for my duke 200 (2015 model) It reaching 8 points in the heat bar but the fan didn’t start yet. I just realised that something might be wrong because in my 7 years of the bike experience with duke 200 it never took this much for fan to start in! Waiting for the ktm service to inspect and repair!

[@MechanicsDIY]

ktm is a never ending repair bike

[@davisbriska3235]

@@MechanicsDIY lol I agree. I have a 2011 ktm duke 125cc and I have put into repair +1100$. Know the struggle

[@marklouiecereno2542]

I have a problem with my fan, it always on everytime i used it then there is no heat display on my panel. It never stop. :(

[@MechanicsDIY]

the fan have a small sensor that looks like an led with 2 wires on it ( a thermostate ) if the sensor is dead the fan will not shut off as a protection feature you need to test that unit to be sure ,

[@Rey_khaila]

Hello mate, my radiator fan is not working, and as soon as I start the bike, the radiator fan fuse blown... Please help

[@MechanicsDIY]

even if it's working it will only start when you have 6-7 bars of heat this is how it is on this model and it's normal

[@rizzogr8382]

Hi bro, I have problem with my Duke 125, the fan olny strated at top of the bar ! even when I ride or idle ! I also changed the water coolant sensor and it didnt worked ! plz help me out.

[@lekir5johor349]

same with me..own duke 200.. just buy 2021..the fan only works at high of the bar

[@MechanicsDIY]

ktm shuld not idle it needs air to coll via riding , get 10w60 4t oil if you want less heat and use proper green coolant -------------------------------------------------- also if it's 37c outside on a hot day do not ride fast on low gears first gear 0-15 km second gear 15 -40 third gear 40 -60 forth gear 60-80 fifth 80 -100 kip on 7000 rpm it will ride cooler at night you can ride more crazy , oil level test every day and enjoy riding ,

[@gamingwithmuyal]

Which oil is the best for duke 200?

[@MechanicsDIY]

ktm reccomend 10w-50 4t . i use liqui moli brand ( made in germany ) unsponserd . 10w-60 is better but cost more . it kips the engine 20% coller under hard work . and gets fluid faster on cold days . from my experience .

[@gamingwithmuyal]

@@MechanicsDIY thank you so much brother and how much is the price for 10W-60 oil?

[@MechanicsDIY]

@@gamingwithmuyal usaly 4 litters is cheaper then 1 - the oil engine capacity is 1.6 litters . about 1 litter is about 15 $

[@ngilakhawlhring7375]

How can i check relay or thermoswitch is working or not??duke 200

[@MechanicsDIY]

take one that works that have the same numbers on it and replace between them - and see if it helps there are at least 5 or more relays on the duke

[@balbonstv4784]

I have the same problem with my duke 200 2013 model. The fan only kicks in when the heat indicator reach the 11th bar. How to fix it? Can someone help me here?

[@MechanicsDIY]

make sure your heat sensor wire on the radiator is attachet to the rediator if it's fallen it will take longer for the sensor to feel the heat also you might need to replace it if it's bad ( it's very cheap 12v heat sensor wire

[@idhammuchtar6870]

Where does it located?

[@balbonstv4784]

@@idhammuchtar6870 you can see the heat indicator on the left side of the panel dash board.

[@idhammuchtar6870]

@@balbonstv4784 i mean the heat sensor wire.

[@AmrutKatigar]

When the fan starts? After reaching which heat level point in display?

[@MechanicsDIY]

about 5-6 bars only . not before

[@AmrutKatigar]

@@MechanicsDIY thank you Sir, how to identify if the fan is started, because in city traffic often the sound is unheard.

[@whatsnext162]

My fan only gets on in the first gear wat will be the solution for this...If I change the gear to the second fan gets off

[@MechanicsDIY]

sounds like a faulty ecu the computer / or one of the relays gone bad not sure since i never had that issue

[@purabmundra9780]

Hey bro!! Yesterday ive purchased rc 390 ii second hand which is of 2018 model 10k km driven !And what i felt is that radiator of my bike is been starting just with the riding of 2 to 3 km max!And it continuously runs around 3 to 4 min non stop with a huge sound! Again after a 2km it starts running ! I think this is not normal

[@MechanicsDIY]

the 2018 cooling is better on ktm dukes in this video the fan did not work at all , due to a wire connection gone bad - the currotion prevents conductivity once the connectors was cleaned with contact cleaner (not wd-40 oil) and sandpaper the issue was solved and the fan was back,

[@sangaydzongpa5044]

Bro same problem here Can u tell me what was the problem and how did u manage ur problem.?

[@HariKrishna-mw2rr]

My Radiator isn’t turning on . It’s showing high level . The bike Age is 18 months

[@sunil2144]

bro same mine have you got solutions

[@MechanicsDIY]

. ktm duke 5 - 7 bars is normal be sure to test oil level often small window in the engine gear case shuld be full 80% with small air buble on top to test hold thje bike in ride position on a leveld ground

[@manidreamhunter7465]

Awesome bro ..

[@Mr.surya1133]

I have this same problem pls help

[@Mr.surya1133]

Temperature can goes high on 10 kms pls help I'll change the coolent oil also

[@MechanicsDIY]

the radiator is cooled by the air flow generated by driving at 50km or so . and not at 10 km . using the first gear too much and doing some vooom.. voom... for the chicks . will raise the engine heat . maybe you'r also using the wrong type of oil (ktm duke 125 is using 10w50 4t oil) / cheap coolant . that reduce preformance . in any way .. usualy low speeds + high rpm = engin heat goes up fast on ktm.

[@sunil2144]

bro i am using 20 w 50 but still my bikr heat at 10 km. raditr fan works but still heat

[@SK_vlogs05]

Hlo Sir, my bike also heat up when I drive 10-15 km,when my bike is heated some loude noise is coming…..!!

[@mrbritcoinnakamoto2793]

if you disconnect the blue plug under the carb (sat on bike right side the fan will come on you will get an engine light flash on the clocks but it will kick the fan in to go flat out just incase you need to get home iv got a problem when the plug is not connected its runs very well when its connected it stalls ie wont idle seems to be a short some where or broken wire

[@MechanicsDIY]

is this a bot comment ?

[@skrambo1]

good job

[@MechanicsDIY]

it was an odd one t figure out . i was quite happy its not a bad fan. just connectors

[@mehditorreto6234]

Hello I own a 2011 KTM Duke 125 and it is overheating when standing idle and of course when driving........ The radiator fan ONLY turns on when the coolant temperature is at the max. :crying2: I even changed the coolant several times thinking it maybe was bad quality.. Does anybody know how to solve this??? Thanks

[@MechanicsDIY]

ktm not supose to idle they are air+water cooled no ride = no cooling

[@MechanicsDIY]

if your engine's oil is low quality or old it will cause engine heat . oil flash is cheap to do

[@Mr.surya1133]

Fan is work on the battery but it's not run on going

[@MechanicsDIY]

clean the connectors shown in the video contact cleaner and sand paper only

[@sathish5457]

I have same problem. So make clearly what do to sir.

[@MechanicsDIY]

if fan is not turning on clean the connector it might be just water damage that is fixed by cleaning to test the fan use 12v battery on the connector

[@candy____24]

Same problem

[@MechanicsDIY]

ps old ktm duke 2011 only kicks in on 7 bars of heat if you have this - it's no problem but if the heat rise up fast new coolant and engin oil is needed

[@pauldean8638]

Seriously you ain’t got a clue , connect yourself tester correctly cause contact cleaner wouldn’t of fixed the problem if connection is clean already

[@MechanicsDIY]

the fan wasn't turning on the cause - rain got in the connector and it stopped conducting once the green/ black stuff was removed (connectors are brass) it started working again the meter shows same both ways apart from the - minus mark

[@freddywalker2515]

А можно по русски

[@MechanicsDIY]

It can be in Russian