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  • 1 Post By arya809

Thread: Duke 390 Engine issue

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    Default Duke 390 Engine issue

    Hi,


    This is about my 2016 Duke 390. Starting few weeks back, I started facing this issue where the bike would suddenly shut off after 20-30 min of riding. Here's what I've noticed,


    1. Engine gets hotter than usual. I've been riding this bike for a couple of years now and I can tell this level of heat is not normal.
    2. When I cross 7-8k RPM, or I go above 100, bike starts stuttering. Almost like lack of fuel.
    3. Tried keeping the revs under 5k, doesn't shut off as soon, but still does after a while.
    4. When the bike does shut off, the temperature indicator spikes to the top (but weirdly, no warning about coolant temp) and the FI warning lamp comes on (2 short blinks).
    5. I need to wait for 10-15 mins for the bike to cool down before I can start again. But it shuts down in another 5 mins.


    Attaching a video for reference. I looked up what the blink code means. This doc says it's something to do with crank shaft position sensor. Though its for RC-390, I'm assuming it'll be the same for duke as well.
    https://www.manualslib.com/manual/10....html?page=167


    Tried taking the bike back to the SVC. THRICE. But they haven't been able to fix it. First time they changed the air filter box. Second time they tightened the spark plug adapter. Third time they cleared the ECU error history is what I was told. Not sure how to go about fixing this. Should I try taking the bike to a different service center? or find some outside mechanic to take a look? Any possible causes that I can check myself?

    Thank you.

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    Super Moderator sunilg's Avatar
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    Default Re: Duke 390 Engine issue

    Query approved.
    (Been There Done That) x 3.25

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    Default Re: Duke 390 Engine issue

    This seems to be a faulty design and the engine is obviously shutting off due to high temperature which is not your fault in any case.

    You have paid a lot of money (for the motorcycle) to be treated this way by the illiterates working in the service center. You need to contact the KTM head-office, tell them to send an engineer to rectify your problem. There must be a complaint/feedback form on KTM's website, write an aggressively worded complaint, also send the same matter as an email to some top-shot working in KTM HO. Tell them that you have every intention of filing a case in consumer court for sub-par product and/or service. Believe me, they will start calling your phone the moment they get the complaint. Don't back down untill they solve the matter completely.
    punit likes this.

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    Default Re: Duke 390 Engine issue

    It could be the engine oil and coolant mixing problem. Check coolant level, that could be causing the bike to heat up too much and shut down.

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    Default Re: Duke 390 Engine issue

    I heard this issue before , colant mixes with engine oil , causing low compression ration , thats why engine is struggling while accelerates.
    Remember, if coolant is mixing with oil at a high rate, then yes, the coolant will eventually mix with the oil and change the appearance of the oil, that's one. Secondly, extremely slow rate consumption would mean, the coolant is getting burnt inside the combustion chamber, albeit at an extremely slow rate, but eventually it is burning coolant. Reason can be bust head gasket. This kind of consumption leaves no trace as burns the coolant, opposed to coolant leak from water pump seals or internal sealing gasket failure which makes it very much visible with the oil getting murkier by the time. I hope you are getting what I am trying to say here.

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    Default Re: Duke 390 Engine issue

    Quote Originally Posted by arya809 View Post
    This seems to be a faulty design and the engine is obviously shutting off due to high temperature which is not your fault in any case.

    You have paid a lot of money (for the motorcycle) to be treated this way by the illiterates working in the service center. You need to contact the KTM head-office, tell them to send an engineer to rectify your problem. There must be a complaint/feedback form on KTM's website, write an aggressively worded complaint, also send the same matter as an email to some top-shot working in KTM HO. Tell them that you have every intention of filing a case in consumer court for sub-par product and/or service. Believe me, they will start calling your phone the moment they get the complaint. Don't back down untill they solve the matter completely.
    Quote Originally Posted by arya809 View Post
    This seems to be a faulty design and the engine is obviously shutting off due to high temperature which is not your fault in any case.

    You have paid a lot of money (for the motorcycle) to be treated this way by the illiterates working in the service center. You need to contact the KTM head-office, tell them to send an engineer to rectify your problem.
    @vastadevil

    I have a contact number for the Pune head office Customer experience research team if that helps. Don't know if it's allowed to share it straight away on this platform.

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    Default Re: Duke 390 Engine issue

    Quote Originally Posted by arya809 View Post
    This seems to be a faulty design and the engine is obviously shutting off due to high temperature which is not your fault in any case.

    You have paid a lot of money (for the motorcycle) to be treated this way by the illiterates working in the service center. You need to contact the KTM head-office, tell them to send an engineer to rectify your problem. There must be a complaint/feedback form on KTM's website, write an aggressively worded complaint, also send the same matter as an email to some top-shot working in KTM HO. Tell them that you have every intention of filing a case in consumer court for sub-par product and/or service. Believe me, they will start calling your phone the moment they get the complaint. Don't back down untill they solve the matter completely.
    Quote Originally Posted by elvin.mad View Post
    I heard this issue before , colant mixes with engine oil , causing low compression ration , thats why engine is struggling while accelerates.
    Remember, if coolant is mixing with oil at a high rate, then yes, the coolant will eventually mix with the oil and change the appearance of the oil, that's one. Secondly, extremely slow rate consumption would mean, the coolant is getting burnt inside the combustion chamber, albeit at an extremely slow rate, but eventually it is burning coolant. Reason can be bust head gasket. This kind of consumption leaves no trace as burns the coolant, opposed to coolant leak from water pump seals or internal sealing gasket failure which makes it very much visible with the oil getting murkier by the time. I hope you are getting what I am trying to say here.

    So I ended up giving the bike to a different service center. Spent a good deal of time explaining the issue. This time the stator coil was replaced. I got the bike back couple of days ago but didn't get a change to take it out for a proper test run yet. Spent nearly an hour in traffic after taking it out from service center. Engine didn't shut off once. So I'm hoping that actually fixed the issue. I'll be taking out for a spin today, I'll update if the issue persists.
    @arya809. It is indeed frustrating. I'm definitely going to write to the HO if this issue still isn't resolved.

    Thank you for responding.

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