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Thread: Duke 390 engine oil leakage

  1. #1
    Rookie iamarjung's Avatar
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    Default Duke 390 engine oil leakage

    Please help me fellow xBhpians.

    After cleaning the chain, and washing my motorcycle I fired it up for warm up. Suddenly I found out that engine oil is leaking from the chain sprocket cover screw hole.

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    Last edited by xBhp; 04-06-2020 at 11:50 AM.

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    Default Re: Duke 390 engine oil leakage

    Thread approved.

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    Default Re: Duke 390 engine oil leakage

    Quote Originally Posted by iamarjung View Post
    Please help me fellow xBhpians. After cleaning the chain, and washing my motorcycle I fired it up for warm up. Suddenly I found out that engine oil is leaking from the chain sprocket cover screw hole.
    Welcome to XBhp. The three bolts you removed have the primary duty to hold the magneto cover and additionally do the job of holding the plastic drive sprocket cover. A high pressure oil line passes just adjacent to these 3 bolts - what a wonderful & thoughtful design by KTM! The vehicle should not be idled/pressure-washed/driven without these 3 bolts in. When you put the sprocket cover and these 3 bolts tightened - the leak should stop. If it doesn't, the magneto cover gasket should be replaced. In future, Try not to remove the plastic cover as much as possible - because removing/fitting the bolts frequently will weaken and tear the paper gasket and cause a leak. NS/RS/Duke series all give this pain in the neck.


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    Addicted Throttlefreak's Avatar
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    Default Re: Duke 390 engine oil leakage

    Quote Originally Posted by ashwanth.r View Post
    Welcome to XBhp. The three bolts you removed have the primary duty to hold the magneto cover and additionally do the job of holding the plastic drive sprocket cover. A high pressure oil line passes just adjacent to these 3 bolts - what a wonderful & thoughtful design by KTM! The vehicle should not be idled/pressure-washed/driven without these 3 bolts in. When you put the sprocket cover and these 3 bolts tightened - the leak should stop. If it doesn't, the magneto cover gasket should be replaced. In future, Try not to remove the plastic cover as much as possible - because removing/fitting the bolts frequently will weaken and tear the paper gasket and cause a leak. NS/RS/Duke series all give this pain in the neck.
    Same thing in my Dominar. The design is really stupid. The guys in the SVC ended up spilling a lot of oil during the previous service. Also the bolts in my Dominar are poor quality. They get rounded off pretty easily.
    #bpk likes this.

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    Rusted Zapps's Avatar
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    Default Re: Duke 390 engine oil leakage

    I'm astonished, OP doesn't bothers about the missing bolts clearly visible in the pic
    Quote Originally Posted by ashwanth.r View Post
    Welcome to XBhp. The three bolts you removed have the primary duty to hold the magneto cover and additionally do the job of holding the plastic drive sprocket cover. A high pressure oil line passes just adjacent to these 3 bolts - what a wonderful & thoughtful design by KTM! The vehicle should not be idled/pressure-washed/driven without these 3 bolts in. When you put the sprocket cover and these 3 bolts tightened - the leak should stop. If it doesn't, the magneto cover gasket should be replaced. In future, Try not to remove the plastic cover as much as possible - because removing/fitting the bolts frequently will weaken and tear the paper gasket and cause a leak. NS/RS/Duke series all give this pain in the neck.

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    Default Re: Duke 390 engine oil leakage

    Quote Originally Posted by Throttlefreak View Post
    Same thing in my Dominar. The design is really stupid. The guys in the SVC ended up spilling a lot of oil during the previous service. Also the bolts in my Dominar are poor quality. They get rounded off pretty easily.
    My hunch is that these family of engines descended from old KTM off-roaders where the engine is overhauled after every event or after a set number of 'hours'. If bolts are getting rounded, one has to make sure they are using the right tool (No C-spanners, no ring spanners - only 6-point sockets whenever possible). Sometimes, corrosion of Aluminum will tightly hold those bolts - a slight tap on their head before removal might help. If it still rounds off, quality is poor.

    Which bolts are getting rounded off in your Domi?

    Quote Originally Posted by Zapps View Post
    I'm astonished, OP doesn't bothers about the missing bolts clearly visible in the pic
    He didn't expect that, I think. On most motorcycles, the sprocket cover bolts are not shared. I don't know how difficult it is to extend that U-shaped bracket and make it hold the cover instead of those 3 bolts. You're an engineer, you tell me!


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    Rookie iamarjung's Avatar
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    Default Re: Duke 390 engine oil leakage

    Quote Originally Posted by Zapps View Post
    I'm astonished, OP doesn't bothers about the missing bolts clearly visible in the pic
    I guess I know what I was trying to show. Well check the attached image for further analysis. Loosen these bolts for cleaning the front sprocket is absolutely necessary, does that mean oil will mix with the coolant due to less pressure in the magneto cover! The circled bolt is the one where oil was leaking from. Shall I go for a Gasket replacement? I only rode my motorcycle for 3000KM in 2 months after purchase.

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    Addicted Manoj Sivaraman's Avatar
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    Default Re: Duke 390 engine oil leakage

    Quote Originally Posted by iamarjung View Post
    I guess I know what I was trying to show. Well check the attached image for further analysis. Loosen these bolts for cleaning the front sprocket is absolutely necessary, does that mean oil will mix with the coolant due to less pressure in the magneto cover! The circled bolt is the one where oil was leaking from. Shall I go for a Gasket replacement? I only rode my motorcycle for 3000KM in 2 months after purchase.

    #StayHomeStaySafeName:  Screenshot_20200328-191111_YouTube.jpg
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    Hi,
    Don't panic bro.
    Since the bolt is shared for sprocket cover and the high pressure oil gallery for stator coil cooling jets. It will leak if it's loosened up.
    No need to go for a gasket replacement and coolant mixing is entirely different from this. So no issues.
    Also 390 uses no packing gaskets on its centre case. So retight the bolt. That should do it.
    Regards
    Manoj Sivaraman
    iamarjung likes this.

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    Default Re: Duke 390 engine oil leakage

    Since KTM India and Bajaj have literally the same engines,it is wonderful to note that the intelligent engineers and design team arent capable to deliver a hassel free product.For instance look at hero and honda bike engines,the best till date.
    #bpk and iamarjung like this.

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    Default Re: Duke 390 engine oil leakage

    Same My Duke 390 bike In the wake of cleaning the chain, and washing my cruiser I terminated it up for warm up. Out of nowhere, I discovered that motor oil is spilling from the chain sprocket spread screw gap

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