Re: KTM Duke 390 - Ownership Reviews and Experiences

Hi my name is Tushar Moily. I'm 26 years old and I stay at Thane, Mumbai.

Currently I ride a 2013 KTM Duke 390. Bike was purchased brand new from showroom so I'm the only owner. I purchased the bike on Jan 2014.

Bike - KTM Duke 390
Year - 2013
Kms on odo - 63k

Last November 2018 I got major engine works done which includes block piston change, all head internals change, and complete gaskets overhaul because the engine was on the verge of ceasure and oil was leaking from basically everywhere. I got these works done from a workshop at Mira Road, Thane. In spite of getting these works done, my bike was still leaking oil from somewhere down below. Changed gear oil seal, front sprocket oil seal but still leakage would not stop. Folks at workshop had no idea why it is still leaking. Then finally I gave my bike to authorised SVC at Thane. They cleaned the engine nicely with water and test rode my bike. They found out that oil was not leaking from any seals but from the plain surface of crankcase itself ! The crack was not even visible from naked eye and the oil used to leak only when the bike is ridden really hard. That's how minute the crack was. There was a dent too on crankcase which mostly occurred because I may have hit a high speed breaker with a pillion.

So the SVC guys placed an order for new crankcase. Part was delivered on the second week of order placement. Got the crankcase changed, the leakages stopped permanently. But the story does not end here.

After changing the crankcase, I started facing performance issues in my bike. Performance issue was mostly at the top speed. Top speed had taken such a beating that my bike was reluctant to cross 120kmph in 4th gear. We all know that a healthy duke 390 reaches 130 kmph with a blink of an eye. I was feeling that I was riding a Duke 200. To add to my horror, speedometer started flashing 'low oil pressure' !! I couldn't believe it. I spent so much money on engine rebuild and crankcase but still I'm getting this warning. I took my bike to SVC again. Told them about these two problems. For the low oil pressure, they changed the oil pressure switch on the head twice. Then I took my bike for testing and I trashed my bike really really hard in order to be satisfied that low oil pressure problem is solved. Speedometer then stopped flashing low oil pressure but then some weird noises started coming from the engine head because of extreme trashing and speedo showed 'high coolant temp'. Boiling coolant was literally overflowing from the reservoir. They told me that it's simply the sound of the sims. About the top speed, they told me that my chain sprocket and clutch plates are gone. So I got both of them changed. Test rode my bike after that but still there was top speed performance issue. Then the SVC guys test rode my bike with a pillion. The pillion had diagnostic tool in his hand which was attached to my bike. They came back and assured me that top speed is okay. But I was not satisfied since I've been riding my bike for 5 years now and I know how she pounces like crazy post 6k rpm. That pouncing was not there.

So I decided to take my bike to a different SVC. I went to KTM SVC at Vikhroli. Showed them the weird 'khat khat' sound coming from the engine. After opening the head and checking, they old me that intake camshaft's lobe had become uneven because the head was not getting oil. Got it changed which costed me 4.7k with labour. Took my bike and test rode it only to find 'low oil pressure' warning again ! Took my bike back to SVC again. They fitted a brand new oil pressure switch. Test rode it again but I got the same warning again. Went back there again. They checked pressure with pressure guage. Duke 390 should have 1.5 kg of pressure at idling rpm. Guage was showing zero pressure. So they also fitted a brand new oil pump which pumps from crankcase to head. Checked with guage again. It showed only 1 kg of pressure.They told me to leave my bike here for few days so that we can take a long test ride and check the actual problem.

They called me day after tomorrow and asked me whether have I changed the crankcase or not before. I say yes. They told that my bike is 2013 model and the crankcase they fitted is 2017 model (i.e crankcase of new Duke 390). Because of that there was mismatch in alignment of oil ducts and so the head was not getting oil. The solution of this problem was to change the magnet cover also (the one on which 'racing KTM' is written) to the latest model so the alignment is perfect. I wasn't convinced that simply changing magnet cover will solve my problem but I trusted them and gave a go ahead anyway.

Next day I went to collect my bike. Found a nice stretch of road, opened the throttle fully, and I was so happy with the results ! The original acceleration of Duke 390 was back ! She was pouncing like crazy post 6k rpm..so much that it was almost overwhelming and so I had to slow down and contain my happiness and excitement. Who would have thought that simply changing the magnet cover will solve all of my problems? She is now performing like a brand new Duke 390 straight out of showroom. I expected the folks at Thane SVC to tell me that I should change magnet cover also but they did not. How unprofessional ! I cannot thank the folks at Vikhroli SVC enough for fixing the problems in my bike.

What I feel is that since there was misalignment in oil ducts, there was a lot of back pressure to the oil pump and so it got damaged and top speed took a beating. Oil pump is not motor operated but rather from the engine itself.

So there are two reasons for this long post.

1) If you own a 2013 Duke 390 and your crankcase has got cracked, change the crankcase and also the magnet cover. There won't be any loss in performance.

2) My ABS has stopped working on it's own. The folks at Mira Road workshop tells me that mostly some ABS motor is gone and the motor costs 20k rs ! Damn that's almost my 1 month salary. Is there a cheaper alternative to fix my ABS?


Thanks for reading my long post.

Re: KTM Duke 390 - Ownership Reviews and Experiences

Hi B7ACKTHORN,
Thanks for your message. Was wondering if KTM doesn't test these extensively in the Indian conditions. I haven't really faced this issue with any other bikes that I have ridden over the years.

Also going by our roads even if you hit the potholes at a low speed it's really disheartening to see the impact it leaves on the tyre/rim. Is there a permanent solution to this? Better tyres/aftermarket parts?

Parallel another issue has resurfaced in the rear tyre. I have noticed a bulge on one of the sides. Fighting with the OEM/SVC to change it FOC since it's still under warranty.

Re: KTM Duke 390 - Ownership Reviews and Experiences

Appreciate the heads up airazen. You're in part of the world that it is extremely mod friendly and there ain't dearth of after market spares and knock-offs, and the good part is they work well to an extent. Do keep your observations posted. And yes, coupled with those lovely calipers a good radial master cylinder would go well too. My opinion honestly would be that you get great stuff there, keep search a little bit, and you'll eventually end up with a good el cheapo deal from your country itself.

Cheers!
VJ

Re: KTM Duke 390 - Ownership Reviews and Experiences

Hi VJ, yes you're right, as for the high end parts, i can find it online, but i'm looking for an OEM parts, i live in Indonesia, there is so much dealers in here, but for some of the parts, they still hard to find...

For the brembo's caliper, they are genuine, 100 mm pitch caliper, ex. ducati to be exact, with stock pads, right now, i'm still waiting from my friends to let me borrow his Brembo M4 and M50, i hope i can use the same bracket with different kind of calipers...

As for the front rotor disc, i'm using a 320 mm chinesium that i found on aliexpress...

Re: KTM Duke 390 - Ownership Reviews and Experiences

I'm afraid, our members don't sell anything specifically high end components for the Duke, apart from radiator guards, crash bars and nitty-gritty. You have a wide variety of offerings abroad and from international sellers. Coming to your Brembo caliper, is that a genuine caliper or are these the first copy ones? I haven't come across such a design. What was the cost and which pads are you using stock or upgraded, do post some details on the pad setup and the rotor setup.

It isn't a quality issue per se, these things happen on almost all Dukes, given the wrong circumstances unfortunately. These things happen due to the extremely low sidewall thickness of the tire. Mild bends can be tinkered with, but I don't recommend them as hammering can lead to poor structural integrity of alloy even more. You can get them mended at a tire walla, albeit with the pain of losing some paint, as some heat and hammer, and some just hammer it out.

There shouldn't be any other damage apart from this. Do check your steering freeplay just in case, sometimes they can damage the steering bearings and induce a grabby feeling, but that's worse case scenario. Get it checked at your SVC as a precautionary measure. Keep your observations posted.

Cheers!
VJ

Re: KTM Duke 390 - Ownership Reviews and Experiences

hi, i've been reading some of the posts in here, but i never posted one before...

i was wondering, is there any possible or anyone in here who sold the parts online? a recommended seller maybe?

ps. just got my brembo attached, feels nice when you hit the lever... but still need some small adjustment on the bolts placement...

Re: KTM Duke 390 - Ownership Reviews and Experiences

So while coming back from work today I hit a pothole. Must be riding at a speed of 40-50 but because it was a nasty one I got home and checked the rims and found them to be bent from two different regions on either side of the tyre.

Is this a quality issue? Has anyone faced a similar situation? What other damage I should be wary of? Solutions? Please help.

Re: KTM Duke 390 - Ownership Reviews and Experiences

Google throttle body cleaning for the Duke 390. If you're a DIY guy, it's pretty much easy. If you find you lack the tools or worried about the finer details, your SVC can do it for you.

Cheers!
VJ

Re: KTM Duke 390 - Ownership Reviews and Experiences

no,5000 kms it must he changed for better fuel flow.

Re: KTM Duke 390 - Ownership Reviews and Experiences

The recommended interval is 15k only.

Re: KTM Duke 390 - Ownership Reviews and Experiences

air filter I changed thrice.
for throttle body if anybody knows about the DIY ,please let me.know

service centre charges alot and plus their work is in hurry .
if no DIY then I will get it done at service centre.

Re: KTM Duke 390 - Ownership Reviews and Experiences

Great that you've replaced your fuel filter after such a long interval. What I'd suggest is, KTM sells the service kit that includes, oil filter with O ring, air filter and inline fuel filter, costs 550~ rupees approximately, which I'd have recommended at this juncture. Nevertheless, I'd recommend you to replace your air filter, spark plug and clean your throttle body if feasible.

Cheers!
VJ

Re: KTM Duke 390 - Ownership Reviews and Experiences

replaced finally after 14800 kms ,
service centre didn't care to replace.
finally after odd 2 hours.
got it done with tool kit

Re: KTM Duke 390 - Ownership Reviews and Experiences

Hi Raju, great to hear from you. The reason your bike is struggling to start after the engine has warmed up can be due to a faulty exhaust valve decompressor arm? I am guessing it so. Summating from it, it can be normal wear and tear on the exhaust cam and the decompressor arm which can cause the starting issue once the engine is heated up or requiring a little gas. I'd recommend you to check your decompressor mechanism along with the replacement of the piston on the forthcoming project.

Cheers!
VJ

Re: KTM Duke 390 - Ownership Reviews and Experiences

First of all, sorry for the late reply gentlemen.

The idling is fine. But the starting is erratic. The bike starts perfectly the first time but if I turn it off and start again it does not start. It just keeps cranking and starts only if the throttle is opened. That too after repeated tries. Went for a 100 km ride last Sunday and everything felt good, and the good thing was that it never turned off when I changed gears from third to second. It used to happen at least 3 or 4 times but not even once this time. I guess the throttle body cleaning really worked.

Thanks for checking the video and confirming Vijay sir. Went for a long ride last Sunday and the temps were all OK.Except for starting issue the bike felt good. No more vibrations on the foot pegs. I also did a compression test(warm and cold) and I got a value of 30 psi. Will a bike even start with 30 psi compression? I tried it with the throttle open and the air filter out but still only 30 psi. I'm confused here. I went through the thread and looks like 5.5 bars(79psi) is the accepted value for the duke with decompression lever. I always get around 2 bars(30psi). Didn't do a wet test.

I also cleaned the throttle body and injector(battery and spray method) completely. Removed all the sensors and cleaned all the ports.

You are right about the piston though. I should've replaced it while I had the chance. This is a project for next month if things don't improve.