Re: KTM RC 390 Ownership Experience

The oil filter compartment, it's cover and water pump cover are all located on the RHS crankcase. Either the engine has to be split or the broken bolt should be dealt in situ (would require an extremely experienced and patient lathe guy).

Re: KTM RC 390 Ownership Experience

You're right, I did confuse that one myself. The clutch case is separate and the oil filter is with the center case. Yes, you can use an extractor, if you are careful enough not to damage the diameter of the bolt insert. If you can drill and get the bolt out with an extractor, you can use the old bolt size. But if you have a thread that's gone too, you'll have to go for a bigger sized bolt. Stainless bolts are strong and don't slip easily as the OEM cheese bolts.

Cheers!
VJ

Re: KTM RC 390 Ownership Experience

The only bolts that are known to break off are the ones holding the crash guard. All other bolts are of normal quality. It looks like whoever did the service earlier had over-tightened the bolts resulting in them breaking off when you tried to undo them. Let's not blame component quality for shoddy labor.
A failed O ring can leak lots of oil, I've seen this happen myself on a couple of friends bike.. in your case bad luck the bolts broke while removing them. Get new oem bolts and don't over tighten them (once they seat, just a 1/4 turn max should be good enough.. or torque spec if you have a torque wrench)
I think a decent welding or lathe shop should be able to help you extract the broken bolt, i've seen it being done to extract broken bolt from the frame . Pl check with your svc or a local mechanic for guidance.

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i've seen worse from a failed O ring, as much as 300ml leak out and form a pool under the bike. just a failed O ring no broken bolts.
the bike in question was [MENTION=70615]Ajay Vishwanath[/MENTION] rc200 a couple of yrs ago.

Re: KTM RC 390 Ownership Experience

Oh that's bad, indeed. Though I have observed mild leaks and weeps due to failed O rings. It's surprising to know such much oil leaks with the O ring in place, could it be poorly torqued bolts is anyone's guess. But, it's strange how these leaks escalate quickly.

Cheers!
VJ

KTM RC 390 Ownership Experience

Couldn’t find a left handed drill bit or an extractor here in lko (people don’t even know what these are)
Had to take it to a welder as lathe weren’t doing it

The welder took the bolt out but f’ed up the surface

Oil still still leaks (like a person whose about to finish his peeing session) but at least the cap stays on and I could take it to the svc

Tried compunds and other stuff but no use

Changed the O ring twice but surface isn’t flat for it to be seal tight

All the oil has been thrown out in the past 3 days (1300 down the drain)

Adding mineral oil and taking it to the svc tomorrow (would keep topping it up on the way)

I’m literally about to cry now

Re: KTM RC 390 Ownership Experience

QuadrupleagentZ, that's bad. Escalate this issue to KTM. This is not just a KTM 390 issue.I faced the exact same issue in my 200NS where in the bolt got broken and stuck inside after an oil change and oil was leaking. Luckily for me, took it to lathe and they removed the stuck bolt without any damage. I'm sure this problem is due to the crap quality bolt that KTM/Bajaj uses. This part is a very critical one. I think, it's the RHS crankcase cover. At least in critical places/parts like this, we expect Bajaj/KTM to use a good quality bolts/screws. But, that's not the case.

Now, I have replaced all these bolts with a genuine TVS one.

Do keep us posted how KTM/Bajaj deals with this issue

Re: KTM RC 390 Ownership Experience


Already replaced the bolts with high quality ones, but the damage is done. It's not the cover that has been damaged and that's the problem. I could have easily replaced the cover. It's a part of the engine that's been damaged.

And I don't know how to get this fixed other than replacing the downside engine compartment and that would cpsy a shit ton of money.

Will send an email to KTM about this quality issue

And yes there is a quality issue cause I just broke one of the bolts one this bike with my bare hands yesterday.

Re: KTM RC 390 Ownership Experience

Just as I told you earlier right. There are high chances of people ruining the casing when doing such things. The art of taking out a broken bolt or rethreading without screwing up the casing is something left to professionals. I see, the lip of the oil filter is scored. Now, what happens is, your oil filter cap won't sit flush with the engine casing, irrespective of how much you torque the bolts, because the sealing lip is damaged and oil "WILL" weep and leak and will worsen if you ride the bike really spiritedly and can in fact cause a seizure due to low oil. You can either replace the the center casing for a new one or glaze the surface to evenness, which again should be done by a professional and then try your luck. Just exactly what I predicted would happen. Lo and behold, I'd recommend you to replace the casing for good, because no point removing and installing again and again and not getting the results.

Keep your observations posted.

Cheers!
VJ

Re: KTM RC 390 Ownership Experience

33k km, 2.8 years and the bike is still running great. Both my earlier Yamaha R15 V2s didn't make it past 25k km (all the claims of quality & bulletproof engine is all bollocks). RC390 has already exceeded my expectations and i think it might go well into late 30's or even 40k km.

Re: KTM RC 390 Ownership Experience

and ever since then, I've ALWAYS replaced my O ring.. those svc guys hardly replace them. just 25 or so rupees.. it's better every year than surprise 300 ML of oil loss..

Re: KTM RC 390 Ownership Experience

30K kms to early and very less mileage to barely have any impact on the engine. Max you might need is a top-end rebuild around 40K kms like say valve job, de-carbonation, timing kit replacement and adjustment etc etc.

If bike was maintained really well with it will easily cross 50K kms before needing a full engine job.

Re: KTM RC 390 Ownership Experience

There's a lot of conflicting info on this. But i have found out through experience that everything else being equal, the life of the engine will depend upon how you ride and specifically what % of time the engine spends in the top 30% of it's rpm range. For my kind of riding (as you can tell from the video i posted) i only expect around 50-60% life compared to an average rider. So, by that measure the KTM is doing very good.

Re: KTM RC 390 Ownership Experience

Indeed. The fact that I almost recommend everyone to replace the nitty-gritty O rings after service, validates your point.

I sincerely wish your bike stays that way, and as a matter of fact, KTM do last long, provided it's given the extra attention that it needs. Apart from that, it's a punchy maniac. But, as a note, no point comparing this to a Yamaha or a Honda, purely for the sake of it. They do last waay long, but it's just bad luck in your case with the Rs. In your case, your bike KTM has exceeded expectations, but there are many who's didn't even last 20k without a major work or pestering repeated issues and some who have a smooth sailing like you. Enjoy the KTM, and wish she keeps that smile on your face for a long time to come, which she will.

Your escalation would fall to deaf ears, at least with the problem we have on hand. It takes quite a while for them to respond and act back based on actual phone calls and this is for a troubled brand new bike. Yours is an old bike, and we call them to complain about bad quality and what not, they won't bat an eyelid. All they'll assure you with us, sir yes saar, sorry saar, noted saar. They can and will turn it against you since you've taken it to a welder and ruined the surface, here they have an upper hand, purely because they can.

Anyway, don't bother about the money, get a loan if you have to, and get that center case replaced. It's better getting it replaced rather than end up seizing your motor, and that definitely will cost you a urinary organ.

Cheers!
VJ

Re: KTM RC 390 Ownership Experience

Actually, there is. See, i am not like those motorcycle reviewers on TV or Youtube who ride a bike for an hour and then spout their opinions. I have owned and ridden not one but two R15s, properly, for two years each. Both bikes were well maintained, both deteriorated in the same way. And what i am saying is that the quality of this bike is definately overhyped.

Yes the KTM has had several well known issues, head gasket failure, water pump seal failure etc. And for someone facing those issues i can their understand their frustration. I have had a few issues too but thankfully none engine related. I have come to realize and accept that there is a certain risk involved with this bike. One thing though, the boffins and designers at KTM must be some of the best in the business, because inspite of the faults they have built a cracker of a bike!

KTM RC 390 Ownership Experience

It’s not about the money
Just have a special connection to this one

Dad’s saying to buy a new one but won’t want to.

The problem is that KTM here actually rips people off


Saw them once when a customer came to buy a can of chain lube and cleaner

These guys took the mrp sticker off and sold it to them for 2,000( double the price)

They usually go and buy cheap ass covers for 100 bucks and just stick a KTM LOGO on it and sell it for 800

That’s why I just don’t like going to their svc so much and prefer to do stuff by myself

Gave it for service and look what happened 🤦🏻*♂️

Most of the svc here are getting shut down cause they can’t turn a profit

Any idea for the cost of the engine case to be changed so that they don’t rip me off?

Can the right side be changed individually or do I need to change both of them as it shows a common part number for it

Thanks for the prompt replies btw


Edit: saw some posts online that JB Weld works good on these stuff. Anyone tried it?