PowerPig! KTM Duke 390 - October 2014


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UPS charger reminds me of my old days. Just a warning, Those UPS outputs are not isolated from the mains. It could give a nasty jolt. Ask me how I know. [roll]
 
Thread Starter #184
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May 2020 - New foot pegs.

Due to Corona shortage, no signs of KTM spares any time soon. Thanks to @varunkumar2910, who swapped a 200NS footpeg on a KTM to check the fit for me. Now gotta find 200NS spare instead of KTM ones.

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As usual, the neighbourhood spare shop, Spark Automobiles, came to the rescue, but with a duplicate one. Wanted to buy only the replacement for broken one, but since there is no specific time frame for KTM parts to come, decided to change both sides. Brand was Zodix. I bought 14T sprocket for FZ of the same brand. Seems they make replacement parts for most bikes and quality seems good. Foot rest per side cost ₹ 130.00. Original 200NS peg without the fittings costs that much. This included all the fittings including the spring.


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No nut and bolt. Removed the splint pin and pulled out the pin and broken part removed.

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New one.

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Installed. Retained the original KTM springs as 2000NS springs were not slotting in properly to the hole.

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Original 200 NS ones have longer curb feeler.

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LH replaced as well.

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Original KTM foot peg.

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More damages from the crash.

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Thread Starter #185
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May 2020: New Front Tyre - Apollo Alpha-H1 110/70ZR17

Been running on bald tyre due to Corona shut down and with relaxation and tyre shops opening, got hold of an Apollo Alpha-H1. It's a great tyre indeed. Been using it on rear. Got for ₹ 4,535.00 (MRP ₹ 6,499.00) from Nayana Tyres.

Got it changed at tyre shop itself instead of removing the tyre at home and taking to tyre shop. Work was neat without any drama.


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Old Michelin Pilot Street.

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Michelin's latest offering, Road 5. Soft compound like Metzler and Diablo Rosso II.

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TVS's new option.

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New tyre.

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Z rated.

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Made in India. November 2019 make.

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Thread Starter #186
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May 2020 - Weird-acting seat lock

It was behaving stupid, sometimes it will unlock, sometimes it won't. Disassembled and checked and as expected, cable was popping out of the slot. It won't stay in despite multiple attempts.

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Managed with a cable tie. Part was not available at KTM. Facing acute shortage of spares since lockdown. Gotta clean up everything at the time of cable replacement.

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Thread Starter #187
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May - June 2020 - Misc additions/replacements

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Yamaha OE accessory mobile holder. Comes as accessory for R15 V3. Since speedometer died for ever, came handy for mobile speedo apps.

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Replaced broken plastic rivets.

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Peeping tom.

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Reinstalled the long-lost and found 12 V port. Note the rusting clutch cable.

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Getting washed in a long time.

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Clutch cable, as mentioned above, was rusted badly and was frequently getting stuck. Annoying at signals and U-turns. Clutch wasn't fully getting released causing neutral effect and grumpy faces. Hardly any spares available at KTM due to COVID situation.
 
Thread Starter #188
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August 2020 - Bizarre moment

PowerPig! has been giving more troubles lately. Battery frequently discharges despite new battery and proper charging. Removed battery and put to charge with Bosch C7 borrowed from @vishnu vichu as we doubted the other SMPS and UPS were not doing their work properly. Plugged it to the bike and boom. Bike got engulfed in smoke. Disconnected immediately. Thought connected battery in wrong polarity and fried the ECU. Everything was right and bike was also off.

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Didn't check for anything then as there was no hope. In the evening, removed tank and checked and no smell or burns in the ECU, moment of relief. Checked for the source of smoke and voila, it's the already dead ABS controller. Disconnected the ABS and there was smokey-smelling liquid inside the connector. I think the controller itself or that liquid shorting was draining the battery frequently. Anyway, permanently disconnected the ABS. Connected the battery and cranked and Pig started as usual. No more drama.

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Thread Starter #189
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August 2020 (Almost September) - Finally got the Clutch Cable

Clutch cable, as mentioned above, was rusted badly and was frequently getting stuck. Annoying at signals and U-turns. Clutch wasn't fully getting released causing neutral effect and grumpy faces. Hardly any spares available at KTM due to COVID situation.
Waited almost 3 months for such a vital part due to COVID-induced parts shortage.

Clutch Cable - JY161200 - ₹ 172.00

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Thread Starter #190
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August 2020 - Clutch Cable Installation.

Old rusted cable.

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Remove the head light.

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and then the weirdo clutch switch. Never seen this kind in other bikes than the Pulsars. It is mounted from bottom and slots into notch under the clutch lever. Removing lever without removing the switch would damage it. Last time changed cable without removing the lever.

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Loosen up the cable.

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Then the lever (or cable alone).

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Track the routing before removing. It's a bit tricky behind the crash guard.

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Remove from the clutch side and take out the whole cable.

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The lever hole became oval. This causes too much play and impossible for proper clutch adjustment. Lever out of stock at dealer. Need both clutch and front brake levers. Heard P220 levers would suite. Also checking for new 390 adjustable levers.

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Made by Minda.

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Old vs new cables.

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Routed the cable properly.

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Connected at both ends.

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Installed the clutch switch.
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Adjusted for proper play. I believe this is the proper way of installing the adjuster nuts. Every KTM I saw had the nuts on the same side.

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Thread Starter #191
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August-September 2020

Yamaha OE mobile holder. Doing well post 4 months of use. No vibes.

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Screws started rusting.

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Can be aligned vertical or horizontal.

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Holding capacity can be adjusted with the thumb screw behind. Aspect ratio maintained [lol]

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12V socket sits just fine.

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New trouble in the making - Low oil pressure [frustration]

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Thread Starter #192
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November 2020 - Messing with oil level

Oil pressure error disappeared on its own. Usual weekly warm up continued since FZ and Dio were on primary duty. Took it for a long spin and after 10-15 km, the oil pressure warning popped up and stayed on.

Back home, cooled the bike and warmed up and checked the level. Level was low. Took 300 mL to reach normal level. Happy and peace.

Not really. Started the bike after an hour and [cry][cry]. Oil was not disappearing from the window. So oil is now being pumped. Drained that 300 extra milliliters. Repeated again and again after complete cool down and things were totally weird. Sometimes it will disappear, sometimes it won't, sometime it will froth. Since not to safe to run without oil, parked it for the time being.

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Thread Starter #193
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December 2020 - New Air Filter

On checking the history, found in horror that air filter, fuel filter and spark plug was not changed in 2 years. Lost the track due to the non-working speedometer and the minuscule use and of course the pandemic. Luckily got them from the dealer. Now parts supply is kinda normalized.

Decided to give the bike to garage for rectifying the oil pumping issue. At the same time, RC390 of my close friend developed same issue. Coincidentally, both bikes were of similar age and of similar odo reading. Fault was debris in the pump and a faulty oil pressure switch.

Air Filter - JG581004 - ₹ 290.00

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Damage caused by stress from the seat.

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Old vs new.

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Installed.

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Inferior quality. Cracking mounts. Fixed the outside crack earlier.

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The battery was completely drained due to disuse. Charged with the 12V 5A adapter. After disconnecting the blown ABS controller, it is not discharging as quickly as before.

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Thread Starter #194
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December 2020 - Salvation

Called up a couple of flatbed operators for rates to haul it to the garage, but just started it and no warning and bike was behaving normal with proper oil circulation. Rode it straight to MotoNerdz without any second thoughts. The other RC390 had a block in the channel, so Pig's symptoms were similar. Duke got 2 pumps on either side. Cleaned the pumps and reused the same oil. Oil was relatively fresh and was still red. They filtered using a paint strainer and topped up the balance. Replaced packing on both sides since both sides opened.

Bill:
Magneto Cover Gasket - JY541276 - ₹ 65.00
Clutch Cover Gasket - JY541225 - ₹ 63.00
Motul 7100 10W50 - 300 ml - ₹ 238.50
Labour - ₹ 1,300.00

Total - ₹ 1,666.00

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Back home.

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Oops again. They didn't change oil pressure sensor since it didn't show error then.

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Took back and replaced the oil pressure switch as well.

KTM Oil Pressure Switch - DK101225 - ₹ 148.00
Labor - ₹ 195.00
Total - ₹ 343.00

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Insurance Renewed (October 2020)

Continued with New India.
IDV - ₹ 1,00,000.00.
Total premium - ₹ 3,341.00
Third Party Premium - ₹ 2,323.00
Own-Damage - ₹ 484.00.
NCB - 50%
 
Last edited:
Thread Starter #195
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January 2021 - Fuel Filter

Night vibes

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Fine Fuel Filter - JG171802 - ₹ 84.03
Another forgotten with odo reading part. During oil sensor work, they were complaining of slight missing during idling. Bought this along with the air filter, but didn't install.

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Removed one tube at a time to avoid confusion. Circlips are tight or deformed always making it a mess.

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Installed.

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Up and running.

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Old filter.

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