PowerPig! KTM Duke 390 - October 2014


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DIY time

View attachment 249863

Hoseclips were bit messy to remove.

View attachment 249860

In place.

View attachment 249862

Fuel quality. Right old filter, left new filter.

View attachment 249861

Old filter was Discover had more pleats.

View attachment 249865
View attachment 249864

4.5k old 7100

View attachment 249866

Strainer not dirty like before. Think no on ever cleaned it.

View attachment 249867

300v

View attachment 249868

Soaked filter.

View attachment 249869

Filled.

View attachment 249870

Leveled.

View attachment 249871

Service reminder reset.

View attachment 249872

Design disaster. Rubber keys started disintegrating.

View attachment 249873

Temp fixed with 3M lamination film. Searching for used meter to swap casing.

View attachment 249874
DIY time

View attachment 249863

Hoseclips were bit messy to remove.

View attachment 249860

In place.

View attachment 249862

Fuel quality. Right old filter, left new filter.

View attachment 249861

Old filter was Discover had more pleats.

View attachment 249865
View attachment 249864

4.5k old 7100

View attachment 249866

Strainer not dirty like before. Think no on ever cleaned it.

View attachment 249867

300v

View attachment 249868

Soaked filter.

View attachment 249869

Filled.

View attachment 249870

Leveled.

View attachment 249871

Service reminder reset.

View attachment 249872

Design disaster. Rubber keys started disintegrating.

View attachment 249873

Temp fixed with 3M lamination film. Searching for used meter to swap casing.
DIY time

View attachment 249863

Hoseclips were bit messy to remove.

View attachment 249860

In place.

View attachment 249862

Fuel quality. Right old filter, left new filter.

View attachment 249861

Old filter was Discover had more pleats.

View attachment 249865
View attachment 249864

4.5k old 7100

View attachment 249866

Strainer not dirty like before. Think no on ever cleaned it.

View attachment 249867

300v

View attachment 249868

Soaked filter.

View attachment 249869

Filled.

View attachment 249870

Leveled.

View attachment 249871

Service reminder reset.

View attachment 249872

Design disaster. Rubber keys started disintegrating.

View attachment 249873

Temp fixed with 3M lamination film. Searching for used meter to swap casing.

View attachment 249874
Hi Deville 56,
Check out this video to fix these speedo buttons
 
Thread Starter #197

deville_56

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Hi Deville 56,
Check out this video to fix these speedo buttons
Good idea, but replaced the cover. There was another video, fixing with black gasket maker. Bought gasket maker for that, but never got time to try.

January 2021 - New Speedometer Cover

Been following MySpare Market on both Facebook and Instagram for some time, but was skeptical about purchasing from an unknown seller, but when he listed this part, couldn't resist and straightaway ordered with some other parts. Dealing was neat, sent message confirming availability and price, transferred money, shipped same day, received intact. He offered new, refurbished, and used parts for KTMs and other brands, with discount and free shipping.

Now coming to the part, some rubber parts of the KTM are crappiest. The speedometer shell is mostly covered with rubber and the switch part disintegrates in no time. Mine was the second cover scavenged from another speedometer. Shell was not available as child part and new speedometer assembly costs 8 to 10 grands. Similarly, the indicators also falls off without any impact over time.

KTM Refurbished Meter Shell - ₹ 850.00
(Listed both new and refurbished shell, but I never understood the difference. Item received was unused)

2020-12-26 14-32-18.jpg


Flip the headlight and disconnect the meter to remove.

2021-01-03 16-33-26.jpg


Old disintegrated shell.

2021-01-03 16-40-45.jpg


Old vs new shell.

2021-01-03 16-45-09.jpg
2021-01-03 16-45-34.jpg


Screw holes look virgin.

2021-01-03 16-45-56.jpg


Compared to marks from old one.

2021-01-03 16-46-12.jpg


Meter minus cover.

2021-01-03 16-47-17.jpg


New shell installed.

2021-01-03 16-49-14.jpg
2021-01-03 16-55-30.jpg


Fixed on bike.

2021-01-03 16-59-11.jpg
 
Last edited:
Joined
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Messages
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Location
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Good idea, but replaced the cover. There was another video, fixing with black gasket maker. Bought gasket maker for that, but never got time to try.

January 2021 - New Speedometer Cover

Been following MySpare Market on both Facebook and Instagram for some time, but was skeptical about purchasing from an unknown seller, but when he listed this part, couldn't resist and straightaway ordered with some other parts. Dealing was neat, sent message confirming availability and price, transferred money, shipped same day, received intact. He offered new, refurbished, and used parts for KTMs and other brands, with discount and free shipping.

Now coming to the part, some rubber parts of the KTM are crappiest. The speedometer shell is mostly covered with rubber and the switch part disintegrates in no time. Mine was the second cover scavenged from another speedometer. Shell was not available as child part and new speedometer assembly costs 8 to 10 grands. Similarly, the indicators also falls off without any impact over time.

KTM Refurbished Meter Shell - ₹ 850.00
(Listed both new and refurbished shell, but I never understood the difference. Item received was unused)

View attachment 285719

Flip the headlight and disconnect the meter to remove.

View attachment 285720

Old disintegrated shell.

View attachment 285721

Old vs new shell.

View attachment 285722 View attachment 285723

Screw holes look virgin.

View attachment 285724

Compared to marks from old one.

View attachment 285725

Meter minus cover.

View attachment 285726

New shell installed.

View attachment 285727 View attachment 285728

Fixed on bike.

View attachment 285718
Nice now it looks brand new[clap]
 
Thread Starter #199

deville_56

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January 2021 - Husqvarna Indicators

Another part bought from MySpareMarket along with the meter cover. He usually lists original KTM type 1 and 2 as well as their replicas at discounted price, but one day these popped up and ordered a pair as the listed price was cheaper than stock indicators, got a pair for ₹ 800.00 at free shipping.

2020-12-26 14-31-58.jpg


Made by Varroc, part number JU401016. KTM ones were Rinder make, which suffered quality issue on long run.

2020-12-26 14-44-52.jpg


SMD Leds look prominent unlike the diffused look of stock ones.

2021-01-03 11-58-40.jpg


Same connector and mount, 100% plug and play.

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Issue with stock ones, rubber quality poor and falls off on its own and resistant to superglue.

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Installation. Got to remove the underside panel, 8 bolts and 4 screws.

2021-01-03 12-02-44.jpg

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Just undo the nuts and disconnect and pull out the wires.

2021-01-03 12-06-53.jpg


Inside the sleeve of the wire is some protection circuit, which makes it a bit tricky to pull out, which is not present in the Husky unit.

2018-03-19 20-49-19.JPG


Stock vs Husky.

2021-01-03 14-32-00.jpg
2021-01-03 14-36-42.jpg
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Both installed.

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Husky off.

2021-01-03 14-45-53.jpg


Husky on. Bright enough.

2021-01-03 14-45-56.jpg


Replaced the broken front one using undamaged rear LH unit.

2021-01-03 16-33-19.jpg


Cracking issue. Both indicators broke at the same point in same pattern. Similar was the quality of the speedometer case rubbers. These were inert to FewiKwik and no way was sticking together, managed to fix with prolonged exposure of glue after removing.

2021-01-03 16-59-42.jpg


Fixed. Contacted him for another pair, but sadly whole stock sold out. No chance of restock in the near future.

2021-01-03 17-23-02.jpg

The outcome.

2021-01-03 17-23-23.jpg
 
Thread Starter #200

deville_56

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January 2021 - Finally Gets Back Original Cover

Wash time.

2021-01-25 11-09-52.jpg


We actually placed order for original KTM bike cover during first service and lost hope after multiple followups. After almost a year, the spare guy rang up, asking to pick'em up. We also ordered a side stand bypass contraption as well, which sadly didn't make it through. It was my engagement round the corner and all of were busy and was left in the cupboard in original packing and completely forgotten.

Two years later, Kinetic was gathering dust and accidentally found the cover and it was doing duty on Kiney since 2017, gathering dust and dirt and grease and whatever.
During lockdown 1.0, Duke and GT was covered with old torn cover of Beat. Was expecting lockdown 2.0 and was checking the covering requirements and felt PowerPig! deserved its original cover.

By this time, the cover had turned brown with all the dirt and black and many places with the greasy parts kept over.

2017-10-27 07-34-28crop.JPG


It was a Herculean task getting it back to its original glory. Dipped in high-concentric Surf Excel solution for hours and did multiple rinses. Except the black spots, its almost cent percent clean. It's a good quality cover with KTM printing in black on both sides and front and reflector stripe on sides.

2021-01-25 16-12-58.jpg


Made by Polco India. Came in exact same orange colour storage pouch, which again got misplaced.

MRP ₹ 800.00. Part number 75324297.

2021-01-25 17-03-34.jpg


Parked with original cover.

IMG_20210427_195957.jpg
 
Thread Starter #201

deville_56

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February 2021 - Adjustable Brake Lever
The brake lever was bent for some time and the clutch lever had too much play and needed replacement. Had interest in adjustable one from new 390, but no stock at dealer and price was like ₹ 2.2k for a pair, for which price we could buy 2 pairs aftermarket levers. Scrolling through Instagram stories caught eye on MySpareMarket's story of adjustable brake levers at discounted price. Stock lever was ₹ 1,829.00 and this guy was selling for ₹ 799.00 inclusive of shopping, a whopping ₹ 1,030.00 difference. But no clutch lever with him. Ordered right away.

The package.

2021-02-10 12-00-10.jpg
2021-02-10 12-00-30.jpg


Adjustable levers. Part number - 36JY0186.

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5-Step adjustable.

2021-02-10 12-04-02.jpg


Old bent lever.

2021-02-10 21-21-54.jpg


Removing is pretty easy, just the nut and bolt business.

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Brake plunger.

2021-02-14 17-39-12.jpg


Unconventional brake light switch.

2021-02-14 17-39-41.jpg


Comparison. New one comes with steel shim/insert in the hole, which reduces/eliminates ovalling.

2021-02-14 17-36-25.jpg


New lever in.

2021-02-14 17-33-50.jpg


Setting 1, farthest.

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Setting 5. Closest. Lever is more than a centimeter closer. Easier for short-fingered guys like me.

2021-02-14 17-43-00.jpg


Setting 1 in action.

2021-02-14 17-42-36.jpg


Setting 5 in action. Will get a psuedo-spongy feel due to the closer travel.

2021-02-14 17-42-43.jpg


These fits most of the Pulsar family like Dominar, 200NS, RS, 220, etc. Now in desperate hunt for adjustable clutch lever.
 
Thread Starter #202

deville_56

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April 2021 - Misc Update

Missed the OE bolt at one of the services and replaced with a commonly available MS Allen bolt and it rusted up in no time. Almost all vendors had MS bolts only. KTM dealer never stocked any in over a year's time.

2021-04-12 15-35-03.jpg


@bikerharis one day found a shop selling SS bolts and a good deal of interesting stuff remote from the city, run by an enthusiastic chap. He had a couple of scale models on his table [evil] . Direction > RV Group - Engineering Arena

M6x15 Allen Bolt - ₹ 8.67/each. Interestingly, he gave detailed bill. Stock one's head was a bit shallow compared to the commercially available one.

2021-04-12 15-24-02.jpg


Replaced with MS bolt. Peace of mind. OCD with missing/wrong bolts [frustration]

2021-04-12 15-35-47.jpg


Fork leak getting severe. Seal out of stock at KTM. Dominar seal fits according to @varunkumar2910.

2021-04-12 15-36-05.jpg
 
Thread Starter #203

deville_56

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April 2021 - Adjustable Clutch Lever

Finally, got hold of the adjustable clutch lever from 2017-current Duke 390 after multiple visits to dealer.

Adjustable Clutch Lever - JY161008 - ₹ 338.00

2021-04-13 09-22-17.jpg


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Made by Minda. Like the brake lever, there is steel shimming in the bolthole to prevent oval'ing.

2021-04-13 09-24-54.jpg


Replacement was simple. Loosen the adjuster.

2021-04-13 09-31-39.jpg


Remove clutch switch.

2021-04-13 09-31-46.jpg


Removed the holding bolt and nut. Voila, lever comes off.

2021-04-13 09-32-41.jpg


Comparison of adjustable vs non-adjustable.

2021-04-13 09-33-24.jpg
2021-04-13 09-33-33.jpg

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Reverse the process for installation. Adjust free play.

2021-04-13 09-38-00.jpg


Set with position 5, the closest. Clutch operation is much more easier, boon for short-fingered guys.

2021-04-13 09-41-21.jpg


Stock boot fouls with the new lever. Post-2017 390s got a different boot, which according to a YouTuber was available for ₹ 26.00 at dealership, but dealer claims it's part of clutch cable and not available as separate part. Checked 2017 MY parts manual and found part number JG161009, yes, it is available as separate part.

2021-04-13 09-41-57.jpg


Indicator broken for Nth time. Gotta order another pair.

2021-04-13 09-25-44.jpg


Marathon wash.

2021-04-18 17-17-59.jpg


Parked for lockdown 2.0.

2021-04-18 22-53-00.jpg
 
Last edited:
Thread Starter #204

deville_56

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June 2021 - Post-Lockdown 2.0 Startup

As always, battery drained over time. Recharged and reinstalled. Took a couple of cranks, and it started with an exploding sound and died soon showing check engine light. Restarted and the check engine remained and the idle was vague and soon died again.

2021-06-17 19-41-04.jpg
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Plugged in the scanner and gave a scan and no error popped up.

2021-06-20 18-20-40.jpg


Disconnected and reconnected battery and cranked once more and voilà, back to life, spitting smoke.

2021-06-20 18-23-39.jpg


Broke

2021-06-22 23-24-42.jpg


and fixed. Hoping, it's the last time, waiting for Husqvarna indicators to get restocked.

2021-06-22 23-31-16.jpg


Boys getting together after a long gap.

2021-06-20 18-29-32_2.jpg
 
Thread Starter #205

deville_56

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August 2021 - ABS - Ray of Hope

Our bike's odo stopped ticking at some 48k km due to the dead ABS pump, and it's an annoying feel using the bike without odo, because of which use of the bike was much restricted, not because of the fault of the bike, but our uneasiness using it without the track of miles. A complete check was done once at MotoNerdz with scan showing showing no clue and sensor and meter swaps and sensor ring replacements without any positive outcome. Only items left swapping was the ABS pump and wiring kit, which was a difficult task, so they zeroed it's either of them is the culprit (or both). I did a complete continuity check of all the wires and everything was okay.

In the meantime, Fayad, a friend of mine, whose RC390, which was of the same vintage as our Duke, had the same issue. We both had been searching for used modules without success and one day the MySpareMarket guy posted a couple of ABS pumps for sale, and we decided trying our luck. The issue with Indian brands (read Bajaj here) was constant upgrading with umpteen non-reverse-compatible (or sometimes-compatible-by-god's-grade) parts with infinite part numbers. He had some 8 part numbers in stock. Dug deep through Google for compatible ones, and it was even more tricky with over 15 part numbers for Duke/RC/RS/Dominar combined. We were confused as to which one to buy. Even the same model year RC and Duke had different numbers and multiple numbers used in same year and same part numbers shared over years, depending on country of sale [frustration]. Contacted many KTM mechanics and even the seller (and his mechanic) and the KTM service and spare guys and no one had a clue of it. They were more confusing as well, half of them said any of them will fit, half were like only the specific one will fit.

Played akkad-bakkad and chose 90542031044, which was the closest from our stock numbers, 90342031000 for Duke and 90542031000 for RC. It arrived just before lockdown 2.0 and sat with Fayad for 2-3 months. We didn't check it either before the one-month warranty offered.

2021-07-31 09-57-07.jpg


He entrusted me for installation and as a bonus, I could test that on my bike and confirm what's gone before order one for us [angel]. Tested the unit on his RC, and it worked flawlessly.

2021-08-03 16-30-20.jpg


Our plug has been long disconnected, so testing wasn't hard. (For RC, had to pull the plug out and tagged on frame for testing).

2021-07-31 00-24-55.jpg


Plugged and tied it on the crash guard with a cable tie and took a test drive. Meter still dead showing no reading.

2021-08-03 18-26-31.jpg


By instinct, checked the ABS ECU fuse (third 10A from left) and it was blown. Replaced with spare. Repeated TD and no signs.

2021-08-04 15-04-14.jpg


There was a pair of fuses outside the main fuse box, 15 A for ABS hydraulic unit and 25 A for ABS return pump. (These fuses are missing in later model years). Checked and both of them were blown. Replaced them with spares. Repeat TD and victory, ABS warning light was gone and speedo was working [clap]. Meter was intermittently showing 0, which has been a long-standing issue before the ABS pump blew up and indicated faulty stator coil.

2021-08-04 15-04-07.jpg


Checked stator resistance between all three terminals.

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All were within the prescribed rating of around 1 Ω. Then checked continuity of each with respect to ground and was open. Stator was okay.

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Checked stator voltages similarly across all three terminals and was near the recommended range, 28V AC.

2021-08-08 11-15-19.jpg

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Checked charging voltage and 14.1 V DC at the accessory socket (el cheapo voltmeter module)

2021-08-08 11-17-01.jpg


and 13.91 V at the battery on multimeter. With stator and ABS pump working fine, decided to go ahead with purchasing one for the PowerPig!

2021-08-08 11-19-46.jpg


Did installation on Fayad's RC390 late night, but needed replacing copper washers, so carried over to next day. Worth a DIY thread, couldn't find one in any forum, will post later.

2021-08-01 22-44-45.jpg


Since everything was out, replaced the coolant as well. Mission was successful, his ABS is working 100% fine with no error, rode it for 25 km to make sure. Replaced his rear tyre with Apollo Alpha H1 and returned the bike. Happy ending.

2021-08-02 17-29-54.jpg
 
Last edited:
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Here, my attitude is similar, but what I try to do is club all the works and get it done in service centre. But risking your time, search for a part extensively (Better than the service centre fellas, who doesn't have any clue or info about the ride), and getting it done with proper know how is ...no words[cheers].
 
Thread Starter #209

deville_56

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August 2021 - Husqvarna Indicators (again)

MySpareMarket restocked the Husqy indicators and ordered another pair right away for front. More details on above post. ₹ 850.00 for a pair including shipping.

2021-08-04 13-46-25.jpg
2021-08-04 13-46-41.jpg
2021-08-04 13-46-49.jpg
2021-08-04 13-47-00.jpg
2021-08-04 14-08-39.jpg


Broken front indicator(s).

2021-08-04 14-22-52.jpg


Fixed previously with superglue. It breaks at all 3 points, one after the other, each indicator breaks 3 times [lol]

2021-08-04 14-23-02.jpg


Installation.

2021-08-04 14-24-07.jpg


Stock vs Husqvarna in front.

2021-08-04 14-28-30.jpg


Installed.

2021-08-04 14-52-54.jpg


Got a clean swept back look.

2021-08-04 14-55-19.jpg


Hazard mode [evil], just for the snap.

2021-08-04 14-53-05.jpg
2021-08-04 14-52-28.jpg


Connector for security system. After-market strobe flashers connects into this, plug-n-play.

2021-08-04 14-50-31.jpg


Short the grey and green and turn on indicator and all 4 will blink.

2021-08-04 14-53-27.jpg


Handy engine immobilizer [lol]. Remove the connector and bike won't start. Can be of use while on road trips and parking outside hotels. KTM original security system is not available in India, but aftermarket units can be connected without messing with the stock wiring through this port.

2021-08-04 14-50-41.jpg
 
Last edited:
Thread Starter #210

deville_56

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August 2021 - Fork Overhaul and Cone Set Replacement

Leaking fork and tight steering were long pending jobs, kept extending as the bike wasn't being used due to ABS issue. Thought of fixing the issues and put it back to regular use.

During the initial lockdown when editing Google Maps, stuck on this relatively new garage, Prime Motors, barely a kilometre away from home. Reviews were positive and mostly 200 and Dominar owners who were fed up with Bajaj service. Going through their gallery and reviews, spotted some KTMs too Fast forward to present time, checked with them whether KTM parts are available there for servicing the Pig! and they said they can arrange if needed, but won't stock KTM parts. Fixed a date and left the bike with them.

Parts:
Fork Oil Seal x1 - ₹ 366.00 (Replaced only the damaged one, preferred replacing both)
Steering Cone Kit - ₹ 396.00
Fork Oil - ₹ 275.00 x 2
Consumables - ₹ 80.00

Labour - ₹ 900.00

Total - ₹ 2292.00 (rounded to ₹ 2280.00)

That place was filled with 200NS/AS/RS.

2021-08-09 10-05-06_1.jpg


We couldn't make it on the day, picked up next day.

2021-08-10 11-29-09.jpg


Test drive before (payment and) delivery. Quality of work was good except abundance of grease. I always wonder why mechanics love flooding joints with grease.

2021-08-10 11-34-23.jpg
 

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