There is practically no material on the Internet for repairing these KTM motorcycles. Your videos are a godsend. Thank you for sharing this information.
Another super helpful video!! My clutch went this weekend and I was bricking it at the thought of having to change it. Now I know what I'm doing! Thank you!
Masterful work, David! Watching you is like meditation for me. I pray for your well-being so that you can continue teaching us more! Quick question: Would using the quickshifter result in quickly worn clutch plates?
Thank you, much appreciated. A quick shifter is likely to increase wear - it is designed to help win races, not for road riding, so winning is worth the increased cost, but it should not significantly increase wear since there is an ignition cut creating a momentary loss of power at the time it happens.
I was expecting to need at least a clutch basket tool, though I understand you need that for the125, but otherwise, aside from user error putting it back together it was fine! All good now, just need to ride it!
Great channel! I absolutely love how detail your explanations are and how you aim to show every angle with the camera when assembling/disassembling a part! Thanks for all the info! On another topic, I have an issue with my 390 duke, 2017, when riding the bike it goes to neutral for 2-3 seconds for no reason and then reengages the same gear, sometimes it stalls and i have to start the engine again. Any clues what it might be causing this? It is quite anoint and dangerous when riding it. The problem started after an oil change, the oil was over the maximum, but this could just be a coincidence. Thanks in advance!
Thanks. The way motorcycle gearboxes work is very different from say a car gearbox. With bikes the gearbox is always in gear unless it is in neutral - it can't slip into neutral between gears or in gear like a car gearbox can. So if it goes "into neutral", it is most likely the clutch slipping - so when it re-engages it is still in the same gear it was before. If it does it in the same gear repeatedly, it could be a broken gear or worn out gearbox, but not my first assumption. There are many causes of stalling, but in my opinion, the most likely cause is the one that is by far the most unpopular - user error with the clutch. People are really resistant to this one because everyone wants it to be the bikes fault - but this is not a standard road bike engine. What you are telling me is pointing me towards the clutch. I'm going to assume that a motorcycle wet clutch type oil was used and not a car oil because car oils will make the clutch slip. Good luck with the diagnosis!
@@MotoMirius, thanks! I spend a few hours disassembling everything around the clutch and there were no visible wears or problems. I started thinking about the stalling problem, what might be causing it and it turned out that there was a bad connection going from the battery. I changed the cable and now everything seems to be working fine, no stalling, and the bike does not go into neutral and back into gear when riding. : )
Great video David, you always show the job as it is done very simple and it looks like everybody can done it. I have two questions: a) is it need to drain the oil from the bike before start doing the job? and b) I can see that you didn't use any silicone gasket is it necessary to use it or not?. Thanks again and congratulations...!
Thanks Pablo. The reason the bike is on its side is so that you don't spill any oil. No, not necessary to use a liquid gasket and I would not recommend - you could use something like gasgacinch to stick it in place. Be very careful with silicone gasket - it must be one suitable for use with a motorbike engine. If you use the wrong type of silicone you can cause significant engine damage.
Hey @motomirius. I have a problem in my 2018 390 duke. When the engine is cold, pulling in the clutch makes a rattling noise from the engine(from the clutch basket)After the engine heats up, the sound dissappears. What could be the issue? I've already changed the clutch plates that didn't help:(. Pls reply
I was changing my clutch cable and the black slipper clutch arm/handle and post came out of the crankcase hole. I pushed it back in and now the transmission won’t shift.
David love! love! your video's , just saying! would it be ok to use a metal maker pen on the plates, a small dot, to make sure to fit them on correctly, when re-building the plates just saying. for beginners, like my self? other then that, Awesome Dave! just Awesome! stay Amazing
Hi and thanks. If you want to make a pen mark then do so but bear in mind the plates are oily so you'd want to clean that off - you are adding an extra step which make the process more complicated. It's pretty simple as it is, just put the plates all back the same way round. As a beginner it's a good lesson that stamped plates (like most washers) have a rounded face and sharp face and there is a right way round! Good luck
@@MotoMirius your right! Thanks for your feedback, always looking for your videos, This should be a thing with most motorcycle manufacture, for small maintenance of your bike, so glad people like your self, with a unselfish knowledge and tke the time to share with their community, thanks again David! UK
Life will depend on use not mileage. You can use a gasket glue if you want. If you do then it's common in the racing oriented community to glue it to the cover and use oil on the other side so it can be easily removed without braking the gasket
Hi and thank you. If you are working on your bike I always recommend buying a set of spanners or sockets as it's cheaper than buying them individually. But if you do need to buy then just measure across the flats of the bolt or nut with a ruler to find the size. I don't have the measurement off the top of my head, unfortunately.
@@MotoMirius yes right now just want to work on clutch side of my bike, but unfortunately i'm still don't have complete set of tools. Just few of socket wrences and some spanners 😅 yeah now i''m planning to but set of socket. Just a little low on budget right now 😅
@@soemardi8885 the pain of buying tools never goes away - but I'm still using the same spanners that I bought 40 years ago. So the long term saving of money is very big.
Thank you for the instructions. I need to replace the clutch lever arm (clutch side, not handlebar side) and I assume it is possible to do so without removing the clutch cover, right? I watched your videos and it seems like it's possible, but I just wanted to double check. Thanks a lot!
Yes, no problem at all with that. Sometimes you can remove the lever without changing even the cable adjustment, but sometimes you just need a little slack in the cable to unhook the lever and replace it.
Thanks. Changing gasket isn't optional in most cases, because the old one will either tear as you take it off or be too hard so won't reseal. Your KTM dealer can supply them.
hi, i just bought a used duke 250 and finding its a bit hard to change into 3rd from 2nd and into 4th from 3rd. can it be because of the plates? i had installed new cable and it didn't help. thanks
It could be, but worn plates tend to slip which makes it easier to change gear as they don't properly engage. More likely a gearbox issue, or it could simply be that the cable isn't properly adjusted. This sort of diagnosis is very unreliable over the internet - much better hands on.
Hello, I would like to ask you. We have ktm duke 390 2019, the problem is, when I pull the clutch lever and downshift or upshift then I feel the little kick in to the clutch lever. Bike fell of to the left side one time during wheelie lesson at low speed. Cable looks fine same as chain tension, but when i tighten the chain as manual says, then the kick in to the clutch lever is stronger. Thanks for any advice :)
The most obvious cause would to adjust the clutch cable. It sounds as though it’s not fully releasing the clutch when you pull it in. Check the lever and cable again as it might have been moved in the crash.
Hey mirius i have a big Problem i did a oil change with the 15w50 motorex oil and it worked finde but i added from liqui moly oil additive and the bike turned off and the oil light was on the bike i already draned it out but idk if it still workes if i put the right oil in agan Would it worke agan? And how do i clean everything so there is no old oil in the ktm duke It would be really helpful if u respond thanks 👍
Mirius, Excellent videos. I ask you from Argentina, is it dangerous to put all the edges down or up on the metal plates? After assembling everything I know that I put all the edges to one side but I don't remember which one. On the other hand, after putting the shaft that holds the cable and assembling it, the clutch fails to operate well and the gears hardly fit, what should I check? i have a duke 390 2016.
I'm afraid the only answer is to take it apart again - I suspect you will find that the top plate is not properly seated - this is part of the slipper clutch and if it's not fully seated (it can stick a bit) the clutch will not operate properly - but this is a ten minute job to check and you can check the plates at the same time. So long as they are all the same way it should be fine, but potentially fitting them incorrectly could cause an issue. Of course, I am assuming that the cable has been reset. Good luck with this, with the plates properly fitted there should be no issue. Check also that the final plate fits on yours as it does in mine - I suspect it will be the same clutch unit.
Nice job there. I race a non slipper clutch 2015 model rc390 and its done 10000 race kms with no clutch issues at all. Do you think the slipper clutch might have something to do with the premature wear on yours?
Thanks. I attribute the wear to two factors - low speed traffic filtering which requires regular slipping of the clutch and basic stunt practice where slipping is part of the learning process (and not at all necessary for the proficient)
Thank you for video sir. You're helping us as always. I got a question to you: for a while, I noticed my shifting became hard especially 1 to 2. It's like there is same kick sound as you shift N to 1. I do not notice clutch slipping at all and I adjusted clutch pedal + lever + wire 2 times but it's still same. I suspect of my clutch plates. Any thoughts about this? (2016 Duke 390 bs3)
Thank you, you are welcome. If the clutch plates were slipping then you would normally run out of adjustment on the clutch cable. You may need to inspect the clutch and plates. Good luck.
@@jamesjay1987 Its more likely the problem is in the gearbox but I would recommend checking the clutch first - if it was a clutch problem it would affect all gears. But, if you are not used to working on your bike, I would first get someone who knows what they are doing to check the cable adjustment as it can be tricky.
@@MotoMirius I actually do basic repairing jobs on bikes but gears seems pretty normal when accelerating or cruising. There is no issue. Shifting to 3-4-5-6 smooth. Just N-1 (sure it's normal) and 1-2 is hard.
@@jamesjay1987 Shifting gear is not the same as being in gear. The first thing wear in the gearbox is the dogs which syncronise the change into the most commonly used gears - first and second
Hi Sir, the clutch is tight in my duke 250. I haven't checked it with the expert. I just want to know how much does it effect on the acceleration of my vehicle. The bike is almost having zero pull from the 3-7000 rpm's. I have changed my fuel pump and also the throttle body is cleaned and serviced. The baffle from the silencer is being removed and it is driven around 24000 kms. I just want to know whether resolving clutch issue will it solve my acceleration problem. I have zero errors while checking in the ECU. All the sensors are working and the vehicle struggles to reach 100kmph or top speed is unachievable right now.. It would be very helpful if you can reply to this.
If the clutch is slipping then it will have issues with accelerating - if the bike revs quickly but there is no increase in speed then the clutch may be slipping.
@MotoMirius what would happen if the first plate was in the same notch as all of the other plates? I was planning to replace the clutch but now I’m not sure if I need to replace or if I just need to align them correctly. Thanks for the video
There will always be lemons, no matter what you buy. Indian and Asian made entry level bikes tend to have a higher failure rate - too many supply chain and budget issues.
Hello Mirius I have a RC 390 2017 and the clutch start to slip . The problem is that the bike have 4000 km and i could not ajust the cable because it was at the minimun lengh and with no free play ? I took the bike to the KTM service and they say that the clutch pack was worn . In my opinion there was an issue with the clutch and they are trying to charge my the repair of the bike . I will be gratefull if you gave my your oppinion .Thanks and regards
If you've run out of adjustment on the clutch cable then its because the clutch plates are worn out. I would guess 95% the KTM service are right. Now I would expect much longer life from a clutch but it depends how and where the bike is ridden. If you are often slipping the clutch because you are riding in traffic then this can wear the clutch out quickly. I find the clutch plates wear out very quickly on this bike, but it is a quick job to change.
You just have to be patient - they are like buses, none at all then six come at once. If you don't want the graphics then you have wider options because you can peel off the existing ones from the other capacity bikes. I rode for quite a while with 125 graphics on the panels.
@@mightysolutions2660 I see them on eBay - but at too much money - more than I can buy them from the dealer. Your location may be different and COVID may have restricted supply of new ones since they are on back order at my dealer. I suggest also searching by part number
@@ladyshep No, not normal. That said the 125 has a different clutch from the 390 but even so, these are not Ducati. Are you sure it's from the clutch? These are typically a little rattly at the top end/ timing chain (which runs next to the clutch).
Hi there, great video. I'm at the point of putting the clutch cover back on after replacing the plates (EBC) and it doesn't quite sit flush - seems like there is something maybe sticking out. I also noticed that my pressure plate isn't sitting as flush as yours (there's like 0.5cm gap where it can't be screwed in any further). Any ideas what might be causing it to stick out?
Hi i was watching your videos and decided to get a set of EBC clutch pack steel and friction plates. Do you still have the product code available? Mine is a 2015 390 with the same slipper clutch basket. I have already had the number for the EBC springs from your later video [AH2782]. Cheers
How do u feel about the Rear Shock of 390 Duke, in my opinion it really soft when u got some packed or some one sit on the rear. Can u Rebuilt it to be stiffer ?
I don't carry a passenger. It will depend on weight of rider and passenger. You would be better off changing the rear shock - OEM entry level shocks tend not to rebuildable (depends where in the world you live and if your local shop will do it). Nitron for example offers a choice of spring depending on weight).
My 2021 duke 200 started leaking oil through the gasket after 4k miles of use. Is there a stronger gasket/material than the ones provided by ktm? Or do i just keep replacing the gasket every 4k miles? It seems unnecessary to do so. (This is my first motorcycle and im not so mechanicly inclined to say the least) I already made and appointment with the dealer to get it replaced since at first glance i didnt know it was the gasket but i just want to avoid any unnecessary expenses.
You will lose oil, and it can create damage on the gasket surface - both of which can trash the engine. Gaskets are designed to be one use and aren't overly expensive (but not cheap either). You should expect to replace every time you go into the clutch as they will harden. If you are racing etc and have the clutch cover off a lot then there are other things you can do but then you are much more on top of oil levels etc than the average street rider.
I'm not sure you can. If I recall correctly the 250 may have the same bottom end as the 390, but I think the 200 is an overbored 125 so shares the same clutch design as the 125.
@@MotoMirius Thanks for your concern. I think 2017 and 2018 duke are the same. but 5666 = 4+3 disks. 5665= 6+1 discs. 4+3 disc from my motorcycle. Still, I wonder if the 6+1 disc will fit my motorcycle.
Doesn't really need one. As with any new part, take it easy at first and make any adjustments. You might want to change the oil after a few hundred miles to clear any initial particles from bedding in.
Hi David Vernon here. Do you have any videos on replacing the timing chain tensioner? Looking at doing mine and don't want to over tighten it or under. Looking for that just right tension on it. Thank you.
@@vernonhochstetler7608 OK thanks. I might see about buying one so I can do a video. I'm of very mixed opinions about fitting them - I see them mentioned a lot on the forums but manufacturers switched to auto tensioners on road bikes for very good reasons. I'm glad you asked. Since it will take a while before any video is posted, standard install is: Fit the tensioner, rotate the engine forward (turn the back wheel in gear), turn in the tensioner until you just feel it touch, back off a quarter turn and lock off). Don't even consider fitting one unless you can guarantee that you will regularly check and adjust - these are a race type application not fit and forget.
@@MotoMirius okay thank you very much. My bike is new only 4K on it. I don’t plan on doing it right away. I been told they are better then the auto ones and they switched because people did not check them often enough.
@@vernonhochstetler7608 Yes, that is exactly why they switched them. The average rider struggles to correctly oil and adjust the chain to the rear wheel. Incorrectly adjusting or failing to remember to adjust the timing chain will destroy the engine. In a racing context, there are checklists and things are checked and adjusted regularly - on the street not so much . They are something I would recommend to engineers or people who are used to the routines enforced by racing. I don't recommend them to the average street rider who want them because they are cool (not cool to older riders who remember them as stock fitting) - six months later, will they still remember to adjust them? Remember also that fitting will invalidate the KTM warranty.
Yes. You can always check by pushing the screws into place before doing up - all should sit at the same height from the case, but it's just good practice on something you aren't familiar with to put them down in order
@@MotoMirius when I adjust the left then the right goes off and vice versa. I realized today that the dealership mechanic didn't align the chain well so I tired to do it myself. I've been riding it past few months and I took for granted that the mechanic is more experienced than me. So I am not able to get the alignment done properly. Also wanted to say thanks for posting videos. It really helps us with this stuff. I've been learning a lot from your videos. Keep up the good work 👍🏼😁
@@kevinpinheiro2485 Both sides need to be exactly at the same setting, because as you have realised, every change on each side changes the other side. So, it's just a process of getting the same and then adjusting slowly both to achieve what you want. It's just practice, but thanks - you will get there!
@@MotoMirius had to ask. Before when my chain was looking aligned. When I used to see between the front sprocket cover and the chain guard. There is a space near the rider foot pegs. So I could see the chain moving left and right and it's about 5mm total movement. Is that really bad. That's when the chain is moving with the engine.
@@kevinpinheiro2485 That isn't chain alignment. Remove the front sprocket cover and check the that bolts holding on the front sprocket are tight. There shouldn't be any significant movement in the front sprocket.
There is no rule as to when a clutch needs changing - most of my bikes have over 50,000 miles on the original clutch plates. It all depends on how you ride, not on the bike.
Hello, in 2:48 you picked up the stopper with a screwdriver, which I also did, but when I tried to put it back in its original position it broke. Is it important? Any idea how to replace it or what to put in place of the original one? Thank you very much!
If you are referring to the safety tab which prevents the cable leaving the holder, then this will break sooner or later. You can buy a complete new lever from your KTM dealer - part no 90232048133. Or you can leave it. I don't see any practical way that the cable can ever accidentally leave the cage unless the cable is really badly adjusted.
There is practically no material on the Internet for repairing these KTM motorcycles. Your videos are a godsend. Thank you for sharing this information.
Glad to help!
You couldn't of uploaded this video a better time, thankyou mate !
Good luck with that!
Another super helpful video!! My clutch went this weekend and I was bricking it at the thought of having to change it. Now I know what I'm doing! Thank you!
Good luck with that. Just be sure when putting the pressure plate back on that you get it slid down on the ramps.
Surgically done David, no cursing, throwing tools, or busted knuckles!👍
You didn’t even have any Beer!😂🍻
Thanks Andrew. Editing is the most important skill!
As always, an excellent tutorial - thank you David!!
My pleasure! Always appreciated. Skäl David
Great descriptions & demonstrating the techniques required to maintain the bike yourself
Thanks! 👍 Much appreciated
Great video as always! Gonna use this when I have to do it eventually 🤣
Thanks - hopefully you won't need to do it as soon as me!
Good tutorial David . Imagine trying to explain that without the bits on show !
Peace and love brother 👍🏻☮❤
Thanks Springy, ah what fun! At least it's easier than a block of carbs! Hope you are keeping well. Skäl David
Thank you for your videos. I have a 2012 duke 200 and your videos are a big help
Thanks. Much appreciated.
Nice video I really enjoy your tutorials keep it up, and always ride safe😁
Glad you like them! Much appreciated. Skäl David
Very nice and useful video🙏🏼 will be needing this soon
Thanks, good luck with that!
Masterful work, David! Watching you is like meditation for me. I pray for your well-being so that you can continue teaching us more! Quick question: Would using the quickshifter result in quickly worn clutch plates?
Thank you, much appreciated. A quick shifter is likely to increase wear - it is designed to help win races, not for road riding, so winning is worth the increased cost, but it should not significantly increase wear since there is an ignition cut creating a momentary loss of power at the time it happens.
A darn sight easier than my old Bonnie T140V! Hope it’s better for you now.
I was expecting to need at least a clutch basket tool, though I understand you need that for the125, but otherwise, aside from user error putting it back together it was fine! All good now, just need to ride it!
Hi, without ts videi i couldnt fish my assrmbly thankbyou so much, and the 2 last disc is tin, i offset them both is it ok? 390 asv here
Thanks. Yes, they are a different size. Different versions of the clutch may be different - for example the gen 1.
Thanks for the advice and method.
No problem!
Even after your death you will have huge Ktm Army watching your Videos ❤ wish you good Health for next 100 years
Thank you and good fortune to you
Best video specially in english
Glad you liked it. Thanks
Great channel! I absolutely love how detail your explanations are and how you aim to show every angle with the camera when assembling/disassembling a part! Thanks for all the info! On another topic, I have an issue with my 390 duke, 2017, when riding the bike it goes to neutral for 2-3 seconds for no reason and then reengages the same gear, sometimes it stalls and i have to start the engine again. Any clues what it might be causing this? It is quite anoint and dangerous when riding it. The problem started after an oil change, the oil was over the maximum, but this could just be a coincidence. Thanks in advance!
Thanks. The way motorcycle gearboxes work is very different from say a car gearbox. With bikes the gearbox is always in gear unless it is in neutral - it can't slip into neutral between gears or in gear like a car gearbox can. So if it goes "into neutral", it is most likely the clutch slipping - so when it re-engages it is still in the same gear it was before. If it does it in the same gear repeatedly, it could be a broken gear or worn out gearbox, but not my first assumption.
There are many causes of stalling, but in my opinion, the most likely cause is the one that is by far the most unpopular - user error with the clutch. People are really resistant to this one because everyone wants it to be the bikes fault - but this is not a standard road bike engine. What you are telling me is pointing me towards the clutch. I'm going to assume that a motorcycle wet clutch type oil was used and not a car oil because car oils will make the clutch slip.
Good luck with the diagnosis!
@@MotoMirius, thanks! I spend a few hours disassembling everything around the clutch and there were no visible wears or problems. I started thinking about the stalling problem, what might be causing it and it turned out that there was a bad connection going from the battery. I changed the cable and now everything seems to be working fine, no stalling, and the bike does not go into neutral and back into gear when riding. : )
@@yavorgochev5838 Fantastic. Excellent work on the diagnostic and fix! Well done.
Great video David, you always show the job as it is done very simple and it looks like everybody can done it. I have two questions: a) is it need to drain the oil from the bike before start doing the job? and b) I can see that you didn't use any silicone gasket is it necessary to use it or not?. Thanks again and congratulations...!
Thanks Pablo. The reason the bike is on its side is so that you don't spill any oil. No, not necessary to use a liquid gasket and I would not recommend - you could use something like gasgacinch to stick it in place. Be very careful with silicone gasket - it must be one suitable for use with a motorbike engine. If you use the wrong type of silicone you can cause significant engine damage.
Do the sharp edges of the last metal disc go facing the engine or me ? Great video!
They all face the same direction
Hey @motomirius. I have a problem in my 2018 390 duke. When the engine is cold, pulling in the clutch makes a rattling noise from the engine(from the clutch basket)After the engine heats up, the sound dissappears.
What could be the issue? I've already changed the clutch plates that didn't help:(. Pls reply
I was changing my clutch cable and the black slipper clutch arm/handle and post came out of the crankcase hole. I pushed it back in and now the transmission won’t shift.
Thank you!
You're welcome!
Duke 250 gear shaft change tutorial
The 125 and 200 has different type of clutch, you need special socket to access and remove the plates.
Thanks - I can see that at least the early versions used a different system.
Can anyone tell me if this looks the same for the 125ccm?
Thanks David, will do the same this week, BUT gasket costs $20... WTF? Will do gasket myself from paronite sheet that costs me $2 for 0,5x0,5 m2
Of course you can make your own gaskets and no reason not too - but a step too far for most people new to this. Thanks
David love! love! your video's , just saying! would it be ok to use a metal maker pen on the plates, a small dot, to make sure
to fit them on correctly, when re-building the plates just saying.
for beginners, like my self? other then that, Awesome Dave! just Awesome! stay Amazing
Hi and thanks. If you want to make a pen mark then do so but bear in mind the plates are oily so you'd want to clean that off - you are adding an extra step which make the process more complicated. It's pretty simple as it is, just put the plates all back the same way round. As a beginner it's a good lesson that stamped plates (like most washers) have a rounded face and sharp face and there is a right way round! Good luck
@@MotoMirius your right! Thanks for your feedback, always looking for your videos, This should be a thing with most motorcycle manufacture, for small maintenance of your bike, so glad people like your self, with a unselfish knowledge and tke the time to share with their community, thanks again David! UK
Great video! David, I need to check my 18 duke390's clutch, should I drain the cooling oil before I start to open the clutch cover?
Thanks. I recommend following the same procedure as shown in the video. It makes no difference if you are changing the clutch or checking it.
Great video! How many miles are "many" for the clutch? What's the average life of it?
Also, no gasket glue needed?
Life will depend on use not mileage. You can use a gasket glue if you want. If you do then it's common in the racing oriented community to glue it to the cover and use oil on the other side so it can be easily removed without braking the gasket
@@MotoMirius at what mileage did yours start to slip?
@@cnrom I think I replaced them around 8,000 miles - but as I say, that means nothing because it doesn't compare to normal road use.
Hi David, nice video for explaining all the things to get the job done. But can you tell me what size socket you use to open bolt for clutch spring??
Hi and thank you. If you are working on your bike I always recommend buying a set of spanners or sockets as it's cheaper than buying them individually. But if you do need to buy then just measure across the flats of the bolt or nut with a ruler to find the size. I don't have the measurement off the top of my head, unfortunately.
@@MotoMirius yes right now just want to work on clutch side of my bike, but unfortunately i'm still don't have complete set of tools. Just few of socket wrences and some spanners 😅 yeah now i''m planning to but set of socket. Just a little low on budget right now 😅
@@soemardi8885 the pain of buying tools never goes away - but I'm still using the same spanners that I bought 40 years ago. So the long term saving of money is very big.
Nice video! Maybe you could make a video about the power commander for ktm duke 390 next?😁
Well first I would need one, but I'm Apple based which makes life a little harder for that.
@@MotoMirius ok, i understand, but what does Apple based mean?
@@sondrings8612 It means I don't have a Windows laptop to run the map software
@@MotoMirius ok, understand. But if i want to download a map to a power commander, do i only need a windows pc?
@@sondrings8612 You will need software to manipulate the map and the cables to connect. Of course this assumes you are going to manipulate the maps.
Thank you for the instructions. I need to replace the clutch lever arm (clutch side, not handlebar side) and I assume it is possible to do so without removing the clutch cover, right? I watched your videos and it seems like it's possible, but I just wanted to double check. Thanks a lot!
Yes, no problem at all with that. Sometimes you can remove the lever without changing even the cable adjustment, but sometimes you just need a little slack in the cable to unhook the lever and replace it.
@@MotoMirius excellent, thank you!
Hey there, great video! I have a question: Is it neccessary to change the gasket? And if yes, where can you purchase those online?
Thanks. Changing gasket isn't optional in most cases, because the old one will either tear as you take it off or be too hard so won't reseal. Your KTM dealer can supply them.
hi, i just bought a used duke 250 and finding its a bit hard to change into 3rd from 2nd and into 4th from 3rd. can it be because of the plates? i had installed new cable and it didn't help.
thanks
It could be, but worn plates tend to slip which makes it easier to change gear as they don't properly engage. More likely a gearbox issue, or it could simply be that the cable isn't properly adjusted. This sort of diagnosis is very unreliable over the internet - much better hands on.
Dear Moto Mirius, please give me info max torque for tightening 3 bolts clutch and bolt clutch cover . thank you
I have updated the description - Torque:
Clutch spring screws: 10Nm 7.4ft lb
Clutch cover screws: 12Nm 8.9fl lb
Thanks
I hope you don't mind sharing the link of where you purhcased those clutch lining/clutch plates.
Clutch plates are from wemoto.com but any similar supplier should stock them.
@@MotoMirius Thank you.. I hope they ship in the Philippines. It's hard to get by with KTM parts here. And if it's available, its super expensive.
I want a mechanic like u in Kerala
Thanks - this is one reason I do the work myself.
Hello, I would like to ask you. We have ktm duke 390 2019, the problem is, when I pull the clutch lever and downshift or upshift then I feel the little kick in to the clutch lever. Bike fell of to the left side one time during wheelie lesson at low speed. Cable looks fine same as chain tension, but when i tighten the chain as manual says, then the kick in to the clutch lever is stronger. Thanks for any advice :)
The most obvious cause would to adjust the clutch cable. It sounds as though it’s not fully releasing the clutch when you pull it in. Check the lever and cable again as it might have been moved in the crash.
Same problem in my rc390 bs6 so how to re salved sir please help me
@@rc_199rider2 still not solved the problem. Our bikes going to mechanic anyway
Hey mirius i have a big Problem i did a oil change with the 15w50 motorex oil and it worked finde but i added from liqui moly oil additive and the bike turned off and the oil light was on the bike i already draned it out but idk if it still workes if i put the right oil in agan
Would it worke agan?
And how do i clean everything so there is no old oil in the ktm duke
It would be really helpful if u respond thanks 👍
There is really no way to clean it except to flush out the oil. It may have created an issue with the oil pressure switch or the pump.
Mirius,
Excellent videos. I ask you from Argentina, is it dangerous to put all the edges down or up on the metal plates?
After assembling everything I know that I put all the edges to one side but I don't remember which one. On the other hand, after putting the shaft that holds the cable and assembling it, the clutch fails to operate well and the gears hardly fit, what should I check? i have a duke 390 2016.
I'm afraid the only answer is to take it apart again - I suspect you will find that the top plate is not properly seated - this is part of the slipper clutch and if it's not fully seated (it can stick a bit) the clutch will not operate properly - but this is a ten minute job to check and you can check the plates at the same time. So long as they are all the same way it should be fine, but potentially fitting them incorrectly could cause an issue. Of course, I am assuming that the cable has been reset. Good luck with this, with the plates properly fitted there should be no issue. Check also that the final plate fits on yours as it does in mine - I suspect it will be the same clutch unit.
Sir plz could you explain the wire of Duke 390 bs6
Which wire?
Did you just pull the clutch arm out?
Yes, it pulls out. You can leave it in, but you will need to pull it towards you when refitting the cover.
Nice job there. I race a non slipper clutch 2015 model rc390 and its done 10000 race kms with no clutch issues at all. Do you think the slipper clutch might have something to do with the premature wear on yours?
Thanks. I attribute the wear to two factors - low speed traffic filtering which requires regular slipping of the clutch and basic stunt practice where slipping is part of the learning process (and not at all necessary for the proficient)
Thank you for video sir. You're helping us as always. I got a question to you: for a while, I noticed my shifting became hard especially 1 to 2. It's like there is same kick sound as you shift N to 1. I do not notice clutch slipping at all and I adjusted clutch pedal + lever + wire 2 times but it's still same. I suspect of my clutch plates. Any thoughts about this? (2016 Duke 390 bs3)
Thank you, you are welcome. If the clutch plates were slipping then you would normally run out of adjustment on the clutch cable. You may need to inspect the clutch and plates. Good luck.
@@MotoMirius Then I should look inside for what's happening. Thank you.
@@jamesjay1987 Its more likely the problem is in the gearbox but I would recommend checking the clutch first - if it was a clutch problem it would affect all gears. But, if you are not used to working on your bike, I would first get someone who knows what they are doing to check the cable adjustment as it can be tricky.
@@MotoMirius I actually do basic repairing jobs on bikes but gears seems pretty normal when accelerating or cruising. There is no issue. Shifting to 3-4-5-6 smooth. Just N-1 (sure it's normal) and 1-2 is hard.
@@jamesjay1987 Shifting gear is not the same as being in gear. The first thing wear in the gearbox is the dogs which syncronise the change into the most commonly used gears - first and second
Hi Sir, the clutch is tight in my duke 250. I haven't checked it with the expert. I just want to know how much does it effect on the acceleration of my vehicle. The bike is almost having zero pull from the 3-7000 rpm's. I have changed my fuel pump and also the throttle body is cleaned and serviced. The baffle from the silencer is being removed and it is driven around 24000 kms.
I just want to know whether resolving clutch issue will it solve my acceleration problem. I have zero errors while checking in the ECU. All the sensors are working and the vehicle struggles to reach 100kmph or top speed is unachievable right now.. It would be very helpful if you can reply to this.
If the clutch is slipping then it will have issues with accelerating - if the bike revs quickly but there is no increase in speed then the clutch may be slipping.
@MotoMirius what would happen if the first plate was in the same notch as all of the other plates? I was planning to replace the clutch but now I’m not sure if I need to replace or if I just need to align them correctly. Thanks for the video
The clutch will still work if you don't but you may find it doesn't engage quite as smoothly and it can put more stress on the clutch on the basket.
Clutch completely failed on my 390 at 500 miles. Sold it at 600 miles after the 1st service after many issues.
There will always be lemons, no matter what you buy. Indian and Asian made entry level bikes tend to have a higher failure rate - too many supply chain and budget issues.
Hello Mirius I have a RC 390 2017 and the clutch start to slip . The problem is that the bike have 4000 km and i could not ajust the cable because it was at the minimun lengh and with no free play ? I took the bike to the KTM service and they say that the clutch pack was worn . In my opinion there was an issue with the clutch and they are trying to charge my the repair of the bike . I will be gratefull if you gave my your oppinion .Thanks and regards
If you've run out of adjustment on the clutch cable then its because the clutch plates are worn out. I would guess 95% the KTM service are right. Now I would expect much longer life from a clutch but it depends how and where the bike is ridden. If you are often slipping the clutch because you are riding in traffic then this can wear the clutch out quickly. I find the clutch plates wear out very quickly on this bike, but it is a quick job to change.
Please can you send me a link to where you got the gasket ? I can only find 125 Duke and I need the 390
Your KTM dealer. For a gen 2 bike that’s part number 90230027000. It also fits the 250. www.fowlersparts.co.uk/parts/view/90230027000
What is the cost ..😟😟N Tq U So much For Information about it❤
It will depend where you are. I can only comment on cost in the UK.
Quick one where I can find front side tank fairings to buy I'm looking like whole month already can't find anything cheers
You just have to be patient - they are like buses, none at all then six come at once. If you don't want the graphics then you have wider options because you can peel off the existing ones from the other capacity bikes. I rode for quite a while with 125 graphics on the panels.
@@MotoMirius yeah but I do need panels itself have damaged them a bit and now looking for the new ones but find them is impossible..
@@mightysolutions2660 I see them on eBay - but at too much money - more than I can buy them from the dealer. Your location may be different and COVID may have restricted supply of new ones since they are on back order at my dealer. I suggest also searching by part number
Would you know the torque settings for the clutch basket bolt on the ktm duke 125 2019 thanks
Unfortunately no.
@@MotoMirius is it a usual thing to have a rattle from your clutch basket on these ktm dukes
@@ladyshep No, not normal. That said the 125 has a different clutch from the 390 but even so, these are not Ducati. Are you sure it's from the clutch? These are typically a little rattly at the top end/ timing chain (which runs next to the clutch).
@@MotoMirius pull your clutch lever the noise goes, clutch is fine not on its way out.
Hi there, great video. I'm at the point of putting the clutch cover back on after replacing the plates (EBC) and it doesn't quite sit flush - seems like there is something maybe sticking out. I also noticed that my pressure plate isn't sitting as flush as yours (there's like 0.5cm gap where it can't be screwed in any further). Any ideas what might be causing it to stick out?
Thanks. You need to make sure that the pressure plate slips down the ramps, it needs to twist into place - it's easy to have it sitting up too high.
@@MotoMirius Yep that was the issue. Thanks for the help.
Hi i was watching your videos and decided to get a set of EBC clutch pack steel and friction plates. Do you still have the product code available? Mine is a 2015 390 with the same slipper clutch basket. I have already had the number for the EBC springs from your later video [AH2782]. Cheers
Try this link ebcbrakesdirect.com/motorcycle-clutch/ktm/390-duke/2015-2017/506995
Is dominar 400 have the same clutch lining as duke 390?
We don’t have them here but if they are using the same engine then quite likely!
How do u feel about the Rear Shock of 390 Duke, in my opinion it really soft when u got some packed or some one sit on the rear. Can u Rebuilt it to be stiffer ?
I don't carry a passenger. It will depend on weight of rider and passenger. You would be better off changing the rear shock - OEM entry level shocks tend not to rebuildable (depends where in the world you live and if your local shop will do it). Nitron for example offers a choice of spring depending on weight).
My 2021 duke 200 started leaking oil through the gasket after 4k miles of use. Is there a stronger gasket/material than the ones provided by ktm? Or do i just keep replacing the gasket every 4k miles? It seems unnecessary to do so. (This is my first motorcycle and im not so mechanicly inclined to say the least) I already made and appointment with the dealer to get it replaced since at first glance i didnt know it was the gasket but i just want to avoid any unnecessary expenses.
The standard gasket is all you need. The real question is what has caused the leak - loose bolts, warping of the cover etc.
How does the blown clutch gasket effect the bike? Do we need to replace it at a certain point?
You will lose oil, and it can create damage on the gasket surface - both of which can trash the engine. Gaskets are designed to be one use and aren't overly expensive (but not cheap either). You should expect to replace every time you go into the clutch as they will harden. If you are racing etc and have the clutch cover off a lot then there are other things you can do but then you are much more on top of oil levels etc than the average street rider.
Thank you so much. I am a squid 🦑 and am trying to learn everything possible about motorcycles.
Love and good wishes from Bhutan 🇧🇹
Can we fit 390 slipper clutch in duke 200
I'm not sure you can. If I recall correctly the 250 may have the same bottom end as the 390, but I think the 200 is an overbored 125 so shares the same clutch design as the 125.
I encourage you to change the title of your video, add to it husqvarna 401 as well
A very good point, thank you. I always forget about the 401!
@motomirius any suggestions for a broken spring screw?
Just order it from your dealer.
Hello there. for 2018 duke390. Does the EBC CK5665 fit.
For the 2017 EBC quote CH5666. As far as I know the 2018 uses the same clutch - I think this replaces the 5665.
@@MotoMirius Thanks for your concern. I think 2017 and 2018 duke are the same. but 5666 = 4+3 disks. 5665= 6+1 discs. 4+3 disc from my motorcycle. Still, I wonder if the 6+1 disc will fit my motorcycle.
@@kerimturan25 There used to be a link, so the 5665 was listed for the 390 but the link now takes you to the 5666.
@@MotoMirius Thanks so much for your concern. Even if I stop using KTM, I will always follow you.
Hi what kit did you uses I got a 2018 390 but cart find any kits
I used an EBC kit from a parts factor, but you could buy from your dealer
What happened next does topspeed increased or decreased?
Clutch plates don't change your speed except when they slip you will never reach top speed.
You also could have put the wrong oil in. That will kill a wet clutch too.
Ask me how I know.
I could have done yes, but the oil I use is all specified by the manufacturers as suitable for the bike.
Do you have to a do a break in process?
Doesn't really need one. As with any new part, take it easy at first and make any adjustments. You might want to change the oil after a few hundred miles to clear any initial particles from bedding in.
It's Duke 390 clutch is multi disc clutch type ?
I don’t know any bike that doesn’t have a multi disk clutch.
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Hi david, wat stock number is the lining ftom ebc?
Standard set is CK5666
Dear, what different to use motorex SAE 15/50 Formula Synthetic Blend with motorex SAE 15/50 Top Speed Synthetic Performance for Duke 390 2018 ?
One is synthetic the other is part synthetic. Fully synthetic is typically more expensive.
@@MotoMirius Thank you 👍
Hi David Vernon here. Do you have any videos on replacing the timing chain tensioner? Looking at doing mine and don't want to over tighten it or under. Looking for that just right tension on it. Thank you.
Hi Vernon. Are you looking to replace with a manual tensioner? What year is your bike?
@@MotoMirius 2021 and yes the APE 400kt I believe it is.
@@vernonhochstetler7608 OK thanks. I might see about buying one so I can do a video. I'm of very mixed opinions about fitting them - I see them mentioned a lot on the forums but manufacturers switched to auto tensioners on road bikes for very good reasons. I'm glad you asked. Since it will take a while before any video is posted, standard install is: Fit the tensioner, rotate the engine forward (turn the back wheel in gear), turn in the tensioner until you just feel it touch, back off a quarter turn and lock off). Don't even consider fitting one unless you can guarantee that you will regularly check and adjust - these are a race type application not fit and forget.
@@MotoMirius okay thank you very much. My bike is new only 4K on it. I don’t plan on doing it right away. I been told they are better then the auto ones and they switched because people did not check them often enough.
@@vernonhochstetler7608 Yes, that is exactly why they switched them. The average rider struggles to correctly oil and adjust the chain to the rear wheel. Incorrectly adjusting or failing to remember to adjust the timing chain will destroy the engine. In a racing context, there are checklists and things are checked and adjusted regularly - on the street not so much . They are something I would recommend to engineers or people who are used to the routines enforced by racing. I don't recommend them to the average street rider who want them because they are cool (not cool to older riders who remember them as stock fitting) - six months later, will they still remember to adjust them? Remember also that fitting will invalidate the KTM warranty.
Doesn’t it have a slipper clutch?
Yes it does. Makes no difference to the clutch plates.
are the screws all the same??
Yes. You can always check by pushing the screws into place before doing up - all should sit at the same height from the case, but it's just good practice on something you aren't familiar with to put them down in order
Seen your video on duke chain alignment. I'm still finding it hard to adjust the chain. Any tips ?
What issue are you having?
@@MotoMirius when I adjust the left then the right goes off and vice versa. I realized today that the dealership mechanic didn't align the chain well so I tired to do it myself. I've been riding it past few months and I took for granted that the mechanic is more experienced than me. So I am not able to get the alignment done properly. Also wanted to say thanks for posting videos. It really helps us with this stuff. I've been learning a lot from your videos. Keep up the good work 👍🏼😁
@@kevinpinheiro2485 Both sides need to be exactly at the same setting, because as you have realised, every change on each side changes the other side. So, it's just a process of getting the same and then adjusting slowly both to achieve what you want. It's just practice, but thanks - you will get there!
@@MotoMirius had to ask. Before when my chain was looking aligned. When I used to see between the front sprocket cover and the chain guard. There is a space near the rider foot pegs. So I could see the chain moving left and right and it's about 5mm total movement. Is that really bad. That's when the chain is moving with the engine.
@@kevinpinheiro2485 That isn't chain alignment. Remove the front sprocket cover and check the that bolts holding on the front sprocket are tight. There shouldn't be any significant movement in the front sprocket.
What millage you change this clutch plate?
There is no rule as to when a clutch needs changing - most of my bikes have over 50,000 miles on the original clutch plates. It all depends on how you ride, not on the bike.
@@MotoMirius Thank you. 👍
❤❤
Power✨️✨️♥️
Thanks
Hello, in 2:48 you picked up the stopper with a screwdriver, which I also did, but when I tried to put it back in its original position it broke. Is it important? Any idea how to replace it or what to put in place of the original one? Thank you very much!
If you are referring to the safety tab which prevents the cable leaving the holder, then this will break sooner or later. You can buy a complete new lever from your KTM dealer - part no 90232048133. Or you can leave it. I don't see any practical way that the cable can ever accidentally leave the cage unless the cable is really badly adjusted.