KTM RC390 Top End Rebuild

[@debyttt1]

My KTM is a Duke 390. It's the same engine. And now, I have the same problem. But i will just clean up. One of the valves is damaged and the oil sinks to the bottom. I'm waiting for the parts. I'm doing the work myself and your video helped me through the process. Thanks.

[@GarageAddiction]

Glad it was helpful!

[@bretthawton]

That looks like a first generation 390 motor since KTM changed the cooling passages to give the gaskets more reinforcement in 2016. You're going to have to do this about every 4-5K miles with that motor based on my experience. My head gasket blew 3 times during the first 11K miles before I replaced it with a 2016 motor. My bike now has 55K miles (44K with new motor) and still runs flawlessly.

[@GarageAddiction]

Came out of a 2017 but I wouldn't be surprised if they threw an older generation motor in some of the first run.

[@bretthawton]

@@GarageAddiction hopefully I'm wrong about what I saw. I was looking at the video on my phone (small screen).

[@GarageAddiction]

This bike was great for a while but has started with trouble again so you may be right

[@bretthawton]

@@GarageAddiction the dealer screwed mine up three times and then when the warranty expired KTM conveniently forgot all the conversations we had about this. Spent my own money to buy a newer motor with less than 300 miles and it's been great ever since.

[@GarageAddiction]

Glad to hear! I’m not sure what I’ll end up doing but it seems like another engine out is in the cards

[@jasonwilliams9570]

Fantastic video. Just got one in as top end destroyed. Valves snapped.

[@GarageAddiction]

Thanks! I can't imagine the carnage in there with snapped valves, going to fix it up or source a new engine?

[@shubhamnayak5840]

I m back ready to race

[@atvan933]

Thanks, your video so great. I wonder if i can upgrade engine ktm rc250/200 upto 390 by using KTM RC390's cylinder, piston, engine cylinder head, cam? or using another cylinders, piston?

[@chrisracer4094]

Great video! thanks for posting.

[@GarageAddiction]

Thank you for watching!

[@wernerxldata]

Once it's out it's not a complicated engine at all. The video shows everything well visible, nice job ! I was wondering why you removed the cam followers, if you keep them in you can inspect valve clearance even before you dismount the head, saves you some time and you can order the right shims a lot sooner. Of course you need to recheck with new shims installed.

[@GarageAddiction]

It would have saved me some time for sure but I think I pulled the cam 2 times to get it perfect anyway haha

[@wernerxldata]

@@GarageAddiction It was meant to prevent the waiting time for ordering the shims... Sometimes I've got them a day later, sometimes more than a week ;)

[@backmarker7040]

The cylinder is tapered at the bottom. You can compress the rings by hand one at a time and install the piston from bottom of the cylinder instead of using a ring compressor and installing it from the top.

[@GarageAddiction]

I don't know if I'd be able to juggle the rings and cylinder on this bike. Easy enough on minis though!

[@beomon3449]

very helpful video! Great narration as well

[@GarageAddiction]

Thank you!

[@heidhouarbi]

I just worries may somebody can convert this solid crankshaft to be regulary pin bigend but stil with metal bearing.

[@bve7397]

Is it neccesary changing the bottom gasket if the engine is using coolant?

[@GarageAddiction]

Depends on where it's leaking from :) Most likely no, the head is the usual culprit but I also swapped the piston so a base gasket was easy enough while there.

[@jiadisheng9851]

good job

[@TheFrida0603]

How did you break in the engine after the rebuild?

[@hoysalak5742]

So i have adventure 390 (2020model)done around 52000 km there is not even a single noise still runs like brand new so do i need overhaul or anything replaced in the engine my engine is never touched till today

[@GarageAddiction]

You should check the valve clearance for sure, with oil and filter changes I wouldn't worry about cracking the engine open unless something feels different or you see some smoke out the exhaust, coolant loss. I don't think KTM provides intervals for pistons on these engines.

[@hoysalak5742]

@GarageAddiction there is no smoke no coolant loss will get it checked with valuve clearance thank you so much 👍

[@freshconnekt]

Awesome video

[@GarageAddiction]

Thank you!

[@eddisonburgos6806]

Very good. Saludos desde colombia 🇨🇴

[@GarageAddiction]

Thank you!

[@brucedelight9512]

Great video mate, planning on doing this myself, bike has started blowing smoke after sitting and around the same as yours 8800km. What year is yours, the only Piston kit i can find is 2013 even though I search my bike 2017. Also did you use any other parts or will the Piston kit surfice?

[@GarageAddiction]

Thanks! I have a 2017. The piston kit is the same for tons of years since there have been almost no changes. No real need to replace the piston, I did so while I was in there as it was caked in crazy hard carbon. The part number I went with is 90230007010 which I think lists 2013 as the year. I picked up a bunch of parts when I went through the engine, mainly all the orings in the head, a new oil pressure sensor because I accidentally smacked mine, spark plug, and a fuel filter. I would get new head studs if I was going to do it again, I didn't think about them when I ordered everything.

[@cadillacmoto]

did you get a new valve kit? i'm struggling to find a whole top end kit (valves, valve buckets, etc.)

[@GarageAddiction]

I just got the hot cams shims, the valves, buckets, retainers etc are all stock. I did see that you can get most of the valve train as a kit through dealers: VALVE KIT 390 DUKE ON DEMAND 90236030010

[@austingraham5633]

Just wondering..... when u installed the piston I remember from the tear down there was notches for the valves when u installed the new piston u didn't show it if the new notches line up with the head correctly? I can reference what I'm talking about from ur previous video

[@GarageAddiction]

At 44 seconds you can barely make out the marking on top of the piston which points to the exhaust port

[@nictarver2988]

Super helpful. I'm going to be doing this same job. do I need to buy new head bolts or can I re use them? (30,000kms on the engine) Or any other parts other than a gasket set? Can I leave the piston on the conrod if I'm not replacing it?

[@GarageAddiction]

I didn't get new head bolts but after some reading it looks like that's a good idea. You can leave the piston and rod if they're in good condition. They probably will be, I replaced mine while I was in there with the amount of carbon on it and slightly worn side skirts. There is a thin head gasket kit that sounds like it bumps the compression and runs well but I opted for stock right now. While you're in there check the valves and swap the plug since it's a nightmare to get to.

[@nictarver2988]

@@GarageAddiction thanks. I was thinking after I posted, that it might be very difficult to get the piston rings squeezed in from the bottom, without getting the ring compressor thing stuck in there...

[@GarageAddiction]

Yeah no need to mess with the cylinder or piston if they look fine. It’s a lot easier of a job to just swap the head gasket and studs. Also I’d be very impressed if anyone could keep the piston on the rod and get it into the cylinder haha

[@nictarver2988]

@@GarageAddiction oh I see, I was thinking of doing the lower gasket between cylinder and block while I was there, but I guess there is no need if it's not leaking.

[@GarageAddiction]

@@nictarver2988 yeah I wouldn't worry about the base gasket if you're just in there for the head.

[@arcticp4230]

around how much did the the parts cost? thanks

[@GarageAddiction]

Been a minute since I did it but I want to say it was about $300 tools/parts

[@shyams335]

Hello great video . Please tell we’re did you get the service manual if online kindly share the link

[@GarageAddiction]

www.ktmduke390forum.com/threads/ktm-duke-390-self-study-manual.1810/page-4 Linking a forum thread reminds me of my youth.

[@shyams335]

Thanks ! Keep up the good content

[@GarageAddiction]

Thank you!

[@boogieman065]

Why didn't you go with a larger coolant passage gasket or high compression gasket?

[@GarageAddiction]

I didn’t see any with a larger coolant passage, I’m interested though. I skipped the high compression because of how high strung they are and I’d wanted to make sure everything was working well at stock power before throwing a bit more at it.

[@amalvp2744]

Hi , where can I find the service manual for 2016 rc390

[@GarageAddiction]

Check out this thread: www.ktmduke390forum.com/threads/ktm-duke-390-self-study-manual.1810/page-4

[@snoopdeckin]

is this throttle body is equipped with Ride By Wire Technology ? or accelerator cable connected ?

[@GarageAddiction]

My bike is ride by wire, I think that was a 2017 change but I could be wrong.

[@snoopdeckin]

@@GarageAddiction yeah right I found online manual for duke 390 2016 study material I couldn't see RBW tech or unit on TB. Change was done in 2018

[@gressshap8200]

Having watched your videos showing all the changes made to fix the coolant mixing issue I can only think of one other possibility….. the joint between the two engine casings. The coolant passes into the casing at the front of the barrel and has to pass the casing joint prior to entering the pump. Anyone have any other suggestions?

[@GarageAddiction]

Yeah I've eliminated most possibilities now. Planning on drilling a weep hole and pressure testing the cooling system (not by the rad cap as the seal is poor) If it turns out to be the cases it'll be fun tearing the whole engine apart :/

[@austingraham5633]

9:30 second on tear down video. Is there any way to miss align the new piston when installing just curious had me thinking when u installed

[@GarageAddiction]

There is a marking on the top of the piston that goes on the exhaust side. I think I mumbled something about exhaust instead of properly explaining what I was doing.

[@austingraham5633]

@@GarageAddiction okay was just making sure they were aligned right didnt want u to have any problems just makin sure thing were good

[@GarageAddiction]

Much appreciated, I actually rotated the cylinder at one point and installed it backwards. I threw something across the garage and took a beer break after that.

[@mohanmano4969]

Hi i have ktm rc 390 bike.i got a issue of high coolant temperature and noise from magneto cover side like ticking sound sometimes not continuously so suggestions feom your side

[@GarageAddiction]

Not sure what the noise would be, being intermittent it may be something knocking around. Coolant temp could be anything from high ambient temps with a stock setup, water pump seals leaking, or a blown head gasket.

[@mohanmano4969]

Everything is new coolant lvl is ok no leak and the head is new one

[@mohanmano4969]

Is it possible for any sensors error

[@GarageAddiction]

@@mohanmano4969 hmm it's possible, I have zero experience with that though

[@mohanmano4969]

Anyhow thanks mate for sharing your thoughts

[@usitharanjana2762]

Wow🙂❤️

[@tommygun_traveller]

how many km has the engine done? does it last long? I would like to buy the 390 adventure ... great video thank you greetings from Germany

[@GarageAddiction]

It had about 5500 miles / 8850km on it when I rebuilt it and it's at about 6200m / 9977km now. I bought it with the head gasket leaking so I can't speak to what it went through before me but it's probably my most finicky bike. Cheers!

[@gabrielimartincalvo2879]

gran trabajo

[@GarageAddiction]

Thank you!

[@nadeeprider1806]

What's the Valve clearance..?

[@GarageAddiction]

ex. 0.13 - .017mm int. 0.08 - 0.12mm

[@nadeeprider1806]

@@GarageAddiction thanq from agera automotive ❤️

[@michaelcrouch5708]

I think ktm have since enlarged these figures a bit.

[@dissonantiacognitiva7438]

Is it a direct injection engine?

[@GarageAddiction]

It's got a throttle body injector

[@dissonantiacognitiva7438]

@@GarageAddiction so it's a closed loop single point injection system I am looking at the feasibility of an lpg conversion for a Duke 390

[@GarageAddiction]

That sounds like an interesting project for sure

[@dissonantiacognitiva7438]

@@GarageAddiction it's more like a stupid project for me 😁 The issue is the tank, I think under the seat there is enough seat for a gas tank, something like 5 to 7 liter, but it would be fiberglass internally lined with nitrile rubber Because the main issue here is actually where to put the new lpg tank or whether you can use the main tank for lpg - easy to find out with a compressor to pressure test

[@dissonantiacognitiva7438]

@@GarageAddiction what's the deposit material? Is it steel? Aluminium?

[@balmoralpjk]

Do you wear any Levi’s jeans in particular with your motorcycle?? Or have in general?

[@GarageAddiction]

I don’t think I’ve ever owned a pair of Levi’s haha

[@AshikAshik-rt6dr]

i am also a mechanic i want to do job you will call me