How to Fix the KTM 890 Duke R Coolant Leak - Common Issue SOLVED

[@AlejandrosEngineeredLifestyle]

Hey Everyone! I prioritized this video based on everyone’s questions. Are there any other maintenance items you’d like me to address for you, if so leave them in the comments below? Also, please consider supporting the channel by using my affiliate links, it would really help me out!

[@godzillacat1291]

Let me know if you get a sprocket seal leak or valve cover gasket leak. I had both of those as well as the coolant leak on my 790 Duke

[@godzillacat1291]

I also had a throttle hunting issue when starting the bike the first time for the day, which was fixed eventually by a software update

[@AlejandrosEngineeredLifestyle]

@@godzillacat1291 thanks for the comments! After about how many miles did you see these issues?

[@AlejandrosEngineeredLifestyle]

@@godzillacat1291 like wandering RPM’s? Was there a leaning out, like a sputtering, or an RPM spike? Also, what software version is the bike now running?

[@godzillacat1291]

@@AlejandrosEngineeredLifestyle the engine would begin to stall and studder when idling after start, then the electronics would bring the RPMs up and rev the bike. The RPM would swing up and down untill finally it would swing too low and stall out the bike. It would Rev up to like 6k or so. I'll have to double check on the software version.

[@cizur7626]

Perfect. Just called KTM about this exact problem. Mine has started leaking and dripping onto the exhaust causing smoke on startup. Excellent video. Thx!!

[@AlejandrosEngineeredLifestyle]

Thanks for watching and your comment! I just took mine for the first ride of the season this afternoon here in CO and it was gorgeous! Hope you rip it soon 👌🏽

[@cizur7626]

@@AlejandrosEngineeredLifestyle I just ordered a new bottle of coolant & will follow your video. Back on the road in no time. Can't wait for the warm weather, enjoy. Love the KTM duke 890's 😎

[@godzillacat1291]

Had the same problem on my 790 Duke. The dealership fixed it however they filled it with a different type of coolant thats clear so it's nearly impossible to read the level in the expansion tank...

[@dukie1616]

That was an excellent how-to video. I’m quite tentative when it comes to working on my 890r so something seemingly as mundane as adding coolant, I find I was doing it all wrong. Didn’t know to add it right to the radiator and or bleeding out the air. Last time I just added it to the expansion reservoir. Also the coolant level finder is so opaque that I really liked that backlight idea you did. Please please continue to share in this clear and concise format anything you do to your 890r. Again thank you for sharing.

[@AlejandrosEngineeredLifestyle]

The bleeding is only necessary if the expansion tank is empty like mine was so don’t fault yourself if that wasn’t the case. I agree, the opaque indicator is quite terribly designed. Thank you for your compliments, I will certainly do my best to continue. I have the tire replacement video coming out next and it is equally (if not more) in depth!

[@dukie1616]

@@AlejandrosEngineeredLifestyle I’m looking quite forward to that video

[@florian_edinger]

I had exactly the same problem, just tighthen it up and you are good to go!

[@AlejandrosEngineeredLifestyle]

Glad this took care of your problem as well. I admit mine seems to have leaked a little over this last winter but I’m gonna top it off again and report back. I hear samco hoses can help if the issue persists but I’ll have to test that out if I see more leakage. I appreciate the comment, ride safe out there!

[@florian_edinger]

@@AlejandrosEngineeredLifestyle Thank you for your reply, appreciate it! UPDATE: it began leaking again, at about 1000km. My KTM dealer said it is dripping out of the thermostat. At the moment it is getting fixed by them. I also have a issue with my breaking system on the front wheel. I have some weird vibrations and a crazy sound at a certain point while decelerating. Of course everything is getting fixed on warranty, just bought it in January. Greetings from Austria!

[@mjones53]

Thank you, I just noticed my '22 890r is doing this so I will try this and hope it fixes it!

[@AlejandrosEngineeredLifestyle]

I hope it is the fix you need as well 👌🏽 If you notice further leaks let us know!

[@michaelmotam]

Funny I started having this same exact issue yesterday on my 890R'20 and this video shows up! Thanks Alejandro, keep the 890R videos coming!

[@AlejandrosEngineeredLifestyle]

Hell yeah, happy to help man. I hope it fixes it for you. I have to admit, as the seasons change I have noticed some small leakage as the evening get colder. My bike lives in the garage but still seems to be affected. I am working on a samco evaluation, I’ll let you know if I can get any discount code or anything. For some it seems associated with the thermostat housing which neither of these solutions will help but here’s to hoping yours isn’t among them! Cheers 🔥

[@franksantarcangelo6014]

So I have an 890 Duke and I’m glad I caught this video I subscribe to your channel the flange on mine actually cracked I had it replaced under warranty my coolant leaked into the engine I’ve also had to replace the timing chain tensioner twice so there’s been three in the bike and the timing chain and most recent I need camshafts …for me this was a dream bike that turned into a nightmare Had the whole summer of riding taken from me😔

[@AlejandrosEngineeredLifestyle]

Oh shit, I’m so sorry to hear that. That’s a lot to go wrong. I’m assuming the bike was bought new? I’ve not heard of one needing camshafts yet, wow. Sorry about your summer friend, my first was also a busy because I’ve been injured. What’s the ETA on having the camshafts replaced?

[@PadmaDorjee]

This is very helpful mate, thank you.

[@mammocas]

Thanks! Found your video from a Reddit thread. My Duke was leaking a tiny bit from that spot, seems to be a cold winter thing, when the temps in my garage get into the 40s. Tightened it a bit, let's see if it holds! And why did they make the expansion tank so hard to see into?...

[@AlejandrosEngineeredLifestyle]

Hey thanks for the comment! That is so awesome, I had no idea my links are up there. I agree completely, the tank and cutout combo were very poorly designed, I’ve been toying with the idea of making my own covers with a local custom carbon shop nearby. I really should check that thread out for more content ideas/questions I can answer. Are there any videos in particular that you’d like to see?

[@MrWiskin]

Each of these I only saw you thighten one! Also a flat blade screwdriver is a lot easier! Mine took two turns very loose...

[@AlejandrosEngineeredLifestyle]

Oh wow, that is loose. Thanks for the tips 🔥

[@Zacharywes]

Have the same problem happening rn thanks for the video

[@AlejandrosEngineeredLifestyle]

Glad I could help! Let me know what other videos you need and I’ll try and get them uploaded. Hope you’re ripping out there, the weather is perfect for it lately 👌🏽

[@sadeqalbana]

I had coolant loss issues and I thought that it's just evaporating, the original coolant was transparent so I couldn't note the leak, but once I changed to Motul's red coolant I started to notice the leak immediately.

[@AlejandrosEngineeredLifestyle]

It’s not a fun discovery I’ll give you that. Hopefully you can fix yours with some tightening, mine is back after a couple years and I’m looking into either hoses or thermostat replacement at this point. I’ll keep you updated!

[@OneBigPuzzle]

Thank you! Mines doing the same hopefully this fixes it for me

[@AlejandrosEngineeredLifestyle]

Here’s to hoping! Let me know if you’re in need of any other maintenance videos

[@M530H]

Can you provide more info on the ratchet. Length, make, model? I think I just need to tighten everything up on my bike just like your video shows, I just want to get the right tool for the job. Also, you mentioned being able to diagnose the bike using a phone. I don't think I saw that video in you playlist. Appreciate all the info in the video.

[@mikaelborjesson3339]

Seems to have the same problem also now. See that it also leaks from the water pump area.

[@TomDw94]

i have exactly the same problem, sometimes a little water drop on the floor, landed on the exhaust and then on the floor.

[@AlejandrosEngineeredLifestyle]

Sorry to hear it! Mine hasn’t leaked yet, I did notice for me it was happening on fall/early winter evenings when the temps would get very low at night in the garage. Otherwise, on warmer weeks it wouldn’t leak, very odd. Anyways, the tightening in the video helped me eliminate it but I know so people end up going with the SAMCO hoses which you should look into if need be. Hope it helps, cheers!

[@sadeqalbana]

It's no problem overfilling the expansion tank, any extra coolant will leak from the hose behind the radiator when it heats up

[@AlejandrosEngineeredLifestyle]

Ahhhh… I’ve never thought about that. That’s actually very insightful, I made a fuss when I overfilled mine using a pump to extract and all lol. Thanks for the tip, I appreciate the comment!

[@rustcohle6248]

I'll have to give this a try and hope i dont lose anymore coolant in the future! Did you get the quick turn throttle yet? I just got one and an install video for that would be greatly appreciated. Also in the last video your rear tire was worn and wanted to know how many miles you got out of it? With gas prices this high I plan on riding my bike as much as possible so looking to get an all weather tire instead of the cup 2's.

[@AlejandrosEngineeredLifestyle]

Let me know if the leak is occurring in the same place and if it’s remedied. I actually haven’t… it’s been three months since the first was ordered and lost in the mail and I’m waiting on my second order to clear customs. Who did you order through? It will definitely be something I will create and review when I receive it! I hear you about gas… I switched to the S22 and have a video about tire replacement coming out next! The Cup 2’s were actually 5k miles but that was really stretching them obviously, not advisable. From what I hear the S22 triple compound in the rear really helps with longevity.

[@AlejandrosEngineeredLifestyle]

@HahrtDood that’s music to my ears! So far I’m loving them

[@CjsGfX]

Did you do the diagnostic from your phone video?

[@AlejandrosEngineeredLifestyle]

I did, that is one of the first videos that will be coming out now that I’m healthy again! Look out for a diagnostic DIY soon! Cheers

[@siksniper1996]

How many miles did this happen at? Mine has some very very minor seepage at the upper radiator hose at 1500miles

[@AlejandrosEngineeredLifestyle]

My leak was present at the time of my purchase which was also at 1500 miles unfortunately. Do you have the 2020 model year? I have noticed my leakage is related to cold temperature (even though it's garage kept) which is a confirmation that CTE mismatch of the hose and flange material is a factor.

[@siksniper1996]

@@AlejandrosEngineeredLifestyle I have the 2021 model, I ended up buying a worm gear clamp and it sealed right up

[@AlejandrosEngineeredLifestyle]

@@siksniper1996 glad to hear it!

[@RamiH]

my bike has around 550 Miles, due for service soon, i just checked the coolant and that thing is empty. SHould i usually check when it is warm?then you can see the coolant level where it should be in the white reservoir ? or should it show cold or warm on any day . i havent driven it for like 9 hours it has just been sitting there and i just saw this video. I have checked for leaks but noticed none at all.

[@AlejandrosEngineeredLifestyle]

Ahhh yes, this has happened to me before as well sorry to hear that friend. There have been people reporting the tanks weren’t adequately filled from factory so if you’re not leaking this may be the case. Also, there are other people reporting a clear coolant was used instead of the 3.0 which could also explain why you can’t see it. Unfortunately, the stupid reservoir siding is quite translucent so I’d use the light shining up as I demonstrating in the video while the bike is level (on stands/being held upright) to properly assess. The coolant should come to the halfway mark on the clear siding, there won’t be much difference cold versus warm. When the bike is on its kickstand if the coolant is at the low point it will show nothing if evaluated at that angle.

[@RamiH]

@@AlejandrosEngineeredLifestyle you are absolutely right. When I first got it, I could barely see the pink coolant at the minimum which I found strange. Now, nothing shows even with the light. It’s gng to its first service in 2 days so let see what happens. Thanks for this awesome channel.

[@AlejandrosEngineeredLifestyle]

Thanks for the comments, let us know if you run into any new info during service!

[@RamiH]

@@AlejandrosEngineeredLifestyle I certainly will. This is my first bike and I need to learn a lot of mechanical and technical things because it would help down the road for DIY maintenance and small quirks!

[@AlejandrosEngineeredLifestyle]

@@RamiH Definitely, well if there’s anything you need please just ask and I’ll try and put together videos we can all use. I’ve got deep cleaning/chain maintenance and suspension adjustment coming out next as far as the 890 goes!

[@tiolibikes8663]

Very good thank you

[@Mr4321aldo]

Thank you

[@AlejandrosEngineeredLifestyle]

Thank you for the support and comment! Let me know what other videos you need

[@1031shadowwolf]

Mine is leaking in the same spot

[@AlejandrosEngineeredLifestyle]

Sorry to hear it, I have to admit mine did leak a little over this winter as well. I may look to a different hose solution or talk to my AD about the thermo replacement if it persists.

[@okie-rider]

Mine had the drips this morning!

[@AlejandrosEngineeredLifestyle]

Sorry to hear that, hopefully you can snug up the hose!

[@okie-rider]

@@AlejandrosEngineeredLifestyle had every ratchet but the right one! Fingers crossed it’s done dripping

[@AlejandrosEngineeredLifestyle]

Yeah, I had to go buy that 1/4" because everything I had was too large... isn't that how these things go. Was there a change in temperature overnight by chance? I've noticed mine still drips a little with temperature swings.

[@okie-rider]

@@AlejandrosEngineeredLifestyle not really I don’t think on the temp change.

[@santhoshbk7056]

Bro ! you’ve earned my sub! 🫡

[@AlejandrosEngineeredLifestyle]

Thanks bro! Hope the channel helps you 😁