KTM RC390 Disassembly and Engine Removal

[@larryalaimo4973]

Very helpful. Thanks for taking the time to film this!

[@lanl1845]

Thanks for helping me remove the storage box under the seat 😂 a bolt fell under the box and i couldn’t find a way to take it out until i found ur vid

[@sayingnigromakesyoutubecry2647]

Hey, this video is great. I noticed many things like the coolant overflow at 16:20 that I thought it was disconnected from the plastic canister before (at 16:00 or something). So thanks. You are doing a great service to KTM users!

[@marccaya8412]

Dismantled my RC390 without taking enough pictures; your video served me well as a reference for many bolts, attachments and parts placement. This bike is by far the worst I've worked on in the past 30 years! 😞 Thank you a thousand times for your detailed video.

[@GarageAddiction]

Haha glad it was helpful! Hope it's running well for you now!

[@marccaya8412]

@@GarageAddiction Last bolts where installed on dec 17th (yesterday). Even got a chance to try it on the road before the snow arrived today (up north in Canada). 🙂Having reajusted the valves (out of spec badly) and discarded the stupid rubber sheet over the engine I can clearly hear the clickety of the valves; nothing alarming.

[@1000sofusernames]

Nice work. Taking mine out this winter as I bought it cheap with 13000 on and a full service history...... Except when I looked at the service history in detail its never had valve clearances done. Useful video at least I know what awaits me!

[@GarageAddiction]

Thanks! I’ve got another video doing the valves too. They’re not so bad but I’d pick up a shim kit before you dive into the engine. Sounds like you got a steal on the bike!

[@francoisg9154]

Thank's very much to share your experience about extract engine. Now I can see that it's possible if you take a time.

[@snoopdeckin]

most detailed video if you want a open heart surgery of RC 390 instead of desperately rushing for online manuals btw there is another channel called Jeet Basker he mostly works on duke

[@pareeks]

25:06 that might be glycol base from coolant, getting mixed with engine oil and getting blown by into air filtrr box. I suspect this as your engine oil colour is way off that what is expected to be. This is just my assumption though. Great work on video and descriptive analysis.

[@alexsanchez4955]

Very painful to watch. But thats because I work the same way haha. Awesome video man. Helped me a ton!!!!!

[@GarageAddiction]

Haha thanks! Glad it was helpful.

[@moherhat]

Looking at the amount of work I think I will never check those valves.... it makes more sense to buy a new bike

[@GarageAddiction]

Haha it’s really not that bad, I’d do valves on this any day over an in-line 4.

[@DreamGrowls]

26:04 ideally this breather pipe should be routed to a closed filter externally. You can get many adtermarket breather filters. There would be 2 of these one from the crankcase which would have some liquid exhaust vapors coming through, the other from the top engine case with only vapor. Inhave removed these from the air box. Companies also do this to cheat on emisson norms is what i heard. Cheers!

[@GarageAddiction]

Yeah I’ll probably tie these into a catch can at some point. It seemed like a decent amount of fluid made its way into the air box previously. Cheers!

[@AshikAshik-rt6dr]

Nice 👍👌 video

[@mor3frame]

free pink lemonade :) 3:32

[@GarageAddiction]

Comes with a lovely and expensive trip to the hospital!

[@Freddi922]

Hi there - i'm starting on this project myself this week. The donor motor is a 2018 Husky 401 motor which from what I heard was made in Austria so hopefully I wont run into any issues with the head gasket. Question for ya - which parts did you find was not really necessary to remove in the end (if you had to do it all over again?) great video this is going to serve alot of people well especially newbies who dont know what a pile the early gen RC390's are like me ha!

[@GarageAddiction]

It's been a while but I think almost everything I pulled off needed to leave to get the engine out comfortably. Interested in how the 401 does in there!

[@Freddi922]

@@GarageAddiction I will def keep you posted!

[@Freddi922]

Just wanted to let you know I got the 401 motor in and running. Only thing with swapping older to newer motors is that the gear indicator connections and coil pick up connections have changed. Its easy to splice the coil pick up in there but rather impossible to do integate the gear indicator without swapping them out and splitting cases. Not a big deal but the bike wont idle with the kickstand down because it doesnt know what gear its in. I will use a bypass to fix that and just live with it for now...just wanted to give you an update. Thanks for all your help with the video, it helped. I did not remove any harnesses or cables out of laziness and fear of not remembering how it all came together but your video was clutch in the whole project. Many many thanks to you.

[@GarageAddiction]

@@Freddi922 Glad it went well! That sounds like a fun project!

[@Freddi922]

Keep up the great valuable work!

[@Claudio.d]

hi, i just wanted to know since i wanted to make an engine swap, if like the duke also the rc 125 and 390 have the same chassis

[@GarageAddiction]

No idea, I've only ever had the 390

[@khmerghost]

I like raw videos where there is no fast forward and skipping some parts of opening the parts.

[@GarageAddiction]

I do too from an editing perspective but they definitely don't get as many views as the shorter videos :(

[@isaacmojica5699]

Could anyone help @ 43:29 there is two black connections on the middle left a couple inches above the motorex logo what are these my Duke 390 has a oil buildup there

[@isaacmojica5699]

He points exactly to them at 43:03

[@herbycarlos6794]

That glue mess on the airbox is factory. Experienced the same on buddy's Duke. KTM India quality.

[@GarageAddiction]

It looks someone went ham with wood glue.

[@herbycarlos6794]

Yeah, looks same way on the Duke, like someone haphazardly went nuts gluing the airbox together.

[@debyttt1]

Which oil do you use? Here in Brazil, MOTOREX full synthetic 15w50 is indicated. But this changes in each region.

[@GarageAddiction]

I use Motul 300v 15w50, amzn.to/3Uc6hHX It doesn't get very cold here so it's perfect.

[@debyttt1]

@@GarageAddiction Thank you.

[@mysteryport]

​@@debyttt1 In India, we use 10w50 grade for 390 Only and Motul, Castrol and Liqui Moly are the standard brands for KTM. Castrol is the BEST for Duke-RC 390.

[@caseymurray7722]

What were the most common sizes of bolts you used during this? Trying to put together a small toolkit for roadside repair

[@GarageAddiction]

I'd have to go back through and check but I know 5 and 6mm allens, and 10, 12, 14 sockets would be good.

[@steven-vn9ui]

Your bike should have a kit under the seat, if not maybe you can find one on ebay hopefully?

[@pradeepkummu1917]

👌👌👌👌👌👌👌

[@snoopdeckin]

9:11 below your right hand that silver color module what is that ? power commander ?

[@GarageAddiction]

Similar, it’s a Rapid Bike.

[@prashantkanojia3534]

Hey bro, i am from India i need some suggestion...i dontknow if you r aware of Bajaj bikes they are sister concern of jtm, here i would like to know if we can swap engine of duke 390 with Bajaj ns200... If possible can u do some research on it...and plz let me know if possible..i will be waiting.

[@GarageAddiction]

The engine mounts look similar but info on the Bajaj ns200 seems pretty sparse. My guess is that it wouldn't be a straight swap.

[@prashantkanojia3534]

@@GarageAddiction yes it would not, so that's why i thaught if u could help in this mod...anyways best of luck.

[@chrisgermann6658]

Imagine having to do this on a 600 or 1,000 i-4.

[@Dahiya0055]

Can u plss tell me the proper dimensions of engine of this bike .

[@GarageAddiction]

Like physical dimensions or displacement info?

[@Livogela]

Is this engine oil is better than they recommend

[@GarageAddiction]

The great engine oil debate haha. I won't say it's better because I've never run an oil analysis on the two nor do I know what KTM recommends based on additives and contents but Motul has been one of my most trusted oil brands. I've used their oils for multiple 24 hour races and I trust it.

[@snoopdeckin]

this single cylinder bike has lots of electronics than a 2 cylinder ninja 300, Fan made in india by kinetic

[@GarageAddiction]

Many, many connectors in here.

[@snoopdeckin]

@@GarageAddiction where is abs module located i didn't see it ? does it have a separate ecu or integrated to it ?

[@GarageAddiction]

Not sure, it may be under the battery tray where all the brake lines converge but I never looked

[@reneseib6532]

how many km on bike before doing rebuild?

[@GarageAddiction]

It had about 5500 miles / 8850km on it when I rebuilt it.

[@jagsfanrick]

Both of those comments are from bots, xtimer and tom.

[@GarageAddiction]

Seems to be happening more and more these days.

[@mathiarun90]

Hi, nice upload What is the weight of the engine???

[@GarageAddiction]

Thank you! The engine is probably around 75-80lbs, not too bad.

[@snoopdeckin]

battery near to fuel tank ????

[@GarageAddiction]

Its a pretty interesting place for sure, the cover over it sucks.

[@louisjudge5322]

I wonder if you are loosing coolant from the radiator where you see the road grime. If you had a head gasket issue, wouldn't the engine temps rise fairly quickly?

[@GarageAddiction]

I haven’t lost a drop since the rebuild. Before the temp would increase and never drop, the fan would come on and it would remain in the top line. Now it bounces between 1-2 under the line after hitting it. I’m actually thinking of adding another fan or larger rad to keep it 1 under the top line constantly.

[@tru1stdrifts104]

@@GarageAddiction i reccomend the spal racing fan on amazon my bike stays around 6 bars even in az summer

[@GarageAddiction]

@@tru1stdrifts104 yep, rocking the spal fan and it's great

[@sakibansari5740]

Hindi

[@sakibansari5740]

Hindi