640's Service / Maintenance / Modifications thread - TAKE TWO ! - KTM Duke 390 Forum
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post #1 of 74 Old 08-14-2016, 07:21 PM Thread Starter
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640's Service / Maintenance / Modifications thread - TAKE TWO !

Ok, so I felt my first version of this thread drifted a fair way off topic before it really got going, so I decided to start again

I'm really not trying to make any sort of point, it's just that I expect to be spending a fair few hours keeping it updated so would rather it has a more coherent flow - at least at first .

I used to frequent a car forum where threads were regularly edited to keep them 'on topic' by moderators and I have to say that this forum is a much more enjoyable place to hang out.

Less is more - You can only use 150hp .001% of the time, but you can use 150kg 100% of the time ...........


2015 390 Duke / 2001 KTM 640 Duke2 (awaiting carb rebuild) / 1998 Bandit 1200 (half dead) / 1994 DR350 (in bits)

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post #2 of 74 Old 08-14-2016, 07:25 PM Thread Starter
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If a Magpie had a Duke 390 and an Ebay account - a few things I have collected over the last few months......














R6 shock most recent arrival - came yesterday for £33 delivered and looks almost mint !



Printed off the w/s manual.....



.....and spare parts manual as below (see sticky in sevice forum - thanks @malJohann) to make life a bit easier fitting everything.




I shall keep this thread updated with my progress.

Less is more - You can only use 150hp .001% of the time, but you can use 150kg 100% of the time ...........


2015 390 Duke / 2001 KTM 640 Duke2 (awaiting carb rebuild) / 1998 Bandit 1200 (half dead) / 1994 DR350 (in bits)
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post #3 of 74 Old 08-14-2016, 07:31 PM Thread Starter
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You've done well little magpie, you've done well.
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Very nice. I have both the shop and parts manual too. Quite handy. I like the R6 shock. That might be something to look into.
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Very nicely photo-documented and organized, 640. I must say your example of the R6 shock looks rather more pristine than mine! Lucky man!
BTW, just what is the strangely-shaped black plastic part with a hole in the center? Possibly some sort of replacement headlight module?
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Got me stumped too....DarthVader mask? some sort of air intake thingie?, base for tank box?

Less is more - You can only use 150hp .001% of the time, but you can use 150kg 100% of the time ...........


2015 390 Duke / 2001 KTM 640 Duke2 (awaiting carb rebuild) / 1998 Bandit 1200 (half dead) / 1994 DR350 (in bits)
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post #4 of 74 Old 08-14-2016, 07:35 PM Thread Starter
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Sorry, wasn't trying to be deliberately cryptic, originally I was going to post a short description under each photo, but then I thought why bother? Not much to say about a NGK spark plug or 4 litres of Motul oil that you can't already work out from the picture.

Seemed a good strategy untill you get to the mystery object which incredibly actually IS an exclusive limited edition Darth Vader Headlight module, which (complete with D.V. heavy breathing noises run through a P.A. system and three 1 billion lumen LED beryllium lasers) scares the crap out of everything else on the road.

Except it's slightly less exciting than that sadly, here's one @HedsKatoom fitted earlier (bottom of page 2) :

http://www.ktmduke390forum.com/forum...erience-2.html

Less is more - You can only use 150hp .001% of the time, but you can use 150kg 100% of the time ...........


2015 390 Duke / 2001 KTM 640 Duke2 (awaiting carb rebuild) / 1998 Bandit 1200 (half dead) / 1994 DR350 (in bits)
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post #5 of 74 Old 08-14-2016, 07:58 PM Thread Starter
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Ah so, SW Motek... I had finally concluded it must be a cosmic ray filter.
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640,

How has your experience been with the Tutoro chain oiler? Where did you mount the oil reservoir so it is upright? Do you find the unit effective at reducing the PITA of chain maintenance?

As a long-time shaft drive fan, I am contemplating a simple chain oiler to take chain maintenance and hassel off my agenda. I want something basic, without electrical or vacuum connections, light and uncomplicated. I am looking at the two I believe you once suggested: The Tutoro and the MotoBriiz. I'm leaning towards the latter - the ultimate in simplicity - but I am concerned about putting the applicator pad and supply hose so close to the hot exhaust cannister. The Tutoro seems to have a better/less vulnerable oil-feed device, but it is more complicated and expensive. It appears that the manual model Tutoro is no longer available. ??? What are your thoughts?
@Diploman unfortunately (In common with everything else pictured above) I have not got around to fitting my chain oiler yet, however I expect to get to it this week. I don't think that with the manual oiler mounting near vertically will be so crucial, but we shall see. I have been a big fan of Scottoilers in the past, so yes I am confident the Tutoro will mean the chain will stay in adjustment for much longer periods.

Had a quick look at the Tutoro website and I see that all the manual oilers are described as 'Sold Out' perhaps this means they will be making some more in due course? (I got mine about the end of June I think).

Less is more - You can only use 150hp .001% of the time, but you can use 150kg 100% of the time ...........


2015 390 Duke / 2001 KTM 640 Duke2 (awaiting carb rebuild) / 1998 Bandit 1200 (half dead) / 1994 DR350 (in bits)
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post #6 of 74 Old 08-16-2016, 04:34 PM Thread Starter
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The story so far

2015 dealer ex demonstator purchased October 2015 with 1407 miles

Mileage now 4056 miles.

I needed a practical short distance (10 or 20 miles a day depending on route) year round commuter, so initial mods focused on:

crash protection

visibility (mirror extenders & LED DRLs)

practicality (paddock stand bobbins and a rack to mount a topbox).

Longer standing members may have seen some of these mods before but I just wanted to gather them into one thread

With the useless stock mirror position quickly sorted, the illegible tacho, spongy front brake and jerky throttle response were left to battle it out as most annoying feature (over these generally short journeys).

I think I bought the tacho first (although not wired it up yet ) it being somewhat cheaper than a piggyback ECU, the brake action I've become more accustomed to.




Mirror extenders (£13) ideal place to mount LED DRLs (£20)



Front axle crash mushrooms (circa £20 for full front / rear set) SW Motech crash bars (circa £100) and belly pan delete




SW Motech rack (circa £100)



Paddock stand bobbins (£6) & Rear crash mushrooms



Koso tachometer (£77) mounted on instrument binnacle mounting bolt, (but yet to be wired up). Also shows petrol cap decal (£10)



Pillion peg & Belly pan delete


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Less is more - You can only use 150hp .001% of the time, but you can use 150kg 100% of the time ...........


2015 390 Duke / 2001 KTM 640 Duke2 (awaiting carb rebuild) / 1998 Bandit 1200 (half dead) / 1994 DR350 (in bits)
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post #7 of 74 Old 08-16-2016, 10:22 PM
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..I used to frequent a car forum where threads were regularly edited to keep them 'on topic' by moderators and I have to say that this forum is a much more enjoyable place to hang out.
Pleasure. Please feel free to thank the tireless admins and moderators any time you feel the need.

[EDIT] Nice bike too, needs hand guards though. [/EDIT]
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post #8 of 74 Old 08-18-2016, 10:52 AM Thread Starter
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Pleasure. Please feel free to thank the tireless admins and moderators any time you feel the need.

[EDIT] Nice bike too, needs hand guards though. [/EDIT]
Kind of ironic as I was partly thanking the admins for doing less

Or maybe tirelessly doing more to make it look like less

Handguards useful in the depths of winter agreed, so I temporarily fitted an ebay cheapo set (£15). Quite like a more 'classic' look though (and not having to look at the cheap and nasty handguards I bought )


This just arrived



Was a bit dubious about quality for £10.40 (ebay) but all of the parts you would want to be metal are metal, overall quality seems superb for the price (and I even got it on a best offer bid for £9 ). Has a USB port for charging, hence the wires.

Plan is to mount my old android phone and use the speed camera detector app. Don't need it for riding locally but definitely a good idea for longer trips these days

**** - even more stuff to fit, best pull my finger out and start doing something

Less is more - You can only use 150hp .001% of the time, but you can use 150kg 100% of the time ...........


2015 390 Duke / 2001 KTM 640 Duke2 (awaiting carb rebuild) / 1998 Bandit 1200 (half dead) / 1994 DR350 (in bits)

Last edited by 640; 08-18-2016 at 10:54 AM.
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post #9 of 74 Old 08-18-2016, 11:57 AM Thread Starter
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Trial fit


Less is more - You can only use 150hp .001% of the time, but you can use 150kg 100% of the time ...........


2015 390 Duke / 2001 KTM 640 Duke2 (awaiting carb rebuild) / 1998 Bandit 1200 (half dead) / 1994 DR350 (in bits)
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post #10 of 74 Old 08-18-2016, 09:26 PM
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Kind of ironic as I was partly thanking the admins for doing less

Or maybe tirelessly doing more to make it look like less
I know. We moderate enough for grownups. If moderation requests sound like a kid's fight, no go.
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