Prepping my 2014 KTM Duke 390 for an engine rebuild

Also installed fork protectors from the Bajaj Dominar 400, since they share the same suspension.

BHPian Dhruv Shetty recently shared this with other enthusiasts:

During the Malkapur ride, I came across a low oil pressure warning, which used to come on briefly below 80 km/h disappear in 3 minutes and keep coming back at a 10-minute interval. On the way back it became constant and stayed on till I reached back home. In the entire 900 km ride the engine was responding perfectly and shifting smoothly, it even survived peak hour traffic of Mumbai on the way back, found it very puzzling. In Pune, I even stopped at a garage and asked for 10W50 and they did not have it. Next day in the morning, went to the KTM SVC to pick up an oil pressure sensor and 2 bolts for the leg guard, while returning, inquired at a few garages for 7100 10W50 and none of them had it, so put an order for it on Amazon and opted for same-day delivery.

When I saw the status out for delivery in the evening, put the bike on the paddock, and cleaned off the chain with ease with a cloth, the chain had become so dirty during the ride, that it didn’t need the chain cleaner, removed the belly pan, cracked the drain bolt loose and slide a pan underneath and let the oil drain oil, I was expecting 500 to 800 ml of oil to come and the oil pressure sensor to be faulty, but to my shock only 200 ml of oil came out, the oil had done only 1500kms. My brain was attacked with strong emotions, I was questioning how the engine survived the trip, same thoughts were in others' minds. And luckily while the oil was draining, the fresh oil just got delivered, bolted everything up and filled her up with fresh oil, did a test run later in the night to see if everything was proper and it was.

Post all this, had some talks with myself for hours about whether to sell the bike and buy a new bike, store it off forever or still spend on it, after 5 long days of thinking and riding the bike once a while, decided to keep it and start saving up for an engine rebuild as it is burning too much oil, plus the bike has never stranded me anywhere.

Had a long chat with Vighnesh about the plans for the bike, and he suggested to just open the valve cover myself to check the condition of the valves and timing, opened up the cover after a few days and everything looked good in there, some relief to the mind. During the rebuild, we are going to strip the entire engine and make sure nothing else is bad or going bad in the engine, if I am lucky, it will be just the block piston assembly. On the positive side, I am proud of the engine that it has held up well for close to 40k with 3 owners and it still runs how it should, it has been a good 23k of riding from my side, and it comes down to the way the bike is treated, only a select few people are allowed, very particular about maintenance and who works on it.

When picking up the oil pressure sensor and 2 bolts, all three gens are in one frame.

Installed Dominar fork protectors

I always wanted to put the Dominars fork protectors in the duke, I have been searching for them for quite some time, and went to Bajaj SVC also once, but they didn’t have them either. As the Domi and the Duke share the front suspension, I was 100% sure that it would fit. One fine day, post-midnight was casually browsing bike stuff, went on the 99rpm site got myself registered, searched for the part placed an order for it and waited for a week for it to come. Compared to the 1st gen Duke fork protectors which have less coverage, the Dominar ones have a better coverage.

The day it arrived, I wiped out the tool kit and got down to work, removed the old ones and placed the Domi ones in and realised that some portions of the protectors were fouling with the fender, so some adjustments were needed, the right side one I did it Crudely by taking a Swiss knife and flame to do some cutting and the left one, did it in a more sophisticated way after realizing that I can file it off, while I was working on the right side one. Took some time, along with some cutting and scraping, but it fits.

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