[ridewthedevil]

I plan to keep my Duke 390 till the end of its life, and I do like to tour on it every now and again. I've already kitted it out with a remap, Cyclops LED< powerparts seat and the sintered pads.

I was just wondering if spending the money on the latest gen suspension, wheels and brakes would make a ton of a difference. Do let me know about your POV once you've rebuilt your bike. I had to replace my rear shock recently, but they didn't have the part number for the gen 3 shock. Might replace the front suspension with the gen 3 units in the future.

[Vignesh_N/A]

Originally Posted by Motolysis

... till now the bill is around 47k. It also includes the front and rear rotors and the new master cylinder.

Interesting. Please do attach the invoice.

Originally Posted by Motolysis

No matter what though, unless you have some sentimental value or some emotional justification behind this decision, I doubt if a lot of people would see any logic in spending around half a lakh on these upgrades.

Exactly. And the spending dont stop. Just today, I have a feeling the radiator fan is starting to go bad. Mine is from early batches of 2017. 7 years itself is an achievement for KTM.

Originally Posted by ridewthedevil

I had to replace my rear shock recently, but they didn't have the part number for the gen 3 shock. Might replace the front suspension with the gen 3 units in the future.

You could swapped for adv 390 adjustable suspension. The change in length is negligible between the stock and adjustable. It costs 6900 rs.

For the front, you have no option other than the parts from gen 3. But, I recently changed the fork oil to bajaj spec (which I guess is less viscous) and now it is softer than before.

[ridewthedevil]

Thanks for the tip Vignesh. Have you tried using the Adventure 390 shock on your Duke?

It'll be a while before I change the rear again, but the front has leaked a slight bit, so I'll probably change it out in a few years.

Gen 3 Duke parts are difficult to get. Even Bajaj/KTM employees that own the bikes are unable to get their hands on the taller 820mm seat assembly, which Bajaj had claimed they would offer to all customers.

[shadowrider]

Originally Posted by Motolysis

So I am in the process of a complete rebuild of my gen 1 Duke 390.

What all engine internals are being replaced? How many kms have you clocked so far?

[Motolysis]

Originally Posted by ridewthedevil

I was just wondering if spending the money on the latest gen suspension, wheels and brakes would make a ton of a difference. Do let me know about your POV once you've rebuilt your bike.

The complete rebuild might take time as I rarely get time to work on the bike. Also, I have almost forgotten what riding a Gen 1 or any Duke 390 for that matter, feels like, so I might not have a proper benchmark to compare to. If you are in Delhi or around, maybe you can come down and ride it and see if it makes a difference enough to shell out the money needed.

Originally Posted by Vignesh_N/A

Interesting. Please do attach the invoice

The highlighted parts are the ones that are absolutely needed in order to swap out the wheels and front suspension. I am not sure If you can use the original suspension with the new wheels. The from wheel is yet to be delivered so I will know for sure once I have it. Also, the old rotors and Abs plates won't fit the new wheel. Again, I will know for sure only once I have the wheel. There are a lot of other parts here like the bolts and circlips and axels etc. which I have not included in the highlighted price as I am not sure if they are absolutely needed or if we can use the ones from the gen 1. And then there are some parts that are to be changed on my bike as the older ones are either broken or leaking etc. like the fuel tank.





So the total comes out to be 32,557. I am pretty sure you would need some of the other bits but I am not certain yet. I ordered them all together because none of these parts are in stock anywhere in Delhi and they are taking time to come in, so I didn't want to wait around for weeks because I didn't order a set of bolts etc. Parts on my bike are in poor shape anyway and are showing their age as it's closing to be 11 years since I have had it and it was poorly parked (read under open air) for around 6-7 months. So, once the front wheel is delivered it would be another 7-8k taking the total to 40k, and again, this does not include the smaller bits and bobs.




This is the price of the front master cylinder with the adjustable lever if anyone is interested. 948 is the clutch lever. So, 5851 for the front master cylinder assembly.

Originally Posted by shadowrider

What all engine internals are being replaced? How many kms have you clocked so far?

I haven't opened the engine up yet. I am a little scared of doing it, to be honest. I think it would have done somewhere around 55k km as I had to get the console changed around 40k km. Therefore I am not sure. Maybe once I have it back together the OBD scanner will be able to read it off the ECU.

This is the current state the bike is in.





Notice that I had to butcher the rear shock to get it off the chassis.
I will be starting a new thread to share my learnings and updates from this whole ordeal.

Cheers.

[saikishor]

Just an intrusive thought, and Im curious as to what price my bike can fetch.

2021 June,
2nd owner
25000kms run
Maintained with a lot of love and care

[shadowrider]

Originally Posted by Motolysis

I haven't opened the engine up yet. I am a little scared of doing it, to be honest. I think it would have done somewhere around 55k km as I had to get the console changed around 40k km. Therefore I am not sure. Maybe once I have it back together the OBD scanner will be able to read it off the ECU.

Cheers.

When I read about the complete rebuild, I was focused on the engine only. So, was the engine running fine before dismantling? If it was better not to dismantle it. Keep us all updated on your progress.

[Motolysis]

Originally Posted by shadowrider

When I read about the complete rebuild, I was focused on the engine only. So, was the engine running fine before dismantling? If it was better not to dismantle it. Keep us all updated on your progress.

So that is the thing. There was clearly some power loss right before I parked the bike, and I also suspected some oil was being burnt. Around 1.2 litres of engine oil has come out of the bike. The valve clearances have never been checked either. But I am scared to open the engine up because most people seem to mention how once it's opened up an engine can never be the same. But that's also what is inciting a part of me to do it. To see how much truth that statement holds. Let's see.

[Dhruv Shetty]

Originally Posted by Motolysis

The complete rebuild might take time as I rarely get time to work on the bike. Also, I have almost forgotten what riding a Gen 1 or any Duke 390 for that matter, feels like, so I might not have a proper benchmark to compare to. If you are in Delhi or around, maybe you can

I haven't opened the engine up yet. I am a little scared of doing it, to be honest. I think it would have done somewhere around 55k km as I had to get the console changed around 40k km. Therefore I am not sure. Maybe once I have it back together the OBD scanner will be able to read it off the ECU.

Notice that I had to butcher the rear shock to get it off the chassis.
I will be starting a new thread to share my learnings and updates from this whole ordeal.

Cheers.

Going through everything, you really like D.I.Y stuff and best of luck with everything. I am going to keep an eye out on the brake and suspension swap, as i may try to replicate it in the future any many more Gen 1 owners who want explore. The front brake MC kit of the Gen 3 is pretty darn expensive, must be good. With everything dismantled, check the frame for any rust development, because now will be the perfect time to deal with rust by getting it resprayed nicely.

Originally Posted by Motolysis

So that is the thing. There was clearly some power loss right before I parked the bike, and I also suspected some oil was being burnt. Around 1.2 litres of engine oil has come out of the bike. The valve clearances have never been checked either. But I am scared to open the engine up because most people seem to mention how once it's opened up an engine can never be the same. But that's also what is inciting a part of me to do it. To see how much truth that statement holds. Let's see.

For me it was the other way around, no power loss, but there was heavy oil burning going on, like 600ml gets burnt in a 400 km ride, now i dont need to worry about it, as the bike is parked at a very good friends place and being taken care of, in a few months i will be commencing the engine rebuild, after alot of digging and brainstorming with the guys at Zenngine, i will be using BS6 390 engine components.

Coming to the valve clearance topic, if done from a skilled person it wont affect the engine in any way, if the correct procedures for bolt torquing and service intervals are followed then the engine will stay the same. Take my 390 for example (minus the oil burning) it has undergone two valve clearances, there hasn't been any issue. So for the valve clearance, take your time and right tools and every thing will good.

Looking forward to your upcoming saga of 390 build ownership review .

Cheers,
Dhruv Shetty.

[Vignesh_N/A]

Originally Posted by Motolysis

...The highlighted parts are the ones that are absolutely needed in order to swap out the wheels and front suspension...

Thanks for the invoice

I have a question for you guys. From your known circle, what is the ideal life of engine before a rebuild is required? I know it varies a lot with KTM, but I am curious.

Has anyone done recently? Need to I can see the piston block kit and crankshaft in 2020 is about 14K. Not sure if connecting rod is included in the piston block kit.

[Motolysis]

Originally Posted by Dhruv Shetty

The front brake MC kit of the Gen 3 is pretty darn expensive, must be good.

Doesn't seem to be of very high quality by the touch and feel of things, much better than the original one on my bike but the price tag did make me reconsider the purchase twice.

Originally Posted by Dhruv Shetty

With everything dismantled, check the frame for any rust development, because now will be the perfect time to deal with rust by getting it resprayed nicely.

There is no apparent rust on the surface, but I will be looking out for it once I start cleaning the motorcycle, one part and bolt at a time.

Originally Posted by Dhruv Shetty

Coming to the valve clearance topic, if done from a skilled person it wont affect the engine in any way, if the correct procedures for bolt torquing and service intervals are followed then the engine will stay the same. Take my 390 for example (minus the oil burning) it has undergone two valve clearances, there hasn't been any issue. So for the valve clearance, take your time and right tools and every thing will good.

Looking forward to your upcoming saga of 390 build ownership review .

Cheers,
Dhruv Shetty.

I am no skilled mech as this is my first-ever rebuild, but everyone has to start somewhere and since I had decided to do this entire rebuild solo, that's how the engine will be done as well. Fingers crossed or else the motorcycle will make for very expensive wall decoration.

Originally Posted by Vignesh_N/A

Thanks for the invoice

I have a question for you guys. From your known circle, what is the ideal life of engine before a rebuild is required? I know it varies a lot with KTM, but I am curious.

Has anyone done recently? Need to I can see the piston block kit and crankshaft in 2020 is about 14K. Not sure if connecting rod is included in the piston block kit.

The complete cylinder kit costs 19k as I had enquired just in case I need one. Didn't order it as it is readily available in stock, at least here in Delhi.

Regarding the engine life of Duke 390s, as you said yourself, it varies a lot. I know of Duke 390s that have done 70k and are still going strong, and of the ones that have needed rebuilds as soon as 20k. It depends on how it's being ridden, and maintained, the conditions where it is being ridden etc. But by nature of being a relatively higher compression engine, the components are going to be under more stress and hence have a shorter life span.

That being said, I have created a Google form which can help us get a better answer to your question albeit it gets enough responses.

Here is a link.

[Vignesh_N/A]

Originally Posted by Motolysis

The complete cylinder kit costs 19k as I had enquired just in case I need one. Didn't order it as it is readily available in stock, at least here in Delhi.

What is included in the cylinder kit ?

Originally Posted by ridewthedevil

Thanks for the tip Vignesh. Have you tried using the Adventure 390 shock on your Duke?

Yes. I have installed it in my Duke. Here (The KTM Duke 390 Ownership Experience Thread)

[ebonho]

Any issue in cutting away completely the tattered rubber outer dust covers of the rear view mirrors? Will it look ghastly? Of course the mirrors will be fully functional. I do not like the idea of shifting to Dominar (the shape) or later generation Duke (longer stalk) mirrors.

Cheers, Doc

[VijayAnand1]

Originally Posted by Motolysis

So I am in the process of a complete rebuild of my gen 1 Duke 390. And a part of the process is upgrades, which includes both the wheels and adjustable front suspension from the gen 3 Duke 390.

I doubt if a lot of people would see any logic in spending around half a lakh on these upgrades. I see logic in it. But my justification might not have much mileage with someone else's.

Once the idea to resurrect a vehicle has been planted on the venous caverns of the gray matter, it transcends the monetary aspect and it transcends the justification matter, the only thing that matters is to see that thing up and running to her former glory with that wide grin plastered. It's a feeling altogether different. Keep your saga logged, it might turn out to be a long winded one and a good one at that I feel. Recommend you do it at your best time and create a "separate" thread which would mean it's easier for us to get the best out of it.

Originally Posted by saikishor

Just an intrusive thought, and Im curious as to what price my bike can fetch.

2021 June,
2nd owner
25000kms run
Maintained with a lot of love and care

Well, to start of, anything around 1.6 to 1.75 is a good price, if you're lucky you can get a 1.80 to 1.88 that's the base and the best of it. Secondly, a 25 kays on a Duke 390 would most likely degrade the resale value as it's the prime zone for all things that can go wrong, provided the history and maintenance of the bike.

One of the prime reasons the bike getting such attenuated resale value is its finicky and shady service records coupled with servicing costs, all has acted against an otherwise brilliant pocket-rocket of a moto.

Cheers!
VJ

[shadowrider]

Originally Posted by Vignesh_N/A

What is included in the cylinder kit ?

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The cylinder kit consists of the cylinder block and piston installed inside it from the factory. This is how it looks. The connecting rod is separate.