Fuel Tank Removal KTM 390 125 200 250 Duke
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- čas přidán 29. 08. 2024
- There are times when you need to remove the fuel tank on the KTM 390 Duke, such as checking the spark plug or valve clearances. Because it takes a little while to do, I've pulled out this part of the process into its own video so the other videos can be shorter and more to the point.
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Thanks for taking the time to put this together. Helped me fit my Rapid Bike Easy. I’d have struggled without this video.
Glad to hear that you installed it! Great job and well done. Skäl. David
Same here 😀
Thanks David. This video helped me remove my tank much quicker than if I had figured it out as I went.
Glad it helped, for a naked bike, it isn't easy to remove the tank!
@@MotoMirius No sir it is not. I've had a lot of bikes and my 390 is the most tedious one I've ever removed the tank from.
Thanks for taking the time to show us this, helped me out beautifully, cheers👍
Glad it helped and thanks!
Hello, David. Thank you!
You are very welcome
The video that i was looking for, planning to re paint my bike to metallic orange mist, my question is if you still have gas on the tank when removing will it spill gas when i disconnect it to the bike. Your ktm bike tutorial is one of the most indepth on the platform, most are fast forward and does not explain step by step process. More power yo your channel good sir and ride safe as always🧡
When I removed the tank it was full of gas. It's a basic safety feature of any bike tank that it will not spill (don't turn it upside down) - you will get a small spillage of what is inside the hoses. Of course if you paint the tank as well it will need to be empty. Thanks very much, always appreciated and good luck with the respray!
Can you show a video on ignition lock set change for the 390?
Absolutly perfect! Keep it up, ur a great teacher haha!
Thanks Lars. Much appreciated. Skäl. David
Un tubo por fuera del chasis amigo , no obstante eres un máquina.
Man, God bless you
I'm serious, thank very much
You're welcome! Thanks!
Congrats about the video! And I that was thinking that remove the fuel tank of Yamaha XVS 650 was annoying because has to remove 4 bolts and the speedometer.... On Duke is a "little bit" more difficult....
Yes well. Even though it’s a naked bike it has fairings. I hate working with modern bikes 😂😂. But thank you. Much appreciated Jerônimo. Skäl. David
Any video on how to fix leaking fuel from vent hose to over flow pipe just around fuel tank lock?
Hi, your question isn't very clear - is it leaking fuel from the vent hose or the overflow hose? Or both? Fuel from the overflow is normal if the tank is overfilled or if fuel is splashed when filling the tank.
I'm very happy to see your video. Now I understand better.
I understand better the pitfalls to avoid so as not to break the connectors.
I wanted to know the year of your KTM 390 please?
In your opinion, is the tank from a 2017 390 Duke compatible with a 2015 390 Duke?
I want to change the tank of a 390 Duke from 2015 with a tank from 2017 (more fuel capacity).
You have hello from a Frenchman
Hi and thanks. Mine is a 2017. The frame is different so it would not be a straight fit, so it depends how good you are with fabrication.
Am i correct when i say 'even when there is fuel in the tank, it will not drain itself when hoses are off, because the attached fuelpump prevents leaking/draining fuel when not on '
Yes, the fuel in the hoses will leak out but the valves shut off the fuel flow from the tank so no leaks
@@MotoMirius thanx. Good to know. After my accident i have the ability to upgrade/rebuild my bike, so rapidbike, new exhaust from first bend to end, 2 wavediscs, complete decal covering, new plastics, new filters. Lot of fun work. Thanks for all the great videos. They will help me a lot on the rebuild 😀
@@jorgenlannock sounds a great build, have fun with that!
@@MotoMirius thanks. My only concern is the sparkplug now that everything will de opened up. I heard too many opinions, and i can't find good info to know if it's worth to replace with a better version and then which one. But,since i follow you, i think you have the same question about relyability and best pick.
@@jorgenlannock Yes, there are some things about which everyone is an expert yet no one agrees - tyres, spark plugs and exhausts. Iridium is probably better and I will try one sometime, but stock is just fine.
Thank you. This Video really helped me
Glad it helped! Skäl David
Life-saver of a video! Thank you!
Helpful video, do you think there is enough room to just lift the petrol tank and change the ECU without disconnecting the pipes? Cheers
Yes, I think you can do it, though it will be a balance between working slower and more awkwardly.
Thanks, I will have someone taking the weight of the tank while I swap the ecu, one thing I noticed is that there are no CZcams videos showing how to swap ecu’s on this KTM, maybe you could do one sometime? Cheers Ash
I will bear that in mind. I do need to pull the tank on mine sometime soon. Thanks@@ashleyod1346
Can I access the spark plug from the top of I move the fuel tank? My spark plug and grommet are stuck and I can get it out
It is possible to remove the spark plug without removing the tank if you have the right tools and small hands. But most people do it when the tank is removed as it's much easier.
@@MotoMirius Thanks you so much for all your help with videos and on replying to comments. God Bless you my bro
Que fantástico video aunque seria genial si fuera en español o subtitulado al español!!
No puedo agregar subtítulos porque no hablo español. ¿Se ofrece voluntario para agregarlos?
Just getting ready to install my new Powertronics unit and this helped a lot.
The ignition key surround had me stumped as to how it came off.
Great video David🍻
Thanks - yes, it is very very tight fitting!
It was easy to understand and helpful!
Thanks. Much appreciated. Skäl David
Hey David thanks for the vids ,,very useful,,just got a 2020 390 duke and your channel is Really helpful,,,,did a few mods thanks to you ,,fuelx lite , silencer taken out of stock exhaust,,,great sound ,,,,sorry a little long ,,but after removing the tank ,,,when plugging in the fuel filter under the tank,,, on the left side of the filter the longer inlet ,,,does it only click once over the first stopper,, cheers for any info on reinstall of filter thanks tony,,,,Have a clip on fuel line with the green locking tabs
Thanks. It should be just the one click from memory, but make sure it is properly seated - it should go fully in and lock.
I buyed a ktm duke 125 used and there is no aktiv carbon kanister for what is that exaclty?
And were can i buy that bc i didnt find it in the ktm spareparts shop
The carbon cannister is to absorb fuel spills and evaporated fuel so that it does not contaminate the environment - the bike does not need it or use for running.
Thanks used you as a reference for the fueling lines
Good move! Skäl David
Mystery solved, now I know the tank plastics push slide to the rear. Thanks.
I always forget and have to figure out exactly how they come off!
Hey David. Do you need to drain the tank in order to remove it?
No, the lines have a fuel shut off. You will get some leakage of the fuel that is in the pipes.
Hi mate can you please do me a favour the 2 black block connectors
I dont have a gas filter on the side on my ktm duke 125 2019? So i need to replace it?
It will have come from the factory with a filter, so yes, you should reinstall one.
Thank you again David
You are very welcome, thanks!
I don't know about the rest of you but when I heard the police sirens in the background, I immediately pictured MAD MAX chasing the ToeCutter.... Oh hell yeah!!!
Welcome to my world!
@@MotoMirius do you get chased by the cops a lot?
@@Robocoppat They have the helicopter for when they chase bikes around here.
@@MotoMirius I'm a cop...ride safe. Love your channel.
@@Robocoppat Thanks. Round here the police are authorised to, and do, knock riders off their bikes. It was a pretty effective response to the moped gang issue we had here a few years ago.
Hi, I'm currently stuck with an error that says "fuel lev s" and the bike does not fire up. It was unused for about 2 months but battery is fine. Could you please let me know if there is any advice you could give. Bike is a duke 390.
Sounds like an issue with the fuel sensor in the fuel tank. Bike may think it has no fuel, hence not starting. Could be a connection issue, maybe the sensor has gone bad. Sounds like an electrical connection issue.
@@MotoMirius hey, thanks for replying. Will let you know what it was when I finally get it fixed. There's no service station in my town so got to ship to the closest one now I guess.
Hi, so someone tried to steal my petrol, and now there's a little tube hanging out of the rightside of the tank with the word 'drain' on it. I don't think it is supposed to be connected anywhere, but do you know for sure?
Not supposed to be connected
Hi bro please make a video of the ignation cover remove in this vidoe u have shown to open but cant abel to open
Hi, I'm not quite sure what the ignition cover is?
You just have to pull harder, don't be scared to really go for it, it's never snapped yet
Sorry if this has been asked before and it's a bit off topic BUT did you ever finish the Lomax? I've just sat through 26 episodes looking forward to seeing the finished car AND nothing!
It’s a great question and you aren’t the first to ask. I need it out of the shed and finished so it is a high priority but I haven’t managed to find the time. But soon! Skäl. David
Have you ever seen the fuel pressure regulator in 21+ models ? Doing research it has a hex hole in the top of it, to screw and give more pressure to the spring i assume, i way to raise the fuel pressure, do you know anything more about it ? Or have you even try it or done it ?
I've not seen the newer models so I can't really comment.
@@MotoMirius right at this moment i pulled the tank out of the bike and go for it, in effect, it does come with an adjustable fuel pressure regulator, has a 6mm allen hex on the top, i give it a couple or turns down to push the spring a little, i’ll be testing it this afternoon. The ideal case was to measure the presure but i dont have a gauge.
@@Calvingarage Let us know how that works.
Hello David, thanks for yet another great video. I think I need to change the oil pressure sensor because of an intermittent low pressure warning. It doesn't look it can be changed without taking the tank off so this will be useful. If you have any tips that would be appreciated.
I've not needed to change it, so I can't offer any specific advice.
@@MotoMirius thanks anyway Dave. In the end I had the sensor changed at Fowlers of Bristol. It did the job, didn't cost much and gave me a chance to take out a demonstrator! I was happy with my fault diagnosis and no damage done.
Hi David, my water vent, underneath the fuel cap is clogged, any idea how to unclog this?
The water vent has a rubber hose running from the bottom of the tank. It has a cover at the bottom end you will need to remove, or it may be kinked stopping the water running out - I don't recall which side of the bike it comes out and may depend where it was routed if the tank was removed.
@Moto Mirius thank you. That's useful; the tank was never removed before. I'll try to look for it.
Did you emptied the tank before disconnecting all the hoses?
No. Having low fuel makes the tank lighter but it will always happen that you need to pull the tank when it is full and heavy. No need to drain. Skäl. David
@@MotoMirius ♥️♥️
Just to be sure: if I unplug the fuel hose from the bottom of the tank it will not result in all the fuel leaking on the floor?
Is there some sort of valve that prevents that?
Doesn't fuel just leak on the floor with the help of gravity?
The line is designed to be removed without leakage - aside from a little fuel that is inside the line itself. There is a pump inside the tank that delivers fuel - it is not gravity fed from a hole in the bottom of the tank.
Thanks @@MotoMirius! Sounds completely logical. Just had to double check before attempting.
Hello, I have done it, but when I was putting back the body panels (around the tank) the left one doesnt fit as normal (there is around 5mm more space between the tank and panel / plastic). Interesting is that the right one is fitting perfectly. I have been trying to fix it for an 2 hours, but I cant resolve this issue. Have you any idea how to fix it?
Hi, I have done that - it is always something that you are overlooking - there are several places where the panels need to fix down at the same time but you can't see them. Take a break and come back to it normally works for me - if it all fitted before and you haven't broken any fixings then something is simply in the wrong place or not clipped in properly.
@@MotoMirius Okay, thanks I will try 😁
Olá amigo.
5:10 filtro carbono, é possível remover para melhorar performance?
Espero que entenda a minha dúvida. Abraço!
O filtro de carbono é para evitar derramamento de óleo e fluidos semelhantes, não há impacto no desempenho
Very helpful as always. Quick question, how did you route the two open ends of the carbon canister? I know they aren’t connected to anything but I cannot figure out how to reroute them. Any tips?
I'm not clear what you are asking. The front pipe is short and just sits where it is. What two open ends?
@@MotoMirius the charcoal canister has tube that ends with a box-like tip. I ended up tucking behind the frame. At first I freaked out then I read somewhere that they really aren’t connected to anything. Thanks and cheers!
@@jakejones8354 OK. Yours sounds different to mine. Mine only has one tube at the front, the rear ones feed into the cannister so are connected elsewhere, routing isn't that important so long as nothing is kinked.
What issues would be caused if the carbon filter is failing?
What does the activated carbon filter truly do on the ktm duke?
As with all vehicles from bikes to trucks where these are fitted by law, it reduces emissions by trapping fuel vapour. It has no functionality for the bike itself, the same can be said for the rest of the emission control systems found on the bike.
Thank you soooo much for the video. Super helpful.
Thanks, glad it was of help! Skäl David
thanks a lot 🙏🏼
Someone please help I changed my gas tank and put everything back together and now the damn bike wont start it starts for at most 2 seconds then dies
Most often caused by a kinked hose. Unbolt the back end, lift it up a bit and check the hoses aren't trapped or kinked.
Well this is useful for polishing the tank, paint is a bit too soft
Good luck with the polishing!
Can you run the duke 390 on regular unleaded (RON 91) instead of premium (RON 95)
Manual recommends 95. I know people who run on 91 but you'd need a long term test to be sure if it is safe to do so without damage.
hi! do you have a video on how to replace ktm duke 390 rectifier? Thanks!
Sorry no, but to be honest you just remove the bolts, unplug it, plug the new one in and replace the bolts.
@@MotoMirius thanks! I’m a bit curious ‘coz the bigger socket is located under the gas tank and the wire as well is routed underneath the gas tank.
@@fender9747 Power runs directly from the alternator to the regulator then back into the bike to charge the battery etc so yes, will connect into the main wiring loom. There should be no reason to remove the tank.
@@MotoMirius thanks a lot!
I am from India bs6 Duke 390 TFT display how get in duke 125
BS6 125 in Euro spec has TFT as stock. The bike will run the TFT but you may have a different wiring harness and ECU.
How difficult is it to remove the rear frame (white part) and have it repainted/powder coated?
It's something I've considered. I even have a tail frame on watch on eBay.... It's not difficult, but it is time consuming because there is a fair bit of unbolting - but the same is true of the tank.
Please do it so I can also do the same lol.. Great videos, everything is clear, well thought off and explained.
Just subbed to your channel sir, now I have a question for you. I recently purchased a 2020 duke 200. I’ve done a few cosmetic mods as well as modded the under belly exhaust added a k&n air filter and just today I installed a booster plug. I managed to get to the AIT sensor and install the plug without removing the fuel tank, it was kinda challenging but my 14 years of being automotive mechanic helped me out there. While I was there I wanted to install a iridium spark plug but I noticed cable is sort of tall so I called it a night. Am I better off removing the fuel tank and then installing the plug? Or will it turn into a 🐒🏈 situation? Thanks!
Hi Dan and thanks. My advice would be to remove the tank. There are people who can change the plug in situ but there are many more who have failed and I'm not sure if you might have more room with the 200. Tank isn't too bad to remove, biggest pain is just getting the fairing out of the way - which is sort of unexpected with a naked bike! Good luck! Skäl David
Thanks a lot for your advice Skäl. The fairings indeed where somewhat of a pain lol I managed to removed the ignition cable and swapped out the spark plug by just lifting up the fuel tank a few inches with some small blocks I had handy. It was enough room so the need to disconnect the entire tank was not necessary. The NGK iridium plug made a huge difference! Thanks a lot for the great content and keep up the great work! I did this on my 2020 second gen duke 200 bs6 model.
@@danzam374 Great work. I guessed that you had a BS6 from the exhaust reference. Interesting for the Iridium - some mixed opinions as to whether they make a difference.
From my personal experiences on my personal vehicles and that of my customers iridium plugs are definitely the way to go. I won’t make claims that they make power or anything crazy, but the engines do run smother and that tells me the combustion is that more efficient. I have a customer who has 256 thousand miles on a bmw 325 with original engine that makes a 140 mile round trip commute everyday Monday - Friday . Every 5 thousand miles the oil is changed and every 60 thousand he comes in for a tune up. I’ve had the opportunity to do his tune up 3 times now and when I inspected the plugs they are clean, no signs of excessive carbon buildup or irregular spark ware on the probe. His also getting optimal fuel mileage out of nearly 20 year old car. I’ve noticed the same on my vehicles so I decided to give it a try on my bike. My duke has now 700 miles sense it is new and my commute is fairly short, I pulled out the factory conventional Bosch plug and replaced it with the ngk iridium. Here where I’m from it’s been 37-40 degrees US morning and I did I cold start at 5:30 am when I normally go to work and the time of cranking at a cold start was reduce. Also a re warm start up was that much faster and just seems to idle a heck of a lot smoother. Have not had a chance to go for a ride being that it’s raining. I’m not after any type of power gains or expecting any. After I go for ride I will report back to you and give you my final thoughts sir!
@@danzam374 Sounds good. I might give them a go on my next plug change! Thanks!
I took my left ferring off of my 2018 rc390 and now can't figure out where to put the two hoses back on to.
RC does things a bit differently - does the parts diagram help? www.fowlersparts.co.uk/parts/5964085/road-390cc/evaporative-canister
@@MotoMirius lol I figured it out. One is just a coolant run off an the other the wierdest gas tank air tube I've seen. So pretty sure both hang. I've only owned Japanese until now, an wow they are way easier. Thanks a lot ill look it up.
@@apophisrides1237 Good stuff. Not so much hangs any more - environmental regulations - those that do are normally plugged so they can be manually drained during service, otherwise typically they will run into a container of some sort.
@@apophisrides1237 KTM being an EU manufacturer has to comply with the highest levels of environmental regulations - just like being in California
2:45 the plastic in your hand. Is it interchangeable between the Duke 125 and the Duke 390? I’d like to order 390 plastics for my 125 because i’m a liar, Lol.
The panels are the same. The difference is the decals. You can buy the decal sets from KTM. How to tell a 125 from a 390 KTM Duke czcams.com/video/P9GGTEVwYmA/video.html. Skäl. David
Hi my 2018 duke cuts out when slowing down and runs bad at low speed do you know what could be the problem thanks
Cutting out on hard braking is common, but doesn't sound the issue here, sounds more an idle issue and could be a number of issues. Has the bike been serviced recently? If not then I suggest a good check over of the connections, make sure that the spark plug is connected properly etc, clean the air filter etc, just rule out normal service stuff/ electrical connectors etc. Good luck
@@MotoMirius My 2018 duke 390 too cuts off at times and does not start up as I press starter once, but engine keeps cranking. I have to switch the key off, wait and switch on again, wait till display is ready, then only it starts up sometimes. any help, please?
and how often the fuel filter to be replaced?
@@jagathhettiarachchi9373 Could be any of a number of issues - this is one of those occasions where internet diagnosis is almost impossible as the fault almost always turns out to be the thing not mentioned but would be obvious with the bike in hand. Valve clearances could be an issue.
@@MotoMirius Thank you David, for your wonderful reliability. I guess I'd better take it for an OBD reading. it is 2018 model but did not ride much till recent. [odometer is still 13900km], that's why I thought that has to be a simple issue.
Thank you again.
@@jagathhettiarachchi9373 Quite likely it is a simple issue, but hands on is always faster since there are a number of different things that could give the same result.
Please make video on RC/DUKE 390 ride by wire tech how it works ?
Hi, depends what you want to know. In practice it isn't a lot different except that the ECU has the ability to modify the signals for things like ignition cut, but given the ECU is locked this doesn't help very much. You'll only be able to make changes with external boxes and if you already have that technical knowledge you won't need a video - and if you don't the video probably won't help a lot. Skäl David
@@MotoMirius in indian RC 200 rev limiter locks speed @ 135 kmph & in RC 390 rev limiter locks speed @ 173 is this to prevent engine damage ? or emission norms ? 2014 RC 390 was doing 179 on speedo ...
@@snoopdeckin to prevent engine damage because of compliance with higher emissions standards. The solution is a box which will add more fuel and break the emissions standards but also allow a higher rev limiter - this has nothing to do with ride by wire.
Where can I get a 14 tooth countershaft sprocket for a 19 duke 390????
Depends where you are Tom. Pretty common sprocket and for example JT makes one. Skäl. David
Fantastic. Thank you so much! Your videos really help me with maintenance jobs. Quick question, once the tank is removed, is there a specific way to sit it to stop petrol leaking out or can you just sit it on the table on top of the fuel pump as it sits on the bike?
Unless you run the pump or you have a leak, no fuel will leak out - aside from a few drips from the fuel in the pipes. Try to put something under the tank so you so not crush any pipes etc. Skäl David
Do you know who sells the OEM black tank? I need a new one....
KTM. Or eBay. Good luck in finding one without dents on there! Skäl. David
Can we fit this tank in duke 200 2012 model
I have not tried it, but I think it would be possible - the frame is similar, but probably not bolt on. Then too the fuel pump will be different so you will have a lot of things to work on - the seat is different for example so may need to be modified where it meets the tank.
@@MotoMirius okh thank you so much for the information ❤️
Very quiet audio, I only say this as I am watching this at work on full volume and still can't hear you...
Unfortunately there must be an issue with your connection as the audio is fine for me.
Do you need to take the tank off to change the fuel filter ?
Fuel filter is attached to the bottom of the tank so yes. You are supposed to drain the fuel tank too. Skäl. David
Moto Mirius you done what I would have done filled it up first lol 😂
@@thomaswilliamfirby180 Its a law isn't it? I don't think I've ever removed a tank that wasn't just filled.
A little fiddly but nothing difficult 👍🏻
Yah. Time consuming but well within everyone’s ability to do I reckon. Skäl. David
Muito bom vídeos se tivesse legenda em português seria de mais
Infelizmente eu não falo português então seria muito difícil para mim adicioná-los
Sr please give me 1 video KTM rc 200,390 how to install piston ring
That is a little vague. Fitting a piston ring can be found in one of my 2CV videos - technique is much the same. I have no plans to take apart my engine until it blows up.
If you need a video on installing piston ring, you definitely should not be doing piston ring install. lol
I think that’s a little harsh. Engine rebuilds aren’t that technically challenging but wrong compression ring install technique will leave you with a bent and binding ring.
Please video clean injector ktm duke
I will add it to the list but I have other work to complete first. Thanks
can you use this tank to an old model of ktm duke 200. Because the old tank and cover looks ugly. 😂
I'm sure it's possible, but you will need to make new tank mounts.
what is the unite in under left side tank cover
3:53
Charcoal canister for emissions.
@@MotoMirius its havent in my bike. ktm125 eu 2019.
@@naveenperera1304 someone may have removed it, or it might be relocated on the 2019 model - it's emissions so won't have much impact on the bike.
When you turn on your bike can you hear your fuel pump activates like the older model?
Yes. That’s pretty much normal for any bike with a fuel pump. Skäl. David
How much did a new tank cost?
A new tank would cost you £344 in the UK plus shipping. One day I might replace mine, but no real reason to do it yet. Skäl. David
@@MotoMirius - One day you might replace it why? Why would there ever be a need to replace it unless it's damaged like mine?
Because mine is also damaged. I can’t imagine any other reason for replacing it. Of course you could always fill the dent and respray. Skäl. David
@@MotoMirius OMG here in india a new fuel tank including fitting will cost £68
They is off Faders An On!!!!! Ylss Yes Foster De People thi is An struggled dad twenty Are You Duke 250 model 2019 An tanc soludurs is Friom México !!!!!!!
Show separately not mixed
Fuel tank removal is one task. But used as part of several other different jobs, so one video not repeated in other videos.