BHPian SVS_23 recently shared this with other enthusiasts. Update on the Duke, I had been getting “low oil pressure” message on the dash for about 1000kms now. I had been putting off taking it to an ASC for a while since the oil level was okay, there was no white smoke from the exhaust nor any oil leaks. My guess was that the oil pressure sensor was shot (this was the diagnosis at an FNG also). Two weeks ago I had gone to Bangalore and decided to get the Duke serviced. Fellow bhpian @VijayAnand1 had suggested BTM Layout and Banashankari service centre. But I decided to try out Sarjapur Road service centre as it was the nearest to where I lived (basically it is also a branch of Amba KTM, same as BTM Layout). Things that needed attention,Chain sprocket needed to be replaced”Low oil pressure” needed diagnosisGeneral checkup and oil changeUpon initial inspection, the technician told me that coolant level has dropped, so this might be a case of coolant mixing with engine oil (although oil looked okay from the oil window), which could cause blockage in oil jets and oil couldn’t circulate properly, hence the low oil pressure warning. He told me that he’ll check the water pump oil seal for damage. If that was intact then he’d have to dismantle the engine and look for damages in the gaskets, for which I was quoted Rs.13000. Water pump assembly was relatively new (replaced when I bought the bike). So worst case scenario, I end up with an engine overhaul and my pocket gets lighter by 13k. The other repairs and maintenance were estimated to 10k, totalling to 23-24k in approximate. I told the technician to go ahead with the repairs. It would be at least 3-4 days till I get my Duke back. After 2 days I got a call from the ASC, informing me that upon draining, they found coolant mixing with the engine oil. However, the water pump was intact. They would now proceed to dismantle the engine to check for worn out gaskets. Alas, a minor electrical issue turns out to be a catastrophic affair needing an engine overhaul . I decided to go ahead with the repairs. A couple of days later, I called up the technician for updates and got to know that the 3rd and 4th gear drive had broken. A piece of the locking thread had got cut and the gear had to be replaced. I could’ve used the same part, as most of the threads were intact and it was only one thread that had got cut, but I didn’t want to take that chance and told the technician to replace the 3rd 4th gear drive. But the part was not in stock anywhere in Bangalore and I was told that it takes 10-15 days for it to arrive once the order was placed. But as luck would have it, one of the ASCs had placed an order for the same part and these guys were able to get hold of it! After another 3-4 days, I was informed that my bike was ready. I went immediately to collect it. Everything looked perfect upon inspection. On taking it for a short spin, I found the clutch to be a bit heavy. Also the steering was stiffer. The technician told me that the clutch felt heavy since it was taken apart and put back. The cone set had been tightened, thus stiffer handling. Satisfied with the service (for the time being that is!), I paid the bill and returned home. The technician and the service manager were very friendly and told me to return if there were any issues. I was advised to ride gently for a 1000 kilometres and get the oil changed post that. Coming to the work that was done on my bike,General checkup and oil changeEngine overhaul and replacement of all internal gasketsReplacement of 3rd 4th gear driveRadiator flush and coolant changeWater pump seal replacementTyre hugger installedValve lappingFront and rear brake fluid replacement and bleedingChain sprocket replacementRear wheel hub cushions replacementOil pressure and coolant temperature sensors replacementSpark plug replacementThrottle body cleaningAll these came out to Rs.23987/- which was within the estimate provided. Attaching a copy of the bill, After riding for about 5-10kms, I noticed a ticking sound from my engine. Upon inquiring the technician, he told me that it is common after adjusting valve clearance and that it is not something to worry about. With his assurance, I rode back home to Madikeri the next day. After doing a bit of research online and consulting some friends, I’m starting to worry that valve clearances haven’t been adjusted properly. So I called up the service manager today and told him the issue. He is asking me to get the bike to the ASC to check it once again. But it is not practical for me to travel to Bangalore again, so I’ve postponed it until my next visit to the city. Manager was also very understanding and told me to bring the bike in whenever I’m in the city. Here’s a video of the ticking noise. I have mixed feelings about the valve noise right now, not sure how to proceed… Cheers, SVS Check out BHPian comments for more insights and information.
