Simple Clutch Cable Change KTM Duke 390 250 200 125

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My clutch cable was damaged so it's time to replace it. It's a simple job, so one most people should be able to do easily. Check how your current cable is adjusted and install the new one with the same adjustment and it should be easy to fine tune in.
Note that if you have a longer handlebar such as the Magura X-Line then skip the top mounting by the headlight to allow a bit more length.
Parts Links For This Video:
Clutch cable part No: 90802090000
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2 апр 2020

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Комментарии : 94

@voodoo2hot4U 3 месяца назад

Thank you for the clear instructions on this "how to" replace clutch cable! This made my job a lot easier!

@andrewwiltse8882 4 года назад

Hi David I wanted to say thank you for all your Videos on the Duke 390. I just got back on a bike after 35yrs so your content has helped me to stay out of trouble. 👍✌️

@MotoMirius 4 года назад

Great to hear Andrew, and thank you, much appreciate. Hope you are having fun. Skäl David

@yahoodlums 3 года назад

Just a follow up to this video (and thanks for posting it David). Make sure you route the cable in the same way David did. Thread the new cable back in the same way it came out, otherwise you'll find there is a fatter part (with heat resistant coating) that is impossible to thread through the frame. You can also undo the plastic guide on the frame for more space, it's just a simple crosshead screw.

@MotoMirius 3 года назад

Thanks Ray and great advice!

@convolution0924 Год назад

It was easy to understand the exchange method and it was very good . I was in trouble because the wire was cut, so I was saved.

@MotoMirius Год назад

Great job!

@danrosemon9084 6 месяцев назад

Thank you, this helped significantly with replacing the clutch cable on my 2015 rc390!

@MotoMirius 6 месяцев назад

Glad it helped

@teddybowker7309 Год назад

Thanks for this video. The solutions for moving the bolts on the adjustment rod has worked for me. I have aftermarket levers fitted and they have been a curse to adjust. Clutch pull was so hard could never get it to function correctly. This simple solution has resolved my issue. KTM 390 Adventure 😀

@MotoMirius Год назад

Thanks and great work there, one thing to watch, another to put it into practice!

@biggesthuckler 2 года назад

Gday from aussie. Just fitted my new clutch cable, thanks heaps for the video. Very helpful!

@MotoMirius 2 года назад

Thanks and good work there!

@tonytrevino3204 4 года назад

I would lose sleep if I had to do that repair, You made that look easy.

@MotoMirius 4 года назад

It looks easy because it is - but of course anything looks hard if you've no experience!

@MichaelLee26 3 года назад

Thanks for the step by step tutorial... very detail too

@MotoMirius 3 года назад

Glad you liked it. Thanks

@BeastOnStreet 4 года назад

very informative video as always! keep up the good work

@MotoMirius 4 года назад

Thanks. Always appreciated. Skäl David

@aurelienboirie9284 2 года назад

Thanks a lot. You explain clearly

@MotoMirius 2 года назад

You are welcome

@jean-arthurgonin3663 2 месяца назад

Very helpfull thankyou !

@MotoMirius 2 месяца назад

Glad it was helpful! Thanks!

@ChenWagshall 3 года назад

thank you David

@MotoMirius 3 года назад

You are welcome Chen. Skäl. David

@tinks43 4 года назад

Always fun and games but satisfying at the end of the job! Hope you were enjoying the bike before lockdown?

@MotoMirius 4 года назад

Ha! Yes, it was going well and finally we had enough dry weather to be able to play supermoto and get the bike properly leant over. Hope you guys are surviving ok! Skäl David

@springy-2112 4 года назад

Hey David hope you are well brother great video as always ..hope we get to ride our toys sometime . peace and love brother 👍🏻☮❤

@MotoMirius 4 года назад

Hey Springy. Getting closer to that magic 500 subscribers! Thanks and I hope you are keeping well. Can't wait to get back out and weather this week is looking great! :( Skäl David

@TylerMoto Год назад

I was wondering will the mzs ktm duke 390 2013-2019 brake and clutch Lever would fit onto the ktm duke 125 2022 sorry if Im bothering you with the questions I'm still new to motorbikes your sincerely tyler

@MotoMirius Год назад

KTM uses different levers between the 125 and the 390. They may fit, but I wouldn't guarantee it.

@gy8132 Год назад

Excellent clip, would it be possible to have part information on the replacement cable. As good enough for you will be good enough for me. Many thanks David.

@MotoMirius Год назад

Thanks. Part number is in the video description - Clutch cable part No: 90802090000 from your KTM dealer. Good luck with the replacement!

@gy8132 Год назад

@@MotoMirius Justin picked this up, thanks for information.

@moherhat Год назад

Hi! Should you or should you not lube the end barrel which goes inside the lever? There is some nylon sleeve around the barrel so Im not sure if I should lube it. BTW great video!

@MotoMirius Год назад

Hi and thanks. Nylon sleeve will self lubricate. Sometimes lube will just attract dirt which gums it up.

@subhoishere 4 года назад

Hi David, thanks for the video... Regarding the front brake line upgrade, do you have any recommendation? As I would like to upgrade the brake line with a different varient to get more progressive bite from the front brake. Thanks in advance.

@MotoMirius 4 года назад

I don't think you will get a noticeable improvement in the brake line. First thing is to make sure it is properly bled - the stock system works well enough for stunt riders to do stoppies, so they are getting plenty of feel from the system. Next upgrade would be a better master cylinder - the 390 already uses a radial brake system. If you are losing feel under heavy braking then a disk upgrade would be necessary. Skäl David

@subhoishere 4 года назад

@@MotoMirius thanks David for the detailed explanation. What master cylinder do you recommend for the 2017+ KTM DUKE 390? Also I am in a plan to upgrade the front disc rotor with motomaster wave rotor one. And also in a process to get the EBC brake pads. So the next upgrade I was planning is to get the aftermarket brake lines such as HEL lines. Please reply.

@MotoMirius 4 года назад

@@subhoishere Brake pads are already sintered, so no point changing just like the brake lines - HEL are no better than stock - these are not the rubber lines that were fitted twenty years ago by the manufacturers. Master cylinders by Brembo or Frando - you will need a single caliper one.

@GeorgeYusuf Год назад

Aftermarket levers always have a problem with... 12:13 😂🎉

@MotoMirius Год назад

Cheap after market levers yes! You get what you pay for.

@GeorgeYusuf Год назад

@@MotoMirius it's all about deeez nuts 🥜🔩

@peterlin2541 4 года назад

Great video!There's something wrong with clutch cable line of my rc390.Is that the same to rc390?

@MotoMirius 4 года назад

Thanks Roy, it is the same for 2017 RC390. Earlier RC seem to have a different part number. Skäl David

@peterlin2541 4 года назад

Moto Mirius that's fine,and the clutch cable line of duke 390 also fit rc390，right?😃

@MotoMirius 4 года назад

@@peterlin2541 Did you read my reply? It fits some RC390, it does not fit all RC390.

@peterlin2541 4 года назад

Moto Mirius Oh yep.I just wanna know this line fit my rc390 or not… My bike is 2018 model rc390,and I'm looking for the one to replace it.

@MotoMirius 4 года назад

@@peterlin2541 Buy the 2018 RC390 clutch cable from your KTM dealer - it will cost the same as the clutch cable from the 2017 Duke 390 and it will fit your bike.

@glory3693 2 года назад

Hi Davit Can you help me with something? My Duke 390 2017 model engine takes the clutch too late and does not reflect it to the wheel although the engine enters the cutterbar.

@MotoMirius 2 года назад

Check your cable adjustment. If the cable cannot adjust enough then you should check the clutch plates.

@indianfuturecryptos2525 4 года назад

Hi sir which Paint select for exhaust that is black , light scratch i want fullfil that, my bike ktm Duke 390 2019 model.. And one more question where is connect the number plate connection for lighting the number plate

@MotoMirius 4 года назад

High temperature exhaust paint. All black exhaust paints tend to fade a little to grey with heat. If connection isn’t under seat then it may be under tail mounting plate. Skäl. David

@indianfuturecryptos2525 4 года назад

@@MotoMirius sir which oil used for chain lub... Duke 390.. please buy link

@MotoMirius 4 года назад

I use worth dry lube as I have an orange chain. Google for a link to get the best price.

@tariq3877 2 года назад

I am having same problem with an aftermarket lever and the bike feels like kind of grinding. Not watery smooth

@MotoMirius 2 года назад

Lever shouldn't affect the feel of the bike, but many aftermarket levers are poorly made.

@superbyke125 Год назад

Hi mate I have a pretty new ktm duke 125 that's done 1600 mile I've noticed when I change up gears mainly 5th and 6th on hight revs the revs are going up slightly when changing do you know what this could be?

@MotoMirius Год назад

Hard to know exactly what you are experiencing, but it would be normal for revs to increase at the same throttle position as the clutch is pulled in and the drag of driving the rear wheel is taken off the engine.

@superbyke125 Год назад

@@MotoMirius do you think it's anything to worry about?

@MotoMirius Год назад

@@superbyke125 No, I would not be concerned about it.

@olliemontague23 Год назад

Just tried to install this very cable onto my 125 duke, and it doesn't fit (the clutch won't disengage). Is this cable not for the 125 duke?

@MotoMirius Год назад

If you bought the cable for the 125 then it will fit the 125. If you bought the 390 cable it might not fit, or might fit if you change the routing.

@arashstar98 4 года назад

Hey david, how do you order parts during this pandemic and having all KTM dealers closed for the time being? I was planning on buying 2 exhaust gasket and one clip for the slip-on exhaust. I watched ur video before on having the leo-vince mid-pipe install and damn, i regret making a custom mid pipe and having brackets broken multiple time due to strong vibration of KTM bikes, mine is 250 2017. Now i lost my old clip for the slip-on and im hanging by a thread due to having KTM dealers closed 😢

@MotoMirius 4 года назад

Not all KTM dealers are closed - it depends how the lockdown is working where you are - here the retail side of selling bikes is closed but some online parts can be bought. But even here they may close as they run out of stock. This cable though I bought a long time ago when I noticed that the cable was damaged - I've been keeping an eye on it and it wasn't getting worse, but I'm changing the clutch lever. Good luck in finding the parts! Skäl David

@arashstar98 4 года назад

@@MotoMirius Appreciate the reply, bro. Keep it up. Having more knowledge of our bikes thanks to you 👍

@isms80 Год назад

Hi, I was struck by the fact that you said that the two nuts should be on the right side of the clutch cable bracket. Moreover, I went to the KTM store in my city to see new bikes, and indeed many have the 2 nuts on the right, and others have one nut on each side, which in my opinion makes more sense, since you are adjusting exactly the position of the clutch cable. Please could you clarify this issue a little more. Greetings from Quito, Ecuador.

@MotoMirius Год назад

Hi, ultimately you end up doing what you need to in order make the cable fit. You may be thinking one each side to lock the cable against the bracket - but in reality the outer is held in place by pressure from the clutch spring, not by the nuts. When you pull the clutch, the outer is pushed against the cable bracket. Normally you lock two nuts together to stop them turning - this is stronger than two nuts just tightened against something, especially something as flimsy as the cable bracket where there is little surface for the nut to lock against.

@amandamccoy3809 3 года назад

So I switch to some aftermarket shortly levers. The bike will not start in 1st with clutch pulled and side stand up obviously.. There is not an indication that the side stand senor is malfunctioning at all. I have a 2019 390. Any suggestions????

@MotoMirius 3 года назад

Have you tried changing the switch position on the clutch switch? After market levers do not always properly engage the switch.

@amandamccoy3809 3 года назад

@@MotoMirius I have. That did not work. I think it may be the clutch sensor. I guess there is some pin or something that can break if you are not careful. Anyway you can take a picture of your sensor so I can compare it to mine and see if I broke something?

@MotoMirius 3 года назад

@@amandamccoy3809 There isn't anything to see and in any case my clutch switch is no longer on the handlebars as I don't have a KTM type clutch lever.

@hadrian1 Год назад

is the clutch cable of the duke 390 compatible with the duke 200?

@MotoMirius Год назад

I'm going to say no - though I'm not entirely sure why it shouldn't be as the difference in the clutches is internal.

@crinshelfochad2270 2 года назад

Hello David. My duke 200 has a problem, the RPM is suddenly increasing without increasing its speed. Especially on incline roads. Do you have any idea what’s the problem is and how can I fix it? Or does it have something to do with the clutch?

@MotoMirius 2 года назад

Most likely is clutch slip if it happens when the engine is under load. Check the clutch adjustment. If you’ve run out of adjustment then you will need new clutch plates.

@crinshelfochad2270 2 года назад

@@MotoMirius thanks a lot appreciate your help

@curlyclaire 3 года назад

My 390 Duke's clutch lever is wobbly? I can't see where to tighten it. The big screw is tight enough. Any ideas please? 😁

@MotoMirius 3 года назад

Wobble is normal with most levers and can't be adjusted. You can shim it with a thin nylon washer if you can find one the right size and thickness - this is what Harley Davidson do with their clutch levers.

@curlyclaire 3 года назад

@@MotoMirius Thank you for replying so quickly! Mine has got wobblier! 😁 She's still under warranty so may pop her in.

@jimmytorello7041 Год назад

Replaced my clutch cable and the black clutch arm/handle cam out of the hole in the case. Now my gears won’t shift.

@MotoMirius Год назад

Yes, it can come out if you twist it or it falls to the side - there isn't anything actually holding it in place except the cluch pull rod. There is no reason it shouldn't work if you put it back in at the right angle as it will then hook against the pull rod, but if it doesn't just pull the cover and see what the issue is - you are likely to need a new gasket but so long as you are ok with a slight oil seep you can replace it when the order arrives.

@jimmytorello7041 Год назад

@@MotoMirius Thanks for replying back. I’m going to have some time today and tomorrow to work on it. I’ll let you know what happens.

@mionggg 2 года назад

Is there a clutch sensor switch?

@MotoMirius 2 года назад

Not built into this lever, no. I learnt to ride bikes before they were fitted, and I still have a bike where one was not fitted, so I am trained to pull in the clutch lever when it needs be pulled in.

@mionggg 2 года назад

@Moto Mirius I meant the switch on the handlebar that let's you start the bike in gear. Or did you just connect the wires?

@MotoMirius 2 года назад

@@mionggg The switch has two positions, on and off - it is not a sprung switch. So you set to the clutch position which allows the bike to start in gear even if the switch is not on handlebars - this is shown in the video.

@mionggg 2 года назад

@Moto Mirius sorry must have missed it in the video. Aside from allowing you to start in gear, it has no effect on the ECU and how the bike runs?

@MotoMirius 2 года назад

@@mionggg No problem. It has no effect on the bike running - it is a safety check to avoid people crashing the bike because the starter motor drives the bike forward because it's in gear - it only has an effect when you press the starter button - there is no connection with the ECU.

@-R-. 4 года назад

I live in Thailand, KTM is not so famous in here. Last big trip i went to, my cable broke in the middle of nowhere, one local guy push me with his scooter to the nearest motobike shop, then install for me a cable from a Honda cb300, it was a bit hard to pull the lever but I finally manage to go home!

@MotoMirius 4 года назад

Glad to hear you got it fixed. I hear a new KTM shop is being set up in Thailand so hopefully it will be easier again for you again soon! Skäl David