KTM 3CM088249GEN User Manual
660 RALLYE FAC.REP. 2007
SPARE PARTS MANUAL: ENGINE
ART.NO.: 3CM088249GEN
ENGLISH
SPECIAL TOOLS
ENGINE CASE
CYLINDER
660 RALLYE FAC.REP. 2007
CRANKSHAFT, PISTON
BALANCER SHAFT
TRANSMISSION II - COUNTERSHAFT
3x
CARBURETOR
8x
SHIFTING MECHANISM
4x
CLUTCH
9x
COOLING SYSTEM
6x
11x
7x
TRANSMISSION I - MAIN SHAFT
12x
WATER PUMP
1
13x
14x
15x
17x
TIMING VALVE
VALVE DRIVE
CYLINDER HEAD
660 RALLYE FAC.REP. 2007
LUBRICATING SYSTEM
OIL FILTER
18x
23x
ENGINE EXHAUST
All information contained is without obligation. KTM-Sportmotorcycle AG particularly reserves the right to modify any equipment, technical
specifications, prices, colors, shapes, materials, services, service work, constructions, equipment and the like so as to adapt them to local
conditions or to cancel any of the above items, all without previous announcement and without giving reasons. KTM may stop manufacturing
certain models without previous notice. KTM shall not be held liable for any deviations of availability and/or ability to deliver, illustrations,
descriptions, printing and/or other errors. The illustrated models partly contain extra equipment, which is not applied to standard models.
© by KTM-SPORTMOTORCYCLE AG, Mattighofen AUSTRIA; All rights reserved; Reprint, also in extracts, with written allowance of KTMSPORTMOTORCYCLE AG, Mattighofen only.
19x
24x
IGNITION SYSTEM
20x
25x
22x
ELECTRIC STARTER
26x
2
x
SPECIAL TOOLS
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 56012001044 UNIVERSAL MOUNTING RACK CPL. 1
2 58329003000 CLUTCH HOLDER D=160MM LC4'94 1
3 58012005025 MOUNTING SLEEVE D=25MM 1
FOR CRANKSHAFT SEAL L/S
4 58429009000 MAGNETO EXTRACTOR 1
5 58429031000 PROTECTOR CAP F.CRANKSHAFT M16 1
6 58529015102 PISTON RING COMPRESSOR D=102MM 1
660 LC4
7 59029021044 EXTRACTOR PRIM. GEAR CPL. 1
FOR INNER CLUTCH HUB
8 58012019000 VALVE INSTALLATION KIT 1
9 6276470 PUSH INSERT 1
10 59029019000 VALVE SPRING LEVER 1
11 6899785 LOCTITE 243 BLUE 6CCM x
12 58429059000 LOCTITE 648 GREEN 24ML x
15 15112017000 BUSHING EXTRACTOR 1
16 15112018000 INTERN.BEAR.PULLER 12-16 MM 1
16 15112018100 INTERN.BEAR.PULLER 18-23 MM 1
17 58429012000 HOLDING WRENCH FOR WHEEL 1
18 309098 SILICON GASKET THREE-BOND 1
19 58429037040 MOUNTING TOOL F.BEARING NJ 306 1
19 58429037043 MOUNTING TOOL F.BEARING NJ 207 1
20 58030080000 LOCATING SCREW M8 L=23 1
22 51012012000 HOLDING SPANNER FOR SPROCKET 1
23 54629027000 RIVETTING TOOL FOR CLUTCH 1
25 58529005000 MOUNT.SLEEVE F. SH.S.RING WAPU 1
26 58029026007 LIMIT PLUG GAUGE F.VALVE GUIDE 1
D=7,05 MM
30 59030022000 BLEEDER FLANGE M8 WS=10 '99 1
31 31007107001 PVC-HOSE 6X9 MM PER METER x
32 0934080003 HEXAGON NUT DIN0934-M 8 1
39 58329039000 WRENCH SCREW FILTER 1
41 59029041000 FEEL. GAUGE SET 10,12,15,20,25 1
48 58429048000 INJEKTION FOR FRONT PIPE '99 1
DEAERATE FOR FRONT PIPE
3
05585290 / C065852900
* NEW PART
X AS REQUIRED
ENGINE CASE
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 5853000054430 ENGINE CASE CPL.W.TRAN.BEAR.04 1
BLACK
3 58530088000 PLUG VISUAL CHECK TRANSMISSION 1
4 0770020020 O-RING 20X2 VITON 1
5 50130027000 DOWEL 19 X15,1X12 1
6 51030026100 DOWEL 17 X 13 X 12 1
7 58530010000 CRANK SHAFT BUSH RALLYE 2001 2
9 58033097000 NEEDLE BEARING HK 2216 1
10 58330011000 SHIFT MECHANISM SUPPORT LC4'94 1
11 49030090000 DOWEL 9,8 X 7 X 10 4
15 56530017000 RETAINING PLATE 1
16 0991060166 FL.HEAD SCR.DIN7991-M6X16 10.9 2
18 58530080000 LOCATING SCREW 1
19 0603082121 SEAL RING CU DIN7603- 8X12X1 1
20 58530039200 ENGI.CASE GASKET SIL C-4400 1
21 0985050103 OVAL HEAD SCR. DIN7985-M 5X10 1
22 0472200010 LOCKRING DIN 472 20X1MM 1
23 0412174012 CYLIND.ROLL.NJ 203 ECP/C3 2001 2
24 0625618050 BALL BEARING 61805 C3 1
26 58030010100 %HOSE CONNECTOR M20X1,5 SPLICE 1
27 58430095100 INSPECT.GLASS GW 20-7 MINERAL 1
28 58440091000 STOP DISK 33 X 58 X 1,5 1
29 5853002600030 CLUTCH COVER OUTS.CPL.BLACK 04 1
30 5853000100030 CLUTCH COVER BLACK 2003 1
31 58530025000 CLUTCH COVER GASKET 2001 1
32 0770165024 O-RING 165X2,4 2001 1
33 58030020100 PLUG CPL. M24X3 1
34 0770191015 O-RING 19,00X3,00 NBR 1
35 60030064090 OIL JET 90 M6X0,75 WS8 03 2
38 54403135000 PLASTIC CAP SFL10 1
39 44011076305 CABLE TIE 300/4,8MM BLACK 1
40 58530060000 SPROCKET COVER RALLYE 2001 1
41 54613038150 BUSHING 6,5X8X11 1
42 58530047000 CHAIN DAMPERSHEET 16/17T RAL. 1
44 58030021000 OILDRAIN PLUG W.MAG. M 12X1,5 2
45 58038017100 CU-SEAL RING DIN7603-22X27X2 1
4
065853000 / C065853000
* NEW PART
X AS REQUIRED
ENGINE CASE
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
46 58038019100 OIL DRAIN PLUG M22X1,5 1
47 58038022000 CU-SEAL RING DIN7603-12X18X1,5 4
48 0908120153 PLUG DIN0908-M12X1,5 2
50 58538023000 OIL PRES.SPRING 5 BAR RED 2001 1
51 58038028000 VALVE PISTON D=10MM 1
52 58033090000 NEEDLE BEARING RNA 4903 1
53 0760223270 SHAFT SEAL RING 22X32X7 BSL 1
55 58530399100 GASKET SET 660 RALLYE 03 1
60 0015060253 HH COLLAR SCREW M 6X25 WS=8 12
61 0015060303 HH COLLAR SCREW M 6X30 WS=8 7
62 0015060353 HH COLLAR SCREW M 6X35 WS=8 2
63 0015060403 HH COLLAR SCREW M 6X40 WS=8 2
66 0015060553 HH COLLAR SCREW M 6X55 WS=8 4
68 0015060653 HH COLLAR SCREW M 6X65 WS=8 1
5
065853000 / C065853000
* NEW PART
X AS REQUIRED
CYLINDER
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 5853000530030 CYLINDER 102MM 660 RAL. BLA.04 1
BLACK
2 58530035000 CYL. BASE GASKET 0,33MM 2001 1
3 58530043000 STUD M10X75 4
4 0331100003 COLLAR NUT DIN6923-M10 WS=15 4
5 0402040980 NEEDLE ROL.DIN5402 NRB 4X9,8 2
6 58530014000 DOWEL 10,2X12,5X10 2001 2
6
04585304 / C065853001
* NEW PART
X AS REQUIRED
,
CRANKSHAFT
PISTON
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 58530018300 CRANKSHAFT CPL. RALLYE 2002 1
HUB 80MM
2 58530015144 CONNECT. ROD REPAIR SET LC4 05 1
640/660 CCM L=141,5MM
4 56530081000 SHIM WASHER 36X48X0,10 x
4 56530081100 SHIM WASHER 36X48X0,15 x
4 56530081300 SHIM WASHER 36X48X0,30 x
5 0888030050 WOODRUFF KEY DIN6888-3X5X13 1
6 6946005 WOODRUFF KEY 5X6,5 HARDED 2
9 56530123000 CYL.ROLLER BEAR. NJ 207 ECP C3 2
10 0760304071 SHAFT SEAL RING 30X40X7 BSL 1
15 58330095000 STEEL WASHER 16 X 30 X 3 1
16 58430028000 HEX NUT M16x1,25 L/S 1
21 58030019000 LOCKING RING VSK 20 1
22 0936200155 HEXAGON NUT DIN0936-M20X1,5 1
23 0760122270 SHAFT SEAL RING 12 X 22 X 7 B 1
30 58530007300 I PISTON I CPL. D=102MM 03 1
30 58530007300 II PISTON II CPL. D=102MM 03 1
40 58530031144 PISTONRING SET ELKO 660 RALLYE 1
44 58330833000 PISTON PIN 22 X 13 X 60 1
45 58430074000 CIRCLIP 22 X 1,6 2
7
05585302 / C065853002
* NEW PART
X AS REQUIRED
BALANCER SHAFT
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 58530057144 BALANCER SHAFT CPL.WAPU RAL.03 1
4 0412174012 CYLIND.ROLL.NJ 203 ECP/C3 2001 2
6 0988172410 SHIM WASHER DIN988-17X24X0,1 2
8
03585304 / C065853004
* NEW PART
X AS REQUIRED
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