Page 1
660 RALLYE FAC.REP. 2007
SPARE PARTS MANUAL: ENGINE
ART.NO.: 3CM088249GEN
ENGLISH
Page 2
Page 3
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
Page 4
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
Page 5
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
Page 6
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
Page 7
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
Page 8
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
Page 9
,
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
Page 10
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
Page 11
CARBURETOR
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 58531001000 CARBURETOR 4100A BSKJ RALLYE06 1
5 57331027044 CARBURETOR COVER WITH GASKET 1
10 57331080000 BRACKET PLATE FOR THR. CABLE 1
11 57331055000 SCREW M 5 X 8 2
12 57331046000 THROTTLE SHAFT CPL. 1
14 57331046050 COIL SPRING THROTTLE SHAFT 1
16 57331035051 LINK ARM THROTTLE VALVE CPL. 1
18 58331029014 SLIDE STOP L=34,5MM 03 1
19 57331035000 THROTTLE VALVE CPL. 1
20 59031035050 BUSHING THROTTLE VALVE 4
21 57331035153 GASKET PLATE THROTTLE VALVE 04 1
22 59031035052 GASKET WASHER THROTTLE VALVE 1
23 57331034100 JET NEEDLE KEIHIN OBEKP x
23 57331034200 JET NEEDLE KEIHIN OBEKQ x
23 57331034300 JET NEEDLE KEIHIN OBEKR 1
23 57331034400 JET NEEDLE KEIHIN OBEKS x
23 57331034500 JET NEEDLE KEIHIN OBEKT x
24 59031029000 BAR CLIP 1
25 57331032000 NEEDLE SET SCREW CPL. 1
26 59031121000 NEEDLE JET FCR-MX 1
27 54531623172 MAIN JET 172 KEIHIN x
27 54531623175 MAIN JET 175 KEIHIN 1
27 54531623178 MAIN JET 178 KEIHIN x
27 54531623180 MAIN JET 180 KEIHIN x
27 54531623182 MAIN JET 182 KEIHIN x
27 54531623185 MAIN JET 185 KEIHIN x
28 54531607042 IDLE JET 42 KEIHIN x
28 54531607045 IDLE JET 45 KEIHIN x
28 54531607048 IDLE JET 48 KEIHIN 1
29 59031051085 STARTER JET 85 1
30 57331007100 IDLE AIR JET 100 KEIHIN 1
31 57331037200 MAIN AIR JET 200 KEIHIN 1
32 59031017100 ADJUST SCREW CPL. FCR-MX 1
35 57331085000 BUFFER PLATE 1
39 57331009000 FLOAT CPL. 1
40 57331008000 ARM PIN FLOAT 1
9
065853100 / C065853100
* NEW PART
X AS REQUIRED
Page 12
CARBURETOR
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
42 57331020000 NEEDLE VALVE CPL. 1
46 57331155000 DRAIN SCREW FLOAT CHAMBER 1
47 57331060000 COVER ACCELERATOR PUMP 1
49 57331011000 FLOAT CHAMBER CPL. SET 1
52 57331090000 AIR CUT VALVE 2002 1
53 59031059000 COIL SPRING 1
56 57331098000 BREATH.HOSE FCR-MX KEIHIN CPL. 1
60 0965050103 FLAT HEAD SCREW DIN0965-M 5X10 1
61 54531699000 PLUG M 18X1 1
64 57331062000 INTERMEDIATE LEVER CPL. 1
65 57331056000 LINK LEVER 1
66 57331059000 SPRING LINK LEVER 1
67 57331159000 SPRING INTERMEDIATE LEVER 1
68 57331038000 CARBURETOR COVER 1
69 57331087000 WASHER LINK LEVER 1
70 57331084000 E-CLIP 1
72 57331061000 ROD ACCELERATOR PUMP 1
83 59031013044 HOSE CONNECTOR CPL. 1
85 59031040200 INTAKE FUNNEL FCR/FCR-MX 02 1
87 59031040010 O-RING FOR INTAKE FUNNEL 1
89 0912050123 AH SCREW DIN0912-M 5X12 2
90 57331025000 STOP SCREW CPL. FCR-MX 1
91 58302095251 SLEEVE FOR CHOKE CABLE 1
92 50208020000 SPACER BUSHING 7X10X7,5 1
93 58502095200 CHOKE CABLE RALLYE 2001 1
94 0015060403 HH COLLAR SCREW M 6X40 WS=8 1
95 58502096000 CONNECTION CHOKE-CABLE 2001 1
96 57331077100 TPS-SENSOR FCRMX 320MM 03-04 1
99 57331099000 GASKET SET FCR-MX KEIHIN 1
10
065853100 / C065853100
* NEW PART
X AS REQUIRED
Page 13
CLUTCH
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 58532001144 OUTER CLUT. HUB CPL. RALLYE 01 1
2 58532001100 OUTER CLUTCH HUB MILLED 2001 1
3 58332026000 DAMPING ELEMENT '94 8
4 58532000131 PRIMARY GEAR WHEEL 31-T 2001 1
5 58532000079 CLUTCH WHEEL 79-T 2001 1
6 58332028000 BRACKET 57 x 132 x 1,5 '94 1
7 58332112000 STEEL DISK 1,5 MM LC4'94 9
8 58332011300 LINING DISK 2,7MM FCC 02 10
10 58532002100 INNER CLUTCH HUB RALLYE 2004 1
11 58332018000 LOCK WASHER '94 1
12 0936181505 HEXAGON NUT DIN0936-M18X1,5 R. 1
13 58332003300 PRESSURE CAP LC4/LC4-E 04 1
14 58332080000 CLUTCH SPRING 2,8 X 37 6
15 58132081000 SPRING RETAINER 6,2 X 20 X 3,2 6
16 0015060203 HH COLLAR SCREW M 6X20 WS=8 6
25 58332017000 PUSH ROD 224 MM LC4'94 1
26 58332032000 PRESSURE BOLT LC4'94 1
27 58332007000 RIVET 6 X 23 X 11,2 8
28 57532013000 SUPPORTWASHER 22,2X35X3 HARDE. 1
29 0625060016 GROOV.BALL BEAR. 6001.2RSR C3 1
30 0094020163 PIN DIN0094-2,0X16 1
31 50332070000 INNER RING WITH COLLAR 1
32 56532095000 NEEDLE BEARING K26X30X22ZW.KSE 1
61 58532061044 CYLINDER D=25MM CPL. RALLYE 01 1
62 50332062000 HOLLOW SCREW CPL. M 10X1 '98 1
65 58632065000 CLUTCH RELEASE GASKET 1
66 0401070003 BALL DIN5401-7 1
68 42013226000 CU-SEAL RING DIN7603-10X16X1 1
69 58532066000 PISTON WITH O-RING D=25MM 2001 1
70 0912060303 AH SCREW DIN0912-M 6X30 1
71 0984060163 AH SCREW DIN6912-M 6X16 1
WITH LOW HEAD
72 0912060253 AH SCREW DIN0912-M 6X25 1
75 50329050000 VENT INJEKTION HYDR. CLUTCH 1
11
05585320 / C075853200
* NEW PART
X AS REQUIRED
Page 14
TRANSMISSION I - MAIN SHAFT
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 58333002000 MAIN SHAFT 15T '94 1
2 56533010300 SOLID GEAR 2.G 15-T (2G3) 1
3 58333004002 IDLER GEAR 3.G 18-T "02" 1
4 58333006004 SLIDING GEAR 4.G 20-T "04" 1
5 58333008008 IDLER GEAR 5.G 22-T "08" 1
6 58533021000 NEEDLE BEAR. K22X26X13 DIVIDED 2
7 56533016300 STOP DISK 22,7 X 32 X 1,5 2
8 52033096000 LOCK RING DIN0471-25X1,64SD 2
9 56533015000 STOP DISK 20,2 X 35 X 1 1
10 56533093000 NEEDLE BEARING RNA 4902 KSE 1
11 58533025000 CYL.ROLL BEARING BC1-0076A 1
13 0015060123 HH COLLAR SCREW M 6X12 WS=8 1
12
03583330 / C065853300
* NEW PART
X AS REQUIRED
Page 15
TRANSMISSION II - COUNTERSHAFT
FIG PART NUMBER DESCRIPTION QTY
1 57533005000 IDLER GEAR 1ST GEAR 33T(1M4)93 1
2 58333113010 IDLER GEAR 2.G 24-T "10" 1
3 58333007003 SLIDING GEAR 3.G 21-T "03" 1
4 58533009012 IDLER GEAR 4.G 19-T 04 1
5 58333011009 SLIDING GEAR 5.G 18-T "09" 1
6 58533010000 COUNTERSHAFT 15-T 04 1
7 56533016300 STOP DISK 22,7 X 32 X 1,5 3
8 52033096000 LOCK RING DIN0471-25X1,64SD 3
9 58533022000 BUSHING BOX 04 1
10 56533018300 STOP DISK 22,2 X 35 X 1,5 1
12 0412303914 CYL.ROLL BEARING NJ204ECP/C3 1
13 58533021000 NEEDLE BEAR. K22X26X13 DIVIDED 1
14 56533098000 NEEDLE BEARING K22X26X13H 1
16 49030023000 CYL.ROLL BEARING NJ205 1
17 58033017000 SPACER BUSHING 1
18 0760324771 SHAFT SEAL RING 32X47X7 BSL 1
19 0770250021 O-RING 25,00X2,00 SILICONE 1
20 58033029014 ENGINE SPROCKET 14 T x
20 58033029015 ENGINE SPROCKET 15 T x
20 58033029016 ENGINE SPROCKET 16 T 1
21 0770220010 O-RING 22,00X1,00 NBR 70 1
22 59033034044 SCREW+SPRING WASHER 1
660 RALLYE FAC.REP. 2007
13
05585331 / C065853301
* NEW PART
X AS REQUIRED
Page 16
SHIFTING MECHANISM
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 58534005044 SHIFT SHAFT WELDED 2001 1
2 56534013100 TENSIONING SPRING 0,8MM 1
3 58034010000 STEEL WASHER 14 X 28 X 2 1
4 58034014000 RETURN SPRING 1
5 58334020000 SPRING SLEEVE 1
6 0770125020 O-RING 12,50X2,00 NBR 70 2
7 58033027000 V-SEAL RING V-14-A 1
8 58534006000 SPACER SHAFT 2001 1
9 54632090000 SEAL RING DH/GR 12X16X3 1
10 58034002300 SHIFT FORK 1ST/4TH+2ND GEAR'98 2
11 58034004000 SHIFT RAIL 1ST/4TH + 2ND GEAR 1
12 58034001300 SHIFT FORK 3RD/5TH GEAR '98 1
13 58034003000 SHIFT RAIL 3RD/5TH GEAR 1
14 0015060653 HH COLLAR SCREW M 6X65 WS=8 1
15 58334024044 LOCKING LEVER CPL. '94 1
16 58034023500 SPRING 1
17 58334017000 SPRING SLEEVE 1
18 50334018100 SHIFTING ROLLER 6X8X5,2 3
20 58334012100 SHIFT ROLLER ALU '98 1
21 0625006087 GROOVED BALL BEAR. 608 2RS C3 1
22 0625618050 BALL BEARING 61805 C3 1
23 58434015044 SHIFT LOCATING DRUM CPL. '98 1
24 0912060404 AH SCREW DIN0912-M 6X40 A2 1
26 51006097000 WASHER 6,2X22X1,ST30,W.GALV. 1
28 58534031144 SHIFT LEVER CPL. 05 1
31 50232050000 WASHER 6,2X18X2 1
32 0912060203 AH SCREW DIN0912-M 6X20 1
33 50233041000 PAIR OF WASHERS M 6 NORDLOCK 1
56 54634032100 SHIFTING LEVER SPRING 250 1
57 54634031050 BOLT 6X25 FOR SHIFT LEVER 1
58 54634131000 STEP PLATE FOR SHIFT LEVER 250 1
14
05585340 / C065853400
* NEW PART
X AS REQUIRED
Page 17
COOLING SYSTEM
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 58535007000 RADIATOR L/S RALLYE 2001 1
2 58035016000 RADIATOR CAP SMALL 20,3 PSI 1
3 58535008000 RADIATOR R/S RALLYE 2001 1
4 58503007000 RADIATOR PROTECTOR CPL. L/S 01 1
4 58503008000 RADIATOR PROTECTOR CPL. R/S 01 1
7 0991060163 FLAT HEAD SCR. DIN7991-M 6X16 4
8 0085060160 PLASTIC-SCREW M6X16 MM 4
9 0985060003 SELF LOCK. NUT DIN0985-M 6 2
10 0934060003 HEXAGON NUT DIN0934-M 6 4
11 58335099000 HOSE CLAMP GEMI 10-16 2
12 10001020000 HOSE CLAMP GEMI 16-27 12
13 54435024001 HOSE ID 7,5 PER METER x
14 58031005000 CLAMP YDNAC 10128 12MM 2
15 55007016001 PVC-HOSE 7X10 PER METER x
16 44011076200 CABLE TIE 200/3,6MM BLACK x
18 50235033300 SNAP-NUT HOLDER M6 KP142 10
19 58011039100 BUSHING 6,5X11,2X10 6
20 41001052000 RUBBER SLEEVE D=12MM 6
21 0021060003 WASHER DIN9021-A 6,4 4
23 0015060123 HH COLLAR SCREW M 6X12 WS=8 2
24 0015060163 HH COLLAR SCREW M 6X16 WS=8 2
25 0015060203 HH COLLAR SCREW M 6X20 WS=8 2
27 43205062100 RUBBER GROMMET 20X15-M6X10 (1) 2
29 58107011000 FOAM RUBBER STRIP 2
30 58035045000 THERMOSWITCH 80-85 DG '94 1
31 0603142015 ALU SEALRING DIN7603-14X20X1,5 1
35 58535013044 THERMO.CASE CPL.55 DEGREES 05 1
36 0770320020 O-RING 32,00X2,00 1
37 54635017000 THERMOSTAT 55 DEGREES '94 1
38 0016040183 SCREW FOR PLASTIC D=4X18 3
40 58535041044 FAN CPL. WITH HOUSING L/S 05 1
40 58535141044 FAN CPL. WITH HOUSING R/S 05 1
41 0014060103 HH COLLAR SCREW M 6X10 WS=8 4
44 44106018000 PLASTIC CAP 2
48 58535020008 ALU TUBE 18X22 RADIA.D./WAPU 1
49 58535020007 PREFORMED H.90°CURVE TUBE/WAPU 1
15
05585350 / C065853500
* NEW PART
X AS REQUIRED
Page 18
COOLING SYSTEM
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
50 58535020005 PREFORMED H. 18X25/21X28 50MM 1
51 58535020004 PREFORMED HOSE 30°CURVE 18X25 2
52 58535020006 PREFORMED H.18X25/50 RAD.D-ALU 1
53 58535020002 PREFORMED H. 90°CURVE 18X26 01 1
54 58035024001 RADIATOR HOSE 12 X 3 MM x
60 58535050000 RADIATOR BUSHING 2001 2
61 0797050003 TOOTH LOCK WASH. DIN6797-J 5,3 2
62 0015050123 HH COLLAR SCREW M 5X12 WS=8 2
16
05585350 / C065853500
* NEW PART
X AS REQUIRED
Page 19
WATER PUMP
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
3 0402031780 NEEDLE ROL.DIN5402 NRB 3X17,8 1
4 0760123070 SHAFT SEAL RING 12X30X7 2001 2
6 58535055100 WATER PUMP WHEEL 04 1
7 0471100011 CIRCLIP DIN0471-10X1 1
8 0472030012 CIRCLIP DIN0472-30X1,2 1
9 58535057000 WASHER 10X16X1 A2 (NIRO) 04 1
12 58535053000 WATER PUMP COVER GASKET 2001 1
13 58535052144 WATER PUMP COVER CPL. SP 04 1
15 0015060203 HH COLLAR SCREW M 6X20 WS=8 2
16 0015060353 HH COLLAR SCREW M 6X35 WS=8 1
17 0015060603 HH COLLAR SCREW M 6X60 WS=8 1
18 0015060103 HH COLLAR SCREW M 6X10 WS=8 1
19 58036065100 CU-SEAL RING 6 X 10 X 2 1
20 58535020001 PREFORMED H. 18X25 WAPU-CYL.01 1
21 10001020000 HOSE CLAMP GEMI 16-27 2
17
05585351 / C065853501
* NEW PART
X AS REQUIRED
Page 20
TIMING VALVE
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
2 58036014000 TIMING GEAR 17-T 1
3 58336011001 CAMSHAFT GEAR 34-T "01" '94 1
4 58036013000 TIMING CHAIN C107C / 100 LINKS 1
5 58036001000 TIMING CHAIN GUIDE 1
6 58036009000 CHAIN GUIDE SCREW 1
7 0137060003 SPRING WASHER DIN0137-B 6 1
8 0912060253 AH SCREW DIN0912-M 6X25 2
9 58536002044 CHAIN TENSIONER RALLYE 1
10 0923080120 FLAT HEAD SCR. M 8X12 1
11 0912060208 AH SCREW DIN0912-M 6X20 SS 2
13 58038022100 CU-SEAL RING 12 X 16 X 2 1
15 58336018000 SECURING GUIDE 1
20 58336112000 DRIVING SCREW M10X25 1
21 58036012000 STEEL WASHER 10 X 28 X 3 1
22 58036096000 CIRCLIP SB 42 1
23 0625060040 GROOVED BALL BEARING TMB004 1
24 58536010044 CAMSHAFT RALLYE CPL. 2001 1
25 58036097000 NEEDLE BEARING BK 2012 1
26 36003014200 LOCKING WASHER 10MM 1
30 58036003144 AUTOM.TENSIONER CPL. '88 1
31 58036005100 TENSIONER GASKET 1,5 MM 2
32 58036004100 PRESSURE BOLT 1
33 58036006100 PRESSURE SPRING 0,9MM 1
35 58036007100 RATCHETING PAWL 1
36 58036007050 PRES.SPRING F.RATCHETING PAWL 1
37 0402031780 NEEDLE ROL.DIN5402 NRB 3X17,8 1
38 58536003050 FLANGEPL. F. AUTOM. TENSIONER 1
39 58038022000 CU-SEAL RING DIN7603-12X18X1,5 1
40 58036008100 PLUG M12X1,5 1
43 0417200120 CIRCLIP WS20 1
44 58336015000 STEPPED RING 1
45 58336016052 SPRING FOR AUTO-DECOMPR. '95 1
18
05585361 / C065853601
* NEW PART
X AS REQUIRED
Page 21
VALVE DRIVE
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 58036030000 INTAKE VALVE D=36 MM 2
2 58536031000 EXHAUST VALVE D=32 MM 2001 2
3 57336036000 VALVE SPRING HOLDER GRADED 4
4 58036028000 VALVE-STEAM SEALING 4
6 58536029044 VALVE SPRING KIT RALLYE 2001 4
7 58036032700 VALVE-SPRING RETAINER ALU '95 4
8 58036033000 VALVE COLLET MK7 8
10 58536060144 ROCKER ARM INTAKE CPL. 2005 1
11 58536061144 ROCKER ARM EXHAUST CPL. 2005 1
12 58036062600 ADJUSTMENT SCREW CPL. M 7X0,75 4
13 0934070756 HEXAGON NUT DIN0934-M 7X0,75 4
14 58036061090 ROCKER ARM ROLLER CPL. INTAKE 1
15 58336061090 ROCKER ARM ROLLER CPL. EXHAUST 1
20 58536056100 ROCKER ARM SHAFT L=96MM 7,2MM 2
21 58036095000 O-RING 15,08 X 2,62 NBR 70 2
23 0988162202 THRUST WASH.DIN0988-16X22X0,20 x
23 0988162205 THRUST WASH. DIN0988-16X22X0,5 x
23 0988162210 THRUST WASHER DIN0988-16X22X1 x
30 58036050100 DECOMPRESSION SHAFT 1
31 54334015000 WASHER 10X14X0,5 STEEL x
31 54334015100 WASHER 10X14X0,3 STEEL x
31 54334015200 WASHER 10X14X0,15 STEEL x
32 58036059200 DECOMP.LEVER SPRING 1
33 0770100221 O-RING 10,00X2,20 SILICONE 1
34 58036048000 COVER DISK 1
35 58036049500 DECOMPRESSION LEVER 1
36 0021060003 WASHER DIN9021-A 6,4 1
37 0912060103 AH SCREW DIN0912-M 6X10 1
19
05584363 / C065853603
* NEW PART
X AS REQUIRED
Page 22
CYLINDER HEAD
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 5853602030023 CYLINDERHEAD CPL. GREY 2003 1
3 58036065100 CU-SEAL RING 6 X 10 X 2 3
4 58036152600 VALVE COVER FRONT '99 1
5 58036052200 VALVE COVER REAR 1
6 58036053000 VALVE COVER GASKET 2
7 58530036100 CYLINDER HEAD GASKET D=102 01 1
8 0603061001 CU-SEAL RING DIN7603-6X10X1 8
10 0912060353 AH SCREW DIN0912-M 6X35 1
11 0912060253 AH SCREW DIN0912-M 6X25 2
12 49030028000 COLLAR NUT M8 2
13 54330043000 STUD DIN0835-M 8X40 2
600/612/620/640/660 LC4
14 0125100003 WASHER DIN0125-A10,5 4
15 42011252000 TEMPEMPERATURE SWITCH VDO 1
16 0603070122 CU-SEAL RING DIN7603- 7X12X2 2
17 0993012000 CIRCLIP DIN7993-RW12 4
18 58036026644 VALVE GUIDE INTAKE CPL. 2
19 58036126644 VALVE GUIDE EXHAUST CPL. 2
20 58536065000 PLUG COVER 2001 1
21 0770047015 O-RING 47,00X1,50 NBR 70 1
22 0770049025 O-RING 49,00X2,50 NBR 1
23 58036099100 COLLAR SCREW M10X80 WS=13 10.9 4
24 58530090000 DOWEL BUSHING 9,8X7,2X10 1
NOTCH, MARKING
30 58536040000 EXHAUST FLANGE R/S RALLYE 2001 1
31 58536140000 EXHAUST FLANGE L/S RALLYE 2001 1
32 58036041000 EXHAUST FLANGE GASKET 2
36 58336020090 VACUUM CONNECTION M 6X1 1
42 58536044000 INTAKE BOOT RALLYE 2001 1
45 59030061000 CLAMP D=56MM B=9MM M4X25 2
49 0912060163 AH SCREW DIN0912-M 6X16 6
51 0912060203 AH SCREW DIN0912-M 6X20 6
52 0912060253 AH SCREW DIN0912-M 6X25 6
53 51005074000 RETAINING PLATE 4
54 0912070551 AH SCREW DIN0912-M 7X55 12.9 1
55 0912070601 AH SCREW DIN0912-M 7X60 12.9 1
20
05585362 / C075853602
* NEW PART
X AS REQUIRED
Page 23
CYLINDER HEAD
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
56 0912060653 AH SCREW DIN0912-M 6X65 1
57 0912060703 AH SCREW DIN0912-M 6X70 1
60 0137060003 SPRING WASHER DIN0137-B 6 6
61 58539010000 STICK COIL HOLDER 2001 1
62 56535106000 GASKET FOR CONNECTING ANGLE 1
63 56535006000 CONNECTING ANGLE 1
65 0015060163 HH COLLAR SCREW M 6X16 WS=8 2
66 58530005050 RETAINING PLATE 1
21
05585362 / C075853602
* NEW PART
X AS REQUIRED
Page 24
LUBRICATING SYSTEM
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
2 0402251980 NEEDLEROL.DIN5402 NRA 2,5X19,8 2
3 0015060203 HH COLLAR SCREW M 6X20 WS=8 7
5 58038007700 OIL PUMP MIKUNI G-73-10 1
6 58038007755 STOP DISK 8,1 X 15 X 0,5 4
7 0799060000 TAB WASHER DIN6799-RS 6,0 2
8 58438001000 OIL PUMP GEAR 26-T 2
9 58030021000 OILDRAIN PLUG W.MAG. M 12X1,5 2
10 58538007000 OIL PUMP MIKUNI G-185 660 99 1
12 54313025000 HOLLOW SCREW M10 X 1 4
13 58038028000 VALVE PISTON D=10MM 1
15 58038019100 OIL DRAIN PLUG M22X1,5 1
16 58038017100 CU-SEAL RING DIN7603-22X27X2 1
17 0908120153 PLUG DIN0908-M12X1,5 1
18 58038022000 CU-SEAL RING DIN7603-12X18X1,5 3
19 58538023000 OIL PRES.SPRING 5 BAR RED 2001 1
25 0984060103 AH SCREW DIN7984-M 6X10 1
27 0910160153 PLUG DIN0910-M16X1,5 1
28 0603162220 CU-SEAL RING 16X22X2 1
31 58538053044 OIL L. OIL COOLER-FRAME 295MM 1
37 60030064090 OIL JET 90 M6X0,75 WS8 03 2
38 56331145075 STARTING JET 1
43 59038029000 JET SCREW "100" M8X1 WS=12 1
44 58038030000 % BANJO BOLT M8 X 1 DIN7643 3
45 0603082131 COPPER GASK.DIN7603- 8,2X13X1 4
46 0603100141 COPPER GASKET DIN7603-10X14X1 4
47 0603821220 COPPER GASKET 8,2X12X2 MM 2001 4
49 0603101420 COPPER GASKET 10,2X14X2 MM 01 4
65 0985060003 SELF LOCK. NUT DIN0985-M 6 2
70 58538052000 OIL COOLER RALLYE 2001 1
73 0015060353 HH COLLAR SCREW M 6X35 WS=8 2
74 0021060003 WASHER DIN9021-A 6,4 3
75 31008060000 RUBBER SLEEVE D=8MM OPEN 3
76 50235033300 SNAP-NUT HOLDER M6 KP142 1
77 54431032050 SPACER BUSHING 6X8X8,5 3
79 0125060003 WASHER DIN0125-A 6,4 2
22
05585380 / C065853800
* NEW PART
X AS REQUIRED
Page 25
OIL FILTER
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 58338045100 SCREW TYPE FILTER 1
4 0015060253 HH COLLAR SCREW M 6X25 WS=8 3
12 54313025000 HOLLOW SCREW M10 X 1 2
20 58038005100 OIL FILTER LONG 1
21 58530041000 OIL FILTER COVER GASKET 2001 1
22 58030008700 OIL FILTER COVER 2001 1
30 58538052044 OIL L.OIL FIL.-OIL COOL.1110MM 1
31 58538043044 OIL L. JUNC.B.-ENGI.CASE L 04 1
32 58538046044 OIL L. JUNC.B.-CRANK SH. 300MM 1
33 58538044044 OIL L. JUNC.B.-ENGI.CASE 260MM 1
34 58538045044 OIL L. JUNC.B-CLUTCH C. 465MM 1
35 58538054044 OIL L. FRAME-JUNC.BOX 91MM 01 1
44 58038030000 % BANJO BOLT M8 X 1 DIN7643 4
45 0603082131 COPPER GASK.DIN7603- 8,2X13X1 4
46 0603100141 COPPER GASKET DIN7603-10X14X1 2
47 0603821220 COPPER GASKET 8,2X12X2 MM 2001 4
49 0603101420 COPPER GASKET 10,2X14X2 MM 01 2
50 58538041000 OIL FILT.COVER M10X1 RALLYE 01 1
51 0770400025 O-RING 40,00X2,50 NBR 70 1
52 58538043000 MICRO FILTER HOUSING RALLYE 01 1
53 59038046100 OIL FILTER SHORT 1
55 0015050123 HH COLLAR SCREW M 5X12 WS=8 2
56 58538043010 RUBBER RING 45/52/16 1
57 58338091100 OILPRESSURE SWITCH 03 1
58 0603100141 COPPER GASKET DIN7603-10X14X1 1
61 58538010000 RUBBER GROMMET 20X11/M6X18 01 1
62 43205062100 RUBBER GROMMET 20X15-M6X10 (1) 1
63 58538050000 BRACKET FOR MICRO FILTER 2001 1
64 0934060003 HEXAGON NUT DIN0934-M 6 1
66 0902060083 AH OVAL SCREW ISO 7380 M 6X8 1
67 50233041000 PAIR OF WASHERS M 6 NORDLOCK 1
23
05585381 / C065853801
* NEW PART
X AS REQUIRED
Page 26
ENGINE EXHAUST
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 58430087000 ENGINE BREATHER TUBE TOP 1
2 42013037200 HOSE CLAMP GEMI 12/22 4
3 57530090000 BREATHER TUBE ENGINE '93 1
24
02585388 / C065853802
* NEW PART
X AS REQUIRED
Page 27
IGNITION SYSTEM
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 58439005100 FLYWHEEL KOKUSAN GP9128 '97 1
2 58439004000 STATOR KOKUSAN LOOSE '96 1
4 5843000214430 IGNITION COVER CPL. BLACK 04 1
5 58530040000 IGNITION COVER GASKET 2001 1
6 0912050253 AH SCREW DIN0912-M 5X25 3
7 58430095100 INSPECT.GLASS GW 20-7 MINERAL 1
8 49030090000 DOWEL 9,8 X 7 X 10 2
9 0912050083 AH SCREW DIN 912 M 5X8 2
10 58439034000 PULSER COIL 1
13 58539031100 CDI-BOX RALLYE 03 1
16 58539093000 SPARK PLUG NGK DR9EA 1
17 58539006000 STICK COIL (IGN.C./SPA.P.C.)01 1
30 58439030200 RUBBER BRACKET FOR DIGI-BOX 03 1
31 58439030250 SUPPORT FOR RUBBER BRACKET 03 1
32 0991060103 FLAT HEAD SCREW DIN7991 M6X10 2
35 0015060303 HH COLLAR SCREW M 6X30 WS=8 1
36 0015060803 HH COLLAR SCREW M 6X80 WS=8 1
37 0766060400 THREAD PIN WITH SLOT M6x40 2
38 0934060003 HEXAGON NUT DIN0934-M 6 2
39 58036065100 CU-SEAL RING 6 X 10 X 2 2
25
05585390 / C075853900
* NEW PART
X AS REQUIRED
Page 28
ELECTRIC STARTER
660 RALLYE FAC.REP. 2007
FIG PART NUMBER DESCRIPTION QTY
1 58440001000 E-STARTER ENGINE CPL. LC4-E 1
2 0770250030 O-RING 25,00X3,00 NBR 70 2
5 58440090100 NEEDLE BEARING K30 X 37 X 18 A 1
6 58440020079 FREE-WHEEL-GEAR 79-T 1
7 58440026000 FREE-WHEEL FWD 332008 BLS 1
8 58440025000 FREEWHEEL HUB 1
9 0912060121 AH SCREW DIN0912-M 6X12 12.9 4
10 58440098000 AH CENTERING SCREW M6X12,5 2
11 58511058050 BRACKET FOR STARTRELAIS '99 1
15 58440010100 STARTER FLANGE BLACK '97 1
16 49030090000 DOWEL 9,8 X 7 X 10 2
17 58540042000 STARTER FLAN.GASKET 0,5MM 2001 1
20 58440011100 STARTER COVER BLACK '97 1
21 58440011050 FORM RING F.STARTERCOVER NBR70 1
22 58440022000 INTERMEDIATE GEAR 52-T 1
23 58440090000 NEEDLE BEARING K10 X 13 X 13TN 3
24 58440021018 REDUCTION GEAR 55-T/18-Z 1
25 58440028000 BEARING BOLT 10 X 38,4 1
26 58440029000 BEARING BOLT 10 X 54 1
27 0402040780 NEEDLEROLL. DIN5402 NRB 4X 7,8 2
29 0015060253 HH COLLAR SCREW M 6X25 WS=8 4
32 0015060163 HH COLLAR SCREW M 6X16 WS=8 1
34 0015060453 HH COLLAR SCREW M 6X45 WS=8 1
35 0015060503 HH COLLAR SCREW M 6X50 WS=8 1
36 0015060803 HH COLLAR SCREW M 6X80 WS=8 1
37 0015060303 HH COLLAR SCREW M 6X30 WS=8 1
38 0015060953 HH COLLAR SCREW M 6X95 WS=8 1
26
05585400 / C065854000
* NEW PART
X AS REQUIRED
Page 29
660 RALLYE FAC.REP. 2007
Page 30
660 RALLYE FAC.REP. 2007
Page 31
Page 32
Art.Nr.: 3CM088249GEN 8/2006
www.ktm.at
A-5230 Mattighofen
KTM-Sportmotorcycle AG
KTM Group Partner
3CM088249GEN
*3CM088249GEN*
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