KTM Automobile Parts 3CM088249GEN User Manual
660 RALLYE FAC.REP. 2007  
SPARE PARTS MANUAL: ENGINE  
ART.NO.: 3CM088249GEN  
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660 RALLYE FAC.REP. 2007  
INDEX  
SPECIAL TOOLS  
ENGINE CASE  
CYLINDER  
CRANKSHAFT, PISTON  
3x  
8x  
4x  
9x  
6x  
11x  
15x  
7x  
12x  
17x  
BALANCER SHAFT  
CARBURETOR  
CLUTCH  
TRANSMISSION I - MAIN SHAFT  
TRANSMISSION II - COUNTERSHAFT  
SHIFTING MECHANISM  
COOLING SYSTEM  
WATER PUMP  
13x  
14x  
1
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660 RALLYE FAC.REP. 2007  
INDEX  
TIMING VALVE  
VALVE DRIVE  
CYLINDER HEAD  
LUBRICATING SYSTEM  
18x  
23x  
x
19x  
24x  
20x  
25x  
22x  
26x  
OIL FILTER  
ENGINE EXHAUST  
IGNITION SYSTEM  
ELECTRIC STARTER  
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  
SPORTMOTORCYCLE AG, Mattighofen only.  
KTM-  
2
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660 RALLYE FAC.REP. 2007  
SPECIAL TOOLS  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
2
3
56012001044  
58329003000  
58012005025  
UNIVERSAL MOUNTING RACK CPL.  
CLUTCH HOLDER D=160MM LC4'94  
MOUNTING SLEEVE D=25MM  
FOR CRANKSHAFT SEAL L/S  
MAGNETO EXTRACTOR  
1
1
1
4
5
6
58429009000  
58429031000  
58529015102  
1
1
1
PROTECTOR CAP F.CRANKSHAFT M16  
PISTON RING COMPRESSOR D=102MM  
660 LC4  
7
59029021044  
EXTRACTOR PRIM. GEAR CPL.  
FOR INNER CLUTCH HUB  
VALVE INSTALLATION KIT  
1
8
9
58012019000  
6276470  
1
1
1
x
PUSH INSERT  
VALVE SPRING LEVER  
10 59029019000  
11 6899785  
LOCTITE 243 BLUE 6CCM  
LOCTITE 648 GREEN 24ML  
BUSHING EXTRACTOR  
12 58429059000  
15 15112017000  
16 15112018000  
16 15112018100  
17 58429012000  
18 309098  
x
1
1
1
1
1
1
1
1
1
1
1
1
INTERN.BEAR.PULLER 12-16 MM  
INTERN.BEAR.PULLER 18-23 MM  
HOLDING WRENCH FOR WHEEL  
SILICON GASKET THREE-BOND  
MOUNTING TOOL F.BEARING NJ 306  
MOUNTING TOOL F.BEARING NJ 207  
LOCATING SCREW M8 L=23  
HOLDING SPANNER FOR SPROCKET  
RIVETTING TOOL FOR CLUTCH  
MOUNT.SLEEVE F. SH.S.RING WAPU  
LIMIT PLUG GAUGE F.VALVE GUIDE  
D=7,05 MM  
19 58429037040  
19 58429037043  
20 58030080000  
22 51012012000  
23 54629027000  
25 58529005000  
26 58029026007  
30 59030022000  
31 31007107001  
32 0934080003  
39 58329039000  
41 59029041000  
48 58429048000  
BLEEDER FLANGE M8 WS=10 '99  
PVC-HOSE 6X9 MM PER METER  
HEXAGON NUT DIN0934-M 8  
WRENCH SCREW FILTER  
1
x
1
1
1
1
FEEL. GAUGE SET 10,12,15,20,25  
INJEKTION FOR FRONT PIPE '99  
DEAERATE FOR FRONT PIPE  
05585290 / C065852900  
* NEW PART  
X
AS REQUIRED  
3
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660 RALLYE FAC.REP. 2007  
ENGINE CASE  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
5853000054430  
ENGINE CASE CPL.W.TRAN.BEAR.04  
BLACK  
1
3
4
5
6
7
9
58530088000  
0770020020  
50130027000  
51030026100  
58530010000  
58033097000  
PLUG VISUAL CHECK TRANSMISSION  
O-RING 20X2 VITON  
DOWEL 19 X15,1X12  
1
1
1
1
2
1
1
4
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
2
1
DOWEL 17 X 13 X 12  
CRANK SHAFT BUSH RALLYE 2001  
NEEDLE BEARING HK 2216  
SHIFT MECHANISM SUPPORT LC4'94  
DOWEL 9,8 X 7 X 10  
10 58330011000  
11 49030090000  
15 56530017000  
16 0991060166  
18 58530080000  
19 0603082121  
20 58530039200  
21 0985050103  
22 0472200010  
23 0412174012  
24 0625618050  
26 58030010100  
27 58430095100  
28 58440091000  
29 5853002600030  
30 5853000100030  
31 58530025000  
32 0770165024  
33 58030020100  
34 0770191015  
35 60030064090  
38 54403135000  
39 44011076305  
40 58530060000  
41 54613038150  
42 58530047000  
44 58030021000  
45 58038017100  
RETAINING PLATE  
FL.HEAD SCR.DIN7991-M6X16 10.9  
LOCATING SCREW  
SEAL RING CU DIN7603- 8X12X1  
ENGI.CASE GASKET SIL C-4400  
OVAL HEAD SCR. DIN7985-M 5X10  
LOCKRING DIN 472 20X1MM  
CYLIND.ROLL.NJ 203 ECP/C3 2001  
BALL BEARING 61805 C3  
%HOSE CONNECTOR M20X1,5 SPLICE  
INSPECT.GLASS GW 20-7 MINERAL  
STOP DISK 33 X 58 X 1,5  
CLUTCH COVER OUTS.CPL.BLACK 04  
CLUTCH COVER BLACK  
CLUTCH COVER GASKET  
O-RING 165X2,4  
2003  
2001  
2001  
PLUG CPL. M24X3  
O-RING 19,00X3,00 NBR  
OIL JET 90 M6X0,75 WS8 03  
PLASTIC CAP SFL10  
CABLE TIE 300/4,8MM BLACK  
SPROCKET COVER RALLYE 2001  
BUSHING 6,5X8X11  
CHAIN DAMPERSHEET 16/17T RAL.  
OILDRAIN PLUG W.MAG. M 12X1,5  
CU-SEAL RING DIN7603-22X27X2  
065853000 / C065853000  
* NEW PART  
X
AS REQUIRED  
4
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660 RALLYE FAC.REP. 2007  
ENGINE CASE  
FIG PART NUMBER  
46 58038019100  
47 58038022000  
48 0908120153  
50 58538023000  
51 58038028000  
52 58033090000  
53 0760223270  
55 58530399100  
60 0015060253  
61 0015060303  
62 0015060353  
63 0015060403  
66 0015060553  
68 0015060653  
DESCRIPTION  
QTY  
OIL DRAIN PLUG M22X1,5  
CU-SEAL RING DIN7603-12X18X1,5  
PLUG DIN0908-M12X1,5  
1
4
2
OIL PRES.SPRING 5 BAR RED 2001  
VALVE PISTON D=10MM  
1
1
NEEDLE BEARING RNA 4903  
SHAFT SEAL RING 22X32X7 BSL  
1
1
GASKET SET 660 RALLYE  
03  
1
HH COLLAR SCREW M 6X25 WS=8  
HH COLLAR SCREW M 6X30 WS=8  
HH COLLAR SCREW M 6X35 WS=8  
HH COLLAR SCREW M 6X40 WS=8  
HH COLLAR SCREW M 6X55 WS=8  
HH COLLAR SCREW M 6X65 WS=8  
12  
7
2
2
4
1
065853000 / C065853000  
* NEW PART  
X
AS REQUIRED  
5
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660 RALLYE FAC.REP. 2007  
CYLINDER  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
5853000530030  
CYLINDER 102MM 660 RAL. BLA.04  
BLACK  
1
2
3
4
5
6
58530035000  
58530043000  
0331100003  
0402040980  
58530014000  
CYL. BASE GASKET 0,33MM 2001  
STUD M10X75  
1
4
4
2
2
COLLAR NUT DIN6923-M10 WS=15  
NEEDLE ROL.DIN5402 NRB 4X9,8  
DOWEL 10,2X12,5X10  
2001  
04585304 / C065853001  
* NEW PART  
X
AS REQUIRED  
6
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660 RALLYE FAC.REP. 2007  
CRANKSHAFT, PISTON  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
58530018300  
CRANKSHAFT CPL. RALLYE 2002  
HUB 80MM  
1
2
58530015144  
CONNECT. ROD REPAIR SET LC4 05  
640/660 CCM L=141,5MM  
SHIM WASHER 36X48X0,10  
SHIM WASHER 36X48X0,15  
SHIM WASHER 36X48X0,30  
WOODRUFF KEY DIN6888-3X5X13  
WOODRUFF KEY 5X6,5 HARDED  
CYL.ROLLER BEAR. NJ 207 ECP C3  
SHAFT SEAL RING 30X40X7 BSL  
STEEL WASHER 16 X 30 X 3  
HEX NUT M16x1,25 L/S  
1
4
4
4
5
6
9
56530081000  
56530081100  
56530081300  
0888030050  
6946005  
x
x
x
1
2
2
1
1
1
1
1
1
1
1
1
1
2
56530123000  
10 0760304071  
15 58330095000  
16 58430028000  
21 58030019000  
22 0936200155  
23 0760122270  
30 58530007300 I  
30 58530007300 II  
40 58530031144  
44 58330833000  
45 58430074000  
LOCKING RING VSK 20  
HEXAGON NUT DIN0936-M20X1,5  
SHAFT SEAL RING 12 X 22 X 7 B  
PISTON I CPL. D=102MM 03  
PISTON II CPL. D=102MM 03  
PISTONRING SET ELKO 660 RALLYE  
PISTON PIN 22 X 13 X 60  
CIRCLIP 22 X 1,6  
05585302 / C065853002  
* NEW PART  
X
AS REQUIRED  
7
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660 RALLYE FAC.REP. 2007  
BALANCER SHAFT  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
4
6
58530057144  
0412174012  
0988172410  
BALANCER SHAFT CPL.WAPU RAL.03  
CYLIND.ROLL.NJ 203 ECP/C3 2001  
SHIM WASHER DIN988-17X24X0,1  
1
2
2
03585304 / C065853004  
* NEW PART  
X
AS REQUIRED  
8
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660 RALLYE FAC.REP. 2007  
CARBURETOR  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
5
58531001000  
57331027044  
CARBURETOR 4100A BSKJ RALLYE06  
CARBURETOR COVER WITH GASKET  
BRACKET PLATE FOR THR. CABLE  
SCREW M 5 X 8  
1
1
1
2
1
1
1
1
1
4
1
1
x
10 57331080000  
11 57331055000  
12 57331046000  
14 57331046050  
16 57331035051  
18 58331029014  
19 57331035000  
20 59031035050  
21 57331035153  
22 59031035052  
23 57331034100  
23 57331034200  
23 57331034300  
23 57331034400  
23 57331034500  
24 59031029000  
25 57331032000  
26 59031121000  
27 54531623172  
27 54531623175  
27 54531623178  
27 54531623180  
27 54531623182  
27 54531623185  
28 54531607042  
28 54531607045  
28 54531607048  
29 59031051085  
30 57331007100  
31 57331037200  
32 59031017100  
35 57331085000  
39 57331009000  
40 57331008000  
THROTTLE SHAFT CPL.  
COIL SPRING THROTTLE SHAFT  
LINK ARM THROTTLE VALVE CPL.  
SLIDE STOP L=34,5MM  
THROTTLE VALVE CPL.  
BUSHING THROTTLE VALVE  
03  
GASKET PLATE THROTTLE VALVE 04  
GASKET WASHER THROTTLE VALVE  
JET NEEDLE KEIHIN OBEKP  
JET NEEDLE KEIHIN OBEKQ  
JET NEEDLE KEIHIN OBEKR  
JET NEEDLE KEIHIN OBEKS  
JET NEEDLE KEIHIN OBEKT  
BAR CLIP  
x
1
x
x
1
1
1
x
NEEDLE SET SCREW CPL.  
NEEDLE JET FCR-MX  
MAIN JET 172 KEIHIN  
MAIN JET 175 KEIHIN  
MAIN JET 178 KEIHIN  
MAIN JET 180 KEIHIN  
MAIN JET 182 KEIHIN  
MAIN JET 185 KEIHIN  
IDLE JET 42 KEIHIN  
1
x
x
x
x
x
IDLE JET 45 KEIHIN  
IDLE JET 48 KEIHIN  
STARTER JET 85  
x
1
1
1
1
1
1
1
1
IDLE AIR JET 100 KEIHIN  
MAIN AIR JET 200 KEIHIN  
ADJUST SCREW CPL. FCR-MX  
BUFFER PLATE  
FLOAT CPL.  
ARM PIN FLOAT  
065853100 / C065853100  
* NEW PART  
X
AS REQUIRED  
9
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660 RALLYE FAC.REP. 2007  
CARBURETOR  
FIG PART NUMBER  
42 57331020000  
46 57331155000  
47 57331060000  
49 57331011000  
52 57331090000  
53 59031059000  
56 57331098000  
60 0965050103  
61 54531699000  
64 57331062000  
65 57331056000  
66 57331059000  
67 57331159000  
68 57331038000  
69 57331087000  
70 57331084000  
72 57331061000  
83 59031013044  
85 59031040200  
87 59031040010  
89 0912050123  
90 57331025000  
91 58302095251  
92 50208020000  
93 58502095200  
94 0015060403  
95 58502096000  
96 57331077100  
99 57331099000  
DESCRIPTION  
QTY  
NEEDLE VALVE CPL.  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
DRAIN SCREW FLOAT CHAMBER  
COVER ACCELERATOR PUMP  
FLOAT CHAMBER CPL. SET  
AIR CUT VALVE  
COIL SPRING  
2002  
BREATH.HOSE FCR-MX KEIHIN CPL.  
FLAT HEAD SCREW DIN0965-M 5X10  
PLUG M 18X1  
INTERMEDIATE LEVER CPL.  
LINK LEVER  
SPRING LINK LEVER  
SPRING INTERMEDIATE LEVER  
CARBURETOR COVER  
WASHER LINK LEVER  
E-CLIP  
ROD ACCELERATOR PUMP  
HOSE CONNECTOR CPL.  
INTAKE FUNNEL FCR/FCR-MX 02  
O-RING FOR INTAKE FUNNEL  
AH SCREW DIN0912-M 5X12  
STOP SCREW CPL. FCR-MX  
SLEEVE FOR CHOKE CABLE  
SPACER BUSHING 7X10X7,5  
CHOKE CABLE RALLYE  
2001  
HH COLLAR SCREW M 6X40 WS=8  
CONNECTION CHOKE-CABLE 2001  
TPS-SENSOR FCRMX 320MM 03-04  
GASKET SET FCR-MX KEIHIN  
065853100 / C065853100  
* NEW PART  
X
AS REQUIRED  
10  
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660 RALLYE FAC.REP. 2007  
CLUTCH  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
2
3
4
5
6
7
8
58532001144  
58532001100  
58332026000  
58532000131  
58532000079  
58332028000  
58332112000  
58332011300  
OUTER CLUT. HUB CPL. RALLYE 01  
OUTER CLUTCH HUB MILLED 2001  
1
1
8
1
1
1
9
10  
1
1
1
1
6
6
6
1
1
8
1
1
1
1
1
1
1
1
1
1
1
1
1
DAMPING ELEMENT  
PRIMARY GEAR WHEEL 31-T 2001  
CLUTCH WHEEL 79-T 2001  
BRACKET 57 x 132 x 1,5 '94  
'94  
STEEL DISK 1,5 MM LC4'94  
LINING DISK 2,7MM FCC 02  
10 58532002100  
11 58332018000  
12 0936181505  
13 58332003300  
14 58332080000  
15 58132081000  
16 0015060203  
25 58332017000  
26 58332032000  
27 58332007000  
28 57532013000  
29 0625060016  
30 0094020163  
31 50332070000  
32 56532095000  
61 58532061044  
62 50332062000  
65 58632065000  
66 0401070003  
68 42013226000  
69 58532066000  
70 0912060303  
71 0984060163  
INNER CLUTCH HUB RALLYE 2004  
LOCK WASHER '94  
HEXAGON NUT DIN0936-M18X1,5 R.  
PRESSURE CAP LC4/LC4-E 04  
CLUTCH SPRING 2,8 X 37  
SPRING RETAINER 6,2 X 20 X 3,2  
HH COLLAR SCREW M 6X20 WS=8  
PUSH ROD 224 MM  
PRESSURE BOLT  
RIVET 6 X 23 X 11,2  
LC4'94  
LC4'94  
SUPPORTWASHER 22,2X35X3 HARDE.  
GROOV.BALL BEAR. 6001.2RSR C3  
PIN DIN0094-2,0X16  
INNER RING WITH COLLAR  
NEEDLE BEARING K26X30X22ZW.KSE  
CYLINDER D=25MM CPL. RALLYE 01  
HOLLOW SCREW CPL. M 10X1 '98  
CLUTCH RELEASE GASKET  
BALL DIN5401-7  
CU-SEAL RING DIN7603-10X16X1  
PISTON WITH O-RING D=25MM 2001  
AH SCREW DIN0912-M 6X30  
AH SCREW DIN6912-M 6X16  
WITH LOW HEAD  
72 0912060253  
75 50329050000  
AH SCREW DIN0912-M 6X25  
VENT INJEKTION HYDR. CLUTCH  
1
1
05585320 / C075853200  
* NEW PART  
X
AS REQUIRED  
11  
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660 RALLYE FAC.REP. 2007  
TRANSMISSION I - MAIN SHAFT  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
2
3
4
5
6
7
8
9
58333002000  
56533010300  
58333004002  
58333006004  
58333008008  
58533021000  
56533016300  
52033096000  
56533015000  
MAIN SHAFT 15T '94  
1
1
1
1
1
2
2
2
1
1
1
1
SOLID GEAR 2.G 15-T (2G3)  
IDLER GEAR 3.G 18-T "02"  
SLIDING GEAR 4.G 20-T "04"  
IDLER GEAR 5.G 22-T "08"  
NEEDLE BEAR. K22X26X13 DIVIDED  
STOP DISK 22,7 X 32 X 1,5  
LOCK RING DIN0471-25X1,64SD  
STOP DISK 20,2 X 35 X 1  
10 56533093000  
11 58533025000  
13 0015060123  
NEEDLE BEARING RNA 4902 KSE  
CYL.ROLL BEARING BC1-0076A  
HH COLLAR SCREW M 6X12 WS=8  
03583330 / C065853300  
* NEW PART  
X
AS REQUIRED  
12  
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660 RALLYE FAC.REP. 2007  
TRANSMISSION II - COUNTERSHAFT  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
2
3
4
5
6
7
8
9
57533005000  
58333113010  
58333007003  
58533009012  
58333011009  
58533010000  
56533016300  
52033096000  
58533022000  
IDLER GEAR 1ST GEAR 33T(1M4)93  
IDLER GEAR 2.G 24-T "10"  
SLIDING GEAR 3.G 21-T "03"  
1
1
1
1
1
1
3
3
1
1
1
1
1
1
1
1
1
x
IDLER GEAR 4.G 19-T  
SLIDING GEAR 5.G 18-T "09"  
04  
COUNTERSHAFT 15-T  
04  
STOP DISK 22,7 X 32 X 1,5  
LOCK RING DIN0471-25X1,64SD  
BUSHING BOX  
04  
10 56533018300  
12 0412303914  
13 58533021000  
14 56533098000  
16 49030023000  
17 58033017000  
18 0760324771  
19 0770250021  
20 58033029014  
20 58033029015  
20 58033029016  
21 0770220010  
22 59033034044  
STOP DISK 22,2 X 35 X 1,5  
CYL.ROLL BEARING NJ204ECP/C3  
NEEDLE BEAR. K22X26X13 DIVIDED  
NEEDLE BEARING K22X26X13H  
CYL.ROLL BEARING NJ205  
SPACER BUSHING  
SHAFT SEAL RING 32X47X7 BSL  
O-RING 25,00X2,00 SILICONE  
ENGINE SPROCKET 14 T  
ENGINE SPROCKET 15 T  
ENGINE SPROCKET 16 T  
x
1
1
1
O-RING 22,00X1,00 NBR 70  
SCREW+SPRING WASHER  
05585331 / C065853301  
* NEW PART  
X
AS REQUIRED  
13  
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660 RALLYE FAC.REP. 2007  
SHIFTING MECHANISM  
FIG PART NUMBER  
DESCRIPTION  
SHIFT SHAFT WELDED  
QTY  
1
2
3
4
5
6
7
8
9
58534005044  
56534013100  
58034010000  
58034014000  
58334020000  
0770125020  
58033027000  
58534006000  
54632090000  
2001  
1
1
1
1
1
2
1
1
1
2
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
1
1
1
TENSIONING SPRING 0,8MM  
STEEL WASHER 14 X 28 X 2  
RETURN SPRING  
SPRING SLEEVE  
O-RING 12,50X2,00 NBR 70  
V-SEAL RING V-14-A  
SPACER SHAFT  
SEAL RING DH/GR 12X16X3  
2001  
10 58034002300  
11 58034004000  
12 58034001300  
13 58034003000  
14 0015060653  
15 58334024044  
16 58034023500  
17 58334017000  
18 50334018100  
20 58334012100  
21 0625006087  
22 0625618050  
23 58434015044  
24 0912060404  
26 51006097000  
28 58534031144  
31 50232050000  
32 0912060203  
33 50233041000  
56 54634032100  
57 54634031050  
58 54634131000  
SHIFT FORK 1ST/4TH+2ND GEAR'98  
SHIFT RAIL 1ST/4TH + 2ND GEAR  
SHIFT FORK 3RD/5TH GEAR '98  
SHIFT RAIL 3RD/5TH GEAR  
HH COLLAR SCREW M 6X65 WS=8  
LOCKING LEVER CPL.  
SPRING  
SPRING SLEEVE  
'94  
SHIFTING ROLLER 6X8X5,2  
SHIFT ROLLER ALU  
'98  
GROOVED BALL BEAR. 608 2RS C3  
BALL BEARING 61805 C3  
SHIFT LOCATING DRUM CPL. '98  
AH SCREW DIN0912-M 6X40 A2  
WASHER 6,2X22X1,ST30,W.GALV.  
SHIFT LEVER CPL.  
WASHER 6,2X18X2  
05  
AH SCREW DIN0912-M 6X20  
PAIR OF WASHERS M 6 NORDLOCK  
SHIFTING LEVER SPRING 250  
BOLT 6X25 FOR SHIFT LEVER  
STEP PLATE FOR SHIFT LEVER 250  
05585340 / C065853400  
* NEW PART  
X
AS REQUIRED  
14  
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660 RALLYE FAC.REP. 2007  
COOLING SYSTEM  
FIG PART NUMBER  
DESCRIPTION  
RADIATOR L/S RALLYE  
RADIATOR CAP SMALL 20,3 PSI  
RADIATOR R/S RALLYE 2001  
QTY  
1
2
3
4
4
7
8
9
58535007000  
58035016000  
58535008000  
58503007000  
58503008000  
0991060163  
0085060160  
0985060003  
2001  
1
1
1
1
1
4
4
2
4
2
12  
x
RADIATOR PROTECTOR CPL. L/S 01  
RADIATOR PROTECTOR CPL. R/S 01  
FLAT HEAD SCR. DIN7991-M 6X16  
PLASTIC-SCREW M6X16 MM  
SELF LOCK. NUT DIN0985-M 6  
HEXAGON NUT DIN0934-M 6  
HOSE CLAMP GEMI 10-16  
10 0934060003  
11 58335099000  
12 10001020000  
13 54435024001  
14 58031005000  
15 55007016001  
16 44011076200  
18 50235033300  
19 58011039100  
20 41001052000  
21 0021060003  
23 0015060123  
24 0015060163  
25 0015060203  
27 43205062100  
29 58107011000  
30 58035045000  
31 0603142015  
35 58535013044  
36 0770320020  
37 54635017000  
38 0016040183  
40 58535041044  
40 58535141044  
41 0014060103  
44 44106018000  
48 58535020008  
49 58535020007  
HOSE CLAMP GEMI 16-27  
HOSE ID 7,5 PER METER  
CLAMP YDNAC 10128 12MM  
PVC-HOSE 7X10 PER METER  
CABLE TIE 200/3,6MM BLACK  
SNAP-NUT HOLDER M6 KP142  
BUSHING 6,5X11,2X10  
2
x
x
10  
6
6
4
2
2
2
2
2
1
1
1
1
1
3
1
1
4
2
1
1
RUBBER SLEEVE D=12MM  
WASHER DIN9021-A 6,4  
HH COLLAR SCREW M 6X12 WS=8  
HH COLLAR SCREW M 6X16 WS=8  
HH COLLAR SCREW M 6X20 WS=8  
RUBBER GROMMET 20X15-M6X10 (1)  
FOAM RUBBER STRIP  
THERMOSWITCH 80-85 DG '94  
ALU SEALRING DIN7603-14X20X1,5  
THERMO.CASE CPL.55 DEGREES 05  
O-RING 32,00X2,00  
THERMOSTAT 55 DEGREES '94  
SCREW FOR PLASTIC D=4X18  
FAN CPL. WITH HOUSING L/S 05  
FAN CPL. WITH HOUSING R/S 05  
HH COLLAR SCREW M 6X10 WS=8  
PLASTIC CAP  
ALU TUBE 18X22 RADIA.D./WAPU  
PREFORMED H.90°CURVE TUBE/WAPU  
05585350 / C065853500  
* NEW PART  
X
AS REQUIRED  
15  
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660 RALLYE FAC.REP. 2007  
COOLING SYSTEM  
FIG PART NUMBER  
50 58535020005  
51 58535020004  
52 58535020006  
53 58535020002  
54 58035024001  
60 58535050000  
61 0797050003  
62 0015050123  
DESCRIPTION  
QTY  
PREFORMED H. 18X25/21X28 50MM  
PREFORMED HOSE 30°CURVE 18X25  
PREFORMED H.18X25/50 RAD.D-ALU  
PREFORMED H. 90°CURVE 18X26 01  
RADIATOR HOSE 12 X 3 MM  
1
2
1
1
x
RADIATOR BUSHING  
2001  
2
2
2
TOOTH LOCK WASH. DIN6797-J 5,3  
HH COLLAR SCREW M 5X12 WS=8  
05585350 / C065853500  
* NEW PART  
X
AS REQUIRED  
16  
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660 RALLYE FAC.REP. 2007  
WATER PUMP  
FIG PART NUMBER  
DESCRIPTION  
QTY  
3
4
6
7
8
9
0402031780  
0760123070  
58535055100  
0471100011  
0472030012  
58535057000  
NEEDLE ROL.DIN5402 NRB 3X17,8  
SHAFT SEAL RING 12X30X7 2001  
1
2
1
1
1
1
1
1
2
1
1
1
1
1
2
WATER PUMP WHEEL  
CIRCLIP DIN0471-10X1  
CIRCLIP DIN0472-30X1,2  
04  
WASHER 10X16X1 A2 (NIRO) 04  
WATER PUMP COVER GASKET 2001  
WATER PUMP COVER CPL. SP 04  
HH COLLAR SCREW M 6X20 WS=8  
HH COLLAR SCREW M 6X35 WS=8  
HH COLLAR SCREW M 6X60 WS=8  
HH COLLAR SCREW M 6X10 WS=8  
CU-SEAL RING 6 X 10 X 2  
12 58535053000  
13 58535052144  
15 0015060203  
16 0015060353  
17 0015060603  
18 0015060103  
19 58036065100  
20 58535020001  
21 10001020000  
PREFORMED H. 18X25 WAPU-CYL.01  
HOSE CLAMP GEMI 16-27  
05585351 / C065853501  
* NEW PART  
X
AS REQUIRED  
17  
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660 RALLYE FAC.REP. 2007  
TIMING VALVE  
FIG PART NUMBER  
DESCRIPTION  
QTY  
2
3
4
5
6
7
8
9
58036014000  
58336011001  
58036013000  
58036001000  
58036009000  
0137060003  
0912060253  
58536002044  
TIMING GEAR 17-T  
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
CAMSHAFT GEAR 34-T "01" '94  
TIMING CHAIN C107C / 100 LINKS  
TIMING CHAIN GUIDE  
CHAIN GUIDE SCREW  
SPRING WASHER DIN0137-B 6  
AH SCREW DIN0912-M 6X25  
CHAIN TENSIONER RALLYE  
FLAT HEAD SCR. M 8X12  
AH SCREW DIN0912-M 6X20 SS  
CU-SEAL RING 12 X 16 X 2  
SECURING GUIDE  
10 0923080120  
11 0912060208  
13 58038022100  
15 58336018000  
20 58336112000  
21 58036012000  
22 58036096000  
23 0625060040  
24 58536010044  
25 58036097000  
26 36003014200  
30 58036003144  
31 58036005100  
32 58036004100  
33 58036006100  
35 58036007100  
36 58036007050  
37 0402031780  
38 58536003050  
39 58038022000  
40 58036008100  
43 0417200120  
44 58336015000  
45 58336016052  
DRIVING SCREW M10X25  
STEEL WASHER 10 X 28 X 3  
CIRCLIP SB 42  
GROOVED BALL BEARING TMB004  
CAMSHAFT RALLYE CPL. 2001  
NEEDLE BEARING BK 2012  
LOCKING WASHER 10MM  
AUTOM.TENSIONER CPL. '88  
TENSIONER GASKET 1,5 MM  
PRESSURE BOLT  
PRESSURE SPRING 0,9MM  
RATCHETING PAWL  
PRES.SPRING F.RATCHETING PAWL  
NEEDLE ROL.DIN5402 NRB 3X17,8  
FLANGEPL. F. AUTOM. TENSIONER  
CU-SEAL RING DIN7603-12X18X1,5  
PLUG M12X1,5  
CIRCLIP WS20  
STEPPED RING  
SPRING FOR AUTO-DECOMPR. '95  
05585361 / C065853601  
* NEW PART  
X
AS REQUIRED  
18  
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660 RALLYE FAC.REP. 2007  
VALVE DRIVE  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
2
3
4
6
7
8
58036030000  
58536031000  
57336036000  
58036028000  
58536029044  
58036032700  
58036033000  
INTAKE VALVE D=36 MM  
2
2
4
4
4
4
8
1
1
4
4
1
1
2
2
x
EXHAUST VALVE D=32 MM 2001  
VALVE SPRING HOLDER GRADED  
VALVE-STEAM SEALING  
VALVE SPRING KIT RALLYE 2001  
VALVE-SPRING RETAINER ALU '95  
VALVE COLLET MK7  
10 58536060144  
11 58536061144  
12 58036062600  
13 0934070756  
14 58036061090  
15 58336061090  
20 58536056100  
21 58036095000  
23 0988162202  
23 0988162205  
23 0988162210  
30 58036050100  
31 54334015000  
31 54334015100  
31 54334015200  
32 58036059200  
33 0770100221  
34 58036048000  
35 58036049500  
36 0021060003  
37 0912060103  
ROCKER ARM INTAKE CPL. 2005  
ROCKER ARM EXHAUST CPL. 2005  
ADJUSTMENT SCREW CPL. M 7X0,75  
HEXAGON NUT DIN0934-M 7X0,75  
ROCKER ARM ROLLER CPL. INTAKE  
ROCKER ARM ROLLER CPL. EXHAUST  
ROCKER ARM SHAFT L=96MM 7,2MM  
O-RING 15,08 X 2,62 NBR 70  
THRUST WASH.DIN0988-16X22X0,20  
THRUST WASH. DIN0988-16X22X0,5  
THRUST WASHER DIN0988-16X22X1  
DECOMPRESSION SHAFT  
x
x
1
x
WASHER 10X14X0,5 STEEL  
WASHER 10X14X0,3 STEEL  
x
WASHER 10X14X0,15 STEEL  
DECOMP.LEVER SPRING  
x
1
1
1
1
1
1
O-RING 10,00X2,20 SILICONE  
COVER DISK  
DECOMPRESSION LEVER  
WASHER DIN9021-A 6,4  
AH SCREW DIN0912-M 6X10  
05584363 / C065853603  
* NEW PART  
X
AS REQUIRED  
19  
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660 RALLYE FAC.REP. 2007  
CYLINDER HEAD  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
3
4
5
6
7
8
5853602030023  
58036065100  
58036152600  
58036052200  
58036053000  
58530036100  
0603061001  
CYLINDERHEAD CPL. GREY 2003  
CU-SEAL RING 6 X 10 X 2  
1
3
1
1
2
1
8
1
2
2
2
VALVE COVER FRONT  
VALVE COVER REAR  
VALVE COVER GASKET  
'99  
CYLINDER HEAD GASKET D=102 01  
CU-SEAL RING DIN7603-6X10X1  
AH SCREW DIN0912-M 6X35  
AH SCREW DIN0912-M 6X25  
COLLAR NUT M8  
10 0912060353  
11 0912060253  
12 49030028000  
13 54330043000  
STUD DIN0835-M 8X40  
600/612/620/640/660 LC4  
WASHER DIN0125-A10,5  
14 0125100003  
15 42011252000  
16 0603070122  
17 0993012000  
18 58036026644  
19 58036126644  
20 58536065000  
21 0770047015  
22 0770049025  
23 58036099100  
24 58530090000  
4
1
2
4
2
2
1
1
1
4
1
TEMPEMPERATURE SWITCH VDO  
CU-SEAL RING DIN7603- 7X12X2  
CIRCLIP DIN7993-RW12  
VALVE GUIDE INTAKE CPL.  
VALVE GUIDE EXHAUST CPL.  
PLUG COVER  
2001  
O-RING 47,00X1,50 NBR 70  
O-RING 49,00X2,50 NBR  
COLLAR SCREW M10X80 WS=13 10.9  
DOWEL BUSHING 9,8X7,2X10  
NOTCH, MARKING  
30 58536040000  
31 58536140000  
32 58036041000  
36 58336020090  
42 58536044000  
45 59030061000  
49 0912060163  
51 0912060203  
52 0912060253  
53 51005074000  
54 0912070551  
55 0912070601  
EXHAUST FLANGE R/S RALLYE 2001  
EXHAUST FLANGE L/S RALLYE 2001  
EXHAUST FLANGE GASKET  
1
1
2
1
1
2
6
6
6
4
1
1
VACUUM CONNECTION M 6X1  
INTAKE BOOT RALLYE  
2001  
CLAMP D=56MM B=9MM M4X25  
AH SCREW DIN0912-M 6X16  
AH SCREW DIN0912-M 6X20  
AH SCREW DIN0912-M 6X25  
RETAINING PLATE  
AH SCREW DIN0912-M 7X55 12.9  
AH SCREW DIN0912-M 7X60 12.9  
05585362 / C075853602  
* NEW PART  
X
AS REQUIRED  
20  
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660 RALLYE FAC.REP. 2007  
CYLINDER HEAD  
FIG PART NUMBER  
56 0912060653  
57 0912060703  
60 0137060003  
61 58539010000  
62 56535106000  
63 56535006000  
65 0015060163  
66 58530005050  
DESCRIPTION  
QTY  
AH SCREW DIN0912-M 6X65  
AH SCREW DIN0912-M 6X70  
SPRING WASHER DIN0137-B 6  
1
1
6
1
1
1
2
1
STICK COIL HOLDER  
2001  
GASKET FOR CONNECTING ANGLE  
CONNECTING ANGLE  
HH COLLAR SCREW M 6X16 WS=8  
RETAINING PLATE  
05585362 / C075853602  
* NEW PART  
X
AS REQUIRED  
21  
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660 RALLYE FAC.REP. 2007  
LUBRICATING SYSTEM  
FIG PART NUMBER  
DESCRIPTION  
QTY  
2
3
5
6
7
8
9
0402251980  
0015060203  
58038007700  
58038007755  
0799060000  
58438001000  
58030021000  
NEEDLEROL.DIN5402 NRA 2,5X19,8  
HH COLLAR SCREW M 6X20 WS=8  
OIL PUMP MIKUNI G-73-10  
2
7
1
4
2
2
2
1
4
1
1
1
1
3
1
1
1
1
1
2
1
1
3
4
4
4
4
2
1
2
3
3
1
3
2
STOP DISK 8,1 X 15 X 0,5  
TAB WASHER DIN6799-RS 6,0  
OIL PUMP GEAR 26-T  
OILDRAIN PLUG W.MAG. M 12X1,5  
OIL PUMP MIKUNI G-185 660 99  
HOLLOW SCREW M10 X 1  
10 58538007000  
12 54313025000  
13 58038028000  
15 58038019100  
16 58038017100  
17 0908120153  
18 58038022000  
19 58538023000  
25 0984060103  
27 0910160153  
28 0603162220  
31 58538053044  
37 60030064090  
38 56331145075  
43 59038029000  
44 58038030000  
45 0603082131  
46 0603100141  
47 0603821220  
49 0603101420  
65 0985060003  
70 58538052000  
73 0015060353  
74 0021060003  
75 31008060000  
76 50235033300  
77 54431032050  
79 0125060003  
VALVE PISTON D=10MM  
OIL DRAIN PLUG M22X1,5  
CU-SEAL RING DIN7603-22X27X2  
PLUG DIN0908-M12X1,5  
CU-SEAL RING DIN7603-12X18X1,5  
OIL PRES.SPRING 5 BAR RED 2001  
AH SCREW DIN7984-M 6X10  
PLUG DIN0910-M16X1,5  
CU-SEAL RING 16X22X2  
OIL L. OIL COOLER-FRAME 295MM  
OIL JET 90 M6X0,75 WS8 03  
STARTING JET  
JET SCREW "100" M8X1 WS=12  
% BANJO BOLT M8 X 1 DIN7643  
COPPER GASK.DIN7603- 8,2X13X1  
COPPER GASKET DIN7603-10X14X1  
COPPER GASKET 8,2X12X2 MM 2001  
COPPER GASKET 10,2X14X2 MM 01  
SELF LOCK. NUT DIN0985-M 6  
OIL COOLER RALLYE  
2001  
HH COLLAR SCREW M 6X35 WS=8  
WASHER DIN9021-A 6,4  
RUBBER SLEEVE D=8MM OPEN  
SNAP-NUT HOLDER M6 KP142  
SPACER BUSHING 6X8X8,5  
WASHER DIN0125-A 6,4  
05585380 / C065853800  
* NEW PART  
X
AS REQUIRED  
22  
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660 RALLYE FAC.REP. 2007  
OIL FILTER  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
4
58338045100  
0015060253  
SCREW TYPE FILTER  
1
3
2
1
1
1
1
1
1
1
1
1
4
4
2
4
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
HH COLLAR SCREW M 6X25 WS=8  
HOLLOW SCREW M10 X 1  
OIL FILTER LONG  
12 54313025000  
20 58038005100  
21 58530041000  
22 58030008700  
30 58538052044  
31 58538043044  
32 58538046044  
33 58538044044  
34 58538045044  
35 58538054044  
44 58038030000  
45 0603082131  
46 0603100141  
47 0603821220  
49 0603101420  
50 58538041000  
51 0770400025  
52 58538043000  
53 59038046100  
55 0015050123  
56 58538043010  
57 58338091100  
58 0603100141  
61 58538010000  
62 43205062100  
63 58538050000  
64 0934060003  
66 0902060083  
67 50233041000  
OIL FILTER COVER GASKET 2001  
2001  
OIL FILTER COVER  
OIL L.OIL FIL.-OIL COOL.1110MM  
OIL L. JUNC.B.-ENGI.CASE L 04  
OIL L. JUNC.B.-CRANK SH. 300MM  
OIL L. JUNC.B.-ENGI.CASE 260MM  
OIL L. JUNC.B-CLUTCH C. 465MM  
OIL L. FRAME-JUNC.BOX 91MM 01  
% BANJO BOLT M8 X 1 DIN7643  
COPPER GASK.DIN7603- 8,2X13X1  
COPPER GASKET DIN7603-10X14X1  
COPPER GASKET 8,2X12X2 MM 2001  
COPPER GASKET 10,2X14X2 MM 01  
OIL FILT.COVER M10X1 RALLYE 01  
O-RING 40,00X2,50 NBR 70  
MICRO FILTER HOUSING RALLYE 01  
OIL FILTER SHORT  
HH COLLAR SCREW M 5X12 WS=8  
RUBBER RING 45/52/16  
OILPRESSURE SWITCH  
03  
COPPER GASKET DIN7603-10X14X1  
RUBBER GROMMET 20X11/M6X18 01  
RUBBER GROMMET 20X15-M6X10 (1)  
BRACKET FOR MICRO FILTER 2001  
HEXAGON NUT DIN0934-M 6  
AH OVAL SCREW ISO 7380 M 6X8  
PAIR OF WASHERS M 6 NORDLOCK  
05585381 / C065853801  
* NEW PART  
X
AS REQUIRED  
23  
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660 RALLYE FAC.REP. 2007  
ENGINE EXHAUST  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
2
3
58430087000  
42013037200  
57530090000  
ENGINE BREATHER TUBE TOP  
HOSE CLAMP GEMI 12/22  
BREATHER TUBE ENGINE '93  
1
4
1
02585388 / C065853802  
* NEW PART  
X
AS REQUIRED  
24  
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660 RALLYE FAC.REP. 2007  
IGNITION SYSTEM  
FIG PART NUMBER  
DESCRIPTION  
FLYWHEEL KOKUSAN GP9128 '97  
STATOR KOKUSAN LOOSE '96  
QTY  
1
2
4
5
6
7
8
9
58439005100  
58439004000  
5843000214430  
58530040000  
0912050253  
1
1
1
1
3
1
2
2
1
1
1
1
1
1
2
1
1
2
2
2
IGNITION COVER CPL. BLACK 04  
IGNITION COVER GASKET 2001  
AH SCREW DIN0912-M 5X25  
INSPECT.GLASS GW 20-7 MINERAL  
DOWEL 9,8 X 7 X 10  
58430095100  
49030090000  
0912050083  
AH SCREW DIN 912 M 5X8  
PULSER COIL  
10 58439034000  
13 58539031100  
16 58539093000  
17 58539006000  
30 58439030200  
31 58439030250  
32 0991060103  
35 0015060303  
36 0015060803  
37 0766060400  
38 0934060003  
39 58036065100  
CDI-BOX RALLYE  
SPARK PLUG NGK DR9EA  
03  
STICK COIL (IGN.C./SPA.P.C.)01  
RUBBER BRACKET FOR DIGI-BOX 03  
SUPPORT FOR RUBBER BRACKET 03  
FLAT HEAD SCREW DIN7991 M6X10  
HH COLLAR SCREW M 6X30 WS=8  
HH COLLAR SCREW M 6X80 WS=8  
THREAD PIN WITH SLOT M6x40  
HEXAGON NUT DIN0934-M 6  
CU-SEAL RING 6 X 10 X 2  
05585390 / C075853900  
* NEW PART  
X
AS REQUIRED  
25  
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660 RALLYE FAC.REP. 2007  
ELECTRIC STARTER  
FIG PART NUMBER  
DESCRIPTION  
QTY  
1
2
5
6
7
8
9
58440001000  
0770250030  
58440090100  
58440020079  
58440026000  
58440025000  
0912060121  
E-STARTER ENGINE CPL. LC4-E  
O-RING 25,00X3,00 NBR 70  
NEEDLE BEARING K30 X 37 X 18 A  
FREE-WHEEL-GEAR 79-T  
1
2
1
1
1
1
4
2
1
1
2
1
1
1
1
3
1
1
1
2
4
1
1
1
1
1
1
FREE-WHEEL FWD 332008 BLS  
FREEWHEEL HUB  
AH SCREW DIN0912-M 6X12 12.9  
AH CENTERING SCREW M6X12,5  
BRACKET FOR STARTRELAIS '99  
10 58440098000  
11 58511058050  
15 58440010100  
16 49030090000  
17 58540042000  
20 58440011100  
21 58440011050  
22 58440022000  
23 58440090000  
24 58440021018  
25 58440028000  
26 58440029000  
27 0402040780  
29 0015060253  
32 0015060163  
34 0015060453  
35 0015060503  
36 0015060803  
37 0015060303  
38 0015060953  
STARTER FLANGE BLACK  
DOWEL 9,8 X 7 X 10  
'97  
STARTER FLAN.GASKET 0,5MM 2001  
STARTER COVER BLACK '97  
FORM RING F.STARTERCOVER NBR70  
INTERMEDIATE GEAR 52-T  
NEEDLE BEARING K10 X 13 X 13TN  
REDUCTION GEAR 55-T/18-Z  
BEARING BOLT 10 X 38,4  
BEARING BOLT 10 X 54  
NEEDLEROLL. DIN5402 NRB 4X 7,8  
HH COLLAR SCREW M 6X25 WS=8  
HH COLLAR SCREW M 6X16 WS=8  
HH COLLAR SCREW M 6X45 WS=8  
HH COLLAR SCREW M 6X50 WS=8  
HH COLLAR SCREW M 6X80 WS=8  
HH COLLAR SCREW M 6X30 WS=8  
HH COLLAR SCREW M 6X95 WS=8  
05585400 / C065854000  
* NEW PART  
X
AS REQUIRED  
26  
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660 RALLYE FAC.REP. 2007  
NOTICE  
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660 RALLYE FAC.REP. 2007  
NOTICE  
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Download from Www.Somanuals.com. All Manuals Search And Download.  
t
m t . a w . k w w  
A - 5 2 3 0 t
c r y o c t l e o A m p o r t K T M - S  
e n  
G
P a r o t n u e p r  
K T M G r  
G E N  
3 C M 0 8 8 2 4 9  
* 3 C M 0 8 8 2 4 9 G E N *  
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