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KTM 660 RALLYE CUSTOMER BIKE manual

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Table of contents for the manual

  • Page 1

    MOTOR ERSA TZTEILKA T ALOG ENGINE SP ARE P AR TS MANUAL Art.Nr . 3.208.29 11/2000 2001 660 RALL YE CUSTOMER BIKE[...]

  • Page 2

    INHAL TSVERZEICHNIS INDEX LOCTITE 243 LOCTITE 243 SILICON 5 6 7 7 9 10 11 24 21 63 62 20 18 19 23 15 16 11 33 34 29 32 44 47 46 45 48 47 50 51 31 55 28 25 1 1,5,6,7,9,10,11,15,16, 21,23,24,28,47,48,50,51 +GETRIEBELAGER TRANSMISSION BEARINGS (565.33.093.000, 585.33.025.000, 490.30.023.000, 580.33.090.000 0412 303914;) 01 23 27 48 47 52 53 R X Y 2 1 [...]

  • Page 3

    INHAL TSVERZEICHNIS INDEX 30 26 25 32 6 3 27 2 4 5 1 28 10 11 12 29 13 14 15 16 LOCTITE 648 8 7 9 33 66 65 61 68 62 69 6 7 4 4 3 13 12 15 15 17 20 21 FETTFÜLLUNG MOLYKOTE FS3452 GREASE FILLING MOLYKOTE FS3452 29 4 7 8 10 16 13 14 1 2 51 53 54 51 15 50 52 24 21 21 9 25 20 23 27 19 19 18 12 12 12 12 12 11 1 2 12 12 29 30 31 36 38 37 35 3 2 20 20 18 [...]

  • Page 4

    MOTORGEHÄUSE ENGINE CASE 660 Dichtungssatz Gasket-Set LOCTITE 243 LOCTITE 243 LOCTITE 243 SILICON LOCTITE 648 LOCTITE 648 5 6 7 7 9 10 11 24 21 63 62 20 18 19 23 15 16 11 33 34 30 26 29 60 32 44 47 46 45 48 47 50 51 31 55 42 39 28 40 41 60 38 25 1 1,5,6,7,9,10,11,15,16, 21,23,24,28,47,48,50,51 +GETRIEBELAGER TRANSMISSION BEARINGS (565.33.093.000, [...]

  • Page 5

    MOTORGEHÄUSE ENGINE CASE 660 Dichtungssatz Gasket-Set LOCTITE 243 LOCTITE 243 LOCTITE 243 SILICON LOCTITE 648 LOCTITE 648 5 6 7 7 9 10 11 24 21 63 62 20 18 19 23 15 16 11 33 34 30 26 29 60 32 44 47 46 45 48 47 50 51 31 55 42 39 28 40 41 60 38 25 1 1,5,6,7,9,10,11,15,16, 21,23,24,28,47,48,50,51 +GETRIEBELAGER TRANSMISSION BEARINGS (565.33.093.000, [...]

  • Page 6

    KURBEL WELLE, KOLBEN CRANKSHAFT , PISTON 660 KUPPLUNG CLUTCH 16 15 4 4 9 21 22 23 2 1 6 6 5 10 660 geschmiedet 660 forged 30 44 40 45 45 D=102mm 9 01-585.30.2 5 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1* 585.30.018.200 KURBEL WELLE KPL. RALL YE 2001 CRANKSHAFT CPL. RALL YE 2001 1 H U B 8 0M M HUB 80MM 2 585.30.015.044 PLEUEL-REP .SA TZ LC4 C[...]

  • Page 7

    AUSGLEICHSWELLE BALANCER SHAFT 660 1 4 4 01-585.30.7 6 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1* 585.30.057.044 AGW -RAD KPL. WAPU RALL YE 01 BAL.-SHAFT CPL.W APU RALL YE 01 1 4* 0412 174012 ZYLINDERROL.NJ 203 ECP/C3 01 CYLIND.ROLL.NJ 203 ECP/C3 2001 2 * = NEUTEIL / NEW P ART X = NACH BEDARF / AS REQUIRED 01-585.30.7 2001[...]

  • Page 8

    ZYLINDER CYLINDER 660 6 6 2 5 3 4 7 1 01-585.30.4 7 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1* 585.30.005.200 ZYLINDER 102MM 660 RALL YE 2001 CYLINDER 102MM 660 RALL YE 2001 1 2* 585.30.035.000 ZYLINDERFUSSDICHTUNG 0,33MM 01 CYL. BASE GASKET 0,33MM 2001 1 3* 585.30.043.000 STEHBOLZEN M10X75 2001 STUD M10X75 2001 4 4 0331 100003 BUNDMUTTER DI[...]

  • Page 9

    ZYLINDERKOPF CYLINDER HEAD 660 R12 = 660 ccm R XY R XY 2 1 41 39 42 50 45 014 14 19 61 62 63 64 65 018 18 Three-Bond Dichtmasse Three-Bond Gasket 11 22 21 20 7 13 12 53 53 49 60 31 30 32 32 4 6 51 8 8 51 5 6 55 54 16 3 10 3 3 57 56 66 52 16 Loctite blau 243 Loctite blue 243 15 36 01-585.36.2 8 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1* 585.3[...]

  • Page 10

    ZYLINDERKOPF CYLINDER HEAD 660 R12 = 660 ccm R XY R XY 2 1 41 39 42 50 45 014 14 19 61 62 63 64 65 018 18 Three-Bond Dichtmasse Three-Bond Gasket 11 22 21 20 7 13 12 53 53 49 60 31 30 32 32 4 6 51 8 8 51 5 6 55 54 16 3 10 3 3 57 56 66 52 16 Loctite blau 243 Loctite blue 243 15 36 01-585.36.2 9 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 54* 0912[...]

  • Page 11

    VENTIL TRIEB V AL VE DRIVE 660 21 20 23 24 21 20 13 12 23 8 4 3 2 1 3 4 8 14 23 13 12 23 37 36 35 34 33 32 31 30 11 10 6 6 7 7 15 01-585.36.3 10 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 580.36.030.000 EINLASSVENTIL 36 MM INT AKE VAL VE 36 MM 2 2* 585.36.031.000 AUSLASSVENTIL D=32 2001 EXHAUST VAL VE D=32 2001 2 3* 580.36.027.100 ANLAUFSCHEI[...]

  • Page 12

    STEUER TRIEB TIMING DRIVE 660 8 50 25 23 22 3 4 2 21 26 20 9 10 31 32 33 6 5 11 7 15 11 35 37 39 40 36 LOCTITE 243 LOCTITE 243 LOCTITE 243 LOCTITE 243 LOCTITE 243 30 12 13 24 43 44 45 620/640/660 LC4-E 01-585.36.1 11 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 2 580.36.014.000 STEUERRITZEL 17-Z TIMING GEAR 17-T 1 3* 583.36.011.001 NOCKENWELLENRA[...]

  • Page 13

    SCHMIERSYSTEM LUBRICA TING SYSTEM 660 27 28 12 45 47 45 45 45 47 45 47 45 47 45 20 43 12 12 12 12 12 30 31 34 25 26 60 32 49 46 70 76 75 77 74 3 73 75 65 79 74 77 49 46 4 22 21 38 33 35 33 52 53 51 50 55 56 57 58 44 44 44 44 44 44 44 55 9 18 15 16 17 18 19 13 LOCTITE 243 5 6 3 2 6 7 8 LOCTITE 243 4 3 3 10 6 2 8 6 7 37 37 49 46 47 47 47 64 61 62 63 [...]

  • Page 14

    SCHMIERSYSTEM LUBRICA TING SYSTEM 660 27 28 12 45 47 45 45 45 47 45 47 45 47 45 20 43 12 12 12 12 12 30 31 34 25 26 60 32 49 46 70 76 75 77 74 3 73 75 65 79 74 77 49 46 4 22 21 38 33 35 33 52 53 51 50 55 56 57 58 44 44 44 44 44 44 44 55 9 18 15 16 17 18 19 13 LOCTITE 243 5 6 3 2 6 7 8 LOCTITE 243 4 3 3 10 6 2 8 6 7 37 37 49 46 47 47 47 64 61 62 63 [...]

  • Page 15

    MOTORENTLÜFTUNG BREA THER SYSTEM 660 2 2 1 2 2 3 01-585.38.8 14 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 580.35.025.800 ENTLÜFTUNGSSCHLAUCH BREA THER TUBE TOP 1 2 420.13.037.200 SCHLAUCHBINDER GEMI 12/22 HOSE CLAMP GEMI 12/22 4 3 575.30.090.000 ENTLÜFTUNGSSCHLAUCH ‘93 BREA THER TUBE ENGINE ‘93 1 * = NEUTEIL / NEW P ART X = NACH BEDAR[...]

  • Page 16

    VERGASER KEIHIN CR39 CARBURETOR KEIHIN CR39 660 99(#) 6# 1 16 19 20 22# 21 23 27 28 29 # # 45# 39 42 51# 52# 53 54# # 72 # # # # 10 10 # 9 9 11 ACHTUNG !!! V or dem Einbau des V ergasers, Bed ü sung kontr ollieren. CAUTION !!! Before mounting the carburetor , check the jetting. ACHTUNG !!! V om Standardvergaser entfernen! CAUTION !!! Remove from s[...]

  • Page 17

    VERGASER KEIHIN CR39 CARBURETOR KEIHIN CR39 660 99(#) 6# 1 16 19 20 22# 21 23 27 28 29 # # 45# 39 42 51# 52# 53 54# # 72 # # # # 10 10 # 9 9 11 ACHTUNG !!! V or dem Einbau des V ergasers, Bed ü sung kontr ollieren. CAUTION !!! Before mounting the carburetor , check the jetting. ACHTUNG !!! V om Standardvergaser entfernen! CAUTION !!! Remove from s[...]

  • Page 18

    Z Ü NDANLAGE KOKUSAN IGNITION SYSTEM KOKUSAN 660 1 2 4 5 35 36 37 37 38 39 37 7 8 8 10 13 16 17 6 9 LOCTITE 648 LOCTITE 648 LOCTITE 243 LOCTITE 243 30 31 32 SILICON 01-585.39.0 17 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 584.39.005.100 ROTOR KOKUSAN LOSE GP9128 ‘ 97 FL YWHEEL KOKUSAN GP9128 ‘97 1 2 584.39.004.000 ST A TOR KOKUSAN LOSE [...]

  • Page 19

    ELEKTROST ARTER ELECTRIC ST ARTER 660 LOCTITE 648 1 2 5 6 7 8 9 15 16 16 17 20 22 23 23 23 25 29 29 34 35 36 37 38 26 32 24 LOCTITE 648 10 27 21 3 11 29 01-585.40.0 18 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1 584.40.001.000 E-ST ARTERMOTOR KPL. LC4-E E-ST ARTER ENGINE CPL. LC4-E 1 2 0770 250030 O-RING 25,00X3,00 NBR 70 O-RING 25,00X3,00 NBR[...]

  • Page 20

    KUPPLUNG CLUTCH 660 30 26 25 31 32 6 3 27 2 4 5 1 28 10 11 12 29 13 14 15 16 LOCTITE 648 8 7 9 33 66 65 70 71 72 75 61 68 62 69 01-585.32.0 19 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1* 585.32.001.144 KUPPLUNGSKORB KPL. RALL YE 01 OUTER CLUT . HUB CPL. RALL YE 01 1 2* 585.32.001.100 KUPPLUNGSKORB GEFR Ä ST 2001 OUTER CLUTCH HUB MILLED 2001 [...]

  • Page 21

    GETRIEBE I TRANSMISSION I 660 1 11 6 3 7 8 4 8 7 6 5 2 9 10 01-585.33.0 20 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1* 583.33.002.000 ANTRIEBSWELLE 15 Z ‘ 94 MAIN SHAFT 15T ‘94 1 2 565.33.010.300 FESTRAD 2.G 15-Z (2G3) SOLID GEAR 2.G 15-T (2G3) 1 3 583.33.004.002 LOSRAD 3.G 18-Z „ 02 “ IDLER GEAR 3.G 18-T „02“ 1 4 583.33.006.004 S[...]

  • Page 22

    GETRIEBE II TRANSMISSION II 660 1 12 10 13 13 13 2 7 8 5 8 7 4 7 8 3 6 16 19 17 18 22 21 LOCTITE 243 020 20 01-585.33.1 21 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1* 575.33.005.000 LOSRAD 1.G 33 Z (1M4) ‘ 93 IDLER GEAR 1ST GEAR 33-T ‘93 1 2 583.33.113.010 LOSRAD 2.G 24-Z „ 10 “ IDLER GEAR 2.G 24-T „10“ 1 3 583.33.007.003 SCHIEBER[...]

  • Page 23

    SCHAL TUNG SHIFTING MECHANISM 660 1 2 3 4 5 6 7 33 32 14 31 15 17 16 10 10 11 24 23 22 20 26 21 12 13 18 18 18 56 29 57 58 29,56, 57,58 029 8 9 01-585.34.0 22 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1* 585.34.005.044 SCHAL TWELLE VERSCHWEISST 2001 SHIFT SHAFT WELDED 2001 1 2 565.34.013.100 SP ANNFEDER 0,8MM SPANNER SPRING 0,8MM 1 3 580.34.01[...]

  • Page 24

    W ASSERPUMPE W A TER PUMP 660 6 7 4 4 3 13 12 15 15 17 16 20 21 21 FETTF Ü LLUNG MOLYKOTE FS3452 GREASE FILLING MOLYKOTE FS3452 01-585.35.3 23 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 3* 0402 031780 NADELROLLE DIN5402 NRB 3X17,8 NEEDLE ROL.DIN5402 NRO 3X17,8 1 4* 0760 123070 WELLENDICHTRING 12X30X7 2001 SHAFT SEAL RING 12X30X7 2001 2 6* 585.[...]

  • Page 25

    K Ü HLSYSTEM COOLING SYSTEM 660 29 4 7 8 10 16 13 14 1 2 51 53 54 51 60 62 61 15 48 50 52 24 21 21 9 25 20 23 27 19 19 18 12 12 12 12 12 11 12 12 12 11 1 2 12 12 49 29 18 40 41 44 30 31 36 38 37 35 3 2 20 20 18 01-585.35.0 24 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 1* 585.35.007.000 K Ü HLER LINKS RALL YE 2001 RADIA TOR L/S RALL YE 2001 1 [...]

  • Page 26

    K Ü HLSYSTEM COOLING SYSTEM 660 29 4 7 8 10 16 13 14 1 2 51 53 54 51 60 62 61 15 48 50 52 24 21 21 9 25 20 23 27 19 19 18 12 12 12 12 12 11 12 12 12 11 12 12 12 49 29 18 40 41 44 30 31 36 38 37 35 3 2 20 20 18 01-585.35.0 25 FIG TEILNR/P ARTNR BEZEICHNUNG DESCRIPTION QTY 48* 585.35.020.008 ALUROHR 18X22 K Ü HLER U./W APU ALU TUBE 18X22 RADIA.D./W[...]

  • Page 27

    SPEZIAL WERKZEUG SPECIAL TOOL 660 130 35 65 HOLZKLOTZ - SELBSTGEFERTIGT WOODEN BLOCK - HOME MADE 150 5 70 STAHLPLATTE - SELBSTGEFERTIGT STEEL PLATE - HOME MADE 27 16 6 4 5 26 12 20 22 15 23 2 11 39 ThreeBond 1215 Silico ne Liqu id G asket Silicon e Fl ü ssig e D ichtu ng 18 17 648 48 1 7 8 19 30 31 32 01-585.29.0 26 FIG TEILNR/P ARTNR BEZEICHNUNG [...]

  • Page 28

    TECHNISCHE DA TEN – MOTOR 660 RALL YE Customer Bike 2001 Motor 660 LC4 Bauart 1-Zylinder 4-T akt Otto-Motor mit Ausgleichswelle, fl ü ssigkeitsgek ü hlt, mit E-Starter Hubraum 653,7 cm 3 Bohrung/Hub 102 / 80 mm V erdichtung 11,6 : 1 Kraftstoff bleifreier Superkraftstoff mit mindestens ROZ 95 Steuerung 4 V entile ü ber Kipphebel u. 1 Nockenwell[...]

  • Page 29

    15 Z 16 Z f ü r Kette 17 Z 5 / 8 x 1 / 4 " 42 Z f ü r Kette 44 Z 5 / 8 x 1 / 4 " 45 Z 31:79 Prim ä r- ü bersetzung Getriebe ü bersetzung Lieferbare Kettenritzel Orig. Ü bersetzung Hinterrad Lieferbare Kettenr ä der hinten GETRIEBEÜBERSETZUNG 1.Gang 15:33 2.Gang 15:24 3.Gang 18:21 4.Gang 20:19 5.Gang 22:18 17:44 28 # VERGASER - GRU[...]

  • Page 30

    TECHNICAL DA T A – ENGINE 660 RALL YE Customer Bike 2001 T ype 660 LC4 Design Liquid-cooled single cylinder 4-stroke engine with balancer shaft and electric starter Displacement 653,7 cm 3 Bore / Stroke 102 / 80 mm Ratio 11,6 : 1 Fuel unleaded premium gasoline with a least RON 95 V alve timing 4 valves over rocker arm and 1 overhead camshaft, cam[...]

  • Page 31

    15 t 16 t for chain 17 t 5 / 8 x 1 / 4 " 42 t for chain 44 t 5 / 8 x 1 / 4 " 45 t 31:79 Primary ratio T ransmission Available chain drive sprockets A vailable final drive sprockets GEAR RA TIOS 1st gear 15:33 2nd gear 15:24 3rd gear 18:21 4th gear 20:19 5th gear 22:18 Original final drive ratio 17:44 30 # BASIC CARBURETOR SETTING T ype Ke[...]

  • Page 32

    KTM SPORTMOTORCYCLE AG 5230 Mattighofen Austria Internet: www .ktm.at MOTORCYCLE OILS MOTORCYCLE OILS 320829[...]