spare parts manual: chassis660 rallye factory repl. 2007 fig part number description qty 49 48600062...

660 RALLYE FACTORY REPL. 2007

SPARE PARTS MANUAL: CHASSIS

ART.NO.: 3CF9799G9EN

EN

GLIS

H

INDEX 660 RALLYE FACTORY REPL. 2007

TELESCOPIC FORK

4x

FORK LEGS

5x

HANDLEBAR, CONTROLS

8x

ENGINE GUARD

9x

FRAME, SUB FRAME

11x

SUB FRAME

12x

SHOCK ABSORBER DISASSEMBLED

13x

MONOSHOCK

16x

PRO LEVER LINKING

17x

SWING ARM

18x

MANIFOLD, SILENCER

19x

AIR FILTER BOX

20x

1


FUEL TANK, SEAT

21x

FUEL SYSTEM

23x

MASK, FENDERS

24x

DECAL

25x

FRONT WHEEL

26x

REAR WHEEL

27x

WIRING HARNESS

28x

ATTACHMENT PARTS

30x

HAND BRAKE CYLINDER

31x

REAR BRAKE CONTROL

32x

BRAKE CALIPER FRONT

33x

BRAKE CALIPER REAR

34x

2


LIGHTING SYSTEM

35x

INSTRUMENTS, ATTACHEMENT PARTS

37x

x

x

x

x

x

x

x

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 KTM-

SPORTMOTORCYCLE AG, Mattighofen only.

3


FIG PART NUMBER DESCRIPTION QTY

1 14187B10LS FORK LEG L/S WP48 RALLYE 06 1

2 14187B10RS FORK LEG R/S WP48 RALLYE 06 1

3 0912080303 AH SCREW DIN0912-M 8X30 4

4 0984101006 AH SCREW DIN6912-M10X100 2

SHORT HEAD

5 0015080303 HH COLLAR SCREW M 8X30 WS=10 8

6 50233041100 PAIR OF WASHERS M10 NORDLOCK 1


8 58512050000 STEERING DAMPER 1

9 58502006100 PIN F.STEERING STAB. 8MM 05 1

10 0401070003 BALL DIN5401-7 1

11 0912060303 AH SCREW DIN0912-M 6X30 2

28 43205062100 RUBBER GROMMET 20X15-M6X10 (1) 3

29 0985060003 SELF LOCK. NUT DIN0985-M 6 3

30 0902060083 AH OVAL SCREW ISO 7380 M 6X8 3

31 59001039100 HANDLEBAR SUPPORT 28MM SC'99 1

32* 59001032320 BOTTOM TRIPLE CLAMP CPL.X=20MM 1

33* 54801033100 FORK TUBE L=244 1

34 58501034020 TOP TRIPLE CLAMP RALLYE 2001 1

35* 58502003100 GPS MOUNTING PLATE MILLED 06 1

36 58502005051 HANDLEBAR BUSHING 17MM 01 2

37 50301036000 STEER.HEAD SCREW M20X1,5 WS=27 1

38 58502009000 HOLD.F.STEERING SHOCK ABSORBER 1

40 56401042000 WASHER 10,5X32X2 2

41 56401040000 RUBBER BUSHING 4

42 56401142000 WASHER 10,5X31 2

43 0985100003 SELF LOCKING NUT DIN0985-M10 2

44 56401041100 SPACER TUBE 10,2X12X44 2


48 50211096000 CLAMP FOR WIRING HARNESS 1

81* 54201082000 TAPERED ROLLER BEARING 2

82 54601084100 O-RING SUPPORT W. SEALING LIP 1

84 54601184000 STEARING HEAD GASKET TOP 1

86 54201086000 STEERING HEAD COVER 1


05585010 / C065850102

* NEW PART

X AS REQUIRED

4

TELESCOPIC FORK



2 46810340 O-RING NBR 45X2 2

3 48600018 KNOB REBOUNG ADJUSTER 2

5 40540603 STEEL BALL D=3MM 8

6 48600028 SPRING D=2,9 L=7,9 4

7 48600044 O-RING NBR 6X1,5 2

10 48600043 O-RING NBR 12X1,5 2

11 48600019 HOLDER F.ADJUSTMENT TUBE D=4MM 2

12 48600421E OUTER T. L=577 D=54/60 2L ANTR 2

13 48600016 GUIDING RING D=58MM 2

15 48600429 DU-BUSH D48XD52X12DDL02 2

16 48600013 SUPPORT RING 50 X 57,6 X 1,5 2

17 48600399 OIL SEAL RING 48X57,8X9,5 2

18 48600070 LOCK WASHER SB58 2

19 48600400 DUST CAP D=48 58,4X11,8 2

22 48600428 DU-BUSH D47XD49X20DDL02 2

23 48600417 INNER TUBE D=48 L=595 2005 2

24 48600380S1 HYDR.STOP L=200MM D=31,9 CPL. 2

30 48600092 ADJUSTMENT TUBE L=517MM 2

31 48600409 PISTON ROD D=14 L=551 M11X1 2

33 48600189 NEEDLE REBOUND 2003 2

34 48600046 O-RING NBR 3X1,5 2

35 48600033 SPRING REBOUND NEEDLE C=4N/MM 2

36 48600036 SPACER 42X26,5X2,5 2

36 48600037 SPACER 42X26,5X5 4

36 48600053 SPACER 42X26,5X1,5 4

36 48600113 WASHER 32X42X2,5 2

37 48600154 SPACER 43,2X33X15 2

38 91410017S SPRING 4,8N/MM SET 1

39 48600021 INTERM. RING 26,2 X 43 X 3 2

42 48600383S SCREW SLEEVE M29,3X1 L=90 CPL. 2

43 48600239 O-RING NBR 8X1,25 2

44 48600403 REBOUND SPRING D=15MM L=34,5MM 2

45 48600203 TAB REBOUND D=3 03 2

47 35480377 SPRING CHECK VALVE D=0,5 2

49 43570120 SHIM 8X18X0,10 2

49 48600215 CHECK VALVE 8X20X0,1 2

05585011 / C065850103

* NEW PART

X AS REQUIRED

5

FORK LEGS



49 48600062 CHECK VALVE 8X24X0,1 8

49 48600216 CHECK VALVE 8X22X0,1 2

49 48600218 BACKPLATE 8X11X0,40 2

50 40540401 SHIM 6X14X0,1 x

50 40540402 SHIM 6X16X0,1 x

50 40540403 SHIM 6X18X0,1 x

50 40540405 SHIM 6X14X0,15 x

50 40540406 SHIM 6X16X0,15 x

50 40540414 SHIM 6X16X0,25 x

50 40540415 SHIM 6X18X0,25 x

50 40540447 SHIM 6X10X0,3 x

50 40541402 SHIM 6X11X0,2 x

50 40541404 SHIM 6X10X0,1 x

50 48600063 SHIM 6X24X0,1 x

50 48600064 SHIM 6X22X0,1 x

50 48600065 SHIM 6X20X0,1 x

50 48600116 SHIM 6X24X0,1 DELTA x

51 48600060 PISTON RING 5X1X84 2

52 48600201 PISTON REBOUND B=11,2 2

55 40540486 NUT M6X0,5 REBOUND 2

58 48600081 TUBE 29,3X1X390 D=8,5MM 2

59 48600048 O-RING NBR 46 X 2 2

60 48600171S AXLE CLAMP L/S CPL. RALLYE 05 1

61 48600170S AXLE CLAMP R/S CPL. RALLYE 05 1


63 48600163 CHECK VALVE NUT M6X0,5 D=2 2

64 48600202 SPRING CHECK VALVE D=0,7 2

69 48600152S1 TAP COMPRESSION CPL. 03 2

70 48600061 CHECK VALVE 8X24X0,4 2

71 48600047 PISTON COMPRESSION D=27,9 2

72 46811499 O-RING NBR 21X2 2

73 35480320 O-RING NBR 24X2 2

74 48600152 TAP COMPRESSION 2

75 48600190 NEEDLE COMPRESSION 2003 2

76 48600049 O-RING NBR 8X2 2

79 48600051 LOCK WASHER RB12 2

05585011 / C065850103

* NEW PART

X AS REQUIRED

6

FORK LEGS



80 48600034 COMPRESSION ADJ. SCREW 2

81 48600004 COPPER WASHER 29,5X33,5X1 2

82 48600141 RUBBER CAP D=35MM 2

83 48600401S1 FORK OIL SAE 5 2005 1

1,22 LITRE

85 48600075S PRE-LOAD ADJUSTER CPL.(1 PC.) 2

87 48600076 VENT SCREW M4X8 2

88 48600046 O-RING NBR 3X1,5 2

89 48600075 SCREW CAP M51X1,5 2

90 48600073S ADAPTER ADJUST. KNOB + BUSHING 2

91 48600077 O-RING NBR 26X2 2

92 46810010 CIRCLIP 49X1,5 2

93 48600072 LOCKNUT 2

94 48600071 SUPPORT RING FOR SPRING 2

98 T511 SILICONE GREASE F. DUST STRI 1

99 R14013 REPAIR-KIT GASKET 4860 MXMA 06 1

05585011 / C065850103

* NEW PART

X AS REQUIRED

7

FORK LEGS



1 58402001000 HANDLEBAR ALU LC4, ADVENTURE02 1

5 6899792 GRIP GLUE 1

10 58502010000 THROTTLE GRIP 02 1

11 54605057000 RUBBER SLEEVE D=21MM/23MM '93 1

21 59002047000 DECO.LEVER CPL. RACING 2000 1

30 59002030100 MASTER CYLINDER CPL. RACING 03 1

31 54602031000 CLUTCH LEVER SHORT CPL. 2003 x

31 59002031000 CLUTCH LEVER LONG CPL. 2003 1

32 59002032000 REP.KIT PISTON 9,5MM RAC. 2000 1

33 59002033000 COVER HYD.CLUTCH RACING 2000 1

34 50302034000 RUBBER FOR RESERVOIR '98 1

35 59002035000 SPRING FOR CLUTCH LEVER 03 1

36 50302036200 OIL FOR HYD. CLUTCH 75ML 1

37 50302037000 PROTECT.CAP FOR LEVER PERCH'98 1

38 50302038000 LEVER SCREW CPL. 125-200 '98 1

40 58412040100 REAR MIRROR L/S+R/S LC4 2001 2


42 50302030150 CLAMP WITH PIN 2000 1

43 59002044000 CLAMP MIRROR WITH PIN 1

44 0965040123 FLAT HEAD SCREW DIN0965-M 4X12 2

54 58502039044 RUBBER GRIPS PER GRIP 96-05 x

54 58502139044 RUBBER GR. PRO GRIP 06 1

63 50332063100 CLUTCH PIPE 125/200 2003 1

80 44011076200 CABLE TIE 200/3,6MM BLACK x

90 58502094000 DECOMPRESSION CABLE 04 1

91* 59002091300 THR.CABLE"OPEN-CLOSE"KEIHIN 02 1

CONSTRUCTION FOR KNEE PIECE

05585020 / C065850201

* NEW PART

X AS REQUIRED

8

HANDLEBAR, CONTROLS



1 58512099344 ENG.PROTECTOR CARBON CPL. 2002 1

2 58553016144 ENG.PROTECTOR MOUNTING CPL. 02 1

6 58538010000 RUBBER GROMMET 20X11/M6X18 01 2

8 58512099340 ENGINE PROTECTOR CARBON 02 1

9 43205262000 RUBBER GROMMET 30X15-M8X12-(1) 2

10 0912080123 AH SCREW DIN912 M8X12 2

11 58562093051 TANK HOLDER FR. R/S OUTSIDE 01 1

12 58562092051 TANK HOLDER FR. L/S OUTSIDE 01 1

14 58562092050 TANK HOLDER FR.R/S INSIDE 01 1

15 58562093050 TANK HOLDER FR.L/S INSIDE 01 1

16 0931101103 HH SCREW DIN0931-M10X110 1


21 58308045000 SPECIAL WASHER 7X12,5X20 BLACK 6

22 0991060163 FLAT HEAD SCR. DIN7991-M 6X16 6

23 49009082000 SELF LOCKING NUT M10 FK8 1

24 58512099330 PC-OUTER HULL RALLYE LC4 02 1

25 54610052000 SPROCKET SCREW-AH M8X20 WS=6 2

26 58512099360 STONE GUARD RAL. SET 02 1

27 58303061000 SPECIAL WASHER ALU 8 X 24 MM 4


30 0985080003 SELF LOCKING NUT DIN0985-M 8 4

31 0934060003 HEXAGON NUT DIN0934-M 6 2


41 58512099341 BRACE PLATE FRONT 02 1

43 58512099342 BRACE PLATE REAR 02 1

45 0991080203 FLAT HEAD SCREW DIN7991 M8X20 3

48 43205262000 RUBBER GROMMET 30X15-M8X12-(1) 4

49 54603048000 RANGE CHANGE METAL NUT M8 x

68 36003014000 LOCK WASHER 8MM x


75 0125050003 WASHER DIN0125-A 5,3 4

76 58512099365 LINTIL HEAD SCREW M5X12 AH 02 4

80 58553019000 ENG.PROTECT.BR.FRONT FRAME 02 1

81 58553016100 ENGINE PROTECTOR FRONT RAL 02 1

82 58553018000 ENG.PROTECTOR REAR TO PLUG 02 1

83 58553017000 ENGINE PROTECTOR REAR RAL 02 1

065850302 / C065850302

* NEW PART

X AS REQUIRED

9

ENGINE GUARD



84 58512099351 WATERT.CARB.ENG.PROT. R/S 02 1

85 58512099350 WATERT.CARB.ENG.PROT. L/S 02 1

86 58030020000 PLUG M 24X3 2

87 0770160030 O-RING 16,00X3,00 NBR 70 2

88 54605068000 EXHAUST BRACKET RUBBER BLACK 2

89 0933080103 HH SCREW DIN0933-M 8X10 4

90 0797080003 TOOTHLOCK WASHER DIN6797-J 8,4 4

065850302 / C065850302

* NEW PART

X AS REQUIRED

10

ENGINE GUARD



1 5850300154490 FRAME 660 RALLYE E-START 2006 1

3 0910160153 PLUG DIN0910-M16X1,5 1

4 0603162220 CU-SEAL RING 16X22X2 1

7 58503012100 ENGINE PROT. BRACKET 22 2005 2

13 58303070000 STOP RUBBER M8 4


20 0934080003 HEXAGON NUT DIN0934-M 8 2

29 0934080003 HEXAGON NUT DIN0934-M 8 2

32 0912101603 AH SCREW DIN0912-M10X160 1

34 54630044000 COLLAR NUT M10 WS=13 1

35 0797100003 LOCK WASHER DIN6797-J10,5 ZI 2

36 54435024001 HOSE ID 7,5 PER METER x

37 44011076100 CABLE TIE 100/2,5MM BLACK 2

38 0912060203 AH SCREW DIN0912-M 6X20 x

40 58503040250 FOOT REST L/S R/S LARGE 06 1

40 58503041250 FOOT REST R/S LARGE 06 1

42 54603041000 FOOTREST SPRING L/S & R/S 2

44 54603044000 BOLT FOR FOOTREST 9,8 X 50 2

46 0125100003 WASHER DIN0125-A10,5 2

47 0094032253 PIN DIN0094-3,2X25 STEEL 2

49 54603048000 RANGE CHANGE METAL NUT M8 x

51 58503002410 TANK HOLDER DOWN L/S 04 1

52 58503002430 TANK HOLDER DOWN R/S 04 1

53 54804067000 CHAIN SLIDING PIECE 03 1

54 52303053100 CHAIN ROLL D=35MM 125-380 '99 1

55 74003021000 BUSHING 8.2 X 12 X 6 1

56 0625006087 GROOVED BALL BEAR. 608 2RS C3 2

57 54611186000 RUBBER BAND 1

58 58503023170 SIDE STAND RUBBER-RET.PANEL 01 1

59 51103053051 BUSHING 8,2X10X20 1

63 54305069000 BUSHING 7X12X15,4 1

64 0912060203 AH SCREW DIN0912-M 6X20 x

68 36003014000 LOCK WASHER 8MM x

70 0015080353 HH COLLAR SCREW M 8X35 WS=10 x


72 0984060103 AH SCREW DIN7984-M 6X10 1

05585030 / C065850303

* NEW PART

X AS REQUIRED

11

FRAME, SUB FRAME



1 58503023300 SIDE STAND CPL. 06 1

2 58503002300 SUB FRAME STEEL RALLY 2001 1

5 58403030000 SIDE STAND SPRING D=7,7MM '97 1

6 51003021000 SIDESTAND SPRING LONG 1

9 58503002340 SUB FRAME EXTENSION 2001 1

10 0984100356 AH SCREW DIN7984 M10x35 1

11 0984100456 AH SCREW DIN6912 M10X45 1


13 0985100003 SELF LOCKING NUT DIN0985-M10 1




22 58503023060 STAND SCREW RALLY 2001 1

26 58503026350 SIDE STAND BRACKET CPL. 05 1

27 36003014000 LOCK WASHER 8MM 2

28 58503002001 HH COLLAR SCREW S.FRAME RAL.01 2

DIN0931-M 8X35 SEAT 20 MM

32 59036001050 SPACER BUSHING 6,1X8,2X13,1 1

33 58503023070 FLAT HEAD SCREW M6X23 8.8 1

35 76203080000 BELL CRANK SIDE STAND 1

57 54611186000 RUBBER BAND 1

58 58503023170 SIDE STAND RUBBER-RET.PANEL 01 1

065850301 / C065850304

* NEW PART

X AS REQUIRED

12

SUB FRAME



1 50180350 SHOCK ABSORBER TOP H=30,5 B=21 1

2 50180213S4 DCC-COMPR.DAMP.CONTROL CPL. 03 1

3 46180010 BUSH KGW 10X24 2

4 46180003 OIL SEAL KGW D=25 2

5 50180168 WASHER KGW D=25 2

6 50180005 BUSHING KGW 1525 HD 1

8 50180095 BLEED PLUG R 1/8 1

11 46810016 O-RING NBR 48X2 2

13 50180479 RESERV. SCREW L=120 D=52 BLACK 1

14 46180014 O-RING VITON 41X5 1

15 46180002 SEPARATION PISTON D=52, H=32 1

16 46180015 PISTON RING 3,9X1,5X156 1

18 50180236 RESERVOIR CAP D=58 1

19 46810893 O-RING NBR 5,28X1,78 1

20 36120151 SCREW PLUG M5X6 1

25 50180097 O-RING 52X2 1

29 50180241 RETAINING WASHER 1

30 50180442 TUBE L=195 PDS 1

31 50180133 CIRCLIP 50X1,5 2

32 50180081 SPRING GUIDANCE L=40 1

35 50180474 SPRING RETAINER M56X1 1

36 50180327 AH SCREW M5X30 DIN912 1

37 50180226 INTERMEDIATE RING 50X1,5 2

40 91210018 SPRING 66-86/280 (62) D=13 1

43 50180319 SPRING RETAINER D=80 1

44 50180352 O-RING VITON 66,27X3,53 1

45 50180141 PISTON ROD NUT M16X1 1

46 50180099 O-RING VITON 44,17X1,78 2

47 50180135 PISTON RING 50-8 2

48 50180039 SHIM 16X25X0,30 4

48 50180042 SHIM 1

48 50180058 SHIM 16X36X0,20 3

48 50180063 SHIM 16X28X0,25 3

48 50180064 SHIM 16X30X0,25 1

48 50180065 SHIM 16X32X0,25 1

48 50180066 SHIM 16X34X0,25 1

065850402 / C065850402

* NEW PART

X AS REQUIRED

13




56 50180037 SHIM 16X23X0,30 1

56 50180038 SHIM 16X24X0,30 1

56 50180039 SHIM 16X25X0,30 1

56 50180040 SHIM 16X26X0,30 1

56 50180043 SHIM 1

56 50180062 SHIM 16X44X0,20 1

56 50180066 SHIM 16X34X0,25 1

56 50180067 SHIM 16X36X0,25 1

56 50180068 SHIM 16X38X0,25 1

56 50180069 SHIM 16X40X0,25 1

56 50180070 SHIM 16X42X0,25 1

56 50180072 SHIM 16X28X0,30 1

56 50180073 SHIM 16X30X0,30 1

56 50180074 SHIM 16X32X0,30 1

57 50180196 REBOUND DISC D=34, H=8 1

58 50180311 PISTON 6+6X7/4,5 VB 1,0 1

60 50180505 PISTON ROD D=18 L=168 M16X1 1

61 50180201 NEEDLE SEAT M8X1 1

62 50180157 O-RING VITON 7X1,5 1

63 50180200 BUSH M8X1 1

64 50180506 TUBE M8X1 L=169,5 1

65 48600049 O-RING NBR 8X2 1

66 50180279 TUBE ADAPTOR M8X1 L=23 1

70 50180504 NEEDLE L=193,5 (7,5) 1

71 46811265 O-RING VITON 2,2X1,6 1

72 50180349S1 ADAPTOR CPL. D=50, H=28,5 1

73 50180304 STEEL DISC 18,5X43,7X6 1

74 50180107 REBOUND RUBBER 1

75 50180102 BACKUPRING 22,55X1,5 2

76 50180101 QUAD RING 18X2,62 1

79 50180103 O-RING 41X5 1

80 46180119 DU-BUSH 18X20X12 1

81 50180082 DUST SEAL 1835 1

84 46180013 O-RING NBR 12X1 1

85 50180126 CIRCLIP 53X1,75 1

86 50180473 COVER D=50 1

065850402 / C065850402

* NEW PART

X AS REQUIRED

14




87 50180480 BUMP RUBBER SXS 2005 1

88 50180273 CIRCLIP 58,2X2 1

89 46180006 ADJUSTING SCREW L=15,5 1

90 50180503 FORK PART L=94 B=32,5 V=6,5 1

91 50180462 THR. BUSH M10X1,5 B=1,5 H=7,5 1

92 50180297 RUBBER PLUG D=8 1

93 40540603 STEEL BALL D=3MM 2

94 48600028 SPRING D=2,9 L=7,9 1

95 46180005 RESERVOIR CAP M16X1 1

96 50180222 O-RING NBR 4X1,5 1

97 46180016 ADJUSTING ADAPTOR REBOUND 1

98 50180466S1 SHOCK ABSORBER FLUID 5 LT 05 1

0,33 LITRE

99 R12011 REPAIR KIT GASKET 5018 PDS 06 1

065850402 / C065850402

* NEW PART

X AS REQUIRED

15




1 12187B17 MONOSHOCK RALLYE 06 1

13 50233041100 PAIR OF WASHERS M10 NORDLOCK 1

14 58503086200 MONOSHOCK SCREW M10 05 1

15 56503093000 SPECIAL SCREW M10X55 WS=17 1

16 58503087000 WASHER F. SCREW F.MONOSHOCK 01 2

17 54630044000 COLLAR NUT M10 WS=13 1

05585040 / C065850403

* NEW PART

X AS REQUIRED

16

MONOSHOCK



1 58503080044 TRIANGLE LEVER CPL.RALLYE 01 1

2 54603097000 NEEDLE BUSH HK 2016 4

3 54603081000 BUSHING SLEEVE 15 X 20 X 48 2

4 54603090010 STEEL WASHER 15,2X19X0,1 x

4 54603090020 STEEL WASHER 15,2X19X0,2 x

4 54603090030 STEEL WASHER 15,2X19X0,3 x

5 0760253270 SHAFT SEAL RING 25X32X7 6

6 58303090000 SPAC.F.SHAFT SEALRING 15X25X11 4

8 58303085100 BUSHING FOR BEARING LINK '95 2

9 54203083050 LINK BEARING 12X25X22(16-1061) 1

10 72003035000 GREASE FITTING M6 STRAIGHT 1

11 53003099000 CAP WITH LOOP RED 1

15 54403135000 PLASTIC CAP SFL10 4

20 58303083000 LINKAGE ARM L=127MM '93 2

30 58503082044 BOLT CPL. 2001 2

32 54603015000 SELF LOCKING NUT M14X1,5 WS=19 2

50 56503195100 NEEDLE BEARING HK 1816 2


52 58303084100 BUSHING BOLT CONNECTING BAR'96 1

54 49103415000 SELF LOCK. NUT M12X1,75 WS=19 2

05583040 / C065850404

* NEW PART

X AS REQUIRED

17

PRO LEVER LINKING



12 54603014100 SWINGARM BOLT KPL. L=253 1

14 58503014001 SPECIAL TOOL F.SWINGARMBOLT 01 1

15 54603015000 SELF LOCKING NUT M14X1,5 WS=19 1

30 R0504030044 SWINGARM RALLYE CPL. 05 1

38 54611076100 RETAIN.CLAMP FOR BRAKE HOSE'96 2

39 0010050103 SPECIAL SCREW M 5,0X10 2

40 50203081700 BUSHING SLEEVE 15X20X38,75 2

41 59004031000 NEEDLE BUSH HK2012V 4

42 54603036000 STOP DISK 22,2X31,7X1 2


44 54603090000 BUCKET F.SHAFTSEALRING 15X25X9 4

71 72210079000 BUCKET 2


73 58307073000 CHAIN SLIDING GUARD DUKE'94 1

84 56509064100 SELF LOCKING NUT M6 10.9 2

85 54607066100 CHAIN GUIDE REAR '94 1


065850401 / C065850405

* NEW PART

X AS REQUIRED

18

SWING ARM



1 58505007300 EXHAUST MANIFOLD I RALLYE 06 2

2 58505008300 EXHAUST MANIFOLD II RALLYE 06 2

3 58503031000 SPRING CLIP SIDE STAND 05 1

5 58505058000 EXHAUST CLAMP RALLYE 02 2

6 50305016000 TEN.SPRING L=62MM EY.MOVEABLE 18

7 58505171000 ENDCAP SILENCER OPEN 2000 2

8 58505010200 REAR EXH.PIPE RALLYE L/S 01 1

8 58505110200 REAR EXH.PIPE RALLYE R/S 01 1

9 58505040000 EXHAUST BUSH. 25X12,5X14 2001 2

10 58505071300 SILENCER THROTTLED L/S 2001 2

10 58505171300 SILENCER THROTTLED R/S 2001 1


12 5850506700090 EXHAUST SUPP. CENTER RALLY 02 2

13 59005078550 STUFF.YARN 550GRAMM L=550MM SX 2

14 54305068100 DAMP. COMPONENT SILICONE GREY 2


16 0011480800 DUMMY RIVET 4,8X 8 NIRO 6


18 0991080163 FLAT HEAD SCREW M8X16 10.9 2

20 58555065000 EXHAUST BRACKET R/S CPL. 01 1

20 58555066000 EXHAUST BRACKET L/S CPL. 01 1

21 54605068000 EXHAUST BRACKET RUBBER BLACK 2

22 54605069000 BUSHING 7,5X12X28X7,8 '96 4


24 0934060003 HEXAGON NUT DIN0934-M 6 2

25 58505161200 CLAMP FOR SILENCER 03 2

26 50232050000 WASHER 6,2X18X2 2

31 58505071350 HOLE RESTRICTOR RALLYE 2002 2

065850500 / C065850501

* NEW PART

X AS REQUIRED

19

MANIFOLD, SILENCER



1 58506001052 AIR FILTER RESTRICTOR 01 1


5 0021050003 WASHER DIN9021-A 5,3 2

6 58506015000 AIR FILTER TWIN AIR 01 1

7 58506001050 AIR FILTER BOX S. TWIN AIR 01 1

8 0017050181 SCREW FOR PLASTIC D=5X18 6

9 58506001144 AIRBOX W. AIR FILTER BOX S. 1

11 0933050603 HH SCREW DIN0933-M 5X60 2

14 0980050003 HEXAGON STOP NUT DIN0980-M 5 2


17 58432006000 WASHER 6,2 X 20 X 2 '99 1


19 58512066000 TANKDISTANCE 42MM RALLYE 2001 1

27 80006026100 CARB. CONNECT. BOOT 450/501 04 1

28 51006027000 HOSE CLAMP 50-70MM 1

29 58506027000 HOSE CLAMP 70-90MM 1

03585060 / C065850600

* NEW PART

X AS REQUIRED

20

AIR FILTER BOX



1 5850701310004 FUEL TANK FR. L/S RALLYE 2004 1

1 5850711310004 FUEL TANK FR. R/S RALLYE 2004 1


3 58507007001 HOSE 8X5MM RALLYE 03 2

4 58507008000 FUEL CONNECTION CPL. 01 4

5 59031083000 T-JOINT BREATHER HOSE 2

8 49007008044 FILLER CAP CPL. SMALL 4

9 59007009000 GASKET FOR FILLER CAP HIGH 4

10 58312099052 FUEL FILTER ELEMENT 1

11 58554013050 SEAT HOLDING SHEET R/S 01 1

11 58554013051 SEAT HOLDING SHEET L/S 01 1


13 45007040050 QUICK RELEASE LATCHPLATE 4

14 58512067000 THREADPOLE M8 L=226 MM 1

15 55007016001 PVC-HOSE 7X10 PER METER x

17 58507008050 FUEL FLANGE SHEET 01 4

18 0981350133 SHEET MET.SCR.DIN7981-3,5X13 8

19 0770120020 O-RING 12,00X2,00 NBR 70 4

20 42013226000 CU-SEAL RING DIN7603-10X16X1 4

21 49138493000 RING COMPONENT 10/6MM 4

22 58507025000 HOLLOW SCREW M10X1X24 RALLY 02 4

23 0982480163 SHEET MET.SCR.DIN7982 4,8X16 8

24 0603101420 COPPER GASKET 10,2X14X2 MM 01 4

25 58507008010 FUEL FLANGE-STRAINER 03 4

29 0912080203 AH SCREW DIN912 M8x20 4

30 56401040000 RUBBER BUSHING 24

31 58507005000 TANK NUT M8 01 2

WITH AH-SCREW

32 58512062000 BUSHING SLEEVE OUT 2001 10

33 0912080503 AH SCREW DIN912 M8X50 2

34 0912080303 AH SCREW DIN0912-M 8X30 2

35 0912080403 AH SCREW DIN912 M8X40 4

36 58512063000 BUSHING SLEEVE IN.34MM 2001 4

37 58512069000 BUSHING SLEEVE IN. 25MM 2001 2

38 58512068100 FIXING SCREW TANK REAR 2

39 58512064000 BUSHING SLEEVE IN. 40MM 2001 2

04585070 / C065850701

* NEW PART

X AS REQUIRED

21

FUEL TANK, SEAT



40 58507040700 SEAT RALLYE 2006 1

41 0021080003 WASHER DIN9021-A 8,4 2

43 58512065000 TANKDISTANCE 36 MM RALLYE 2001 2

47 58307040551 QUICK RELEASE CPL. '96 1

48 54603048000 RANGE CHANGE METAL NUT M8 2

49 60512063050 NUT F.TANK BRAKET REAR 2

81 5851209530004 SIDE TANK L/S ORANGE 2004 1

81 5851209630004 SIDE TANK R/S ORANGE 2004 1

04585070 / C065850701

* NEW PART

X AS REQUIRED

22

FUEL TANK, SEAT



1 58007015000 T-CONNECTOR FOR FUEL LINE 2

3 58031005000 CLAMP YDNAC 10128 12MM 10

4 58507116100 HOSE OG.ECO 1TBSE 7X13MM x

5 58507016100 FUEL HOSE DIN 73379 5,3X11,3 x

6 42013037000 CLAMP MINI 1 3

7 0934080003 HEXAGON NUT DIN0934-M 8 1


10 58512087000 FUEL PUMP MIKUNI DF52-601 01 1

11 58512088000 HOLDING SHEET F. FUEL PUMP 01 1



16 58507009000 FUEL FILTER 01 1

17 58507003100 COLLECTOR FUEL TAP RALLYE 2001 1

18 58507010500 CLUTCH F. FUEL HOSE CPC 03 4

19 58507010300 PLUG F. FUEL HOSE CPC 2003 4


21 0021060003 WASHER DIN9021-A 6,4 5


23 54635022000 SLEEVE FOR STEERING HEAD 1

24 58507019000 SUPPORT FOR FUEL FILTER 01 1



33 58507003050 LOCKING PLATE F. COLL.FUEL TAP 1

05585079 / C065850709

* NEW PART

X AS REQUIRED

23

FUEL SYSTEM



1 5851100410004 COVER MIDDLE CPL. 04 1

2 5851100210004 COVER R/S CPL. 04 1

2 5851100310004 COVER L/S CPL. 04 1

3 58308045000 SPECIAL WASHER 7X12,5X20 BLACK 12

4 41001052000 RUBBER SLEEVE D=12MM 1

5 58512060000 OIL RADIATOR GRID RALLYE 01 1



9 58307042051 THRUST BEARING QUICK RELEASE 1

10 58312078000 TOOL BAG BLACK SC '99 1

11 5850801010030 FENDER FRONT RALLYE BLACK 04 1

12 51006097000 WASHER 6,2X22X1,ST30,W.GALV. 3

15 0011320800 DUMMY RIVET 3,0X 8 STEEL 2

16 0134030003 WASHER DIN0134- 3,2 2

19 54606010000 SPLASH PROTECT.FOR FILTER BOX 1

20 58506010000 SPLASH PROTECTION TOP 01 1


22 0934060003 HEXAGON NUT DIN0934-M 6 2

23 0021060003 WASHER DIN9021-A 6,4 4


25 72210079000 BUCKET 2

33 58308013051 NUMBER PLATE CARRIER EGS '93 1

34 58412080050 BRACKET FOR REFLECTOR 1

35 58412080000 REFLECTOR RED LC4 '98 1

36 40006006000 WASHER 6MM 2

37 0966050163 OVAL HEAD SCREW DIN0966-M 5X16 2


39 0125050003 WASHER DIN0125-A 5,3 2

53 5850801300004 FENDER REAR RALLYE 02 1

60 58329099000 ORIGINAL EQUIPMENT TOOL KIT 1

61 45007040051 QUICK RELEASE CPL. 50 SXR '97 4

62 0991060166 FL.HEAD SCR.DIN7991-M6X16 10.9 8

63 0991060202 FLAT HEAD DIN7991-M 6X20 4



04585080 / C065850800

* NEW PART

X AS REQUIRED

24

MASK, FENDERS



1 58508099300 DECOR SET 660 RALLYE 05 1

3 52000025 STICKER FRONT FORK-SET WP 48 1

065850801 / C065850801

* NEW PART

X AS REQUIRED

25

DECAL



1 58509010000 FRONT WHEEL CPL. RALLY 2001 1

2 58509009000 FRONT HUB MILLED RALLY 01 1

3 58509011000 BEAR.SPACER BUSHING 1

4 0625069068 GR.BALL BEAR.6906 DDU2CG23S6NM 2

5 58509013044 SPACER BUSHINGS SET FR.WHEEL02 1

2 PIECES (LEFT+RIGHT)

6 0760354771 SHAFT SEAL RING 35X47X7 TC 2

7 58509069000 SPOKES CPL. RALLY 2001 1

18 LE. + 18 RI. + 36 NIPPLES

9 58509071000 SPOKE L/S FR. WHEEL RALLYE 01 18

10 58509171000 SPOKE R/S FR. WHEEL RALLYE 01 18

11 58509072000 SPOKE NIPPLE FOR RALLY 2001 36

12 58509070100 FRONT RIM 1,60X21" 36H RALLY01 1

13 50309073000 RIM BAND 21" 1

15 58509083000 KEY F. FRONT AXLE SCREW 1

19 6899785 LOCTITE 243 BLUE 6CCM 1

20 58309060100 BRAKE DISK FRONT D=300MM '96 1




24 0439060003 HEXAGON NUT DIN0439-M 6 LOW 1

30 58509081100 FRONT AXLE D=30MM 04 1

32 58509082000 COLLAR SCREW FRONT AXLE 03 1

35 51009100100 RIM LOCK VM1 (1,60") 1

36 50310090050 NUT FOR WHEEL HOLDER '96 1

05585090 / C065850900

* NEW PART

X AS REQUIRED

26

FRONT WHEEL



1 58310001044 % REAR WHEEL 2,50X18" DID 1

2 58410010044 REAR WHEEL HUB DAMPED CPL.2001 1

3 58410011000 BUSHING SPACER TUBE L=98,3MM 1

4 0625062052 GR.BALL BEAR. 6205-2RSHC3HMTF7 2

5 0760325272 SHAFT SEAL RING 32X52X7 B 1

6 54610016000 BUSHING FOR HUB 1

7 54610416300 BUSHING FOR REAR DAMPED HUB 1

8 54610471000 SPOKE M5X223-10G 18" 18

9 50310071197 SPOKE M5X197-10G 18" DDE 18

10 58010470100 REAR RIM 2,50X18" DID 1

11 58309072000 SPOKE NIPPLE M5-TA (8X21MM) 36

12 0472052200 CIRCLIP DIN0472-52X2 1

13 50310073200 RIM BAND 18" AND 19" 1

15 58010060600 REAR BRAKE DISK 220MM COUNTERS 1

16 59009062013 SPECIAL SCREW M6X13 WS=8 10.9 6

19 58510151043 REAR SPROCKET 43-T HARD. STEEL x

19 58510151044 REAR SPROCKET 44-T HARD. STEEL 1

19 58510151045 REAR SPROCKET 45-T HARD. STEEL x



23 50310800118 CHAIN Z-RING 118 ROLLS 05 1

CUT TO 116 ROLLS

24 50310366000 MASTER LINK FOR 50310800118 x

24 50310866000 RIVET LINK FOR 50310800118 1

25 58310050044 SPROCKET SUPPORT CPL. 1

26 54610417300 BUSH. F.SPROCKETSUPPORT L=25MM 1

27 54610459000 DAMPING RUBBER '91 6

28 0625032057 GR. BALL BEARING 3205B-2RSRTNG 1

29 54610018000 SEAL WASHER 3205 AV 1

38 55003135000 PLUG FOR RIM x

39 50210086000 COVERING CAP SFL16 2

40 50310085044 WHEEL SPINDLE RE. CPL.265MM 00 1

41 50310084000 CHAIN TENSIONER R/S 2000 1

42 50304040100 SCREW M10X1,25X50 WS=10 2

43 58414030000 HH COLLAR NUT M10X1,25 WS=13 2

44 50310099000 HEXAGON NUT M20X1,5 '98 1

05585100 / C065851000

* NEW PART

X AS REQUIRED

27

REAR WHEEL



1 58511075500 MAIN WIRING HARNESS RALLYE 03 1

2 58511076100 WIRING HARNESS REAR RALLYE 03 1

3 50311070000 H.LIGHT SWITCH CEV 2/4TAKT '98 1

4 50311089200 SHORT CIRCUIT BUTTON 02 1

STARTER BUTTON

5 58511069100 SWITCH ON/OFF RALLYE 03 1

IGNITION ON/OFF

6 58511051100 BRAKE LIGHT SWITCH LONG 1

7 58511075510 FUSE-BOX COVER x

8 58511080000 CABLE F. TEMP. SWITCH 1

9 50311050100 BRAKE LIGHT SWITCH FRONT 2002 1

10 0985050103 OVAL HEAD SCR. DIN7985-M 5X10 2

11 0797050003 TOOTH LOCK WASH. DIN6797-J 5,3 2

12 58511074050 STARTER BUTTON ADAPTER CABLE 1

17 58411057000 STARTER RELAY '96 2




22 50311060000 DC HORN 12V K80/L LEB 1

23 0931050453 HH SCREW DIN931 M5X45 1

24 0934050003 HEXAGON NUT DIN0934-M 5 1


26 58511083100 BRACKET SOCKETS RALLY 2001 1

27 0021050003 WASHER DIN9021-A 5,3 1



30 58411034100 VOLT.REGULATOR-RECTIFIER 12V 1


32 49007439000 CLAMP RSGU 15/12 1

33 0125050003 WASHER DIN0125-A 5,3 1



36 58511054250 BRACKET F. BATTERY BOX 01 1

40 58411053100 BATTERY 12V 8,6AH 03 1

41 58411059200 STARTERCABLE 250MM 1

42 58411097300 GROUND CABLE 275MM 1

065851100 / C065851101

* NEW PART

X AS REQUIRED

28

WIRING HARNESS



43 58511059000 BATTERY CABLE 600MM RALLYE 01 1

44 58411058000 STARTER RELAY WITH HOLD.RUBBER 1

45 58511058050 BRACKET FOR STARTRELAIS '99 1

47 58411058050 HOLD. RUBBER FOR STARTRELAY 1

48 58411098100 CONTACT WASHER M6 VSV-K6 1


52 31008060000 RUBBER SLEEVE D=8MM OPEN x

53 50311029000 FLASHER SWITCH CEV '98 1

54 13011070060 ADAPTER FOR FLASHER SWITCH '98 1

55 0934040003 HEXAGON NUT DIN0934-M 4 2

56 0084040223 CYL.HEAD SCREW DIN0084-M 4X22A 2


60 58511054300 BATTERY BOX 06 1

61 0125060003 WASHER DIN0125-A 6,4 4

62 58111076000 CABLE SUPPORT KHS NR.150-47610 2

63 58511055000 METAMOLLSET BATTERY BOX 06 1

70 58011109105 FUSE 5 A 2003 2

71 58011109110 FUSE 10 A 2000 5

72 58011109115 FUSE 15 A 1

73 58011109120 FUSE 20 A 1

80 50311080100 FLAS.WIRINGHARN. FRONT 125-380 1

81 50311081000 FLAS.WIRINGHARN. REAR 125-380 1

84 49111425000 BULB 12V 1,2W (W2X4,6D) 3

86 58211031100 BRACKET FOR FLASHER RELAISE 1

87 44611207200 FLASHER UNIT 97 1




065851100 / C065851101

* NEW PART

X AS REQUIRED

29

WIRING HARNESS



2 6000207910004 HANDGUARD L/S+R/S CPL.ORANGE04 x

2 6000207910030 HANDGUARD L/S+R/S CPL.BLACK 04 1

9 58511009000 HEAD LIGHT PROTECTOR RALLYE 01 1

10 0021050003 WASHER DIN9021-A 5,3 6


12 0933050163 HH SCREW DIN0933-M 5X16 6

13 58308113051 NUMBER PLATE CARRIER EXC '93 1

20 5021204000030 MIRROR L/S BLACK ACERBIS '97 1

20 5021214000030 MIRROR R/S BLACK ACERBIS '97 1

30 5030801030030 FENDER FRONT BROAD BLACK 03 1

31 59008019000 BRAKE HOSE GUIDE 2000 1

32 58408009050 SPACER BUSHING FRONT FENDER 4


41 58311241000 REAR LIGHT LENS ACERBIS '93 1

42 58414042000 BULB 12V 21/5W (BAY15S)REINFO. 1

43 0981290193 SHEET MET.SCR.DIN7981 2,9x19 2

76 58511076000 WIRING HARNESS REAR RALLYE '97 1

85 58201085000 CLAMP F.SPEED CABLE D=8MM 2001 1

86 0017060203 EJOT PT SCREW K60X20 WS=6 2

92 59001092050 SPECIAL SCREW M6X12,5 WS=8 6

94 5900109400030 FORK PROTECT. L/S+R/S BLACK 02 1

05585120 / C065851200

* NEW PART

X AS REQUIRED

30

ATTACHMENT PARTS



1 50313001200 HANDBRAKE CYL. NAT. SMALL 2004 1

9 50313003000 HANDBRAKE CYL.COVER CPL.NATURE 1

10 50313008300 REP.SET PISTON D=11 EXC 2001 1

11 50313005000 CLAMP CPL. NATURE 1


13 50213050050 SPRING PISTON BRAKE FRONT 11MM 1

15 50313006100 LEVER SCREW CPL. 2001 1

20 50313002100 HANDBRAKE LEVER SHORT 2001 1

21 50313007000 ADJUSTING SCREW CPL. SX 2000 1

23 50313004000 PROTECTION CAP HAND BRAKE CYL. 1

25 50311050100 BRAKE LIGHT SWITCH FRONT 2002 1

30 58513011000 BRAKEHO. FRONT 1300MM 04 1

31 50213025000 HOLLOW SCREW M10X1X19 1


40 58012040150 CLAMP FOR MIRROW '94 1

80 306054 BRAKE FLUID DOT 4.0 1

04585130 / C065851300

* NEW PART

X AS REQUIRED

31

HAND BRAKE CYLINDER





3 58403070044 FOOT BRAKE LEVER KPL. LC4 2001 1


5 0991060203 FLAT H.SCREW DIN7991-M6X20 8.8 1

6 58303063000 BRAKE LEVER STOP '93 1

9 13003062000 RETURN SPRING 1

11 54603069000 SWIVEL HEAD M6 FOOT BRAKE LEV. 1

12 0125080003 WASHER DIN0125-A 8,4 x

13 36003014000 LOCK WASHER 8MM 1


15 0934060003 HEXAGON NUT DIN0934-M 6 1

16 58503068000 PUSH ROD STEEL 100MM M6 01 1

17 58503060050 BRAKE LEVER AXLE RALLY 2001 1


20 54513101044 MAIN BRAKE CYLINDER '89 1

24 54513150000 REPAIR KIT PISTON 13MM 1


32 50213161000 COLLAR BUSHING 2

33 58513038000 BRAKE CYL. PROTECTOR RALLYE 04 1




51 50213025000 HOLLOW SCREW M10X1X19 1

60 54513030044 BRAKE FLUID RESERVOIR '89 1


64 59013068000 BRACKET BRAKE FLUID RESERVOIR 1

66 58031005000 CLAMP YDNAC 10128 12MM 2

67 58007016101 HOSE FOR RESERVOIR 6X1,5 x

80 306054 BRAKE FLUID DOT 4.0 1

065851301 / C065851301

* NEW PART

X AS REQUIRED

32

REAR BRAKE CONTROL



1 58413015144 BRAKECAL.FRONT CPL. 300MM 2000 1

5 54613205000 REPAIR KIT 28MM 1

6 54613206000 REPAIR KIT PISTON 28MM 1

7 54613210100 BOLT CPL. 6X56 1

8 54613212000 RETAINING PLATE SET BREMBO 1

9 58413030000 BRAKE P.SET FR. TEXTART4069 GF 1

10 60013020000 BLEEDER SCREW WITH CAP 1

12 54613218000 CUP SET SHORT 1


21 58513011000 BRAKEHO. FRONT 1300MM 04 1


31 42013026000 CU-SEAL RING DIN7603-10X16X1,5 1

35 50213025000 HOLLOW SCREW M10X1X19 1


05585132 / C065851303

* NEW PART

X AS REQUIRED

33

BRAKE CALIPER FRONT



1 50213301644 BRAKE CALIPER CPL. REAR L/S 1

2 54613318200 REPAIR KIT SEALING RINGS 34MM 1

3 54613310200 BOLT SET 1

4 54613309200 BRAKE PAD SET REAR ID450 1

5 54613305200 BRAKE PISTON 34MM 1

6 60013020000 BLEEDER SCREW WITH CAP 1

7 54613218000 CUP SET SHORT 1

9 54613311200 RETAINING SPRING SET 1

10 58313070000 BRAKE HOSE REAR 790MM '97 1

11 58511051100 BRAKE LIGHT SWITCH LONG 1



14 50213025000 HOLLOW SCREW M10X1X19 x

05585135 / C065851306

* NEW PART

X AS REQUIRED

34

BRAKE CALIPER REAR



1 58414001000 HEAD LIGHT TRIOM CPL. '96 1

3 54611038012 BULB HS1 12V 35/35W WHITE 2

SOCKET PX43T

4 49011435100 BULB 12V 5W (W2,1X9,5D) PHIL. 10


6 0021060003 WASHER DIN9021-A 6,4 4


8 56530060050 SPACER BUSHING 6X12X20 ALU 2

9 0021050003 WASHER DIN9021-A 5,3 x

10 58512091200 CARRIER FOR TRIOM HEAD L. 2001 1

14 58514046000 REAR LIGHT BRACKET 2

15 0981350133 SHEET MET.SCR.DIN7981-3,5X13 4

17 58311049007 TENSIONING SPRING 1 X 12 X 35 1

18 58512006100 BUSHING SLEEVE COVER FRONT 04 1

19 0738060301 COU.SUNK SCR. AH ISO7380 M6X30 1

20 58511099244 EXTRA REAR LIGHT LENS '97 2

21 0933050603 HH SCREW DIN0933-M 5X60 1

22 58511099200 WIRING HARNESS REAR LIGHT '99 4

24 58514004000 SOCKET FOR BRAKE LIGHT '99 4

26 58512091251 FLASHBACKPROTECTION HORIZ. 01 1

27 58512091250 FLASHBACKPROTECTION VERTI.2001 1


28 6899792 GRIP GLUE 1

31 58311040000 REAR LIGHT CPL. CEV 358 '93 1

32 58311041000 LENS '93 1

33 58414042000 BULB 12V 21/5W (BAY15S)REINFO. 1

34 58011039000 SPACER BUSHING 6,5 X 8 X 7 2

35 31008060000 RUBBER SLEEVE D=8MM OPEN 2

36 0021060003 WASHER DIN9021-A 6,4 2


40 0797100003 LOCK WASHER DIN6797-J10,5 ZI 4

41 0125100003 WASHER DIN0125-A10,5 4

43 58514033000 FLASHER SUPPORT RALLYE L/S 01 1

44 58514034000 FLASHER SUPPORT RALLYE R/S 01 1

45 5841402500030 FLASHER CPL.FRONT L/S REAR R/S 2

46 5841402600030 FLASHER CPL.FRONT R/S REAR L/S 2

05585140 / C065851400

* NEW PART

X AS REQUIRED

35

LIGHTING SYSTEM



47 58414028000 FLASHER LENS L/S & R/S '98 4

48 44111015100 BULB 12V 10W (BA15S) 4

49 58414030000 HH COLLAR NUT M10X1,25 WS=13 4



05585140 / C065851400

* NEW PART

X AS REQUIRED

36

LIGHTING SYSTEM



1 58512098144 ROADBOOK CPL. 2005 1

2 58511086000 BRACKET INDICATOR WATER OIL 01 1

3 58512075044 ROADBOOK SWITCH CPL. 03 1

4 10001020000 HOSE CLAMP GEMI 16-27 1




8 58011039000 SPACER BUSHING 6,5 X 8 X 7 2



11 58512098160 NUT W.RUBBER COV. ROADB.SWITCH 1

12 0021050003 WASHER DIN9021-A 5,3 6

13 40006006000 WASHER 6MM 4

14 58512098150 ROAD BOOK BRACKET RALLYE 2004 1

15 58312098003 MOUNTING CLAMP FOR ROADBOOK 6

16 54611186000 RUBBER BAND 1

17 50213161000 COLLAR BUSHING 4

18 60014007000 SPACER BUSHING HEAD LIGHT 03 4

20 58512098100 LIGHT DIODE BRACKET CPL.RALLYE 1

22 58512085100 TRIPMASTER ICO RALLYE 04 1

23 58512085160 BATTERY FOR ICO TRIPMASTER 04 1

24 58512090150 SENSORKIT ITEM NR. 124 05 1


27 58511086200 BRACKET SWITCH INDICATOR 01 1

31 58314069050 MAGNET LOOSE '97 1

34 58214050050 BRACKET SENSOR MAGNET ADV. '97 1

35 54635022000 SLEEVE FOR STEERING HEAD 2

36 58511084000 BRACKET F. FUSE BOX 2001 1


38 0966040203 OVAL HEAD SCREW DIN966 M4X20 1

39 58303063000 BRAKE LEVER STOP '93 1

40 58011025000 OIL LEVEL LIGHT RED EXE 1

IGNITON INDICATOR LIGHT RED

41 58011022400 TEMPERATURE WARN. LIGHT RED'98 1

42 58011021200 HIGH BEAM INDICATOR LIGHT BLUE 1

43 58011024300 FLASHER INDICAT.LIGHT GREEN'98 1

05585141 / C065851401

* NEW PART

X AS REQUIRED

37




44 58512078000 FORK HEAD WITH PIN 1

45 0934050003 HEXAGON NUT DIN0934-M 5 1

46 0125050003 WASHER DIN0125-A 5,3 2

47 0931050603 HH SCREW DIN931 M5X60 1

50 58512089044 SUPPORT F.NAVIGATIONSEQUIPMENT 1

51 58512090000 SUPPORT FOR ROADBOOK 1



54 0021060003 WASHER DIN9021-A 6,4 13


57 58312085100 EDGE PROTECTOR PER METER x

58 58512005000 SPACER BUSHING NAV.SUPPORT 01 1

59 58512077200 SUPPORT F.TROUBL.ST. RALLYE'04 1








69 54431032050 SPACER BUSHING 6X8X8,5 4

71 58512074044 ROADBOOK ENGINE CPL. 03 1

72 58512074020 PLASTIC COVER FOR ROADBOOK 03 1

73 58512074030 ALU-BUTTON TOP FOR ROADBOOK 03 1

74 58512074040 ALU-BUTTON BASE F. ROADBOOK 03 1

75 58512074050 PLASTIC BUSHING F. ROADBOOK 03 7

76 58512074060 O-RING FOR ROADBOOK SHORT 03 1

77 58512074070 O-RING FOR ROADBOOK LONG 03 1

85 55003139600 BLIND RIVET NUT M 6X15,5 STEEL 1

86 58512086000 BRACKET DIGIBOX RALLYE CPL. 03 1

05585141 / C065851401

* NEW PART

X AS REQUIRED

38


660 RALLYE FAC.REP. 2007

SPARE PARTS MANUAL: ENGINE

ART.NO.: 3CM088249GEN

EN

GLIS

H

INDEX 660 RALLYE FAC.REP. 2007

SPECIAL TOOLS

3x

ENGINE CASE

4x

CYLINDER

6x

CRANKSHAFT, PISTON

7x

BALANCER SHAFT

8x

CARBURETOR

9x

CLUTCH

11x

TRANSMISSION I - MAIN SHAFT

12x

TRANSMISSION II - COUNTERSHAFT

13x

SHIFTING MECHANISM

14x

COOLING SYSTEM

15x

WATER PUMP

17x

1

INDEX 660 RALLYE FAC.REP. 2007

TIMING VALVE

18x

VALVE DRIVE

19x

CYLINDER HEAD

20x

LUBRICATING SYSTEM

22x

OIL FILTER

23x

ENGINE EXHAUST

24x

IGNITION SYSTEM

25x

ELECTRIC STARTER

26x

x

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 KTM-

SPORTMOTORCYCLE AG, Mattighofen only.

2



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

05585290 / C065852900

* NEW PART

X AS REQUIRED

3

SPECIAL TOOLS



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


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


065853000 / C065853000

* NEW PART

X AS REQUIRED

4

ENGINE CASE



46 58038019100 OIL DRAIN PLUG M22X1,5 1


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







065853000 / C065853000

* NEW PART

X AS REQUIRED

5

ENGINE CASE



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

04585304 / C065853001

* NEW PART

X AS REQUIRED

6

CYLINDER



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


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

05585302 / C065853002

* NEW PART

X AS REQUIRED

7

CRANKSHAFT, PISTON



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

03585304 / C065853004

* NEW PART

X AS REQUIRED

8

BALANCER SHAFT



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

065853100 / C065853100

* NEW PART

X AS REQUIRED

9

CARBURETOR



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


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


93 58502095200 CHOKE CABLE RALLYE 2001 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

065853100 / C065853100

* NEW PART

X AS REQUIRED

10

CARBURETOR



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


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


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

05585320 / C075853200

* NEW PART

X AS REQUIRED

11

CLUTCH



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


03583330 / C065853300

* NEW PART

X AS REQUIRED

12

TRANSMISSION I - MAIN SHAFT



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


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

05585331 / C065853301

* NEW PART

X AS REQUIRED

13

TRANSMISSION II - COUNTERSHAFT



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


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


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

05585340 / C065853400

* NEW PART

X AS REQUIRED

14

SHIFTING MECHANISM



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


8 0085060160 PLASTIC-SCREW M6X16 MM 4


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


18 50235033300 SNAP-NUT HOLDER M6 KP142 10

19 58011039100 BUSHING 6,5X11,2X10 6


21 0021060003 WASHER DIN9021-A 6,4 4





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


44 44106018000 PLASTIC CAP 2

48 58535020008 ALU TUBE 18X22 RADIA.D./WAPU 1

49 58535020007 PREFORMED H.90°CURVE TUBE/WAPU 1

05585350 / C065853500

* NEW PART

X AS REQUIRED

15

COOLING SYSTEM



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


05585350 / C065853500

* NEW PART

X AS REQUIRED

16

COOLING SYSTEM




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





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

05585351 / C065853501

* NEW PART

X AS REQUIRED

17

WATER PUMP



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


38 58536003050 FLANGEPL. F. AUTOM. TENSIONER 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

05585361 / C065853601

* NEW PART

X AS REQUIRED

18

TIMING VALVE



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

05584363 / C065853603

* NEW PART

X AS REQUIRED

19

VALVE DRIVE



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


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


54 0912070551 AH SCREW DIN0912-M 7X55 12.9 1

55 0912070601 AH SCREW DIN0912-M 7X60 12.9 1

05585362 / C075853602

* NEW PART

X AS REQUIRED

20

CYLINDER HEAD



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



05585362 / C075853602

* NEW PART

X AS REQUIRED

21

CYLINDER HEAD



2 0402251980 NEEDLEROL.DIN5402 NRA 2,5X19,8 2


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


17 0908120153 PLUG DIN0908-M12X1,5 1


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




70 58538052000 OIL COOLER RALLYE 2001 1


74 0021060003 WASHER DIN9021-A 6,4 3


76 50235033300 SNAP-NUT HOLDER M6 KP142 1


79 0125060003 WASHER DIN0125-A 6,4 2

05585380 / C065853800

* NEW PART

X AS REQUIRED

22

LUBRICATING SYSTEM



1 58338045100 SCREW TYPE FILTER 1


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




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


56 58538043010 RUBBER RING 45/52/16 1

57 58338091100 OILPRESSURE SWITCH 03 1




63 58538050000 BRACKET FOR MICRO FILTER 2001 1

64 0934060003 HEXAGON NUT DIN0934-M 6 1


67 50233041000 PAIR OF WASHERS M 6 NORDLOCK 1

05585381 / C065853801

* NEW PART

X AS REQUIRED

23

OIL FILTER



1 58430087000 ENGINE BREATHER TUBE TOP 1

2 42013037200 HOSE CLAMP GEMI 12/22 4

3 57530090000 BREATHER TUBE ENGINE '93 1

02585388 / C065853802

* NEW PART

X AS REQUIRED

24

ENGINE EXHAUST



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



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

05585390 / C075853900

* NEW PART

X AS REQUIRED

25

IGNITION SYSTEM



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








05585400 / C065854000

* NEW PART

X AS REQUIRED

26

ELECTRIC STARTER

spare parts manual: chassis660 rallye factory repl. 2007 fig part number description qty 49 48600062...

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