KTM 660 RALLY 2007 Supplement Manual Download Page 30

ENGLISH

30

MAINTENANCE WORK ON CHASSIS AND ENGINE 

»

CARBURETOR – Adjust idling (Keihin MX 41) *

Idling adjustment of the carburetor strongly affects the engine’s starting beha-

vior. That is, an engine whose idling speed is adjusted correctly will be easier

to start than one whose idling speed has not been adjusted correctly.

The idle speed is controlled by means of the adjusting wheel 

[1]

and the mix-

ture control screw 

[2]

. The adjusting wheel is used to adjust the basic setting

of the slide. The mixture control screw is used to control the idle mixture which

arrives at the engine by way of the idle system. Clockwise turning reduces the

fuel quantity (lean mixture), counterclockwise turning increases the fuel quan-

tity (rich mixture).

TO ADJUST IDLING CORRECTLY, PROCEED AS FOLLOWS:

1 Turn in mixture control screw 

[2]

up to the stop, and turn it back out to

the basic position (see tecnical date engine)

2 Warm up the engine

3 Use the adjusting wheel 

[1]

to set the normal idle speed (1400 - 1500

rpm).

4 Turn mixture control screw 

[2]

slowly clockwise until idling speed starts

to decrease. Memorize this position, and turn mixture control screw slowly

counterclockwise until the idling speed will decrease again. Adjust the

point of the highest idling speed between these two positions. If, in the

course of this procedure, the speed undergoes a relatively high increase,

reduce the idle speed to a normal level and repeat the procedure speci-

fied in 4. Serious competitive racers will choose a setting approx. 1/4 turn

(clockwise) leaner than this ideal value because their engine will heat up

more when used in competitions.

NOTE: If you fail to obtain a satisfying result by following the procedure

described above, an incorrectly dimensioned idling nozzle may be the cause.

In case:

a) the mixture control screw has been screwed in up to the stop without

causing any change in rotational speed, a smaller idling jet has to be 

installed;

b) the engine dies when the mixture control screw is still open by 

2 turns, a larger idling jet needs to be selected;

Naturally, in cases of jet changes, you have to start your adjusting work

from the beginning.

5 Then, use the adjusting wheel to set the desired idle speed.

6 In cases of greater changes in outside temperature and extremely 

different altitudes, the idling speed should be readjusted

Adjusting the mixture control screw *

Accessing the mixture control screw is difficult. For this reasons, we have crea-

ted an appropriate special tool.

Introduce the special tool into the bore 

[A]

at the carburetor bottom. Press

the tool slightly upward and turn the adjusting wheel 

[3]

until the tool enga-

ges the slot of the mixture control screw 

[2]

.

Now, you can go about adjusting the screw. Marks were provided on the adjus-

ting wheel, making it easier to keep track of the turns.

Checking the float level (float height) *

For this purpose, dismount the carburetor and remove the float chamber. Hold

the carburetor in a slanted position such that the float will abut the float needle

valve but not compress it (see photo).

Now, use a sliding caliper to measure the distance 

[H]

between the casing

edge and the float's upper edge.

The float height 

[H]

is to be 9mm.

If the float height does not correspond to the desired value, check the float

needle valve and, if necessary, replace it.

If the float needle valve is o.k., you can adjust the float height by bending of

the float lever 

[4]

.

Mount the float chamber, install the carburetor, and adjust the idle speed.

1

2

A

3

H

4

Summary of Contents for 660 RALLY 2007

Page 1: ...ERG NZUNG ART NR 3 211 217 ZUR BEDIENUNGSANLEITUNG ART NR 3 211 195 SUPPLEMENT ART NO 3 211 217 TO OWNER S MANUAL ART NR 3 211 195 660RALLY2007...

Page 2: ...hmieren z z Luftfilter und kasten reinigen z z z Kabel auf Besch digung und knickfreie Verlegung kontrollieren z z Scheinwerfereinstellung kontrollieren z Elektrische Anlage auf Funktion pr fen Abblen...

Page 3: ...KONTROLL UND PFLEGEARBEITEN DURCH DEN FAHRER Vor jeder Inbetriebnahme Nach jeder Reinigung Bei Gel ndeeinsatz lstand kontrollieren z Bremsfl ssigkeitsstand kontrollieren z Bremsbelege auf Verschlei p...

Page 4: ...vorne 300 mm Bremse hinten Scheibenbremse mit gelochter Bremsscheibe Bremssattel schwimmend gelagert Bremsscheibe hinten 220 mm Bereifung vorne Luftdruck Stra e solo 90 90 21 Michelin T63 1 5 bar Bere...

Page 5: ...OTOR ANZUGSDREHMOMENTE MOTOR Sechskantmutter Prim rrad M20x1 5 Loctite 243 170 Nm Sechskantmutter Schwungrad M16x1 25 links 80 C 150 Nm Sechskantmutter f r Kupplungsmitnehmer M18x1 5 Loctite 243 90 Nm...

Page 6: ...nr der 79 31 Kupplung Mehrscheibenkupplung im lbad Getriebe 5 Gang klauengeschaltet Getriebe bersetzung 1 Gang 33 15 2 Gang 24 15 3 Gang 21 18 4 Gang 19 20 5 Gang 18 22 Z ndanlage kontaklos gesteuerte...

Page 7: ...e 1 abschrauben und Kraftstofffilter 2 reinigen Kraftstofffilter in allen vier Tanks Hohlschraube 3 herausdrehen und Kraftstofffilter 4 reinigen bzw erneuern Entl ftungsfilter erneuern Filter von Tank...

Page 8: ...f hrt werden sonst erlischt die Garantie Der Motor lwechsel ist bei betriebswarmem Motor vorzunehmen EIN BETRIEBSWARMER MOTOR UND DAS DARIN BEFINDLICHE MOTOR L SIND SEHR HEISS VERBRENNEN SIE SICH NICH...

Page 9: ...htungen montieren Verschlu schraube 5 mit 30 Nm und Verschlu schrauben 6 und 7 mit 20 Nm festziehen Die Schraube 8 mit 20 Nm festziehen Dichtfl che am Brustrohr 9 reinigen neuen Feinfilter mit Motor l...

Page 10: ...genfalls Motor l nachf llen ZU WENIG MOTOR L ODER QUALITATIV MINDERWERTIGES L F HRT ZU VOR ZEITIGEM VERSCHLEISS DES MOTORS LKONTROLLE BEI KALTEM MOTOR ERGIBT FALSCHE WERTE AM LMESSTAB UND DAURCH EINE...

Page 11: ...ommt man mit der hier beschriebenen Vorgangsweise zu kei nem befriedigenden Ergebnis kann eine falsch dimensionierte Leerlaufd se die Ursache daf r sein Sollte a die Gemischregulierschraube bis zum An...

Page 12: ...end Platz bieten soda alle Einzelteile des Vergasers ordentlich aufgelegt werden k n nen Vergaser ausbauen und groben Schmutz entfernen Den Drahtb gel 1 entfernen und die Entl ftungsschl uche aus dem...

Page 13: ...oren gehen Die 2 Dichtringe Feder und Membrane aus dem Pumpengeh use nehmen Die Schraube entfernen und Schwimmerkammer abnehmen Die Druckstange 3 der Beschleunigerpumpe aush ngen und abnehmen Plastikt...

Page 14: ...uben entfernen und Ansaugtrichter samt O Ring 2 vom Vergaser nehmen Leerlaufluftd se 3 und Hauptluftd se 4 herausdrehen Alle D sen und anderen Teile gr ndlich reinigen und mit Druckluft durchblasen Ve...

Page 15: ...digung pr fen Die Bohrungen 2 auf freien Durchgang pr fen D sennadel pr fen D sennadel auf Verbiegung und Verschlei pr fen D sennadel und Nadel d se alle 10 000 km erneuern Schwimmernadelventil pr fe...

Page 16: ...keschieber 5 montieren und einige Male bet tigen dabei auf Leichtg ngigkeit pr fen Au erdem kontrollieren ob der Choke richtig arretiert Die Feder Scheibe und den O Ring auf die Gemischregulierschraub...

Page 17: ...darauf achten da die Druckstange 2 der Beschleunigerpumpe in die Bohrung gleitet Die Membrane 3 mit Beschriftung nach oben und Feder in das Pumpengeh use legen O Ring 4 in die Nut legen Den Dichtring...

Page 18: ...er Abstand A sollte nun links und rechts gleich gro sein Anschlie end Seilzugscheibe drehen und Gasschieber auf Leichtg ngigkeit pr fen D sennadel montieren und mit der Schraube 4 fixieren Schieberdec...

Page 19: ...ENGLISH 19 KABEL SCHLAUCH UND SEILZUGVERLEGUNG...

Page 20: ...ENGLISH 20 RUNNING THE CABLES AND HOSES...

Page 21: ...em z z Clean air filter and air filter box z z z Check cables for damage and kink less arrangement z z Check headlamp adjustment z Check electrical system for function low high beams stop light turn i...

Page 22: ...done by the rider VITAL CHECKS AND CARE PROCEDURES TO BE CONDUCTED BY THE OWNER OR THE MECHANIC before each start after every cleaning for cross country use Check oil level z Check brake fluid level z...

Page 23: ...ng Head light Parking light Instrument light Indicator lamps Brake light Rear light Flasher light License plate illumination H4 12V 60 55W Sockel P43t 12V 5W Sockel W2 1x9 5d LED LED 12V 21 5W Sockel...

Page 24: ...ENGINE TIGHTENING TORQUES ENGINE Hexagon nut at primary gear M20x1 5 Loctite 243 170 Nm Collar nut flywheel M16x1 25 left 80 C 150 Nm Hexagon nut for inner clutch hub M18x1 5 Loctite 243 90 Nm Allan h...

Page 25: ...d spur wheels 31 79 teeth Clutch multi disc clutch in oil bath Transmission 5 speed claw shifted Gear ratios 1 Gear 33 15 2 Gear 24 15 3 Gear 21 18 4 Gear 19 20 5 Gear 18 22 Ignition system contactles...

Page 26: ...ilter Unscrew the filter housing 1 and clean the fuel filter 2 Fuel filters in all four tanks Unscrew the banjo bolt 3 and clean or replace the fuel filter 4 Replace the vent filter Replace the tank v...

Page 27: ...period the oil change must be performed by an authorized KTM mechanic Otherwise the guarantee will become void The engine oil change is to be carried out when the engine is still warm AN ENGINE HAVIN...

Page 28: ...h their gaskets Tighten plug 5 with 30 Nm and plugs 6 and 7 with 20 Nm Tighten the screw 8 with 20 Nm Clean sealing surfaces on the frame breast pipe 9 fill new fine screen filter with engine oil and...

Page 29: ...gine venting sys tem Add engine oil if necessary INSUFFICIENT OIL OR POOR QUALITY OIL RESULTS IN PREMATURE WEAR OF THE ENGINE CHECKING THE ENGINE OIL LEVEL WHEN THE ENGINE IS COLD RESULTS IN A FALSE R...

Page 30: ...in a satisfying result by following the procedure described above an incorrectly dimensioned idling nozzle may be the cause In case a the mixture control screw has been screwed in up to the stop witho...

Page 31: ...ough space to lay out all individual components of the carburetor in perfect order Dismount the carburetor and remove any coarse dirt Remove the wire clip 1 and pull the ventilation hoses out of the c...

Page 32: ...e spring and the diaphragm from the pump housing Remove the screw and dismount the float chamber Unhitch the push rod 3 of the accelerator pump and dismount it Take the plastic part 4 off the needle j...

Page 33: ...2 screws and take the intake trumpet together with the O ring 2 off the carburetor Unscrew the idle air jet 3 and the main air jet 4 Thoroughly clean all jets and other parts and blow compressed air t...

Page 34: ...ets for damage Check if the bores 2 are unobstructed Checking the jet needle Check the jet needle for bending and wear Replace the jet needle and needle jet every 10 000 km Checking the float needle v...

Page 35: ...Mount the choke slide 5 and actuate it several times checking whether it can be moved smoothly In addition check whether the choke locks properly Thread the spring the washer and the O ring onto the...

Page 36: ...push rod 2 of the acce lerator pump slides into the bore Place the membrane 3 with the labeling facing upwards and the spring into the pump housing Place the O ring 4 into the groove Secure the sealin...

Page 37: ...the extreme right and tighten the screw 1 Now the distances A on the left and on the right should be identical Then turn the cable disc and check if the throttle valve moves smoothly Mount the jet ne...

Page 38: ...e b w o l h g i h I H O L T H G I L P T H G I L P F F O T H G I L r o l o c h w h c t i w s t h g i l e r r b e l b a c r o l o c h c t i w s n r o h N R O H F F O e r u b e l b a c h c t i w s h c t...

Page 39: ...h U r e i f i t c e r r o t a l u g e r M 0 3 A y r e t t a b y a l e r t r a t s r o t o m r e t r a t s ignition coil 2 S A _ C headlight l a n r e t x e s t n e m u r t s n i m e t s y s r e h s a...

Page 40: ...KTM Sportmotorcycle AG A 5230 Mattighofen www ktm at KTM Group Partner...

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