KTM 660 RALLY 2005 Supplement Manual page 34

MAINTENANCE WORK ON CHASSIS AND ENGINE
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– Now, pull the cable disc approx. 5 mm (0.1968 in) outward and turn it
until the throttle valve can be lifted out of the carburetor and detach the
rollers [1] at the throttle valve.
– Take the throttle valve together with the 4 rollers [2] and the valve paddle
out of the carburetor.
Note: When you turn the cable disc, it must not be blocked by the stop screw
(see photo). Otherwise, pull the shaft further outward.
– Turn the carburetor around, remove the 3 screws and remove the cover of
the accelerator pump.
Note: When dismounting the cover, watch out for the spring and the sealing
rings as they may get lost easily.
– Remove the 2 sealing rings, the 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 jet.
– Loosen the screw [5], pull out the float hinge pin [6] and dismount the
float together with the float needle valve.
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– Remove the screw [7] and use pliers to carefully extract the seat of the
11 float needle valve from the carburetor.
– Turn out the idling jet [8], the starting jet [9] and the needle jet together
with the main jet [10].
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– Turn in the mixture control screw [11] down to the stop, count the num-
ber of turns and write it down.
– Turn out the mixture control screw and dismount it together with the
spring, the washer, and the O-ring.
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Note: The spring, the washer, and the O-ring will usually remain in the bore.
These parts can be removed with the help of compressed air.
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