Royal Enfield Interceptor 650 2018 Owner's Manual
  1. Manuals
  2. Brands
  3. Royal Enfield Manuals
  4. Motorcycle
  5. Interceptor 650 2018
  6. Owner's manual

Royal Enfield Interceptor 650 2018 Owner's Manual

Hide thumbs Also See for Interceptor 650 2018:
Table of Contents

Advertisement

Quick Links

EURO IV

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the Interceptor 650 2018 and is the answer not in the manual?

Questions and answers

Related Manuals for Royal Enfield Interceptor 650 2018

Summary of Contents for Royal Enfield Interceptor 650 2018

  • Page 1 EURO IV...
  • Page 2 FOREWORD Congratulations. You now own a piece of history! The Royal Enfield Interceptor is our heritage-inspired machine, built for the modern, intrepid traveller. With your new machine, we mark the return of one of Royal Enfield’s most loved classic motorcycles - the Interceptor. Harking back to a time when all that mattered was that the California sun was out and the surf was up, this motorcycle retains the charm that made it legendary.
  • Page 3 NOTICE All information in this manual is based on the latest product information available at the time of publication. Due to continuous improvements, there may be discrepancies between the information in this manual and your motorcycle. Royal Enfield reserves the right to make production changes at any time without prior notice and without incurring any obligation to make the same or similar changes to motorcycle previously built or sold.

  • Page 4: Table Of Contents

    CONTENTS Safety Definitions ..................................Personal and Motorcycle Information ............................Safe Riding Tips / Guidelines ..............................Rules of the Road ..................................Accessories and Luggage ................................Technical Specifications ................................Recommended Lubricants ................................. Motorcycle Identification Numbers ............................Engine Number Details ................................Location of Key Parts ................................... Operation of Controls ..................................

  • Page 5: Table Of Contents

    CONTENTS Parking ......................................Tools Kit ......................................Minor Maintenance Tips ................................Long Trip Precautions .................................. 100 Washing Procedure ..................................102 Storage Precautions ..................................104 Trouble Shooting ..................................105 Wiring Diagram .................................... Periodical Maintenance Chart ..............................116 Service Maintenance Record ..............................120 Warranty Terms and Conditions ..............................

  • Page 6: Safety Definitions

    SAFETY DEFINITIONS The information given under the titles: Warning, Caution and Note are for your safety and for the care and safety to your motorcycle and others. Please read these carefully and if disregarded may result in injury to yourself or others and damages to the motorcycle.

  • Page 7: Personal And Motorcycle Information

    PERSONAL AND MOTORCYCLE INFORMATION Name Door No./Street Locality/Town City Country Res : Off : Contact Mobile : Email : Licence No. Valid till : Model Color : Engine No. VIN. No. Tyre make Front : Rear : Tyre Nos. Front : Rear : Battery make Battery No.

  • Page 8: Safe Riding Tips / Guidelines

    SAFE RIDING TIPS / GUIDELINES n Before operating your new motorcycle, we request you to carefully read and follow the operating and maintenance instructions detailed in this manual for the safety of your own, your motorcycle, and also that of others. n Know and adhere to the rules of the road with respect to your driving country.
  • Page 9 SAFE RIDING TIPS / GUIDELINES « DO NOT fill the tank to its brim. Please fill fuel till the bottom of anti splash plate, so as to leave sufficient air space in the fuel tank to allow for fuel expansion. WARNIN G Royal Enfield cautions you against the use of certain nonstandard parts such as aftermarket and custom made extended front forks or suspensions, which may adversely affect performance and handling.
  • Page 10 SAFE RIDING TIPS / GUIDELINES NOTE If you are an inexperienced rider we recommend that you obtain formal training on correct motorcycle riding techniques and become thoroughly familiar with the operation of your motorcycle. New riders should gain experience under various conditions while driving at moderate speeds.
  • Page 11 SAFE RIDING TIPS / GUIDELINES n Wear an approved helmet, clothing, and footwear suited for riding a motorcycle. Bright/light colours are best for greater visibility in traffic, especially at night. Avoid loose, flowing garments and scarves. n When carrying a pillion rider, it is your responsibility to instruct them on proper riding procedures. n DO NOT allow other individuals, under any circumstances, to operate your motorcycle unless you know they are experienced, licensed riders and are thoroughly familiar with the operating conditions of your motorcycle.
  • Page 12 SAFE RIDING TIPS / GUIDELINES W ARNIN G Avoid any contact with the exhaust system when hot. Wear clothing that will completely cover the legs while riding. The exhaust system gets very hot when the engine is running and remains too hot to touch, even after the engine is turned off. Failure to wear proper or protective clothing could result in serious injury.
  • Page 13 SAFE RIDING TIPS / GUIDELINES W AR NIN G Consult your Royal Enfield Authorised Service Centre regarding any questions or problems that occur in the operation of your motorcycle. Failure to do so may aggravate an initial problem, cause costly repairs and jeopardize your personal safety. W AR NIN G DO NOT tow a motorcycle.

  • Page 14: Rules Of The Road

    RULES OF THE ROAD n Be sure your number plate is installed in the position specified by law and it is clearly visible at all times. n Ride at a safe speed that is consistent with the type of road surface you are on. Pay strict attention while riding on the following surfaces : «...
  • Page 15 RULES OF THE ROAD n Actuate your turn signals and exercise caution when passing other vehicles going in the same direction. Never try to pass another vehicle going in the same direction at street intersections, on curves, or when going up/or down a hill. n At street intersection give the right-of-way to the motorcycle on your left or right.
  • Page 16 RULES OF THE ROAD n When parking the motorcycle, park on a firm and flat surface to prevent it from falling over. n Protect your motorcycle against theft. After parking your motorcycle, ensure that the steering head is locked and then remove the ignition key.

  • Page 17: Accessories And Luggage

    ACCESSORIES AND LUGGAGE Royal Enfield offers a range of Genuine Motorcycle Accessories that have been fully approved and extensively tested alongside the motorcycle. Therefore, the rider must be responsible for safe operation of the motorcycle when installing accessories or carrying additional weight.
  • Page 18 ACCESSORIES AND LUGGAGE W ARNIN G DO NOT load weight or install accessories incorrectly on the motorcycle. Doing so may affect the motorcycle’s stability, handling characteristics and safe operation and could result in an accident causing serious injury or loss of life. W ARNIN G Royal Enfield offers a range of Genuine Motorcycle Accessories that have been fully approved and extensively tested alongside the motorcycle.

  • Page 19: Technical Specifications

    TECHNICAL SPECIFICATIONS ENGINE Engine Type ........... Inline Twin Cylinder, 4 Stroke, SOHC Bore ............78mm Stroke ............. 67.8mm Swept volume ........648cc Compression ratio ......... 9.5:1 Max Power ..........34.9 kw @ 7250 rpm Max Torque ..........52.3 Nm @ 5150 rpm Idle RPM ..........
  • Page 20 TECHNICAL SPECIFICATIONS Engine oil capacity Dry Fill ..3.9 litre / 1.03 imperial gallon Refill ..3.1 litre / 0.82 imperial gallon Engine oil grade ........TOTAL ELF MOTO 4 TECH SAE 10W50 API SL, JASO MA2, SYNTHETIC Fuel Supply ..........Fuel Injection Cooling ..........
  • Page 21 TECHNICAL SPECIFICATIONS TRANSMISSION Clutch ............. Wet multiplate Primary drive .......... Gear Primary ratio ........... 2.05 : 1 Gear box ..........6 Speed Constant Mesh Gear Ratio ..........2.615:1 ............2 1.813:1 ............3 1.429:1 ............4 1.190:1 ............5 1:040:1 ............
  • Page 22 TECHNICAL SPECIFICATIONS CHASSIS Frame ............. Steel Tubular, Double Cradle Frame Suspension Front ..........41 mm Front Fork, 110 mm travel Rear ..........Single Coil-over Shocks, 88 mm travel Hydraulic Disc Brakes ......Front and Rear with ABS system..........Front: 320 mm disc, ABS ..........
  • Page 23 TECHNICAL SPECIFICATIONS Tyre Pressure: Solo Front..........32 psi/2.20 kg/cm Rear..........36 psi/2.53 kg/cm With Pillion Front..........32 psi/2.20 kg/cm Rear..........39 psi/2.74 kg/cm Steering Lock.......... Combination Lock Fuel Type ..........Unleaded Gasoline Ethanol content........E10 or less Minimum Octane Rating ....... 91 RON (Research Octane Number) or Higher Induction ..........
  • Page 24 TECHNICAL SPECIFICATIONS ELECTR ICALS System ............ 12V - DC Generation ..........Alternator Alternator Output ........156 W @ 1100 rpm Battery ............ 12V - 12 Ah VRLA Head lamp ..........12V, H4 60/55 W Brake/Tail lamp ........12V, P21/5W (Halogen) Turn signal ..........
  • Page 25 TECHNICAL SPECIFICATIONS DIMEN SIONS Rake ............24 degrees Front Wheel ..........18 M/C x MT 2.50 Rear Wheel ..........18 M/C x MT 3.50 Length............. 2119 mm Width ..........857 mm (with mirrors) Height ..........1120 mm Wheel base ..........1398 mm Ground Clearance ........
  • Page 26 TECHNICAL SPECIFICATIONS WE IGHT S Kerb weight (90% Fuel and Oil) ... 213 kg Max. pay load .......... 200 kg (Inclusive of rider mass) NOTE n Values / dimensions given above only for your guidance. n In view of continuous improvements being done on our products, the specifications could change without prior notice.

  • Page 27: Recommended Lubricants

    RECOMMENDED LUBRICANTS Engine Oil Brake Fluid Front Fork Oil TOTAL ELF MOTO 4 TECH SAE DOT 4 Grade 2W 25 HPCL Grade Grade 10W50 API SL, JASO MA2, Front: 50 ml Capacity SYNTHETIC Capacity 473 ml / Fork Rear: 100 ml 1st Dry Fill : Routine Oil Change : Capacity...
  • Page 28 ISO 14001 OPERATION CONTROL PROCESS As per the guidelines in ISO 14001 Environmental Management System, customers are advised to carry out timely replacement of engine oil, fork oil and brake fluid, ONLY through a Royal Enfield Authorised Service Centre for the safe disposal of the used oils to prevent environmental pollution.
  • Page 29 MOTORCYCLE IDENTIFICATION NUMBERS The VIN is a 17 digit number punched on the right side steering head tube in the form of label. Sample VIN : X X X X X X Manufacturer’s code Type of Frame Type of Engine Commercial Name Ignition System Transmission Type...
  • Page 30 MOTORCYCLE IDENTIFICATION NUMBERS CHASSIS NUMBER Punched on the steering head tube right side VIN INFORMATION LABEL CAUTION It is illegal to tamper with the VIN information label as it is the only means of identifications of the motorcycle.

  • Page 31: Engine Number Details

    ENGINE NUMBER - DETAILS The engine number is punched above the oil filter location. it is the means of identification of the engine serial number and its production details. It is illegal to tamper with the engine number as it is the only means of identifications of the engine.

  • Page 32: Location Of Key Parts

    LOCATION OF KEY PARTS 1. Horn Button 2. Turn Signal Switch 3. Clutch Lever 4. Day Flash Switch 5. High Beam / Low Beam Switch 6. Instrument Cluster 7. Ignition Switch 8. Malfunction Indicator Lamp 9. RPM (Tacho) Meter 10. Engine Kill switch 11.
  • Page 33 LOCATION OF KEY PARTS 1. Right Trafficator R ear 2. Right Trafficator Front 3. Horn 4. Starter Motor 5. Brake Pedal 6. Brake Lever Rear 7. Right Side Panel 8. Brake Lever Front...
  • Page 34 LOCATION OF KEY PARTS 1. Left Trafficator Front 2. Left Trafficator Rear 3. Left Side Panel 4. Side Stand 5. Centre stand 6. Gear Change Pedal 7. Spark plug...

  • Page 35: Operation Of Controls

    OPERATION OF CONTROLS IGNITION SWITCH OFF: Steering unlock, ignition “OFF” ON: Steering unlock, ignition “ON” NOTE n Key is common for ignition, petrol tank lock, steering lock and side panels. n Key can be removed from fuel tank, side panel only in locked position from the key slots. STEERING LOCK n Turn the handle bar to extreme left or right position.
  • Page 36 OPERATION OF CONTROLS FUEL TANK CAP n Lift key flap on fuel tank cap and insert key. n Turn key clockwise to open. n Press cap to lock with key in position. n Remove key from cap and close flap W AR NIN G n DO NOT overfill the fuel tank.
  • Page 37 OPERATION OF CONTROLS FUEL FILLING LEVEL 1. Fuel filler collar 2. Anti splash plate 3. Maximum fuel level ENGINE KILL SWITCH Engine "OFF" Engine "ON" CAUTION n Turn off ignition switch when engine is not running. Failure to do so will discharge the battery due to the headlamp being continuously "ON".
  • Page 38 OPERATION OF CONTROLS E-START SWITCH Depress and hold untill engine starts for a maximum of 5 seconds. HORN Press the horn button to sound horn. HI BEAM / LOW BEAM SWITCH n When the headlamp is in ON condition “High / Low beam” will be selected by toggling the switch.
  • Page 39 OPERATION OF CONTROLS DAY FLASH Press the switch for Day flash. TURN SIGNAL SWITCH Left turn signal "ON" Right turn signal "ON" "OFF" (Push to cancel) Push the button from “OFF” position to either left or right before turning as needed and restore to “OFF” position to stop blinking.
  • Page 40 OPERATION OF CONTROLS SIDE PANEL LEFT n To access the left side panel remove the seat and retaining screw, pull and disengage the side panel from locater and gently remove the side panel. SIDE PANEL RIGHT n Turn key clockwise to unlock the side panel. n Pull the side panel along with key to gently remove the side panel.
  • Page 41 OPERATION OF CONTROLS INSTRUMENT CLUSTER This instrument cluster consists of the following: 11. Neutral Indicator 1. Speedometer 12. Low Oil Pressure Indicator 2. Odometer 13. Tachometer 3. Selection Button 4. Trip Meter 'A' and 'B' 5. Turn Signal Indicator 6. Hi beam Indicator 7.
  • Page 42 OPERATION OF CONTROLS 1. SPEEDOMETER The Speedometer indicates the speed at which motorcycle is travelling and has both kms/ miles calibration. 2. ODOMETER The default display in the odometer is the total kms/miles, the motorcycle has covered NOTE The last selection mode will be displayed whenever ignition is switched "ON". WARNIN G It is illegal to tamper with the odometer display or reset the total kms/miles, the motorcycle has covered.
  • Page 43 OPERATION OF CONTROLS 3. SELECTOR BUTTON The selector knob will help to select between odometer, Trip ‘A’ or Trip ‘B’. 4. TRIP METER A AND B A light push for less than one second on the select button switch will change the display from odometer Trip ‘A’. Again another press on the select button switch will change the display from Trip ‘A’...
  • Page 44 OPERATION OF CONTROLS 5. TURN SIGNAL INDICATOR Indicates that either the left or right indicators are “ON”. 6. HI BEAM INDICATOR Indicates that the high beam head lamp is “ON”. 7. ENGINE MALFUNCTION INDICATOR LAMP A Malfunctioning indicator lamp (MIL) is provided in the tachometer. When both the ignition and engine kill switch is in “ON”...
  • Page 45 OPERATION OF CONTROLS 8. BATTERY LOW VOLTAGE INDICATOR When the ignition switch is turned in “ON” position, low voltage indicator symbol will glow. As soon as the engine is started the battery low voltage indicator turns “OFF” automatically. In case the battery voltage is below 12 volt and the battery is not charging when the engine is started, the battery low voltage indicator will continue to glow in the instrument cluster.

  • Page 46: Warning Indications And Safety Systems

    WARNING INDICATIONS AND SAFETY SYSTEMS Your motorcycle is fitted with the following warning indications and safety systems: 9. FUEL LEVEL INDICATOR The fuel level indicator indicates the level of fuel in the fuel tank. The display bars of the fuel meter fades towards the empty (E) when the fuel level decreases from full tank level (F).
  • Page 47 WARNING INDICATIONS AND SAFETY SYSTEMS 10. ANTI-LOCK BRAKING SYSTEM (ABS) Anti-Lock Braking System (ABS) will help prevent the brakes from locking the wheels, during sudden application of the brakes at high speeds or at low friction surfaces. This will help the rider to have better traction and control over the motorcycle and prevent the motorcycle from skidding which can cause an accident.
  • Page 48 WARNING INDICATIONS AND SAFETY SYSTEMS CAUTION (ABS) ABS is a safety feature to help prevent locking of wheels during panic application of brakes. It is by no means a substitute for good riding practices and anticipatory braking. Please ride carefully and apply brakes cautiously, especially while cornering. ABS cannot estimate the “weight shifts” and momentum of the motorcycle while negotiating a corner and therefore prevent skidding due to loss of traction.
  • Page 49 WARNING INDICATIONS AND SAFETY SYSTEMS DO’S AND DONT’S : (ABS) DO’S DONT’S n While starting the engine do check the ABS indicator glows “ON” and n DO NOT RELEASE the brake lever/ turns OFF when the vehicle speed exceeds 5 km/h (3.1 mph). pedal when pulsations are felt during hard application of the brakes in an n Please check the brake fluid at “MAX”...
  • Page 50 WARNING INDICATIONS AND SAFETY SYSTEMS CAUTION When the indicator glows continously and if the engine speed is above idle, stop the vehicle immediately and get the engine inspected and corrected through a nearest Authorised Royal Enfield Service Centre. Failure to do so can cause engine damage.

  • Page 51: Pre Operational Checks

    PRE OPERATIONAL CHECKS A careful check on the following aspects must be carried out every time before riding and especially after long periods of storage to determine if any additional maintenance is necessary. 1. Adequate fuel in the tank for the journey planned. 2.

  • Page 52: Running In Period

    RUNNING IN PERIOD The Royal Enfield Motorcycle as you would be experiencing is capable of consistent high speeds. However as with any new motorcycle, a “RUNNING-IN” procedure is essential to help in proper “Bedding-In” of the various moving parts in your motorcycle and to achieve optimum performance subsequently.
  • Page 53 RUNNING IN PERIOD During the first 2000 Kms of run, do not exceed the speed limits as shown in the table below. Motorcycle Speed Gear First 500 kms 501 - 2000 kms 15 kmph 20 kmph 25 kmph 30 kmph 30 kmph 40 kmph 45 kmph...

  • Page 54: Starting

    STARTING n To shift into neutral, move the motorcycle back and forth gently, while simultaneously shifting the gear. Ensure gear is in neutral position and the neutral lamp is glowing in the instrument cluster. n Turn ignition key to “ON” position and engine kill switch on right hand side handle bar to “RUN”...
  • Page 55 STARTING n When both the ignition and engine kill switch is in "ON" position and after the vehicle is started, the MIL will glow for a few seconds and turns “OFF”, this indicates that all the function of the electronic fuel injection (EFI) system is functioning normally. In the event of any malfunction in the EFI system the MIL will glow continuously.
  • Page 56 STARTING n Disengage clutch by pulling in the clutch lever and hold it in depressed condition. n Depress and hold electric start switch until engine starts for a maximum of 5 seconds. NOTE In case the engine does not start within 5 second, release starter switch and wait for about 5 second before attempting to start the engine again.
  • Page 57 STARTING CAUTION If the engine does not start. DO NOT hold the starter switch in depressed condition for long periods, this will cause the battery to drain below the threshold level of 10 volt. Please get the motorcycle checked through an Royal Enfield Authorised Service Centre to identify and correct the reason for not starting.

  • Page 58: Gear Shifting, Riding And Stopping

    GEAR SHIFTING, RIDING AND STOPPING The clutch lever must be fully depressed before attempting a gear shift. Failure to fully depress the clutch lever will cause a roughstart OR stalling of the engine besides causing damage to transmission parts. n When the vehicle is in Neutral position, press gear shift lever down with toe to engage 1st gear.
  • Page 59 GEAR SHIFTING, RIDING AND STOPPING CAUTION n If the clutch lever is released abruptly and throttle opening is done insufficiently the motorcycle will have a rough start and cause the engine to stall. n If the acceleration is very high and clutch lever is released abruptly, it will cause motorcycle to move suddenly, which will lead to loss of control leading to an accident resulting in injury and or loss of life to rider / other road users / passed by, besides damage to the motorcycle.
  • Page 60 GEAR SHIFTING, RIDING AND STOPPING NOTE Always start motorcycle with the gear in neutral position. When the engine speed decreases or while climbing a gradient or running at a reduced speed, shift to the appropriate lower gear to prevent the engine from stalling or straining to pull. n Always shift to lower gears as appropriate whenever slowing down to stop the vehicle.

  • Page 61: Parking

    PARKING PARKING MOTORCYCLE ON CENTRE STAND n Select a firm, flat surface. n Hold handle bar firmly in a straight position. n Lower centre stand, such that, both the legs of the stand are resting on a firm ground. n Apply pressure on the fulcrum lever on the centre stand and pull the motorcycle backward. n Lock the steering and ensure the handle bar is locked firmly before removing the key from the ignition barrel.
  • Page 62 PARKING PARKING MOTORCYCLE ON SIDE STAND n Select a firm, flat surface.  n Extend side stand. Tilt the motorcycle to the left side, till it is supported firmly on the ground. WARNIN G Ensure both stands are fully retracted before riding the motorcycle. Please exercise extreme care while parking and ensure it is parked on a firm and flat surface to avoid the motorcycle from falling over and causing injury to you or to others and damage to the motorcycle parts.

  • Page 63: Tools Kit

    TOOLS KIT The tool kit is located in the right side panel of the motorcycle. S.No. Description Qty. C Spanner Allen Key 6mm Allen Key 5mm Allen Key 4mm Extension Tube Ring Spanner 24 x 14 Combination Screwdriver 06 x 160 Double End Spanner 10 x 12...

  • Page 64: Minor Maintenance Tips

    MINOR MAINTENANCE TIPS The following simple maintenance activities will help maintaining your motorcycle. However, for an complete maintenance, we recommend you to get in touch with a Royal Enfield Authorised Service Centre. HAND LEVERS, CENTRE AND SIDE STAND PIVOTS n Clean the pivot points and ensure they are free of any dirt, grime, rust, etc. n Lubricate the pivots.
  • Page 65 MINOR MAINTENANCE TIPS DRIVE CHAIN n Spray drive chain with recommended chain cleaning solvent while simultane- ously rotating rear wheel. n Ensure the drive chain has been sufficiently and completely covered with the cleaning solvent. If necessary use a suitable brush to remove hard deposits from the chain.
  • Page 66 MINOR MAINTENANCE TIPS OIL LEVEL INSPECTION n Ensure motorcycle is in upright position on a firm and flat surface on its centre stand. n Start the engine and allow it to run in idling rpm for about 2 minute and switch off...
  • Page 67 MINOR MAINTENANCE TIPS n Remove the engine oil filler cap for adding the engine oil. n Place a clean tray under the engine oil magnetic drain plug. Remove it along with the washer to drain oil completely from the engine. WARNING DO NOT spill the engine oil.
  • Page 68 MINOR MAINTENANCE TIPS NOTE Ensure the engine oil is drained completely. Drain the oil completely and to avoid oil spilling. ENGINE OIL FILLING n Place a container under engine oil drain bolt. n Gently apply thread sealant on drain plug thread. n Insert the drain plug bolt along with new washer.
  • Page 69 MINOR MAINTENANCE TIPS SPARK PLUG Gap 0.7 to 0.8 mm. CLEANING SPARK PLUG AND ADJUSTING GAP n Disconnect spark plug caps from the spark plugs. n Locate spark plug spanner on the spark plug, loosen spark plug and remove it from cylinder head.
  • Page 70 MINOR MAINTENANCE TIPS BRAKE FLUID FRONT AND REAR n Ensure motorcycle is upright on a firm flat surface on its centre stand. n Check brake fluid level in the window on front and rear reservoirs. n The level is correct if the oil level is between the “MIN” and “MAX” marks. n Open the reservoir cover and remove diaphragm carefully to top up the brake fluid.
  • Page 71 MINOR MAINTENANCE TIPS INSPECTION OF TYRES AND WHEELS n Inspect the tyres periodically for tread wear, cracks and cuts. Minimum tread depth : Front tyre : 1 mm Rear tyre : 2 mm n Check and remove stone, splinters, nails or other particles embedded in the tyre treads. n Periodically inspect wheels for spokes damage and wheel rim for wobbling or run out.
  • Page 72 MINOR MAINTENANCE TIPS FRONT WHEEL REMOVAL n Ensure motorcycle is upright on a firm and flat surface. n Place a wooden block on the front end of engine to support the motorcycle and ensure front wheel is off the ground by minimum 2 inches. n From wiring harness RH side disconnect the speedo drive coupler.
  • Page 73 MINOR MAINTENANCE TIPS n Tap and remove the front wheel spindle, gently tap axle from left side while supporting wheel at the bottom then remove axle from the right side. CAUTION Take care to secure the wheel spacers and speed sensor while removing the axle from the forks.
  • Page 74 MINOR MAINTENANCE TIPS FRONT WHEEL REASSEMBLY n Remove the wooden piece / cardboard sheet placed between the brake pads n Locate speedo drive to its correct position on the right side. n Locate stepped spacer to the wheel hub on left side. n Insert the wheel along with speedo drive and spacer between the fork ends.
  • Page 75 MINOR MAINTENANCE TIPS n Rotate wheel to check for smooth rotation. n Connect the speedo wire coupler and check for proper working of speedometer. n Press brake lever and check front brake efficiency. CAUTION Please exercise utmost caution while reassembling the front wheel on the motorcycle. please ensure the wheel is fitted correctly before attempting to ride the motorcycle.
  • Page 76 MINOR MAINTENANCE TIPS REAR WHEEL REMOVAL n Ensure motorcycle is upright on a firm and flat surface with the rear wheel atleast 6 inches raised above from the surface. n Observe and mark the alignment indexes on both chain adjuster on left and right side swing arm.
  • Page 77 MINOR MAINTENANCE TIPS n Hold wheel spindle on left side firmly and loosen hex nut on right side. n Remove the nut and washer from the wheel spindle. n Push rear wheel fully into the swing arm. n Support rear wheel from bottom and pull out wheel spindle from the left side swing arm.
  • Page 78 MINOR MAINTENANCE TIPS CAUTION Do not press the rear brake pedal when the rear wheel is being removed as this will cause the brake pads to dislocate from the brake caliper. n Place a 4 mm thick wooden piece or cardboard sheet between the brake pads to avoid activation of brake pads if rear brake pedal is accidentally pressed.
  • Page 79 MINOR MAINTENANCE TIPS REAR WHEEL REASSEMBLY n Ensure that the long stepped spacer is located on the brake disc side and the short spacer is located on the sprocket side of the wheel hub firmly. n Ensure that the chain adjuster are located properly inside the swing arm left and right sides.
  • Page 80 MINOR MAINTENANCE TIPS n Tap spindle gently into wheel hub slot till the threads are completely visible on the right side. n Assemble the drive chain on the sprocket and ensure it is seated correctly. n Check for free and smooth rotation of the rear wheel. n Assemble washer and hex nut on wheel spindle on right side.
  • Page 81 MINOR MAINTENANCE TIPS DO NOT TIGHTEN HEX NUT FULLY n Tighten chain adjuster nuts on left and right adjuster such that the index marks are aligned correctly on both sides of the swing arm. n Check and ensure correct chain tension and wheel alignment. n Hold spindle firmly on left side and tighten hex nut on right side set torque to 70 Nm.
  • Page 82 MINOR MAINTENANCE TIPS ADJUSTMENTS - CLUTCH n Loosen the cable outer lock nut . n Turn the nut clockwise to reduce the play or anticlockwise to increase the free play. n Tighten lock nut after adjustment is done. n Check free play 2 to 3 mm at clutch lever pivot on handle bar end, if desired free play is not achieved readjust.
  • Page 83 MINOR MAINTENANCE TIPS DRIVE CHAIN TENSION (Free Play 20-30 mm) Park motorcycle up right on a firm and flat surface. n Ensure the motorcycle is in neutral position. n Measure the drive chain free play as shown. The drive chain free play is 20 mm to 30 mm.
  • Page 84 MINOR MAINTENANCE TIPS d. To increase the free play, loosen the adjuster nuts evenly and push the rear wheel forward. e. Check the chain for correct chain tension. f. Ensure that the index marks on the adjuster and swing arm are same on both left and right side of the swing arm. g.
  • Page 85 MINOR MAINTENANCE TIPS BATTERY AND MAINTENANCE n The Motorcycle is provided with 12V - 12 Ah battery. n The battery must be periodically checked for cleanliness and corrosion free terminals. NOTE The poor contact or loose fitment of battery terminals may cause ECU failure. DISMANTLING n Switch “OFF”...
  • Page 86 MINOR MAINTENANCE TIPS n Remove 3 Nos. Hex head bolts from tool box to access the battery. n Disconnect battery positive (+ve) terminal from battery.
  • Page 87 MINOR MAINTENANCE TIPS n Pull battery strap (belt) downwards and release strap lock from battery strap bracket. n Loosen and remove hex flange head screw from battery strap bracket.
  • Page 88 MINOR MAINTENANCE TIPS n Remove battery strap bracket from battery tray. n Remove battery from tray.
  • Page 89 MINOR MAINTENANCE TIPS WARNIN G Always disconnect the black negative (-ve) battery cable first and then the red positive (+ve) cable while removing the battery connections. NOTE For checking the battery voltage contact Royal Enfield Authorised Service Centre or battery service centre.
  • Page 90 MINOR MAINTENANCE TIPS ASSEMBLY n Assemble battery in to tray. Place battery strap bracket into battery tray.
  • Page 91 MINOR MAINTENANCE TIPS n Locate and tighten flanged head screw into battery strap bracket. Pull battery strap (belt) downwards to fix strap lock into battery strap bracket.
  • Page 92 MINOR MAINTENANCE TIPS n Connect battery red positive (+ve) terminal bolt. Locate and tighten 3 nos. hex head bolts into tool holder.
  • Page 93 MINOR MAINTENANCE TIPS n Connect red battery negative (-ve) terminal bolt. CAUTION Connect the black (-ve) negative terminal after connect red (+ve) positive terminal only. NOTE Clean the wire terminals free from corrosion and keep the terminals coated with petroleum jelly. CAUTION Keep the red (+ve) positive terminal and (-ve) negative terminal cables firmly connected to the respective battery terminals.
  • Page 94 MINOR MAINTENANCE TIPS CHANGING ELECTRICAL COMPONENTS HEADLAMP BULB REPLACEMENT n Loosen the rim holding screw on top and take out the head lamp dome. n Disconnect electrical connections. n Thumb push and remove the bulb holding clamp gently. n Remove the bulb using a clean and soft cloth.
  • Page 95 MINOR MAINTENANCE TIPS n Position the new bulb inside the reflector such that the three projections on the bulb align with the slot on the reflector. n Refit the bulb holding clamp. n Connect the electrical connections. n Position head lamp dome onto the head lamp shell and tighten the mounting screw on top.
  • Page 96 MINOR MAINTENANCE TIPS TAIL LAMP BULB n Unlock the side panel RH. n Remove the seat assembly by pulling seat lock cable. n Remove the tail light cover by unscrewing its mounting screw. n Hold the bulb, press inside and rotate anticlockwise to remove the tail light bulb from its holder using a clean cloth.
  • Page 97 MINOR MAINTENANCE TIPS TRAFFICATOR BULB REPLACEMENT n Remove the screw from the trafficator housing. n Open the indicator housing. n Remove the bulb holder with help of a screw driver. n Remove the bulb and replace the same using a soft and clean cloth.
  • Page 98 MINOR MAINTENANCE TIPS FUSE AND FUSE CARRIER n The fuse carrier is located under the seat. n Unlock side panel RH. n Release seat lock by pulling knob and remove the seat. WARNIN G Electronic Control Unit (ECU ) may fail due to loose electrical connections, loose battery terminals, etc. Hence, it is very important to keep all the electrical connections are intact.
  • Page 99 MINOR MAINTENANCE TIPS MINI BLADE FUSE USAGE LIST Fuse ID Color Rating Remarks Fuse ID Color Rating Remarks Number Number 30 A Alternator 15 A Lighting Fuse (Head Lamp) 30 A Main Fuse 10 A Accessory Fuse 15 A Ignition Fuse-EFI 10 A ABS Fuse 10 A...
  • Page 100 MINOR MAINTENANCE TIPS AIR FILTER CLEAN AND REFIX : EVERY 5000 kms n Remove the screw from the side panel bottom side and remove side panel. n Remove the air filter cover screws and then take out air filter box cover. n Pull out filter element and check for dirt.

  • Page 101: Long Trip Precautions

    LONG TRIP PRECAUTIONS CHECKS PRIOR TO THE COMMENCEMENT OF A LONG JOURNEY n Service the motorcycle at Royal Enfield Authorised Service Centre. n Ensure sufficient quantity of fuel is always available in the fuel tank for the journey planned. n Check and correct tyre pressure if necessary. CHECKS AFTER EVERY 1500 KMS OF RUN n Any loose fasteners.
  • Page 102 LONG TRIP PRECAUTIONS ITEMS TO BE CARRIED n Tools kit. n Bulbs for headlight, trafficator light and mini blade fuses (10 and 15 A). n Accelerator and clutch cable. n Spark plug, spark plug cap. n Spare tubes.

  • Page 103: Washing Procedure

    WASHING PROCEDURE PRECAUTIONS n Remove ignition key and seal the ignition key barrel slot using adhesive tape. n Cover the silencer tail pipe, horn and control switches with suitable plastic bags and tie it firmly to prevent water entry. n Wash the motorcycle only when the engine is in cold condition. n Do not remove side panel while washing to avoid water entry.
  • Page 104 WASHING PROCEDURE n If possible, use compressed air and blow off water particles from the obscure areas of the motorcycle, electrical connections etc. AFTER WASHING n Ensure, the motorcycle is thoroughly dry by wiping with a clean soft lint free absorbent cloth or chamois leather. n Remove all adhesive tapes.

  • Page 105: Storage Precautions

    STORAGE PRECAUTIONS In-case your motorcycle is not going to be used for a month or more, the following precautions should be taken. n Get the motorcycle serviced through a Royal Enfield Authorised Service Centre. n Drain the fuel completely from the fuel tank and induction system. n Remove spark plug.

  • Page 106: Trouble Shooting

    TROUBLE SHOOTING W AR NIN G The trouble shooting section of this Owner’s Manual is intended solely as a guide for diagnosing problems. Carefully read the appropriate sections of this manual before performing any work, repair and maintenance operations not listed in this Owner’s Manual should be performed by your Royal Enfield Authorised Service Centre only.
  • Page 107 TROUBLE SHOOTING CAUSES REMEDIES 3) No fuel in fuel tank Refill fuel. 4) Battery low voltage indicator is glowing Check battery for voltage / charging circuit. continuously 5) Engine Malfunction indciator is glowing Get the motorcycle inspected through a Royal Enfield Authorised continuously Service Centre.
  • Page 108 TROUBLE SHOOTING CAUSES REMEDIES II. ENGINE MISFIRING Loose spark plug cap Fix cap firmly. 2) Spark plug fouled Clean spark plug or non specified heat range plug. 3) Any sensor loose connections * Check MAP or EOT or TPS sensor wiring / coupler loose connections. 4) Water in fuel tank * Clean fuel tank.
  • Page 109 TROUBLE SHOOTING CAUSES REMEDIES III. POOR PICKUP Brake pedal adjusted too tight *Re-adjust properly, refer to respective section. 2) Choked air filter Clean / Replace air filter. 3) Drive chain tigh *Re-adjust properly. 4) Under inflated tyres *Inflate to correct pressure. 5) Accelerator cable free play excessive Adjust accelerator cable free play.
  • Page 110 TROUBLE SHOOTING CAUSES REMEDIES IV. ENGINE OVERHEATING Low engine oil level Check and top-up if necessary. 2) Clutch slipping * Check and correct. 3) Cylinder fins not clogged Clean the cylinder fins at regular intervals. V. EXCESSIVE FUEL CONSUMPTION Under inflated tyres Inflate to correct pressure.
  • Page 111 TROUBLE SHOOTING CAUSES REMEDIES VI. BRAKES POOR Brake pad worn / Uneven wear *Replace brake pads. 2) Oil / grease on disc. *Clean and refit. 3) Spongy brake *Fill brake fluid and perform brake bleeding. VII. MOTORCYCLE WOBBLES Under inflated tyres Inflate to correct pressure.
  • Page 112 TROUBLE SHOOTING CAUSES REMEDIES VIII. ELECTRICALS Bulbs do not glow Bulb fused * Replace bulb. 2) Fuse blown * Check and replace fuse. 3) Loose / improper connection * Check and correct. Horn not working Fuse blown Check and correct. 2) Loose connections Check and correct.
  • Page 113 TROUBLE SHOOTING CAUSES REMEDIES IX. ELECTRONIC FUEL INJECTION (EFI) Malfunctioning indicator lamp (MIL) glowing continuously Sensor coupler loose connection * Check for all EFI sensor coupler loose connection and correct them. 2) Any EFI sensor failure * Check and replace the same. X.

  • Page 120: Periodical Maintenance

    PERIODICAL MAINTENANCE The maintenance schedule detailed here will help you to maintain your interceptor INT 650 motorcycle meticulously to get a long trouble free service. The schedule provided herein is based upon an average riding conditions and indicates the km/miles at which regular inspections, adjustments, replacements and lubrications are to be carried out.
  • Page 121 PERIODICAL MAINTENANCE DESCRIPT ION PERIODIC MAINTENANCE Kms (x 1000) Months Miles (x 1000) Rubber hose, Air filter to Throttle body Rubber hose, Inlet manifold/ Adaptor Evaporative Emission Equipment rubber hoses Fuel filter - External 10 Air filter element Clean/replace more frequently if operated in dusty condition Vent Pipe under air filter box Hose - Secondary Air Accelerator and Throttle pulley cables free play...
  • Page 122 PERIODICAL MAINTENANCE DESCRIPT ION PERIODIC MAINTENANCE Kms (x 1000) Months Miles (x 1000) Brake pads - Front and Rear Disc Brake fluid level - Front and Rear Rear brake pedal and Gear change pedal pivot Brake hose and Banjo Bolt - Front and Rear 20 Front Fork oil leak Replace oil at every 60000 kms or any work carried out whichever is earlier Steering tapper roller bearing Play...
  • Page 123 PERIODICAL MAINTENANCE PERIODIC MAINTENANCE DESCRIPT ION Kms (x 1000) Months Miles (x 1000) 25 Battery terminals (apply petroleum jelly) 26 Battery electolyte levels (Not applicable for sealed battery) 27 Earth wire eyelet tightness 28 Tyre wear pattern front and rear 29 Pivot-Side Stand, Centre Stand 30 Rider and Pillion Foot rest pivot All mounting fasteners in vehicle for tightness...
  • Page 124 kms/ Royal Enfield miles Authorised Dealer...

  • Page 125: Service Maintenance Record

    SERVICE MAINTENANCE RECORD kms/ Job Card Royal Enfield S.No. Date Brief details of work / service miles Authorised Dealer...
  • Page 126 SERVICE MAINTENANCE RECORD kms/ Job Card Royal Enfield S.No. Date Brief details of work / service miles Authorised Dealer...

  • Page 127: Warranty Terms And Conditions

    WARRANTY TERMS AND CONDITIONS Royal Enfield warrants its motorcycle to be free from manufacturing and materials defects, under normal use subject to the following conditions. 1. Warranty shall be in force until the expiry of a period of 36 months from the first date of sale to the first customer and to any subsequent owners for the balance of the remaining period, until expiry of 36 months from the date of first sale/registration of the motorcycle.
  • Page 128 WARRANTY TERMS AND CONDITIONS 6. Cost of Consumables like fuel, oils etc, labour, shipping charges of replacement parts for any warranty replacement are chargeable to the customer. 7. Warranty is not applicable for the following parts: Normal ageing of parts like rubber parts, tyres and tubes, hand grips, glass, plastic, soft items like seat rexene, cushion etc. Dullness of chrome plated parts, discolourisation of chromed exhaust pipe / silencer, buffed parts, painted surfaces etc.
  • Page 129 WARRANTY TERMS AND CONDITIONS Motorcycle used in rallies, off road, dirt track, races etc. Motorcycle involved in accidents, collisions etc. Damages that occur due to extreme operating conditions beyond the limitation or specifications as given by Royal Enfield, such as maximum load carrying capacity, engine speed etc. Damages that occur due to long/improper storage, transportation of motorcycle etc.

  • Page 130: Emission Warranty

    EMISSION WARRANTY In compliance with the provisions of Rule 115(2) of the Central Motor Motorcycle Rules, 1989, Royal Enfield certifies that the following warranty is applicable to those components liable to affect the emission of the gaseous pollutants in its range of motorcycle, in normal use to which it may be subjected to.
  • Page 131 EMISSION WARRANTY In case of acceptance of the component/s under Emission warranty, Royal Enfield will replace free of charge the component/s as required. However, the consumables like fuel, lubricants, solvents, etc shall be chargeable to the customer as per actuals. In case any of the components covered under emission warranty or the associated parts are not independently replaceable.
  • Page 132 EMISSION WARRANTY Royal Enfield will not be responsible for any penalties that may be charged by statuatory authorities on account of failure to comply with the in-use emission standards. The cost incurred to check emission of the motorcycle will have to be borne by the customer. Emission warranty will be applicable irrespective of the change of ownership of the motorcycle provided all the conditions as laid down in this document are met from the date of original sale of the motorcycle.
  • Page 133 EMISSION WARRANTY Production of a valid Pollution Under Control Certificate is necessary to claim Emission Warranty. n Produces the owner’s manual and Log book for verification details. n Produces receipts covering maintenance of the motorcycle is specified in the owner’s manual from the date of original purchase of the motorcycle.
  • Page 134 EMISSION WARRANTY n Replacement parts not specified and approved by Royal Enfield have been used. n The motorcycle, or parts there of, has been altered, tampered with or modified or replaced in an unauthorised manner. n The odometer is not functioning or the odometer and / or its reading has been changed / tampered with, so that the actual distance covered cannot be readily determined.
  • Page 135 EMISSION WARRANTY TIPS TO BE ON THE RIGHT SIDE OF LAW Always get your motorcycle checked to meet the emission regulations through an authorised emission checking centre. Always carry a valid "Pollution Under Control" certificate with you, as and if applicable by law. TIPS TO REDUCE POLLUTION n Ensure that the periodical maintenance is carried out as stipulated in the owner’s manual through a Royal Enfield Authorised Service Centre.

  • Page 136: Evap

    EVAPORATIVE EMISSION CONTROL SYSTEM WARRANTY The following warranty applies to the evaporative emission control system. Royal Enfield Motors warrants the first owner and each subsequent owner, that this motorcycle is designed and built so as to conform, at the time of sale, with applicable regulations specified by the evaporative emission control system related parts fitted to this motorcycle are free from defects in materials and workmanship which may cause this motorcycle not to meet applicable regulations period of 24 Months from the date of first use of the motorcycle.
  • Page 137 EVAPORATIVE EMISSION CONTROL SYSTEM WARRANTY 3. Loss of time, inconvenience, loss of motorcycle use or any other consequential loss or damages. 4. Any motorcycle in which the Odometer has been tampered with OR the speedo cable has been disconnected for any reason OR is broken and not replaced immediately, due to which the exact distance covered cannot be determined.

  • Page 138: Environment Care

    ENVIRONMENT CARE BE AN ENVIRONMENTALLY CONSCIOUS RIDER You’ve ridden through some beautiful places on your Royal Enfield. Won’t you like to keep them that way? Here are some tips to help you keep those places unspoilt so that others can enjoy them too: ENGINE OIL While your liquid waste like engine oil, gasoline, coolant and other cleaning solvents need to be regularly replaced, what happens to them? Make sure they are not dumped in the soil, down the sewers, drains, lakes or rivers around you.

  • Page 139: Notes

    Royal Enfield Authorised Service Centre. They will follow the local authority’s guidelines to get rid of them in an environmentally friendly manner. CLEANING YOUR ROYAL ENFIELD Avoid aerosol sprays; instead, use a biodegradable detergent or dry wash to clean your Royal Enfield. Also, be cautious while discarding the cleaning solvents.
  • Page 140 NOTES...
  • Page 141 Part No. RAM00010/A...

Table of Contents

Save PDF