Royal Enfield INTERCEPTOR 650 2018 Service Training Manual

Royal Enfield INTERCEPTOR 650 2018 Service Training Manual

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650 TWIN SERVICE
TRAINING MANUAL

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Summary of Contents for Royal Enfield INTERCEPTOR 650 2018

  • Page 1 650 TWIN SERVICE TRAINING MANUAL...
  • Page 2 INTERCEPTOR 650 / CONTINENTAL GT 650 TWIN SERVICE TRAINING MANUAL ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL Part No. TA00060 / Revision 2.0 / Qty. 1000 / TRAB / Sep. 2018...
  • Page 3 Passport No. : ............... Validity : ........Blood Group : ............Specs Lense L/R : ........Alergic Medicines : ......................Height : ......Weight : ......On Date :........ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 4: Table Of Contents

    Engine Mounting into frame ......35 34 Compression test process ......187 Engine Exploded Views ......... 36 All Wiring Diagrams ........188 Engine dismantaling process ......51 ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 5: Technical Specification

    2.9 Liters*** Dead Storage Fuel 1.5 Liters 0.75 Liters NOTE : Fuel tank capacity given here is approximate it can vary marginally from the specified value. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 6 320 mm floating disc. ABS Rear Brake 240 mm disc. ABS Brake Fluid grade DOT 4 or above Brake Fluid capacity Front: ..ml + Rear: ..ml = 125ml ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 7 All Dimensions are in ‘mm’ NOTE Above Values / Dimensions are given for your guidelines / reference only. In view of continuous improvements, specifications are likely to change without notice. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 8: General Vehicle Information

    GENERAL VEHICLE INFORMATION ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 9: Salient Technical Features

    Self starter motor - solenoid relay with micro relay controled by ECU Idler gear (52T / 14T) Mounting Tappet cover Bolts Common Tappet cover and its Gasket for both engines Top Cover Rubber Gasket ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 10 Side Piston with Moly coating ‘EX’ index mark Moly coating Connecting rod split type with journal bearing construction - laser fracture cut used Laser cut method ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 11 Crankshaft and Balancershaft journal bearings construction Journal bearing Pin Balancershaft Assembly Timing Sprocket Gear primary drive - interfrance fixed to crankshaft RH side & similarly gear driven interfrance fixed to balancershaft Gear primary drive - interfrance fix ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 12 Common rail pipes - For Secondary Air Injection to Exhaust Air Injection system and petrol for Fuel injecters system Read Valve Re-designed cockpit- Sculptural top yoke, Clip-ons handle bar, Jewel-like branding Recreation of tank badge ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 13 Modulator Front Caliper Rear Caliper Assembly Assembly New design CLIP ON handle bar LH & RH split type with spring mass damper handle bar in Conti. GT 650 model. Split type handle bar ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 14 Swingarm mounting - adjuster nut 4 lug type given for pre loading (3 Nm) towards LH side of vehicle for better riding effort and wheel alignment purpose. 4 lug type adjuster nut ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 15: Power Flow

    Self Motor Magneto Rotor Drive Pinion   Key / Crank Shaft Double Gear  Big / Small  Connecting Rod LH & RH Sprag Clutch  Gear Driven Piston Assembly LH & RH ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 16: C) Gear Box (Transmission) Power Flow

    (GEAR RATIO = 1.19:1) Positive Power Flow Positive Power Flow 5TH GEAR (26T / 25T) (GEAR RATIO = 1.04:1) 6TH GEAR (25T / 26T) (GEAR RATIO = 0.96:1) Positive Power Flow Positive Power Flow ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 17: D) 6 Speed Transmission

    Power Flow from Crank Shaft to Counter Shaft Via Clutch Assembly as shown in following illustrations. NEUTRAL POSITION Input Output 1ST GEAR 2ND GEAR Input Input Output Output 3RD GEAR 4TH GEAR Input Input Output Output 5TH GEAR 6TH GEAR Input Input Output Output ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 18: Oil Lubrication

    (C/C Lower) ( C/C Lower) Upper (Cylinder Head Main Oil Gallery Oil Filter By Pass Oil Cooler Oil Pressure Relief Oil Pump C/C - L Valve > 5bar Strainer C/C - L Oil Pan ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 19 Leg Valve Valve Stem Stem Cam Roller & Cam Roller & Lobe – IN Lobe – EX Cam Roller & Cam Roller & Oil Pan Lobe – IN Lobe – EX Return Passage ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 20 Oil Pressure Gauge Value 4.5 + 0.5 Bar @4000RPM and 80°C at EOT sensor. Journal Bearing Area OIL LUBRICATION - ACG BOLT TO STATOR COIL Oil passage to spray engine oil to Stator Coils Pictorial View Section View ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 21 Oil Pan - Gallery Oil Sump BREATHER CIRCUIT LAYOUT Breather Box Inlet Air – Oil Mixture Entry Hole Clutch Cover Air Oil Mixture Entry Magneto Cover CRANKCASE BOX ASSEMBLY RH SIDE VIEW Air Oil Mixture Exit ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 22 Front View Module Top Crankcase upper RH Switch Module Bottom Switch Modular Screw Rotor Plate Pan Head Screw M5x10 Paper Throttle Cable gasket Oil Pan hole Deceleration Throttle Cable Acceleration Breather oil return Passage ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 23: Single Overhead Cam Shaft Mechanism

    Exhaust bend Pipe WHAT IS A & S CLUTCH ? Assist & Slipper Clutch Assist Function Slipper Function ASSIST & SLIPPER CLUTCH Judder Clutch System Assist & Slipper clutch ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 24 Normal Engine Engine Back driving torque torque torque torque decrea- Clutch center cam on the rear wheel side that receives torque Slipper cam Pressure Plate Engine output ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 25: Valve Timing

    Exhaust Valve Closing (20 after TDC) & get back nut to its wounding position. Mismatching of timing index marks and incorrect tappet adjustment will change valve timing. Clockwise direction ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 26: Engine Overhauling

    Connecting rod or its journal bearing Replacement. Crankshaft / Balancershaft / Drive Shaft / Counter Shaft / Gears replacement. Crankcase journal bearings / ball bearings Replacement. Silent Timing chain, cam chain short tensioner pad replacement. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 27: Special Tools Application (Engine & Vehicle)

    ST-30268/A To dismantle & tighten frame adjuster 4 lug check To install tapper needle roller bearing race to nut for engine assembly rear bottom side. steering head tube on top side and bottom. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 28 Application : Fitment of slide bush and fork oil seal into front fork bottom case. DOL Tool - NACS II Part No. 6000003 To check failures & diagnoise the sensor of ABS & EFI system. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 29 Gears Locking Tool (Common) ST-27533-2 ST-30294/A Application : To hold Startor Double gear and Sprag Application : To remove or assemble oil filter driven gear while dismantling / tightening the catridge on Engine crankshaft bolt. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 30 Clutch Activating Shaft Bottom Bearing Puller Clutch Activating Lever Top bearing installer ST-30263/A ST-30262/A To remove bottom needle bearing from clutch To install Top side needle bearing on clutch activating lever hole. activating lever hole. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 31 Oil Pressure Gauge ST-30295/A To inspect Engine oil pressure. Gear Shifter Drum NRB Installer ST-30270/A To install the needle roller bearing (a) of gear shifter drum (b) in lower crankcase. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 32: Dismounting Engine From The Frame

    Gently lift the tank from rear side to  disconnect fuel pump coupler and then remove fuel hose quick release coupler from throttle body, fuel level sensor connection coupler from wiring harness. Finally remove the fuel tank from frame.  ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 33  silencer assembly from engine. (1st remove 12mm hex flange nuts from cylinder head exhaust port, 2nd rear mounting bolt & nut from pillion rider step bracket. Finally remove bottom centre mounting bolt.) ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 34 LH & RH side nuts, then push the rear wheel towards engine side to release drive chain tension. Gently rotate the rear wheel while skip,  removing drive chain from driven and drive sprocket carefully. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 35 Magneto coil & pulsar coil couplers, Gear position sensor (GPS), Side stand switch coupler, Oil pressure switch (OPS) coupler and RR Unit coupler. NOTE Engine Mounting to Frame, follow the reverse process of this chapter dismounting from frame. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 36: Engine Mounting Into Frame

      Assemble side panel LH and RH Connect breather hose between the breather  box and air filter box Assemble seat  ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 37: Engine Exploded Views

    Cover, Magneto Stator Assy. Hex.Socket Hd.Cap Screw, M6 x 35 _12.9 Clamp, Magneto Wire Hex Soc Head Screw M5 x 15 Plug, Crankshaft Hole O-Ring,Crankshaft Hole Plug Gasket, Magneto Cover Hex Socket Bolt M6x40_10.9 ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 38 10.1 Plate Clutch Pressure 10.2 Ball Bearing Radial 6902 10.3 Seat Spring Clutch Spring Clutch (Compression) 12 Plate Stopper 13 Bolt Flange M6 X 35 14 Nut M17 - Clutch Sleeve Hub 80Teeth 15 Belleville Washer ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 39 BALANCERSHAFT & CRANK TRAIN DESCRIPTION Crankshaft with Balancershaft Assembly Crank shaft with Primary gear sub assembly Balancershaft with Driven gear sub assembly 39 Teeth 19 Teeth Key Nos. 1 & 2 21 Teeth 39 Teeth ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 40 Spacer - Rocker Arm Intake 14 Rocker Arm Carrier, LH, Pt Mc Arm Comp, Valve Rocker Exhaust (Left-4v) Rocker Arm Carrier, RH, Pt Mc Spring - Exhaust Rocker LH Flanged Hexoganal Bolt M6 x 1 x 60 ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 41 18 Hollow Dowel (Od9 x 12) - Cover Cylinder Retainer, Valve Spring - 4v Stud - Exhaust Mounting Seat, Valve Spring - 4v 20 Temperature Sensor (EOT) 10 Cotter, Valve - 4v O-Ring, Temperature Sensor Seal, Valve Stem Oil - 4v ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 42 Ring, Piston Oil Hollow Dowel (Od13x18)-Cylinder Head Pin, Piston Cylinder Barrel, Complete Circlip, Piston Pin Gasket, Cylinder, Steel Conrod - Fracture Split, Assy. Piston - 4v Bolt, Conrod Ring, Piston 1st Bearing, Crankpin ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 43 FD Sprocket Comp - Engine (15 Teeth) Gear, Starter Idle Assy Tab Washer M20 - Engine Sprocket Lock Shaft - Starter Idle Gear No.2 (OD 12 X 18 Nut M20 - Engine Sprocket L58.5) ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 44 Belleville Washer Shim - Gear Shift Shaft Nut M17 - Clutch Sleeve Hub Circlip - Gear Shift Shaft Spacer - Primary Driven Gear Spring, Gear Shift Shaft Return Clutch Assembly (A & S Type) ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 45 Pipe Bypass Aluminuim Washer O-Ring, Pipe Bypass Gasket, Oil Pan Hex Soc Head Cap Screw - M6 X 12 Flanged Hexagonal Bolt M6x1x30 Strainer Comp, Engine Oil Washer / O Ring Oil pressure switch ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 46 Drive Shaft Assembly (Output) Bearing, Crankshaft (Black) Jet - Piston Bearing, Crankshaft (Brown) O-Ring-Piston Jet Bearing, Crankshaft (Yellow) Jet - Cylinder and Cylinder Head Balancershaft Complete O-Ring-Oil Jet Bearing, Balancershaft (Green) Bearing, Balancershaft (Black) ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 47 Shim - Gear shift shaft Fork, Gear Shift No.3 Spring - Gear shift shaft return Shaft - Gear Shift Fork Plate - Gear shift cam drive Spacer - Star index Spring - Gear shift cam drive plate ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 48 O-Ring, Oil Filler Plug Flanged Hexoganal Bolt M6 x 1 x 85 Hex Flange Bolt M8 x 1.25 x 80 Washer Hex Flange Bolt M8 x 1.25 x 105 Flanged Hexoganal Bolt M6x1 x 35 ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 49 O-Ring, Auto Chain Tensioner BREATHER BOX COVER & FD SPROCKET COVER DESCRIPTION QTY. Cover Comp, Breather Copper Washer Adapter Breather Pipe Gasket, Breather Cover Flanged Hexoganal Bolt M6x1 X 25 Cover Sprocket Hex Socket Bolt M6x50_10.9 ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 50 10 Gear 6th Drive (1st 26T, 2nd 16T) 25 Washer - 1st Driven Gear Gear 2nd Drive Thrust Washer 26 Bush 1st Gear Bearing (#6203LU)-Counter 27 Gear 1st Driven Comp (34T) 1 Shaft - LH ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 51 Copper Washer O Ring - Pipe Oil Cooler Bottom End Flange Bolt M6 X 20 Washer M16 Bolt Union Crank Case M16 X 1.5 Flanged Hex Bolt M6x1x27 Bush Grommet Hexagonal Nut M6 Grommet ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 52: Engine Dismantaling Process

     Lift the tappet cover, gently remove half round rubber tab from the cylinder head before taking out. 5. Spark plug RH & LH M10 Plug  Remove LH and RH side spark plugs. socket 16mm, L - rod ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 53  Remove Cover RH crankcase qty 14 nos. Allen key allen screws.  Gently actuate the clutch lever so that RH NOTE cover with gasket to come outwards. Please ensure to keep a tray under engine to collect oil spill. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 54  Use special tool Cam TDC aligning plate on RH side of cylinder head. Ensure properly seated on head surface v/s cam shaft end timing index grooves ref. photo. Cam TDC aligning plate special tool ST-30260/A ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 55  Rotate crankshaft slowly from LH cover 17MM socket side to get compression stroke on RH with tommy cylinder side.  Simultaneously insert special T tool from Special tool RH side as shown in photo. TDC Locator ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 56 & rocker shaft.  Pull out rocker shaft by using M6 suitable M6x1 bolt by holding Inlet roller type rocker threaded tool arm. / bolt  Similarly remove exhaust rocker arm. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 57  Remove "C" ring on LH side cylinder head. NOTE Incase of reuse  Cam chain can be holded or it will go & rest old sprocket, inside chain tunnel. please mark by marker pen on timing sprocket outer face. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 58  Remove MLS gasket and 2 dowel pins. Suitable plier if required for dowel pins  Remove cam chain long guide pad by lifting upwards from cylinder barrel seating slot. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 59  Remove 3 nos. flanged hex bolts (M6 x 35) 10mm Socket from clutch stopper plates, by & Rachet simultaneously loosing all three in sequence.  Remove clutch stopper plate, 3 clutch return springs as shown in photo. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 60 Special tool Clutch hub holder  Remove Bellevelle washer and steel plate washer on countershaft.  Remove clutch inner hub, clutch plates, clutch friction plates, judder clutch bellevele washer and big plate washer. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 61  Remove Clutch actuator spring, washer and oil seal. 10mm socket / Ratchet  Remove Clutch actuator E-clip and then Thrust washer as shown in photo. E-clip Thrust washer ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 62 (ACG) system 8mm long socket /  Remove stator mounting hex socket head T spanner cap screw (M6x35) qty. 3 nos. and pulser coil mounting hex socket head screw (M5x15) qty. 2 bolts. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 63 OD carefully, tighten the puller body first and then rotate the puller bolt, till magneto rotor comes out. 26. Starter double gear removal  Remove starter double with shaft as shown in photo. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 64  Total Qty. 33 bolts (16 nos. M8 bolts securing Crankshaft / Balancer shaft in Lower Crankcase + Qty. 8 nos. M8 bolts securing gear box assembly in Upper Crankcase and Qty. 9 nos. M6 bolts in Upper and Lower Crankcases. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 65  Remove cam chain Tensioner pad from the Upper crankcase.  Remove crankshaft from Upper crankcase alongwith cam chain. NOTE Please mark by marker pen on LH side of cam chain (incase reusing same old cam chain). ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 66 2 nos. by 5mm allen key.  Remove Countershaft sub assembly with gears from the Upper crankcase as shown in photo. 5 mm allen  Flow pattern of Counter shaft dismantling process 2, 6, 3, 4, 5, 1. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 67 - external circlip - 5th gear - blue thrust washer - bush - 1st gear - blue thrust washer. Pls store journal bearings properly stacked. Ref photo given below. Overlap Misalignment ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 68: Service / Wear Limits

    Camshaft Run Out Surface By thick straight edge and feeler gauge V-Block and dial gauge 650 TWIN New Min. New Min. New Max. New Max. 0.015 0.015 0.01 0.01 0.01 0.01 Service Limit Service Limit ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 69 (Inlet & Exhaust) To Check 650 TWIN Micrometer and bore gauge Inlet Qty. 4 guides Ex. Qty. 4 guides New Min. New Min. 5.000 5.000 New Max. New Max. 5.012 5.012 0.05 0.05 Service Limit ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 70 ID LH & RH 650 TWIN Screw gauge 650 TWIN Bore gauge Bore RH Bore LH New Min. 77.940 New Min. 78.000 77.940 78.000 New Max. 78.030 New Max. 77.970 77.970 78.030 Service Limit Service Limit ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 71 B. Second Ring Feeler gauge Micrometer 650 TWIN 650 TWIN B - Top 2 A - Top 1 New Min. New Min. 0.44 0.44 New Max. New Max. 0.55 0.55 Service Limit Service Limit ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 72 Out @ gear (GPD) Check Face Out Feeler gauge V-Block and Dial gauge 650 TWIN 650 TWIN New Min. 0.15 New Min. 0.15 New Max. New Max. 0.30 0.30 0.040 Service Limit Service Limit ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 73 Vernier caliper Journal 1 & 2 LH Journal 3 & 4 RH Thickness Bend / Warp New Min. New Min. 21.976 21.976 New Max. New Max. 22.000 22.000 < 2.7mm Service Limit Service Limit ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 74 Length guide pin OD Vernier caliper Screw gauge 650 TWIN 650 TWIN New Min. New Min. 5.900 5.900 5.900 49.43 New Max. New Max. 5.950 5.950 5.950 < 47.5 Service Limit Service Limit ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 75 Groove width Outer rotor to Oil pump housing clearance Vernier caliper Feeler gauge 650 TWIN 650 TWIN New Min. New Min. 6.050 0.05 New Max. 6.200 New Max. 0.185 0.25 Service Limit Service Limit ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 76: Torque Values - 650 Twin

    TORQUE VALUES - 650 TWIN PRE COAT FASTENERS ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 77 FASTENERS TIGHTENING DETAILS ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 78 ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 79: Engine Assembly Process

    M6 BOLTS (23 - 33) (M6 X 1.0) torque) Lubrication Across Flat 12mm Torque (In order shown 9 - 12 Nm in the below image) Expected final 55.2 to 59.3 Nm reference torque Across Flat Using 8mm socket ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 80 2.0 +0.08 574017 CYLINDER HEAD JET - OIL 575053 6 +0.01/-0.08 1.4 +0.08 574017 Transmission Upper Crankcase SIDE JET - PISTON JET - CYLINDER SIDE JET - PISTON (575098) JET - CYLINDER (575444) ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 81 J2 – A J3 – A  Incase of new journal bearings are fixing, J4 – B match the grade and index numbers / colours properly as per recommended chart index which is given below. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 82 Ø37 + 0.016 Black - 0.002 Brown - + 0.002 Yellow - + 0.006 + 0.008 575352 0.024L 575353 0.025L 575354 0.025L Code - 2 0.048L Code - 3 0.048L Code - 4 0.048L ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 83 & upper.  Assemble Timing chain tensioner pad into upper crankcase slot and ensure that both pegs are seated properly. NOTE Swing the chain tensioner pad and check for free movement. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 84  Try to mark as LH1 and LH2 for left marker pen on connecting rod journal. the back side of journal.  Whereas RH1 and RH2 for right connecting rod journal for easy reference. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 85 Ø41 + 0.016 Black - - 0.013 Brown - + 0.005 Yellow - + 0.005 + 0.009 575358 0.063L 575359 0.063L 575360 0.063L Code - 2 0.04L Code - 3 0.041L Code - 4 0.041L ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 86  If you found excess play beyond service limit, please replace connecting rod sub assembly with journal bearings. Specification 0.09 to 0.20mm  Rotate crankshaft freely on upper crankcase and check for axial play. Service limit - ----mm ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 87  Rotate Countershaft and Drive shaft sub on crankcase assembly, slide away gears and ensure top groove. neutral position.  Apply silicone adhesive over crankcase gasket seating area. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 88  Gear shift drum with bearing install carefully. Gear Shifter Drum NRB Installer Part No. ST-30270/A 5mm allen key  Assemble gear shift fork "1" index mark with fork shaft. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 89  Tighten qty. 2 nos. flanged hexagonal Torque 10 Nm/ bolt (M6x1x14) to specified torque. 1 kgf-m ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 90 Locking Bolt PART DESCRIPTION QTY. NUMBER HEX FLANGE BOLT 575464 M8 X 1.25 X 150 HEX FLANGE BOLT 575465 M8 X 1.25 X 80 HEX FLANGE BOLT 575070 M8 X 1.25 X 120 ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 91  Tighten the bolts to specified torque.  Locate and assemble qty. 6 Nos. flanged Hex bolts (M8) (a) on crankcase rear upper (b). Tighten just sufficiently in criss cross pattern. DO NOT TIGHTEN FULLY. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 92 Please ensure pump roller chain joint plate champered coloured link facing outwards. teeth side ’OUT’ marked  Locate flanged hex bolt (M6x1x20) (a) on facing outside. oil pump. DO NOT TIGHTEN FULLY. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 93 Torque 12 Nm / 1.2 kgf-m Magnetic Plug Assy. - Oil Drain Plug Apply Loctite 542 All Round 360 Flanged Hexagonal Pan, Oil in 1st Three Threads as shown. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 94 3rd Ring Top Rail End Gap.  Piston 3rd Ring Bottom Rail End Gap to be 180 apart from 3rd Ring Top Rail End Gap.  Piston Pin & One side circlip to be assembled. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 95 NOTE dowels. Used piston Dowel support plate Dowel for easy assembly piston. Piston Support Plate Part No. ST-27529-2  Compress piston rings with special tool (a). Piston ring compressor Part No: ST-30296/A ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 96 (b).  Ensure all valves are installed in their original position.  Insert valve spring on valve stem. Long coil pitch facing upwards.  Insert collar (a) above valve spring (b). ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 97  Locate cylinder head on dowel pins (a) coated, hence and fix into cylinder barrel. one time use  Locate new Bolt Cylinder Head M10 (a) 8 only. Nos on the cylinder head. 12 mm Socket with Ratchet ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 98 Lubrication – Apply oil – GL 80W90 –  to BOLT Threads and UNDER HEAD AREA of 1 to 22 BOLT Tightening of bolts done  in sequence as shown in the figure. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 99  Assemble FD sprocket (a) on Drive shaft (b).  Install splined washer into driveshaft.  Assemble FD Sprocket nut (M20) (a) on Drive shaft. NOTE Champered teeth of sprocket facing outwards. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 100 (b) and rotate anti-clockwise to lock the gear starter clutch into magneto rotor.  Locate magneto rotor (a) on crankshaft duly ensuring the slot in the rotor is positioned correctly on the woodruff key. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 101  Hold sprocket in position with one of the slotted holes facing on top. NOTE Incase of fixing old timing sprocket please ensure marked facing properly, otherwise it may lead to noise in operation / running condition. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 102 Ensure reference mark “R” aligned to the cylinder head.  Locate special tool (a) on camshaft RH. Ensure it is properly seated on cylinder head. Cam TDC Aligning Plate Part No: ST-30260/A ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 103 12 mm Socket specified torque. with Torque wrench Torque : 35 Nm /3.5 kgf-m  Locate and fit “C” washer (a) on camshaft and slowly rotate till lock seated properly in its grove. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 104  Locate new O-ring (b) and, assemble 10 mm Socket flanged Hex bolt (M6x1x6.5) (a) on chain with Ratchet tensioner body and tighten to specified torque. Torque 4 Nm/ 0.4 kgf-m ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 105 “ER”and “IR” into carrier “R” as cylinder head. explained in above carrier LH process.  Locate the special tool (a) in camshaft RH and ensure it is properly seated on camshaft. Cam TDC Aligning Plate Part No: ST-30260/A ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 106 Ratchet  Rotate magneto (a) clockwise and ensure reference mark “R” is aligned with cylinder head.  Ensure special tool (a) is located on camshaft RH. Cam TDC Aligning Plate Part No: ST-30260/A ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 107 0.18 mm  Loosen tappet screw lock nut (a) with tappet nut adjusting tool. NOTE Do not measure or Tappet Nut Adjusting Tool adjust tappet Part No: ST-27527-2 setting when engine is hot. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 108  Do not adjust tappet with high clearance as will result in noise and / or insufficient opening of the valves.  Remove screw driver and special tool after adjustment is complete. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 109  Locate the bolts on the cylinder head cover (c) and tighten bolts to cylinder head.  Tighten bolts (a) evenly to specified to 10 mm Socket torque. with Torque wrench Torque 12 Nm / 1.2 kgf-m ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 110  Locate dowel pins (a) and (b) into crankcase.  Install gasket (a) on crankcase if necessary smear engine oil and ensure it is properly seated on dowels. Do not use any sealant or adhesive. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 111 3 nos. flanged hex bolts (M6x35) equally to torque 8 to 12 Nm. NOTE Clutch hub holding special tool For tightening Part No. ST-30266/A / loosening of clutch lock nut use hub holding special tool ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 112 B in yellow part by jig. 2. Fix seat judder washer and then spring judder as a direction shown in correct method illustration. CORRECT METHOD WRONG METHOD Spring Seat Judder Judder > > ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 113 Pan, Oil Bolt (575569) bolt 3 nos. as per sequence shown NOTE in photo. Locate and tighten the hed socket bolt 13 nos. as per Cover Sprocket sequence shown in above photo. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 114  Assemble circlip (a) in the groove in clutch Circlip plier cover to lock the oil level window in place.  Ensure circlip is correctly locked in the clutch cover. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 115 RH cover and tighten it in criss cross socket with pattern. Ratchet  Tighten bolts evenly to specified torque. 5 mm Allen socket with Torque wrench Torque 12 Nm / 1.2 kgf-m ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 116 8 mm Socket with Ratchet &  Locate and install Qty. 2 Nos. flanged Hex Torque wrench bolts (M6x1x30) (b) on stator motor (a). Torque 10 Nm /1.0 kgf-m ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 117 Ratchet  Assemble magnetic drain plug (M14x1.25 and Torque x6g) (a) along with washer. wrench  Tighten drain plug (a) to specified Torque 15 Nm torque. / 1.5 kgf-m Magnetic drain plug ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 118 Ensure beed height & Width is minimum 3 x 2 mm Ensure middle of total width sealant have been dispensed. Box closing (All 16 Bolts) to be done within 10 Min from dispensing of sealant. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 119 Apply Silicone Lube in O Ring - All Round 360 Apply Silicone Lube in O Ring - Hexagonal Head Collar Bolt - GPS All Round 360 Apply Loctite 243 in Clutch cover lens ID 360 ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 120 2. Sealant to be applied minimum 10mm on both upper & lower of ‘T’ joint face. Apply SCRD 1015 3. Side covers to be assembled with in 5 min from dispensing of sealant. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 121 4. Add the chick washer and nut to the end of the upper front crankcase mount bolt - loose assemble the nut. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 122: Efi System

    Clutch Switch Sensor Switch Sensor ENGINE CONTROL UNIT Sec Air Starter Motor Canister Idle Air Fuel Pump Ignition Injector 02 Sensor Injection Mircro Relay Purge Valve Control Valve Relay Coil (Solenoid) Neutral LED ENGINE ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 123 Temperature Clutch Switch Engine Oil Sensor Temperature Sensor Injector O2 Sensor Front Wheel Speed Sensor Throttle Position Crank Position Canister Side Stand Oil Pressure Gear Position Sensor Sensor Switch Purge Valve Switch Sensor ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 124 2. Memory 3. Inputs 4. Outputs 5. Communication Links LH Coupler - Specifications Total No. of Pins - 112 pins 56 Pins Operating Voltage 9 to 16 V Operating Temperature -40°C to + 70°C ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 125 DUMMY SEAL DUMMY SEAL DUMMY SEAL DUMMY SEAL DUMMY SEAL DUMMY SEAL DUMMY SEAL DUMMY SEAL DUMMY SEAL DUMMY SEAL DUMMY SEAL DUMMY SEAL GR-W DUMMY SEAL DUMMY SEAL DUMMY SEAL DUMMY SEAL ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 126 Secondary Filter Poracity < 5 microns capacity Operating Pressure 350 + 2 kPa (3.5 bar) Outer Operating Temperature C to 80 Fuel Flow Rate 20 litre per hour (LPH) O-ring Inner dia O-ring Fuel Compatibility E20, E30 Petrol ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 127 It is mounted under the fuel tank on frame as shown in photo. Specifications Supply Voltage Pressure Range 10 to 115 kPa Temperature Range -40 to 130°C NOTE To see signal, check voltage across the pins 112 & 103. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 128 Sensor heating reduces the influence of the exhaust gas temperature on the sensor-ceramic temperature and therefore the temperature-dependent sensor. Reliable signals working temperature from 300 C to C maximum. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 129 Coupler Specifications Valve Normally Open Resistance 20 to 24 Ohms @ 20 to 30°C 1 – O, 2 – L Operating Voltage 10 to 14.5 V ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 130 1110.9 1276.3 60° 568.16 516.04 620.27 12. CLUTCH SWITCH Clutch switch gives information to the ECU about the clutch status i.e., engaged or disengaged with 2 - LG, 1 - B the gearbox. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 131 Voltage when vehicle is upright 0.36 to 1.5 V Voltage during a fall 3.75 to 4.35V 1 – Dummy, 2 – B Banking Angle 75 + 10 cutoff 3 – GRw, 4 – R/L Operating Temperature C to + 85 ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 132 Cl Side HO2S Heater Control Circuit Open P0030 3 DC O2 sensor heater 1 Cl Side HO2S Heater Control Circuit Low P0031 3 DC O2 sensor heater 1 Cl Side HO2S Heater Control Circuit High P0032 3 DC ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 133 Engine Oil Temperature Note : If the entry conditions are not met within 8 seconds, MIL Sensor Circuit Low 12 = 1- Long, 2 - Short will not blink and the process has to repeated. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 134 This is a safety feature to safeguard the starter motor, Relay solenoid and the starter sprag clutch. Starter Micro Relay Relay Starter RELAY STARTER CIRCUIT Battery Starter Switch Module RH +ve Cable Motor E-Start Kill Switch Switch ECU Connector 1 SP 24A ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 135: Emission System

    EVAP purge control valve for any approx. damage or crack. NOTE  EVAP purge control valve works with EMS commands based on engine speed and throttle conditions.  Basically purge valve works only in one direction. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 136 Fuel installation). cracked. leakage Check and replace the Hoses are dis- defective hoses. (Refer connected, cracked, EVAP purge control valve torn or pinched. removal and installation). ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 137: Fuel System

     Visually inspect fuel filter for any crack or damage. from pipe (b) by Replace if defective. pressing the lock button (c).  NOTE  Remove mud, dust or foreign material from the pipe and quick joint by blowing compressed air. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 138  Block the LH side throttle body Hose, Purge (Item 9). Breather to  Connect a hose to the fuel tank to evap hose to atmosphere allow a pressure to be applied. (Figure 1) ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 139 3. Drop less than 300 Pa over 5 minutes. Front spindle nut 70 Nm SAI solenoid mounting 2 Nm Temperature sensor 2 Nm Upper Frame Adjuster 3 Nm Swingarm Adjuster 3 Nm Lower Frame Adjuster 3 Nm ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 140 4. Rear Shock Valve - 2Nm absorber unit top mounts - 18 Nm 6. Swingarm Spindle 5. Rear spindle nut - 100 Nm nut - 70 Nm 7. Front spindle nut - 70 Nm ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 141: Front Wheel & Suspension

    Spring controlled feel. Outer tube Front fork pipe runout 0.2mm maximum. Hex socket button head screw  Front fork oil 465ml per lug Front fork main spring length 303 + 3mm.  ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 142 NOTE Thickness 4.5 mm service limit from the back of the  Inspect and replace spindle (1) if it has excess braking disc plate. wear, rust or bend. Floating disc runout 0.15mm max. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 143  If required adjust / wheel truving. Lower Yoke Surface Specification Axial Play / Runout 2mm (maximum) Radial Runout 2mm (maximum) Replace if runout cannot be achieved by adjusting / truving. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 144 Seal headstock Upper yoke STEERING BALL bearing Pinch Bolt RACES PLAY Tapper roller Lubricate at Every bearing cup service. Adjust the play at every 10,000 Km. Replace the races at every 40,000 Km. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 145 New RSU (Gabriel) Inverted Piggy 6 to 10 Bar Gas pressure back reservoir is maintained to give consistent damping. Infinite preload Progressive rate tapered adjustment bump stop to ensure smooth progression through RSU stroke. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 146: Rear Wheel

    Swing Arm Spacer - Disc Side Flanged Hex. Nut 8 x M1.25 Grease Seal Plate - Chain Adjuster Deep Groove Ball Bearing (Double Side Sealed) Chain Adjuster LH & RH Set Rear Wheel Assembly ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 147 Inspect and replace spindle (1) if it has excess wear,  rust or bend. Inspect tyre  condition and wheel rim for any damages or bend and replace if doesn’t meet the specification. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 148 Below images only for reference. Vehicle Mid Plane (81.79) Rear Nut M6 147.77 Number Plate Hex Nut M6 Rear Light Bracket, Rear Lamp Holder Front Wheel Rear Wheel Number Plate ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 149 4 Panel Fitting Screw - LH 1 BATTERY REMOVAL DESCRIPTION QTY. DESCRIPTION QTY. ‘O’ Ring Tool Kit Tray Pan Head Screw M6x12, Counter Hex Flanged Bolt M6x1x10 Bracket, Battery Strap Tool Kit Battery 12V - 12AH VRLA Battery Strap ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 150 The right hand lower fixing also mounts a bracket (a Hex Flange Bolt M6 different design is used for Conti. GT 650 and Pilot Lamp Screw Interceptor 650 models). A washer is not required at Hex Nut this position. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 151 Screw cable lock 23 Clutch lever Screw lock plate 24 Clutch cable 10 Throttle twin cable Front brake lever Mirror rear view RH Balancer mounting screw 14 Balancer Counter Weight Grip RH (Accelator / Throttle) ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 152 16 Hex socket head cap screw m6 x 16 Hex Socket Hd. Cap Screw, M6 X 20 17 Hex socket hd. cap screw, m6 x 20 Head Lamp Holder RH 18 Instrument cluster assembly Trafficator Assembly with Bulb-Front/RH ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 153: Instrument Cluster

    Fuel Signal Ground Battery +ve Tacho Ground Tacho Signal Neutral Wheel Ignition Speed Input Low Oil Pressure Turn Left / Right ABS MIL Not Used Turn Left / Right Not Used Hi Beam ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 154 Segment 4 62 + 2.5 68 + 2.5 Segment 3 75 + 2.5 83 + 3 Segment 2 97 + 3 103 + 3 Empty Segment Blinking Will 1 Blink start at >103 ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 155: Drive Chain Adjustment

    VIEW VIEW Flaring pin  Closed / Open wrench #17 (For holding Pressure  bolt head) Closed / Open wrench #27 (For holding Pressure  bolt holder head) Safety Goggles & Gloves  ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 156 Riveting operation of one pin is completed.  Follow the above steps and ensuring the holder in  right most position, rivet the 2 pin too. Now, riveting of the chain closing is completed.  ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 157 Measuring the distance from the swingarm pivot to the rear wheel spindle on both sides can help to ensure the Measurement wheel is adjusted evenly on both sides. Location ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 158: Engine Oil Pressure Checking Procedure

    8. Stop the engine and remove the oil pressure gauge and adapter. 9. Apply the liquid gasket (Refer TDL T4200526) to the thread of the NPT plug and tighten it. Oil Pressure Gauge ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 159: Abs System

    HOW ABS WORKS 1. Rider Pushes Brake Pedal 2. Piston Pushes Brake Fluid ABS Tell-tale Indicator 3. Brake Fluid squeezes brake pads onto brake disc. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 160 Air Gap Between Toner Ring and Wheel Speed Sensor 0.50 mm to 1.50 mm. Front Rear ABS Modulator located under the fuel tank sRFP sRFP Front W/C Rear W/C ABS Modulation 3. Full Pressure decrease ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 161 It is not possible to measure WSS_R 0.2V - 0.6V resistance of the wheel speed sensors as they are WSP_R 12V (Approx) active sensors. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 162 CAN Bus Off failure - Diagnosis is not possible U2922 Check for CAN lines connection. with tester when the failure is current CAN controller failure - Diagnosis is not U2921 Change ABS unit possible with tester in this case. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 163 <0.5mm then a shim must be added to the assembly. This should then be re-torqued once shim removal or addition is complete Rear WSS and the gap rechecked and confirmed. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 164: Control Cables

    “Fig 4-2 “. body inner spigot. Fig 2-2: Map sensor hose through grommet in cylinder head Grommet Hidden mount bracket for Clarity Fig 4-1: Purge hoses and T-joint ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 165 “Evap to T-joint” hose (red) routes back up to connect 4-8” and “Fig 4-10” ). A canister breather hose (white) to the purge valve, see “Fig 4-5” and “Fig 4-7”. is also installed to the canister “vent” port, and routed ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 166 ABS modulator, they are routed underneath the Conti. GT - 650 secondary air hose and guided by the ABS modulator ABS Hose Brake hose retaining bracket bracket as shown in “Fig 5-1 and Fig 5-2”. Bracket ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 167 “Fig 6-1-1” Fig 6-2-1: Front Brake Hose Headstock Interceptor - to “Fig 6-1-3” for Conti. GT - 650 and “Fig 6-2-1” to “Fig 650 Area 1 6-2-2” for Interceptor - 650. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 168 RH fork leg. Fig 1-1: Throttle cables from Fig 6-4: switch cube Front brake Omega Clip hoses to (PT.No.1 Conti. GT 650 Excess length to 48554) loop forwards here modulator ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 169 Conti. GT 650 it passes above the front brake hose (see “Fig 2-3”), but on Interceptor 650 it passes below the front brake hose (see “Fig 2-4”). Fig 1-4: Throttle cables path to throttle bodies ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 170 “Fig 2-9”. Fig 2-6: Clutch cable routing to Fig 2-9: Clutch cable to engine fixing RHS of headstock - Interceptor 650 The cables should be sufficiently secured and be presentable as such. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 171 “Fig 1-2” and “Fig 1-3”. A Zip tie cable tie is used for a second securing location to the LH seat rail, immediately behind the cylinder head bracket, as shown in “Fig 1-3”. Fig 1-5: Front Harness Bracket ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 172 Fig 2-3: ABS 18 Pin Connector Cable tie fir tree  This ABS connector locates into the ABS clips modulator. Zip tie Fig 1-8: Rear Harness Constraints Fig 2-4-1/2: Ignition coil RHS ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 173  The wheel speed sensor connects to the main harness as shown.  The sensor connector is mounted to the ABS bracket shown in “Fig 2-5-2”, and the connector from the harness connects to this. Fig 2-10: Injector Connector, RHS ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 174  The air control valve is located between the seat  The idle speed sensor connector is forms part of bracket and the fuel pump, the connection is the intersection mentioned in “Fig 2-10”. routed directly to the harness. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 175  The rear wheel speed sensor is mounted on the brake caliper bracket. Fig 2-20:  Its cable runs along the length of the RHS Fuse Box swingarm, clipped to the ABS hose. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 176  The side stand switch connector is fixed to a connect to the main harness, and is located on the bracket mounted to the rear of the upper RHS of the motorcycle next to the ECU. crankcase as shown in “Fig 2-28-2”. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 177  This connector is also mounted to the regulator/ the rear mudguard, and travels the length of the rectifier bracket shown in “Fig 2-30-2” above. mudguard. It is located by one cable tie and two ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 178 RH side of the headlamp bowl, as shown in “Fig 4-1” below: Fig 4-1: Right side fly leads Fig 4-4: Left side switch cube and clutch switch cables ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 179 These are connected in the headlamp bowl, and the wire-guide installed to help retain these connectors to the outer edges - this prevents them obstructing installation of the headlamp. Fig 5-1: Wire-guide, Headlamp ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 180: Periodical Maintenance Chart

    If in case the motorcycle is used frequently in very dusty environment / severe climatic conditions / Poor Roads / stagnant water etc., the maintenance will need to be done earlier as may be required. Contact a nearest Royal Enfield Authorised Dealer / Service Center to carry out the periodical maintenance and for any expert advice. PAID SERVICE...
  • Page 181: (Valve Clearance)

    – 0.08 mm Exhaust – 0.18 mm Cam TDC Aligning Tool Lock the Cam Shaft (RH side) Slot using special tool  - Cam TDC aligning plate (Fig 1.2) Fig 1.2 Tappet Nut Adjusting Tool ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 182 Tappet Screw to check by the feeler Gauge and adjust the Valve Tappet nut to its specified tightening torque 8 - 10 Nm. Valve Clearance Specification  Intake 0.08 mm Insert Exhaust 0.18 mm Feeler Gauge ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 183 Primary resistance 2.0 Ohms + 10% Secondary resistance 13.5 K-Ohms + 105 HT LEAD FOR CRACKS Tappet Maintenance Schedule : Replace at every 40,000 Km Spring Loaded Inspect for cracks at Every service.  ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 184: Fuse Identification List

    This is inner side to outer side air flow type – while  cleaning blow the compressed air from outer dia SP-01 to inner dia. Inspect the sealing ring for damage – if found  replace the filter element. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 185 - Head light stay to Steering bottom yoke – 58.65 mm the Arrow as reference towards fuel flow. Not to use any sharp tool to remove or fix the quick - Fork Top to Yoke – 10 mm gap  connecters. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 186: Clutch Lever Play Checking & Adjustment

    Use the adjuster provided in the clutch lever for  finer adjustment. If proper freeplay can’t be obtained or the clutch  slips during test drive disassemble and inspect the Image B clutch. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 187 MICRO RELAYS LAYOUT S.No. Description Qty. Flasher Relay Main Relay Pump Relay Accessories Relay Starter Relay ACCESSORY RELAY CIRCUIT Accessory Relay Accessory Coupler Connector 2 SP - 04 Fuse Box – Fuse 7 ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 188: Compression Test Process

    Specified engine compression pressure - 170 - 185  Also check for smoky exhaust problem. PSI. Repeat the same above process for RH Engine Recommended tool - Pressure gauge range 50 -  compression test. 300 PSI. ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 189: All Wiring Diagrams

    WIRING DIAGRAM WIRING HARNESS - LIGHTING SYSTEM WIRING HARNESS - CHARGING SYSTEM ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 190 WIRING HARNESS - ABS MODULATOR DOL Connector ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 191 WIRING HARNESS - HORN SYSTEM ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 192 COMPLETE WIRING DIAGRAM - CONTI.GT 650 & INTERCEPTOR 650 ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 193 WIRING HARNESS - SIGNALLING SYSTEM ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 194 WIRING HARNESS - ES STARTING SYSTEM ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 195 WIRING HARNESS - EFI SYSTEM (IGNITION) ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 196 NOTES ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...
  • Page 197 NOTES ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL...

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