Engine Overhauling; Engine Job List - Royal Enfield INTERCEPTOR 650 2018 Service Training Manual

ENGINE OVERHAULING

A. ENGINE JOB LIST
SERVICING POSSIBLE WITHOUT
DISMANTLING ENGINE FROM FRAME
S.No. Description
1 Inlet & Exhaust Tappet adjustments.
2 Cam shaft assembly, silent chain long guide
pad & Auto chain Tensioner replacement.
3 Cylinder Head assembly, rockers arms,
rocker shaft, rocker arm spring, rocker
bearing top cover replacement.
4 Cylinder Barrel, Piston & Rings replacement.
5 Clutch assembly overhauling.
6 Oil pump assembly replacement.
7 Gearbox foot control mechanism
overhauling.
8 Magneto Stator / Rotor Assembly
replacement.
9 Sprag bearing assembly replacement.
10 Self-starter Motor, starter double gear
replacement.
11 Final Drive sprocket / gear shift shaft oil seals
replacement.
12 Gear Operator forks / Gear Selector Drum
Replacement.
13 Oil strainer replacement.
14 Oil filter catridge or oil cooler assembly
replacement.
SERVICING / OVERHAULING FOR WHICH
ENGINE HAS TO BE REMOVED FROM FRAME
S.No. Description
1 Crankcase Upper and Lower crancase
Replacement.
2 Connecting rod or its journal bearing
Replacement.
3 Crankshaft / Balancershaft / Drive Shaft /
Counter Shaft / Gears replacement.
4 Crankcase journal bearings / ball bearings
Replacement.
5 Silent Timing chain, cam chain short
tensioner pad replacement.
CASTROL GL 80W90 GRADE OIL HAVE TO
APPLY WHILE ASSEMBLY THE BELOW LIST OF
PARTS TO ENGINE
S.No. Description
1 Cam shaft
2 Rocker arm shaft
3 Valve stem
4 Piton
5 Barrel
6 Gudgeon pin
7 Big end journal bearings
8 Crank journal bearings
9 Balancer journal bearings
10 Gear box
11 One way clutch (Ring gear ID & OD)
12 Idle gear shaft
13 Clutch operating shaft
14 Con Rod Bolts
15 Cylinder head mounting bolts
16 Crankcase box closing bolts
17 Selector fork shaft
18 Cam drum
19 GPS O-ring
20 By pass pipe O-ring
21 Oil filter Gasket
22 Starter motor Assly.
ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL
25