Royal Enfield Interceptor 650 2018 Installationsanleitung

650 TWIN SERVICE

TRAINING MANUAL

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 1

INTERCEPTOR 650 / CONTINENTAL GT 650 TWIN

SERVICE TRAINING MANUAL

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 01

Part No. TA00060 / Revision 2.0 / Qty. 1000 / TRAB / Sep. 2018

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL

Name : ..................................................................................................................................

Address : .............................................................................................................................

..................................................................................................................................................

Contact Phone No. : ....................................... Mobile : ........................................................

E-mail : ..................................................................................................................................

D.L. No. : ....................................................................Renewal Due : .....................................

In emergency Contact Mr. ...................................................................................................

Insurance Policy No. : .........................Amount Rs. ........................ Premium Due Dt : ...............

Vehicle Registration No. ..................................................... Make : .....................................

Vehicle Insurance No........................Amount Rs. ............... Renewal Due Dt : ..............

Passport No. : ....................................................................... Validity : ......................................

Blood Group : ....................................................Specs Lense L/R : ........................................

Alergic Medicines : ............................................................................................................

Height : .............................. Weight : ........................... On Date :........................................

PERSONAL INFORMATION

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 3

1 Technical Specification .................................... 4

2 General Vehicle Information .......................... 7

3 Salient Technical Features............................... 8

4 Power Flow

a) Power Flow - Piston to Rear Wheel............ 14

b) Power flow in Electric start ....................... 14

c) Gear box (transmission) power flow .........15

d) 6 Speed Transmission ............................... 16

5 Oil lubrication ................................................. 17

6 Single Over Head Cam Shaft Mechanism ...... 22

7 Assist and slipper clutch ................................ 22

8 Valve timing ................................................... 24

9 Screw type silent cam chain tensioner .......... 24

10 Engine Overhauling ....................................... 25

11 Engine Job List .............................................. 25

12 Special Tools Application

(ENGINE & VEHICLE)..................................... 26

13 Dismounting Engine from the Frame ............. 31

14 Engine Mounting into frame ......................... 35

15 Engine Exploded Views................................. 36

16 Engine dismantaling process ......................... 51

CONTENTS

SL.NO. DESCRIPTION PG.NO. SL.NO. DESCRIPTION PG.NO.

17 Service / Wear Limits...................................... 67

18 Torque Values - 650 Twin .............................. 75

19 Engine Assembly Process ............................. 78

20 EFI system..................................................... 121

21 Emission System.......................................... 134

22 Fuel System .................................................. 136

23 Front Wheel & Suspension .......................... 140

24 Rear Wheel ................................................... 145

25 Instrument Cluster ....................................... 152

26 Drive Chain Adjustment .............................. 154

27 Engine Oil Pressure Checking Procedure .... 156

28 ABS system .................................................. 158

29 Control Cables ............................................. 163

30 Periodical Maintenance Chart ..................... 179

31 Tappet Checking / Adjustment

(Valve Clearance)......................................... 180

32 Fuse Identification List ................................ 183

33 Clutch Lever Play Checking & Adjustment .. 185

34 Compression test process ........................... 187

35 All Wiring Diagrams...................................... 188

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 03

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL

TECHNICAL SPECIFICATIONS

ITEM CONTI. GT 650 TWIN INTERCEPTOR 650 TWIN

A. ENGINE

1 Type 4 Stroke, Parallel twin Cylinder, SOHC Air cooled

2 Bore 78 mm

3 Stroke 67.8 mm

4 Displacement 648 cc

5 Compression ratio 9.5 : 1

6 Max Power @ RPM 47 BHP @ 7250 RPM (34.9 KW)

7 Max Torque @ RPM 52.3 Nm @ 5150 RPM

8 Idle RPM 1200 + 80 RPM

9 Starting Electric Start

10 Air filter element Paper element

11 Lubrication Forced Lubrication, Wet Sump with pump driver oil delivery

Engine oil capacity

(1st Dry fill) 3.9 litres

Engine oil capacity

(Routine Oil change 3.1 litres

with filter)

13 Engine oil grade SAE 10W 50, SL Grade, fully synthetic oil

14 Cooling Air Cooled with Oil Cooler

B. TRANSMISSION

1 Clutch Wet Multiplate (7 Plates), Assist & Slipper clutch

2 Primary drive Gear

3 Primary ratio 2.05: 1 (80T / 39T)

4 Gear box 6 Speed Constant Mesh

5 Gear Ratios

1st Gear 2.615 : 1 (34T / 13T)

2nd Gear 1.813 : 1 (29T / 16T)

3rd Gear 1.429 : 1 (30T / 21T)

4th Gear 1.190 : 1 (25T / 21T)

5th Gear 1.040 : 1 (26T / 25T)

6th Gear 0.962:1 (25T / 26T)

6 Secondary drive Sprockets & Close Chain (5/8” Pitch) 100 links

7 Secondary ratio 2.533 : 1 (15 / 38)T

C. FUEL

1 Fuel Petrol, upto E10 minimum octane number 91 RON

2 Induction New EFI sytem - Bosch

3 Fuel Tank Capacity 12.5 Liters*** 13.7 Liters***

4 Low fuel warning 2.9 Liters***

5 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 5

ITEM CONTI. GT 650 TWIN INTERCEPTOR 650 TWIN

D. IGNITION Digital spark ignition

1 Ignition Advance 11.25 degree BTDC

2 Spark plug Bosch - UR5CC

3 Spark plug gap 0.70 - 0.80 mm

E. ELECTRICALS

1 System 12V - DC

2 Generation Alternator (ACG)

3 Alternator Output 156watt @ 1100rpm

4 Battery 12V, 12AH VRLA

5 Starter Motor 0.8Kw

6 Head lamp 55/60w, H4 Halogen Bulb

7 Position lamp T4w Halogen bulb

8 Brake / Tail lamp P21/5W Halogen bulb

9 Turn Signal 12V, R10w Halogen bulb

10 Horn

12V, 320 Hz low & 420 Hz High

F. CHASSIS AND SUSPENSION

1 Frame Steel Tubular, Double cradle frame

2 Front Suspension 41mm dia front fork, 110 mm travel

3 Front Fork Oil 2W 25 Grade, 474 + 3cc per lug

4 Rear Suspension Twin, Coil-over shocks, 87.5mm travel

G. BRAKES & TYRES

1 Front Tyre 100 / 90 - 18” M/C 56H

2 Rear Tyre 130 / 70 - 18” M/C 63H

3 Tyre pressure front Solo / Pillion 32 PSI

4 Tyre pressure Rear Solo 36 PSI, Pillion 39PSI

5 Front Wheel rim size J18M/C-MT2.50

6 Rear Wheel rim size J18M/C-MT3.50

7 ABS Brakes Bosch (9.1M), Dual Channel

8 Front Brake 320 mm floating disc. ABS

9 Rear Brake 240 mm disc. ABS

10 Brake Fluid grade DOT 4 or above

11 Brake Fluid capacity Front: ....... ml + Rear: ........ ml = 125ml

WARNING

Using bulbs / other

electrical gadgets other

than specified rating may

lead to over loading / erratic

behavior / premature

failure of electrical system.

Modifications on the bike

which are not approved by

Royal Enfield may not only

disqualify for warranty, but

also affects performance of

the bike.

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 05

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL

ITEM CONTI. GT 650 TWIN INTERCEPTOR 650 TWIN

VEHICLE OVERALL DIMENSIONS

All Dimensions are in ‘mm’

>< L = 2122 mm

< >

WB = 1398 mm

TH = 1120 mm

SH = 804 mm

TOP VIEWSIDE VIEW

NOTE

1. Above Values / Dimensions are given for your guidelines / reference only.

2. In view of continuous improvements, specifications are likely to change without notice.

TW = 833mm

H. DIMENSIONS

1 Rake (Caster Angle) 24 degrees

2 Total Length (L) 2122 mm 2119mm

3 Total Height (H) 1067 mm 1120 mm

4 Width (W) 789 mm 744 mm

5 Total Width (TW) 833mm with mirrors 857mm with mirrors

6 Ground Clearance (GC) 174 mm

7 Wheel Base (WB) 1398mm

8 Seat Height (SH) 804 mm

9 Kerb Weight

(90 % fuel & Oil) 208 kgs 213 kgs

10 Max Payload 200 kgs (inclusive of rider mass)

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 7

GENERAL VEHICLE INFORMATION

CHASSIS NO. ENGINE NO. BATTERY NO. (12V - 12AH)

The engine number is punched on the left hand side Crankcase - below the

Cylinder barrel. It is the means of identification of the Engine and its production

ENGINE NUMBER - DETAILS

The VIN is a 17 digit number punched on the right side of Steering head

tube.

VEHICLE IDENTIFICATION NUMBER - DETAILS

*Thiruvottiyur (Chennai) Plant Code “0” *Oragadam (Kanchipuram) Plant Code “1” *Vallam Vadangal Plant Code “2”

M E 3 X X X X X X X X 000001

Engine Family Name

Engine Capacity

Type of Cooling

Type of Transmission

Type of Fuel System

Month of Manufacturing

Year of Manufacturing

Place of Manufacturing*

Production running Sl. No.

(H-2017, J-2018, K-2019, L-2020)

(A-Jan., H-Aug., K-Sep., N-Dec.,)

(0-TVT, 1-ORG, 2-Vallam)

(F - Fuel Injector)

(6 - 6 Speed)

(A - Air Cooled)

(7 - 648cc)

(P - P Engine)

Engine Family Name

Engine Capacity

Type of Cooling

Type of Transmission

Type of Fuel Feed

Month of Manufacturing

Year of Manufacturing

Place of Manufacturing*

Production running Sl. No.

X X X X X X X X 000001

(P - P1, Parallel Twin Cylinder Engine)

(7 - 648cc)

(A-Air cooled)

(6 - 6 Speed)

(F-Fuel Injection-EFI)

(0-TVT, 1-ORG, 2-Vallam)

(H-2017, J-2018, K-2019, L-2020)

(A-Jan., H-Aug., K-Sep., N-Dec.,)

P1 - 648

WMI – World Manufacturer

Identifier Royal Enfield Code

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 07

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL

SPECIFIC FEATURES

Twin

pipes

650 Twin Engine parallel construction

Cooling fins

Separate

Sprocket

cover

emulates

classic

gearbox

RE Branding

Double

skin

headers

prevent

chrome

discolouration

Clean, elegant forms Classic finishes

Single Idler gear starting system (Reduction ratio 29.58 : 1)

Self starter motor - solenoid relay with micro relay

controled by ECU

Common Tappet cover and its Gasket for both engines

Top Cover

Rubber Gasket

Mounting

Bolts Tappet cover

Meteor

Style Cover

Separate

‘Gear box’

Style

Sprocket

Cover

Idler gear

(52T / 14T)

Starter Motor Pinion (9T)

Driven

gear (73T)

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 9

Return spring

Rocker arms - V type

SOHC Single over head camshaft for both engines,

Silent cam chain heavy duty lacing 5 + 4 plates with rivet system.

Roller type rocker arms - V type

construction.

Inlet & exhaust both rocker

arms loaded with return spring.

Tappet screw with elephant shoes construction

Elephant shoe

4 valves (2 Inlet + 2 Exhaust) per engine = Total 8 valves

Exhaust Valve

Inlet Valve

Piston with Moly coating Exhaust

Side

‘EX’ index

mark

Connecting rod split type with journal bearing construction -

laser fracture cut used

Laser cut method

Moly

coating

ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 09

Return spring

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