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Royal Enfield CONTINENTAL GT 650 TWIN 2018, Service Training Manual

The Royal Enfield CONTINENTAL GT 650 TWIN 2018 is a powerful and stylish motorcycle with a classic design. For those looking to maintain and service this exceptional bike, the Service Training Manual is a must-have resource. Download this manual for free at manualshive.com to unleash the full potential of your ride.

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ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL

14

Slipper

Clutch Hub

FD Sprocket (15T)

POWER FLOW IN ELECTRIC START

650 TWIN

Self Motor

Drive Pinion

Double Gear

Big / Small

Sprag Clutch

Gear Driven

Sprag Clutch

Bearing

Magneto Rotor

Key / Crank Shaft

Connecting Rod

LH & RH

Piston Assembly

LH & RH

POWER FLOW FROM PISTON TO REAR WHEEL

POWER FLOW 650 TWIN

Connecting Rod LH / RH

Crank Shaft Assembly

Primary Drive (Fixed) Gear

Driven Gear / Clutch Drum

Slipper Clutch Steel Plate

Drive Shaft / Gears

Front Drive (FD) Sprocket

(15T)

Rear Drive Close Chain

Rear Sprocket (38T) /

Adopter

Cush Drive (Jerk) Rubbers

Rear Hub/Wheel Assembly

Slipper Clutch Hub

Clutch Judder Washer /

Judder Spring

Clutch Metal Plate

Clutch Friction Plate ‘B’

Clutch Hub

Piston Assembly LH / RH

Counter Shaft  / Gear

Clutch Metal Plate

Slipper Clutch Friction

Plate  ‘B’

Slipper Clutch Steel Plate ‘B’

Clutch Friction Plate

Driven Gear /

Clutch Drum

Primary

Drive Gear

Crankshaft Assly.

Connecting Rod

Piston Assembly

Summary of Contents for CONTINENTAL GT 650 TWIN 2018

Page 1: ...650 TWIN SERVICE TRAINING MANUAL ...

Page 2: ...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 ...

Page 3: ...ntact Mr Insurance Policy No Amount Rs PremiumDueDt Insurance Policy No Amount Rs PremiumDueDt 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 02 ...

Page 4: ... 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 Adju...

Page 5: ...ade fullysyntheticoil 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 Spr...

Page 6: ...t 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 C56H 2 Rear Tyre 130 70 18 M C63H 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 RearWheelrimsize J18M C MT3 50 7 ABS Brakes Bosch 9 1M Dual Channel 8 Front Brake 320 mm floating disc AB...

Page 7: ...w of continuous improvements specifications are likely to change without notice TW 833mm H DIMENSIONS 1 Rake Caster Angle 24 degrees 2 Total Length L 2122mm 2119mm 3 Total Height H 1067mm 1120 mm 4 Width W 789mm 744mm 5 Total Width TW 833mm with mirrors 857mm with mirrors 6 Ground Clearance GC 174mm 7 Wheel Base WB 1398mm 8 Seat Height SH 804mm 9 Kerb Weight 90 fuel Oil 208 kgs 213 kgs 10 Max Payl...

Page 8: ...apacity 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 Manufacturin...

Page 9: ...ion 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 ENFIEL...

Page 10: ...uction 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 ...

Page 11: ...ar Incase of excessive pressure 5bar pumped oil will flow from pump outlet to oil sump through PRV as shown in photo Oil Pressure gauge Value 4 5 0 5 Bar 4000RPM and 80 C at EOT sensor New type gear position sensor GPS all 6 gear positions are mapped with ECU including neutral position Crankcases horizontal split type construction Crankshaft and Balancershaft journal bearings construction Cranksha...

Page 12: ...st of Idle Air controller purge port connector map sensor connector injectors mounted on above throttle body Map sensor common for both engine mounted on Frame under fuel tank taken input from LH side engine T Pipe Secondary Air Injection Common Pipe Fuel line for injectors Read Valve Re designed cockpit Sculptural top yoke Clip ons handle bar Jewel like branding Common Rail System Recreation of t...

Page 13: ... brake Front and Rear Dual channel system Front Master Cylinder Assembly Rear Master Cylinder Assembly ABS Modulator Front Caliper Assembly Rear Caliper Assembly MC1 Front MasterCylinder Circuit MC2 RearMaster Cylinder Circuit F Front Caliper Circuit R RearCaliper Circuit 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 ...

Page 14: ...or ABS disc brake Front wheel construction straight stainless steel spokes brass nipples Qty 36 nos New design hub integrated with adaptor disc Nitrogen Gas filled Rear Shock absorber inverted type damper with 6 steps adjustable spring loading type 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 ...

Page 15: ...haft Assembly Primary Drive Fixed Gear Driven Gear Clutch Drum Slipper Clutch Steel Plate Drive Shaft Gears Front Drive FD Sprocket 15T Rear Drive Close Chain Rear Sprocket 38T Adopter Cush Drive Jerk Rubbers Rear Hub Wheel Assembly Slipper Clutch Hub Clutch Judder Washer Judder Spring Clutch Metal Plate Clutch Friction Plate B Clutch Hub Piston Assembly LH RH Counter Shaft Gear Clutch Metal Plate...

Page 16: ...EAR RATIO 1 19 1 5THGEAR 26T 25T GEAR RATIO 1 04 1 6THGEAR 25T 26T GEAR RATIO 0 96 1 Positive Power Flow C S 1st D S 1st 5th Gear FD Sprocket Positive Power Flow D S 2nd D S 6th C S 2nd FD Sprocket Positive Power Flow Positive Power Flow Positive Power Flow Positive Power Flow Counter Shaft Drive Shaft 1st Gear 2nd Gear 3rd 4th Double Gear 5th Gear 6th Gear 1st Gear 2nd Gear 6th Gear 4thGear 3rd G...

Page 17: ...m Crank Shaft to Counter Shaft Via Clutch Assembly as shown in following illustrations 2NDGEAR 4THGEAR 6THGEAR 1ST GEAR 3RD GEAR 5THGEAR Output Input Input Output Output Input Input Output Input Output Input Output Input Output 6 SPEED TRANSMISSION NEUTRAL POSITION ...

Page 18: ...age Crankcase 9 Balancer Bearing 9 Two Oil Jets to Piston 9 Crank Bearing 14 Cylinder Barrel Circuit 15 Temperature Sensor 16 Camshaft 17 Rocker Arm Shaft 18 2 Oil Jets for Spark Plug Horizontal Running Oil 3 Oil Pump Exhaust Port 1 Oil Pan Main Oil Gallery Oil Pan Strainer C C L Oil Pump C C L Oil Cooler Oil Filter Main Oil Gallery Balancer Shaft Oil Passage C C Lower Crank Shaft Oil Passage C C ...

Page 19: ...amRoller Lobe EX Elephant Leg Valve Stem Elephant Leg Valve Stem Rocker Shaft EX Rocker Arm IN Elephant Leg Valve Stem Elephant Leg Valve Stem EX 7 Oil Passage Crank Case Lower to Upper Cylinder Oil Pan Spark Plug Boss Timing Chain Tensioner Pad Long Short RH Head bottom grove RH MLS Gasket Hole RH Cylinder Top grove LH Head bottom grove LH MLS Gasket Hole LH Cylinder Top grove Spark Plug Boss Ret...

Page 20: ...OIL Oil passage to spray engine oil to Stator Coils Pictorial View Section View OilHole to Gear Starter Clutch Oil Passage to Magneto Assy Oil Hole to Crank pin Journal Dia Crankshaft comp to Connecting Rod Oil Hole Section View Journal Bearing Area OIL PRESSURE STANDARD Oil Pressure Gauge Value 4 5 0 5 Bar 4000RPM and 80 C at EOT sensor ...

Page 21: ...agneto Cover Engine Breather Circuit Crankcase Box Assembly Air Oil Mixture Blow by gas vapor Crankcase RH Rear Side Clutch Cover Breather Ribs passage HOT AIR Oil Air Filter Box Assembly Breather collector box Excess condensed oil return back to breather passage Breather Oil Return Passage crankcase upper Breather Oil Return Passage crankcase lower Oil Relief C C Lower Oil pan Paper Gasket Hole O...

Page 22: ...n gallery Towards Air Filter Box Creankcase upper Side View Side View CONTROL CABLES Clutch Cable Clutch Cable Adjuster THROTTLE TWIN CABLES Rubber Grommet Clutch inner Cable Inner Lock Nut Outer Lock Nut Throttle Cable Acceleration Rotor Plate Pan Head Screw M5x10 Switch Modular Screw RHSwitch Module Bottom RHSwitch Module Top Throttle Cable Deceleration CLUTCH CABLE Paper gasket hole ...

Page 23: ...SLIPPER CLUTCH Assist Slipper Clutch Assist Function Slipper Function Total 4 inlet valve 2 2 4 Exhaust valve 2 2 Single Over Head Camshaft SOHC for both Cylinders Exhaust valve Inlet valve Exhaust bend Pipe Roller type Rocker arms Single valve spring Progressive type Common rail pipe for secondary air injection to exhaust ports Onetime usable TRAX bolts ...

Page 24: ...wheel Engine output Pressure Plate Clutch center cam on the side that transmits the engine torque Clutch center cam on the rear wheel side that receives torque Assist Cam When decelerating Torque fromrear wheel Engine output Pressure Plate Slipper cam This type of clutch has two bases where the first one transmits power when engaged normally and the othersecondarysplinedhubengageswhentheclutch sen...

Page 25: ...thread 0 1mm pitch Torsion Spring Washer O ring Stopper Tensioner Assembly DISASSEMBLY PROCEDURE FOR SERVICE 1 During service condition of Engine servicing person needs to wound the Spring by rotating screw clockwise through upper aperture hole by means of Screw driver or similar tools until its rotation gets stopped while assembling the tensioner to vehicle 2 After assembly tensioner will automat...

Page 26: ...LIST SERVICING POSSIBLE WITHOUT DISMANTLINGENGINEFROMFRAME SERVICING OVERHAULING FOR WHICH ENGINEHASTOBEREMOVEDFROMFRAME S No Description 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 ch...

Page 27: ...RB installer ST 30298 A ST 30299 A Head Stock Bearing Puller Assembly Head Stock Frame Cone Installer ST 30272 A ST 30273 A To remove tapper needle roller bearing race from steering head tube To install tapper needle roller bearing race to steering head tube on top side and bottom To assemble tapper roller bearing on steering T stem tube To dismantle tighten frame adjuster 4 lug check nut for engi...

Page 28: ...bush and fork oil seal into front fork bottom case ST 26485 3 SPECIAL TOOLS COMMON Frame Adjuster ODØ 21 5 x IDØ 18S Arm ST 30269 A To assemble or removing frame adjuster 4 lug nut from swingarm mounting Frame adjuster check nut To check failures diagnoise the sensor of ABS EFI system DOL Tool NACS II Part No 6000003 Swingarm needle bearing extractor To remove Swingarm needle bearings ST 25244 4 A...

Page 29: ... dismantling and assembling SPECIAL TOOLS ENGINE Magneto Puller Assembly Cam TDC Aligning Plate Application To remove magneto rotor from crankshaft LH side ST 30260 A ST 30274 A Valve Spring Compressor Tool Common ST 27528 2 ST 27533 2 Application To compress the valve spring while removal and fitting of valve To align valve timing confirmation of camshaft position at LH RH valve train Application...

Page 30: ...Tool Crank ST 30300 A For locating TDC position of LH Piston insert TDC locking tool in crankcase hole towards crankshaft web To install bottom needle bearing on clutch activating lever hole To install Top side needle bearing on clutch activating lever hole To install oil seal on top side clutch activating lever hole To remove topside needle bearing from clutch activating lever hole Piston Ring Co...

Page 31: ...r ST 30259 A Gear Shifter Drum NRB Installer ST 30270 A Gear Shifter Shaft NRB Oil Seal Installer ST 30271 A Adaptor is to be connected along with compresion tester to check compression pressure To install gear shifter shaft needle roller bearing oil seal on lower crankcase To install the needle roller bearing a of gear shifter drum b in lower crankcase a b Angular Torque Wrench Finally tightening...

Page 32: ...l Usage Precautions Photos 3 Seat Fuel tank EnsureignitionswitchisinOFFcondition Remove side RH cover and pull out seat unlock knob to take out rider seat Remove Fuel tank mounting 2 bolts 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 ...

Page 33: ...air injection valve SAI solenoid outlet pipe connection Remove SAI solenoid mounting top allen key bolts on the top side of air filter body Pull out gently solenoid value from air filter box Remove another end of SAI pipe from cylinder heads common rail of exhaust side 6 Exhaust system Remove LH and RH Hego O2 sensor wiring coupler from wiring harness Remove LH and RH exhaust pipe with silencer as...

Page 34: ...tor cables connection from throttle pulley after removing the RH side cover 12 Drive chain Loosen the rear wheel spindle nut and drive chain adjusters 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 Fastener Size Tool Usage Precautions Photos 7 Connector...

Page 35: ... OPS coupler and RR Unit coupler Fastener Size Tool Usage Precautions Photos 13 LH RH cradles Remove the top and bottom allen bolts mounting engine front bolts on the LH andRHcradleframestothemainframeat the front rear and centre after suitably supporting the engine at the bottom Remove all the bolts nuts mounting engine to LH and RH cradle frames Aggregate to Dismantle Instructions NOTE Engine Mo...

Page 36: ...in frame torque 50 Nm 25 Nm allen bolts 7 8A Connect wire terminal to oil pressure switch 8B Assemble gear shift linkage to gear shaft applicable to Interceptor 650 only 8C Rear sprocket chain fixing tighten wheel spindle nut after adjusting chain play 8D Connect breather hose between the breather box and air filter box 9A Locate spark plug suppressor caps on LH and RH spark plugs 9C Connect hose ...

Page 37: ...sket Magneto Cover 1 9 Hex Socket Bolt 12 M6x40_10 9 DESCRIPTION QTY KEY NO 8 2 4 1 7 9 3 3 5 6 9 9 9 9 E START SYSTEM 5 4 3 2 6 6 1 1 Gear Starter clutch 73T 1 2 Shaft Starter Idle Gear OD 12 x L58 5mm 1 3 Gear Starter Idle Assly Double Gear 14T 52T 1 4 O Ring Starter Motor 1 5 Starter Motor Assly 0 8kw 1 6 Hex FlangeBolt M6x1 x30 2 7 HexSoc HeadScrew M6X20 6 8 Magneto Rotor Assembly 1 9 Sprag Cl...

Page 38: ... DESCRIPTION KEY NO QTY 1 OuterCompClutchSubAssy 1 2 Washer Thick 1 3 CenterClutch 1 4 SeatJudderWasher 1 5 SpringJudder Bellivelle 1 6 DiskClutchFrictionB Slipper 3 7 DiskClutchFrictionA 4 8 ClutchPlateB Metal Slipper 1 9 ClutchPlateA Metal 5 10 PlateCompClutchPressure AL Sub Assy 1 10 1 PlateClutchPressure 1 10 2 BallBearingRadial6902 1 10 3 SeatSpringClutch 3 11 SpringClutch Compression 3 12 Pl...

Page 39: ...haft Assembly 1 Crank shaft with Primary gear sub assembly 2 Balancershaft with Driven gear sub assembly KEY NO DESCRIPTION 1 Cover Cylinder Head 4v 1 2 Cylinder Head Cover 1 Gasket 3 Washer_Seal 4 Rocker Cover 4 Bolt Rocker Cover 4 DESCRIPTION KEY NO QTY 1 3 3 3 3 2 4 4 4 4 2 1 A A Key Nos A1 1 2 39 Teeth 39 Teeth 21 Teeth 19 Teeth ...

Page 40: ...v 1 5 Spring Intake Rocker LH 1 6 Spacer Rocker Arm Intake 2 7 Arm Comp Valve Rocker Exhaust Left 4v 1 8 Spring Exhaust Rocker LH 1 9 Arm Comp Valve Rocker Intake Right 4v 1 10 Spring Intake Rocker RH 1 11 Spacer Rocker Arm Intake 1 12 Arm Comp Valve Rocker Exhaust Right 4v 1 13 Spring Exhaust Rocker RH 1 14 Rocker Arm Carrier LH Pt Mc 1 15 Rocker Arm Carrier RH Pt Mc 1 16 Flanged Hexoganal Bolt M...

Page 41: ...g Valve 4v 8 8 Retainer Valve Spring 4v 8 9 Seat Valve Spring 4v 8 10 Cotter Valve 4v 16 11 Seal ValveStemOil 4v 8 12 Cover Reed Valve LH 1 13 Cover Reed Valve RH 1 14 Reed Valve 2 15 Pipe T Piece 1 16 O Ring T Piece 2 17 Hex Socket Hd Cap Screw M6 x 20 4 18 Hollow Dowel Od9 x 12 Cover Cylinder 4 19 Stud Exhaust Mounting 4 20 Temperature Sensor EOT 1 21 O Ring Temperature Sensor 1 17 12 15 13 17 1...

Page 42: ...l Od13x18 Cylinder Head 2 3 Cylinder Barrel Complete 1 4 Gasket Cylinder Steel 1 5 Piston 4v 2 6 Ring Piston 1st 2 KEY NO DESCRIPTION DESCRIPTION KEY NO 7 Ring Piston 2nd 2 8 Ring Piston Oil 2 9 Pin Piston 2 10 Circlip Piston Pin 4 11 Conrod Fracture Split Assy 2 12 Bolt Conrod 4 13 Bearing Crankpin 4 QTY QTY 3 4 1 5 5 11 11 13 13 13 13 12 12 12 12 10 10 10 10 9 9 2 2 6 7 8 6 7 8 ...

Page 43: ...Washer M12 1 7 Flange Hex Bolt M12x1 25 X 45 1 8 Gear Starter Idle Assy 1 9 Shaft Starter Idle Gear No 2 OD 12 X 1 L58 5 16 15 14 13 11 10 9 8 7 6 5 4 3 2 1 12 17 18 10 Non Contact Gear Position Sensor 1 11 Wire Guide 1 12 Hexagonal Head Collar Bolt M6x1x14 2 13 Seal Drive Shaft Oil 1 14 O Ring Drive Shaft 1 15 Spacer Engine Sprocket 1 16 FD Sprocket Comp Engine 15 Teeth 1 17 Tab Washer M20 Engine...

Page 44: ...Arm 1 12 Arm Gear Shift Cam Stopper 1 13 Bolt Gear Shift Cam Stopper 1 14 Shim Gear Shift Shaft 1 15 Circlip Gear Shift Shaft 1 16 Spring Gear Shift Shaft Return 1 13 11 9 8 12 17 18 19 25 26 27 28 29 30 31 17 Spacer Plate Gear Shift 1 18 Plate Gear Shift Cam or Star Index Gear Shift Cam 1 19 Stepped Bolt Hex Soc Hd Star Index 1 20 Shaft complete assly Gear Shift 1 21 Plate Gear Shift Cam Drive 1 ...

Page 45: ... Comp Engine Oil 1 4 Gasket OilFilter 1 5 Pipe Bypass 1 6 O Ring Pipe Bypass 2 7 Hex Soc Head CapScrew M6 X 12 2 8 Strainer Comp Engine Oil 1 9 O Ring Strainer 1 10 Flanged Hexagonal Bolt M6x1x30 2 11 Pan Oil 1 12 Magnetic Plug Assy 1 13 Aluminuim Washer 1 14 Gasket Oil Pan 1 15 Flanged Hexagonal Bolt M6x1x30 13 16 Washer O Ring Oil pressure switch 1 12 13 14 11 10 7 9 6 6 5 7 1 3 4 2 8 15 16 ...

Page 46: ... 6 Bearing Crankshaft Brown 8 7 Bearing Crankshaft Yellow 8 8 Balancershaft Complete 1 9 Bearing Balancershaft Green 8 10 Bearing Balancershaft Black 8 11 Bearing Balancershaft Brown 8 12 Bearing Balancershaft Yellow 8 13 Counter Shaft Assembly Input 1 14 Drive Shaft Assembly Output 1 15 Jet Piston 2 16 O Ring Piston Jet 2 17 Jet Cylinder and Cylinder Head 2 18 O Ring OilJet 2 1 2 12 11 10 9 8 9 1...

Page 47: ... 14 Shaft Gear Shift Fork 2 15 Spacer Star index 1 16 Pin Gear shift cam 2 17 Plate Gear shift cam Star index 1 18 Stepped bolt hex soc HD star index 1 19 Spring Gear shift cam stopper 1 20 Washer Gear shift cam stopper 1 21 Stopper complete gear shift cam 1 22 Bolt Gear shift cam stopper 1 23 Shaft complete gear shift 1 24 Oil seal Gear shift shaft 1 25 Shim Gear shift shaft 1 26 Circlip Gear shi...

Page 48: ...ug OilFiller 1 5 O Ring OilFillerPlug 1 6 Hex Flange Bolt M8 x 1 25 x 80 12 7 Hex Flange Bolt M8 x 1 25 x 105 2 8 Flanged Hexoganal Bolt M6x1 x 35 9 9 Hex Flange Bolt M8x 1 25 x 45 1 10 Flanged Hexoganal Bolt M6x1 x 55 1 11 Hex Flange Bolt M8x 1 25 x 120 5 12 Hex Flange Bolt M8 x 1 25 x 150 2 13 Flanged Hexoganal Bolt M6 x 1 x 85 1 14 Washer 16 1 8 8 7 9 6 3 2 5 4 8 13 10 14 14 14 14 14 14 6 11 11...

Page 49: ...1 7 Hex Socket Bolt M6x50_10 9 3 DESCRIPTION KEY NO QTY 1 Camchain120 L 1 2 Pad Chain Tensioner 1 Complete Camchain 3 Guide Camchain 1 4 CamshaftComp 1 5 Sprocket Camshaft 42 Teeth 1 6 Flanged Hexoganal Bolt 2 M8x1x16 7 Auto Chain Tensioner Assy 1 Screw Type 8 Gasket Tensioner Assy 1 9 Hexagonal Flange Bolt 2 M6x1x20 10 Hex Flanged Bolt M6x1x6 5 1 11 O Ring Auto Chain Tensioner 1 DESCRIPTION KEY N...

Page 50: ... 12 13 13 28 27 26 25 24 6 18 23 22 21 18 20 19 18 6 17 6 16 15 14 DESCRIPTION KEY NO QTY DESCRIPTION KEY NO QTY 29 30 32 33 34 35 31 14 Shaft Drive Output 1 15 Gear 2nd Driven 29T 1 16 Bush 2nd Driven Gear 1 17 Gear 6th Driven 25T 1 18 Washer 3rd 4th Driven Gear 3 19 Bush Splined Gears 1 20 Gear 3rd Driven 30T 1 21 Washer Thrust Washer Lock 1 22 Bush Splined Gears 1 23 Gear 4th Driven 25T 1 24 Ge...

Page 51: ...er Pipe 2 5 ORing Pipe OilCooler 2 Top End 6 Copper Washer 2 7 ORing Pipe OilCooler 1 Bottom End 8 Flange Bolt M6 X 20 2 9 Washer M16 2 10 Bolt Union Crank Case 1 M16 X 1 5 11 Flanged Hex Bolt M6x1x27 2 12 Bush 2 13 Grommet 2 14 Hexagonal Nut M6 2 15 Grommet 1 DESCRIPTION KEY NO QTY 1 2 3 4 4 6 5 7 5 6 8 8 13 9 9 10 13 14 14 15 12 11 11 12 ...

Page 52: ... then remove allen key 2 bolts 24mmsocket 5mm allen key 3 Oil filter catridge Remove oil filter cartridge by special tool socket with tommy bar turn anti clockwise direction Oil Filter Wrench with tommybar 4 Tappet cover Remove Top side 4 mounting special flange head bolts with rubber washers Lift the tappet cover gently remove half round rubber tab from the cylinder head before taking out 8mm T s...

Page 53: ...tructions 4mm Allen key NOTE Use polythene cover to wrap fule intake common rail tube to avoid dust dirty entry 7 Starter motor removal Remove motor cables mounting flanged hexbolts M6x 1x 30 Qty 2nos andpull outside then lift up starter motor assembly gently 8mm long socket 10mmspanner 14mm Allen key with ratchet 9 Crankcase RH cover Remove Cover RH crankcase qty 14 nos allen screws Gently actuat...

Page 54: ...ad as shown Ensure TDC Locking tool is being seated properly on RH Crankcase 17mmsocket with tommy bar UsespecialtoolCamTDCaligningplateon 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 ST 30300 A Rotate crankshaft slowly from LH cover side to get compression stroke on LH cylinder side ...

Page 55: ... with Tommy bar ratchet Pull out rocker shaft by using M6 suitable bolt by holding inlet roller type rocker arm Similarly remove exhaust V type rocker arm M6x1 threaded tool bolt 17MMsocket with tommy bar 12 RH side valve timing Compression stroke Rotate crankshaft slowly from LH cover side to get compression stroke on RH cylinder side Simultaneously insert special T tool from RH side as shown in ...

Page 56: ...e v s cam shaft end timing index tilted grooves ref photo ST 30260 A Cam TDC Aligning Plate 13 RH side rocker carrier assembly Remove diagonally RH rocker carrier mounting flange nuts qty 4 nos Lift RH side rocker carrier cover with rocker arms rocker shaft 10mmsocket with Tommy bar ratchet Pull out rocker shaft by using M6 suitable bolt by holding Inlet roller type rocker arm Similarly remove exh...

Page 57: ...ension is being released condition Remove auto tensioner mounting flanged hex bolts M6 x 1 x 20 qty 2 nos Pull out tensioner assembly with gasket from cylinder barrel assembly 10mmring spanner socket Fastener Size Tool Usage Precautions Photos Screw driver 8mm ring spanner socket 16 Cam shaft assembly removal Slide away cam chain from timing sprocket gently take out cam shaft with timing sprocket ...

Page 58: ...age Precautions Photos 12mmsocket ratchet NOTE These bolts must to replaced due to one time usable special TRAX bolts Valve spring compressor tool Removevalvecottar2halves collar valve spring valve valve stem seal collar washerfromcylinderheadforeachvalve Remove MLS gasket and 2 dowel pins Remove cam chain long guide pad by lifting upwards from cylinder barrel seating slot Suitable plier if requir...

Page 59: ...ston with rings set sub assembly set SimilarlyfollowtheabovestepforRHside piston Expand properly and then remove piston ringsfrompistoncarefully 1stcompression ring 2nd compression ring 3rd set of three oil scrapper rings pack 20 Clutch removal Remove3nos flangedhexbolts M6x35 from clutch stopper plates by simultaneously loosing all three in sequence Remove clutch stopper plate 3 clutch return spr...

Page 60: ... Remove clutch special tipnut by socket tommybarrotatinginclockwisedirection RemoveBellevellewasherandsteelplate washer on countershaft Fastener Size Tool Usage Precautions Photos 27mmsocket Tommy bar NOTE Left hand side LHS threaded nut used for clutch assy Special tool Part no ST 30266 A Clutchhub holder tool Special tool Clutch hub holder Aggregate to Dismantle Instructions Remove clutch inner ...

Page 61: ...tuator mechanism 22 Clutch actuator removal Procedure Clutch actuator bolt remove and then lift lever assembly upwards gently as shown in photo Remove Clutch actuator spring washer and oil seal Remove Clutch actuator E clip and then Thrust washer as shown in photo 10mmsocket Ratchet RH Cover with Gasket Gasket Oil level inspection window E clip Thrust washer a b Remove pump mounting 4 bolts and 2 ...

Page 62: ...ty 2 bolts 8mm long socket Tspanner Remove Clutch actuator shaft upwards Clutch actuator shaft removal Step up dia NOTE The actuator shaft is having step up dia for oil seal locating purpose Hence requested to remove oil seal first and then remove actuator shaft Remove Clutch actuator shaft needle Roller bearing upper side by using special tool as shown in photo Special tool Part no ST 30265 A Clu...

Page 63: ...tener Size Tool Usage Precautions Photos Magneto Puller Assembly Part No ST 30274 A Double end spanner32mm 26 Starter double gear removal Remove starter double with shaft as shown in photo Aggregate to Dismantle Instructions Use Special tool Remove magneto mounting special hex bolt with thick washer Whiledismantlingmagnetorotorforeasy handling use following special tool as shown in illustration Us...

Page 64: ... right condition 8mm socket T spanner NOTE Inspect for dirt metalchipsclean carefully 5mm Allen key 28 Upper Lower crankcase splitting Remove Total qty 33 bolts flanged hex special bolts Care to be taken while spliting crankcase upper lower 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 Q...

Page 65: ...r and Lower crankcase write index numbers for reference purpose Ensure that the located bearings to be refix in the same place while assembling the engine 30 Crankshaft with con Rod assembly Remove cam chain Tensioner pad from the Upper crankcase Remove crankshaft from Upper crankcase alongwith cam chain Aggregate to Dismantle Instructions Lowercrankcasecanberemovedwithgear shifter shaft Gear shif...

Page 66: ...sembly Loosen the Counter shaft sub assembly bearing retainer clip CSK screw M6x16 qty 2 nos by 5mm allen key Remove Countershaft sub assembly with gearsfromtheUppercrankcaseasshown in photo Flow pattern of Counter shaft dismantling process2 6 3 4 5 1 10mm bi hexagonal socket Ratchet NOTE These bolts are one time usage only 5 mm allen key Fastener Size Tool Usage Precautions Photos Aggregate to Di...

Page 67: ... apply engine oil to avoid rusting of components cylinder barrel gears etc Bearing 6203 RS1 thrust blue washer 2nd gear splined bush 6th gear inside spline washer external circlip 3rd 4th doublegear externalcirclip bigidthrust washer 5th gear Splined ID bush Countershaft built in 1st gear bearing 6304 NOTE If crankshaft balancershaft con rod big end journal bearings are removed Then need to write ...

Page 68: ...A A Cylinder Head Top Surface Cover Area B Rocker cover gasket seating surface 0 01 By thick straight edge and feeler gauge Inlet Exhaust New Min New Max ServiceLimit 650 TWIN 12 000 12 018 12 000 12 018 Rocker Arms ID Inlet Exhaust Inside micrometer Inlet Exhaust New Min New Max ServiceLimit 650 TWIN 11 973 11 984 11 973 11 984 Rockerarm Shaft OD Screw gauge Micrometer 0 01 B 650 TWIN A B New Min...

Page 69: ...Inlet Exhaust New Min New Max ServiceLimit 650 TWIN Visual Inspection Valve Tip Inspection wornout pit marks Inspect Valve tip for any wornout pit marks Replace if defective Inlet Exhaust New Min New Max Screw gauge Micrometer Camshaft Lobe Height 35 590 35 628 LH RH New Min New Max 650 TWIN Camshaft OD to Journal 0 05 0 05 Inlet Exhaust New Min New Max ServiceLimit Screw gauge Micrometer Valve St...

Page 70: ... Max ServiceLimit Thick straight edge and feeler gauge Cylinder Barrel Seating Area Warpage 0 01 Bore gauge check at 3 positions Micrometer and bore gauge LH RH New Min New Max ServiceLimit Feeler gauge S W G Spark Plug Gap 0 70 0 80 0 70 0 80 650 TWIN Bore LH Bore RH New Min New Max ServiceLimit Bore gauge Cylinder Barrel Bore IDLH RH 78 000 78 030 78 000 78 030 650 TWIN LH RH New Min New Max Ser...

Page 71: ...op Ring and B Second Ring LH RH New Min New Max ServiceLimit Screw gauge Piston Pin Outside Diameter OD 19 992 19 997 19 992 19 997 650 TWIN 650 TWIN LH RH New Min New Max ServiceLimit Feeler gauge Piston Ring to Groove Clearance OilRing 650 TWIN LH RH New Min New Max ServiceLimit Feeler gauge Piston Oil Ring End Gap Bottom Top Rail 650 TWIN Top 1 Top 2 New Min New Max ServiceLimit Feeler gauge Pi...

Page 72: ...H RH New Min New Max ServiceLimit Micrometer Connecting Rod Small End ID LH RH 20 006 20 014 20 006 20 014 650 TWIN 650 TWIN Twist Bend LH RH New Min New Max ServiceLimit Check Parallisim Connecting Rod Bend Twist 0 050 0 050 LH RH New Min New Max ServiceLimit Micrometer Connecting Rod big end insert thickness 650 TWIN 650 TWIN 1 483 1 499 1 483 1 499 Check Face Out 650 TWIN New Min New Max Servic...

Page 73: ...Limit Balancer Shaft Face Out 650 TWIN 1 2 3 V Block dial gauge 2 0 040 0 040 0 040 1 3 4 2 Journal 1 2 LH Journal 3 4 RH New Min New Max ServiceLimit Micrometer Balancer Shaft Journal dia 21 976 22 000 21 976 22 000 New Min New Max ServiceLimit Micrometer Crankshaft Journal Bearing Clearance 650 TWIN J 1 LH J 3 J 2 J4RH 0 032 0 040 0 040 0 048 0 016 0 024 650 TWIN Thickness Bend Warp New Min New ...

Page 74: ... Screw gauge Shifter Fork guide pin OD 650 TWIN New Min New Max ServiceLimit Micron Dial for bore ID measurment Clutch Housing Drum ID 650 TWIN New Min New Max ServiceLimit Main Clutch Hub Inner Seating Faceout 650 TWIN New Min New Max ServiceLimit Slipper Clutch Hub Outer Faceout Thickness Bend Warp 2 9 3 1 2 7 0 2 0 3 650 TWIN 1 85 2 15 1 8 0 2 0 3 1 85 2 15 1 8 0 2 0 3 49 43 47 5 Inspecttheoute...

Page 75: ...eler gauge and Surface plate Warpage LH Cover 650 TWIN New Min New Max ServiceLimit Vernier caliper Gear Shift Drum Groove width New Min New Max ServiceLimit Micrometer Vernier Caliper Fork gear Shifter ID No 1 2 3 Shaft 1 Shaft 2 New Min New Max ServiceLimit Screw gauge Shifter fork guide shaft spindle OD 1 New Min New Max ServiceLimit Vernier caliper Shift Fork Lug thickness 650 TWIN 2 3 5 300 5...

Page 76: ... X 35 _12 9IS 2269 BLACKENED 8 575072 PLUG CRANKSHAFT HOLE M34X1 5X14 8 Plug crankshaft hole 1 Seal 14 9 12 9 575054 PLUG OIL GALLERY 3 8 NPT 7 9 8 8 Crankcase oil gallery 1 Seal L542 8 10 575454 CSK SCREW M6 X 16 11 8 8 Retainer Bearing Fixing 2 Lock Precoat 80 4 10 12 11 575455 FLANGED HEXAGONAL BOLT M6X1 X 14 8 8 8 GEAR POSITION SENSOR 2 Lock Precoat 80 10 6 8 12 574018 PAN HEAD SCREW M6X12 COU...

Page 77: ...HEX BOLT M6X1 X 55 C_CASE 8 8 Crankcase box closing 1 8mm LCF 15 575562 FLANGED HEXOGANAL BOLT BARREL 8 8 AUTO CHAIN TENSIONER ASSY Screw 1 10mm 3 5 M6X1X6 5 Type sealing bolt 16 574038 FLANGED HEXOGANAL BOLT M6X1X85 C_CASE 8 8 Crankcase box closing 1 8mm LCF 17 575417 HEX FLANGE BOLT M8X1 25 X 105 C_CASE 10 9 Crankcase box closing gearbox 2 13mm LCF 18 575415 HEX FLANGE BOLT M8X1 25 X 45 C_CASE 1...

Page 78: ...6X50_10 9 ALTERNATOR 10 9 Sprocket cover FD Mounting 3 5mm 10 12 47 575072 PLUG CRANKSHAFT HOLE M34X1 5X14 ALTERNATOR 1 Seal 14mm 18 22 48 575248 BOLT ROCKER COVER CYL HEAD 8 8 Cam cover fixing 4 8mm 10 12 49 575456 HEX SOCKET HEAD CAP SCREW STARTER 12 9 SPRAG CLUTCH HOUSING 6 Precoat 85 6mm 10 12 M6X1X25 50 574317 HEX SOC HEAD SCREW M5 X 15 ALTERNATOR 8 8 Pulsar coil fixing 2 Lock 4mm 8 10 51 575...

Page 79: ... 28Nm in the below image Across Flat Using 13mm socket M6 BOLTS 23 33 M6 X 1 0 Lubrication N A Torque In order shown 9 12Nm in the below image Across Flat Using 8mm socket ACG ROTOR BOLT 575202 M12 X 1 25 Lubrication Apply Transmission oil to bolt threads underhead area of bolt Torque 155Nm Across Flat 17mm CONNECTING ROD BOLT 575390 M9 X 1 GRADE 10 9 Apply Transmission oil to Lubrication bolt thr...

Page 80: ...PISTON 575098 02 7 0 01 0 08 1 2 0 08 8 575443 JET CYLINDER AND CYLINDER HEAD 575444 04 6 0 01 0 08 2 0 0 08 8 574017 JET OIL Transmission 575053 01 6 0 01 0 08 1 4 0 08 14 574017 Pls ensure 4 jets 1 jet with O ring to installed on crankcases as per guidelines given below Fastener Size Tool Usage Precautions Photos Aggregate to Assemble Instructions Compressed air gun NOTE Apply oil Manual GL 4 80...

Page 81: ...umbers for balancershaft bearing journal matching as per chart Incase of new journal bearings are fixing match the grade and index numbers colours properly as per recommended chart index which is given below Fastener Size Tool Usage Precautions Photos Aggregate to Assemble Instructions LHSIDE JET OILTRANSMISSION 575053 Crankshaft Bearing Grade J1 A J2 A J3 B J4 A Balancershaft Bearing Grade J1 A J...

Page 82: ...ft ID Crankshaft Balancershaft OD Bearing Crank Pin Combination Table MarkonCrankshaftOD 575911 A B C Ø34 0 0 008 Ø34 0 009 0 016 Ø34 0 017 0 024 Grade Combination Bearing 1 5 0 002 Bearing 1 5 0 002 Bearing 1 5 0 006 A Ø37 0 007 Green 0 006 Black 0 002 Brown 0 002 0 575069 0 024L 575352 0 025L 575353 0 025L Code 1 0 047L Code 2 0 047L Code 3 0 047L Bearing 1 5 0 002 Bearing 1 5 0 006 Bearing 1 5 ...

Page 83: ...1 5 0 006 Bearing 1 5 0 010 B Ø25 0 013 Black 0 002 Brown 0 002 Yellow 0 006 0 007 575355 0 019L 575356 0 020L 575357 0 020L Code 2 0 041L Code 3 0 041L Code 4 0 041L MARKON CRANKCASE ID 575004 Properly matched crankshaft balancer shaft journal bearings to be fixed on upper crankcase Fastener Size Tool Usage Precautions Photos Aggregate to Assemble Instructions AssembleTimingchaintensionerpadinto ...

Page 84: ...he back side of journal Aggregate to Assemble Instructions CheckconnectingrodLHandRHproperly which was marked earlier Con rodsaremarked H or J Donotmix them advisable use both LH RH connecting rod same group index marks please ref photo Bearing Crank Pin Combination Table MarkonCrankshaftOD 575911 A B C Grade Combination Bearing Bearing Bearing A Green Black Brown 575069 575352 575353 Code 1 Code ...

Page 85: ...aft Pin OD Ref MarkonCrankshaftPINOD 575911 Markonweb 1 2 3 Ø38 0 0 017 Ø38 0 009 0 016 Ø38 0 017 0 024 Grade Combination Bearing 1 5 0 013 Bearing 1 5 0 009 Bearing 1 5 0 005 1 Ø41 0 008 Green 0 017 Black 0 013 Brown 0 009 0 575062 0 063L 575358 0 063L 575359 0 063L Code 1 0 039L Code 2 0 04L Code 3 0 04L Bearing 1 5 0 009 Bearing 1 5 0 005 Bearing 1 5 0 001 2 Ø41 0 016 Black 0 013 Brown 0 005 Ye...

Page 86: ...or axial clearance using feeler gauge If you found excess play beyond service limit please replace connecting rod sub assembly with journal bearings Rotate crankshaft freely on upper crankcase and check for axial play 10mm bi hexagonal socket Torque wrench angle wrench Fastener Size Tool Usage Precautions Photos Service limit mm Service limit mm Aggregate to Assemble Instructions 4 Bolts per Engin...

Page 87: ...kcase wall Rotate Countershaft and Drive shaft sub assembly slide away gears and ensure neutral position Apply silicone adhesive over crankcase gasket seating area NOTE Please check bearing 6203 rubber sealed face towards crankcase wall which is meant for lubrication oil flow purpose NOTE Please ensure bearing 6305 outer dia circlip properly being seated on crankcase top groove Fastener Size Tool ...

Page 88: ...to Assemble Instructions Gear shift drum with bearing install carefully Install gear shift shaft NRB bearing and then oil seal Assembleneedlerollerbearing NRB into crankcase gear shifter drum seating area Install balancershaft and crankshaft journal bearings as per chart index Oil Filter Union Wrench Part No ST 30293 A Gear Shifter Drum NRB Installer Part No ST 30270 A Assemble gear shift fork 1 i...

Page 89: ...d tighten special mounting stepped bolt hex socket head in neutral position Fastener Size Tool Usage Precautions Photos 10mmsocket torquewrench NOTE After tightening bolt ensure free swing of roller arm shift 5mm allen key Aggregate to Assemble Instructions Assemble Gear Position Sensor GPS by locating pin into gear shifter drum slot then locate the spring clip outside for wiring routing purpose T...

Page 90: ...journals oil orifice jets special care to be taken Fastener Size Tool Usage Precautions Photos 21mmLong socket torque wrench Liquid sealant Aggregate to Assemble Instructions External circlip plier Assemble gear shift shaft with thrust washerintocrankcaseholecarefullyfrom RH side Another end on LH side insert washer and then fix by external circlip 4B Oil Pressure Switch Apply Loctite 542 All Roun...

Page 91: ... Angular Torque Bolt Location Torque degrees 1 2 3 4 9 11 14 15 16 65 degree 7 8 10 12 13 110 degree 5 6 140 degree Assemble Qty 9 Nos flanged Hex bolts M6x1x35 a on front and rear lower crankcaseinacrisscrosspattern DO NOT TIGHTEN FULLY Tighten the bolts to specified torque 8 mm Socket with Torque wrench Torque 12 Nm 1 2 kgf m Locate and assemble qty 6 Nos flanged Hex bolts M8 a on crankcase rear...

Page 92: ...oint below crankshaft gear in RH crankcase Assemble 4 Nos flanged Hex bolts M6x1x40 a on oil pump b and tighten bolts to specified torque 8 mm Socket withRatchet Torque 12 Nm 1 2 kgf m Locate and fit oil pump drive chain a on crankshaft gear b and sprocket on oil pump NOTE While fixing oil pump new sprocket champered teeth side OUT marked facing outside Locateflangedhexbolt M6x1x20 a on oil pump D...

Page 93: ...crew M6x12 a to specified torque 7 Oil Strainer Ensure O ring is located properly Installoilstrainer a intolowercrankcase oil gallery and tighten with Qty 2 Nos flanged hex bolts M6x1x30 8 mm Socket withRatchet Torque wrench Torque 12 Nm 1 2 kgf m Locate oil pan gasket a on crankcase andassemble oilpan b tightenthebolts as per sequence shown in photo NOTE Clean crank case lower sump and sump cover...

Page 94: ...wn side Rings should be free Piston2ndRingEndGaptobe180o apart1stRing End Gap Piston 3rdRing TopRail EndGaptobe 180o apart from 2nd Ring End Gap Piston 3rd Ring Spacer End Gap to be 45o apart from 3rd Ring Top Rail End Gap Piston 3rd Ring Bottom Rail End Gap to be 180o apart from 3rd Ring Top Rail End Gap Piston Pin One side circlip to be assembled Top Ring SecondRing OilRing TopRail OilRing Space...

Page 95: ...or RH piston installation Screw Driver 8 Cylinder Barrel Install 2 Nos dowel pins on Crankcase as shown in illustration Ensure the gasket seating area in crankcase is clean Assemblegasket a oncrankcase b and ensure it is located correctly on the dowels Compress piston rings with special tool a Piston ring compressor Part No ST 30296 A NOTE Used piston support plate for easy assembly piston Piston ...

Page 96: ...ons Piston ring compressor Part No ST 30296 A Repeat procedure for RH cylinder Remove special tool a from piston 9 Components in Cylinder Head Valves and Springs Install valve seat a into valve guide b Clean and insert the valve stem a into cylinder head b Ensure all valves are installed in their original position Insert valve spring on valve stem Long coil pitch facing upwards Insert collar a abo...

Page 97: ...Ensure8Nos valvestemsandcotterlocks are installed properly Assemble engine oil temperature sensor EOT withoringsandtightentospecified torque 10 Cylinder Head Assembly on Cylinder Barrel Locate cylinder head on dowel pins a and fix into cylinder barrel Locate new Bolt Cylinder Head M10 a 8 Nos on the cylinder head CAUTION Cylinders bolts are pre coated hence one time use only 12mm Socket withRatche...

Page 98: ...1 65o 2 65o 3 65o 4 65o 5 140o 6 140o 7 110o 8 110o TorqueAngleValues for Assembly Bolt Number Angle 9 65o 10 110o 11 65o 12 110o 13 110o 14 65o 15 65o 16 65o 33 31 29 27 25 16 15 7 8 26 32 28 30 24 4 3 11 12 10 9 1 2 6 5 13 14 23 21 19 17 22 20 18 TIGHTENING SEQUENCE CRANKCASE UPPER LOWER NOTE Lubrication Apply oil GL 80W90 to BOLT Threads and UNDER HEAD AREA of 1 to 22 BOLT Tighteningofboltsdone...

Page 99: ...gular Torque 270 deg CAUTION Torque and angleshouldbe as specified Do not provide over torque as it will damage the bolts 11 FD Sprocket Assemble rubber seal on Drive shaft and ensure itis seatedproperly onplain bush Assembleplainbush a onDriveshaft b from smaller end Assemble FD sprocket a on Drive shaft b Angular torque wrench Torque Wrench Install splined washer into driveshaft Assemble FD Spro...

Page 100: ...ring c to rotor Tighten the bolts just sufficiently Position idle gear a against crankcase with the smaller gear facing outside and insertidlegearshaftintothebossinupper crankcase Ensure woodruff key is located on the crankshaft and facing upwards Position gear starter clutch a with the collar facing outside Insertgearstarterclutch a intomagneto rotor b androtateanti clockwisetolock the gear start...

Page 101: ...25 a to specified torque 5 mm Allen socketwith Torque wrench Torque 10 Nm 1 kgf m 13 Camshaft Sub Assembly Hold the timing chain in stretched condition and gently rotate crankshaft clockwise to bring LH piston to TDC Lock the crankshaft in TDC position through hole in crank web inline with crankcase RH side using special tool as shown Hold sprocket in position with one of the slotted holes facing ...

Page 102: ...Locate and tighten flanged Hex bolt M8x1x16 a into camshaft DO NOT TIGHTEN FULLY Rotate magneto a till another hex head bolt on cam chain sprocket is at top most position Ensure reference mark R aligned to the cylinder head 12mm Socket with Tommy bar 17mm Socket withRatchet Locate special tool a on camshaft RH Ensure it is properly seated on cylinder head Cam TDC Aligning Plate Part No ST 30260 A ...

Page 103: ...ft magneto and then Tighten flanged Hex bolt M8x1x16 a to specified torque 12mm Socket with Torque wrench Torque 35 Nm 3 5 kgf m RemovethespecialtoolcamTDCaligning plate from cylinder head Rotate the magneto a clockwise till other bolt is visible at top most position on cam chain sprocket 17mm Socket withRatchet TightenflangedHexbolt M8x1x16 a to specified torque 12mm Socket with Torque wrench Tor...

Page 104: ...a on chain tensioner adjuster and tighten to specified torque 8 mm Socket with Torque wrench Torque10to12 Nm 1 2 kgf m Locate small connector into chain tensioner adjuster a release screw slowlysothatautomaticallyitwillloadthe timing chain Screw driver Locate new O ring b and assemble flanged Hex bolt M6x1x6 5 a on chain tensioner body and tighten to specified torque 10mmSocket withRatchet Torque ...

Page 105: ...ds Ensure the holes are aligned and insert spindle with its small chamfer side in the carrier Ensure cut away in spindle is correctly aligned to the carrier mounting hole Alignandinsertthespindle c intorocker carrier and rocker arm Intake Rocker Arm in Carrier RH Locate rocker arm with the marking IL into cover L Align rocker arm exhaust into rocker cover Repeat the above process to assemble rocke...

Page 106: ...lves Assemble 4 Nos flange Hex bolts M6x1x60 b on rocker carrier and tighteninacrisscrosspatterntospecified torque Tighten the bolts M6 a to specified torque 10mmSocket with Torque wrench Torque 12 Nm 1 2 kgf m 16 Rocker Assembly on Cylinder HeadRH Ensure the cam TDC aligning plate and TDC locktool crank are removedare from position after tightening bolts Rotatemagneto a clockwise andensure refere...

Page 107: ...clearance refer the section in Periodical Maintenance Page No 182 10mmSocket with Torque wrench Torque 12 Nm 1 2 kgf m 17 Tappet clearance adjustment Tappet clearance cylinder head LHSide NOTE Ensure L markon camshaftis aligned to cylinder head Adjust tappet clearance on cylinder head LH as follows Ensure lock nut on tappet adjuster is sufficiently loose Intake limit 0 08mm Exhaust limit 0 18mm Lo...

Page 108: ...Assemble Instructions Locate screw driver on tappet adjuster screw a byinsertingthroughtappetlock nut special tool Locateafeelerstripbetweentheadjuster screw and valve stem as per thickness mentioned below Gently pull out feeler strip and check if it comesoutfreelyorwithheavyresistance In case feeler strip moves out very freely the adjuster screw has to be tightened In case feeler stripmovement is...

Page 109: ...ure the rubber gasket groove in cylinder head cover and seating surface in cylinder head are clean Locate new rubber gasket in the cylinder head cover slot and ensure it is properly and evenly seated in the groove Locatecylinderheadcover a oncylinder head with the narrow deep slot facing towards front of the engine Assemble new seals a on the 4 Nos flanged Hex bolts M6 b Locate the bolts on the cy...

Page 110: ... into LH cover Locateandtightenqty 3Nos flangedHex bolts M6x1x30 b Tighten the bolts evenly to specified torque 5 mm Allen socketwith Ratchet Torque 12 Nm 1 2 kgf m Assemble Crankshaft Position Sensor CKP a alongwithguideplate b onLH cover and locate and tighten qty 2 Nos Hex socket head screw M5x15 c Tighten the bolts evenly to specified 4mm Allen socketwith Ratchet Torque 10 Nm 1 kgf m Locate do...

Page 111: ...lleville washer and Nut M17 clutch sleeve hub tighten to specified torque Assembly Sequence Install Seat Judder and Spring Judder on Center Clutch Install the Disk clutch Friction plates and Clutch plates as shown in exploded view Install Plate Comp Clutch Pressure on Stack Ball Bearing Seat Spring are already assembled in Plate Comp Install Spring Clutch in Plate Comp Clutch Pressure Use 3 leg Al...

Page 112: ...resence or absence of jigs In case of absence of Jig Asgivenintherightfigure firstassemblyyellowpart and then insert to the green component side Later assembly procedure is similar to the conventional clutch In case of presence of jig Assembly procedure is similar to the conventional clutch but Implement fitting confirmation of clutch plate B in yellow part by jig Deformationofthestopper plateadve...

Page 113: ...per sequence shown in above photo NOTE Locate tighten the hed socket bolt 3 nos as per sequence shown in photo 3 Must Take Care Point During Assembly process NOTE Locate andtighten the hedsocket bolt 12 nos as per sequence shown in above photo CORRECT METHOD WRONG METHOD Single Double Please ensure that single disk friction B plate should be offset fixed on outer comp clutch clutch housing as show...

Page 114: ...Assemblewasher b ontheshaftbottom inside the clutch cover Assemble E clip a in the slot in shaft bottom inside clutch cover Nose plier Assemble oil seal a into clutch cover at the top with the lips facing down Assemble washer b above oil seal 24 Oil Level Window Locatenewoilwindow a onclutchcover with the window facing towards clutch coverouterandgentlypresstillitisseated fully inside Assemblecirc...

Page 115: ...t use any sealant or adhesive Ensureracksontheclutchpullrodisfacing towards the rear of th engine Hold the clutch cover a in position rotatetheclutchactuatingshafttoensure itisengagedcorrectlywiththepullrodand gently tap cover inside to seat it on the dowels and crankcase Hold clutch cover and rotate clutch actuating shaft to check for positive locking Locate 14 Nos Hex socket bolts M6 a on RH cov...

Page 116: ...the arm is aligned to the reference mark a on the clutch cover Tighten pinch bolt sufficiently such that the arm is firmly clamped on the shaft Position the upper leg of the spring against the inside of the clutch release arm and check for proper spring action 8 mm Socket withRatchet Torque wrench Torque 10 Nm 1 0 kgf m 26 Starter Motor Locate starter motor a into the upper crankcase housing b RH ...

Page 117: ...cover on engine Install and tighten 5 Nos flanged Hex bolts M6 a to specified torque 10mmSocket withRatchet and Torque wrench Torque 12 Nm 1 2 kgf m Fit breather hose a into breather box cover and install clamp 19 mm Socket withRatchet and Torque wrench 28 Drain Plug Assemble magnetic drain plug M14x1 25 x6g a along with washer Tighten drain plug a to specified torque Torque 15 Nm 1 5 kgf m Magnet...

Page 118: ...ace Sealant TB1217H Beed Width Height Min 3 x 2 mm Apply three bond TB1217H in marked joint areas Beed Width Height Min 3 x 2 mm Beed Width Height Min 3 x 2 mm Beed Width Height Min 3 x 2 mm NOTE 1 Before applying the sealant in joint face to be clean in Tg rag cloth and IP solution Emery paper Oil stone should not be used in joint face to clean 2 As per supplier technical specification for TB1217...

Page 119: ... RH Bearing Retainer Mounting Precote 85 16 574018 HEX SOC HEAD CAP SCREW M6 X 12 Shifter drum retainer plate Oil bypass pipe Loctite 204 17 574317 HEX SOC HEAD SCREW M5 X 15 PULSOR COIL FIXING Loctite 204 18 575388 HEX SOCKET HD CAP SCREW M6 X 35 STATOR COIL FIXING Precote 85 19 575451 HEXAGONAL FLANGE BOLT M6X1X20 Auto Chain Tensioner Assy Pump Sprocket Fixing Precote 85 20 575597 NUT TAPPETADJU...

Page 120: ...rflex 24 Curing time is 2 Min for sub assembly leak testing NOTE 1 Before applying the sealant in joint face it should be free from moisture oil and other foreign particles 2 Cylinderhead covertobeassembled within5min ffromdispensing of sealant CLUTCH COVER T JOINT AREA Apply SCRD 1015 MAGNETO COVER T JOINT AREA Apply SCRD 1015 NOTE 1 Before applying the sealant in joint face ensure joint face sho...

Page 121: ...13 Tighten the cylinder head mount bolt nut CRADLEASSEMBLY 1 Align the fame cradles to the frame 2 Loose assemble the frame cradle bolts to the frame with the nut plates 3 Insert the upper front crankcase mount boly from the right hand side of the motorcycle including the thick washer under the bolt head 4 Add the chick washer and nut to the end of the upper front crankcase mount bolt loose assemb...

Page 122: ...tion SAI Solenoid EMS COMPONENTS FUNCTIONAL DIAGRAM Crank Position Sensor Manifold Absolute Pressure Sensor Throttle Position Sensor Engine Oil Temp Sensor Intake Air Temp Sensor RollOver Sensor Wheel Speed Sensor Clutch Switch Gear Position Sensor Side Stand Switch ENGINE CONTROL UNIT 02 Sensor Sec Air Injection Solenoid Starter Motor Mircro Relay Canister Purge Valve Idle Air Control Valve Injec...

Page 123: ...el Speed Sensor O2 Sensor Front Wheel Speed Sensor O2 Sensor Clutch Switch ABS Modulator Valve Manifold absolute Air Pressure Sensor Injector Engine Oil Temperature Sensor Intake Air Temperature Sensor Oil Pressure Switch Crank Position Sensor Side Stand Switch Gear Position Sensor Canister Purge Valve Throttle Position Sensor Engine Control Unit ECU Secondary air injection solenoid ...

Page 124: ...ture sensor Hose connector Fuel Injector Canister purge valve CarbonCanister Throttle Position Sensor Idle speed actuator Electronic Control Unit ECU Diagnosis lamp Crank position sensor pick up coil Spark plug Fuel pump Module Pump regulator Ignition Coil Oxygen O2 sensor heated Secondary Air Injection Solenoid Mechanical Throttle Body Bosch core components Non Bosch component for start and idle ...

Page 125: ...51B L 145 DUMMY SEAL 146 DUMMY SEAL 147 147 LG 148 DUMMY SEAL 149 50 R 150 DUMMY SEAL 151 51 L 152 52 G 153 24D B 154 24E B 155 4B BR 156 4C BR 201 19B G W 202 202 L 203 27 V 204 DUMMY SEAL 205 205 G 206 206 W 207 28 B 208 208 B 209 DUMMY SEAL 210 210 R L 211 DUMMY SEAL 212 DUMMY SEAL 213 20B W 214 DUMMY SEAL 215 215 L 216 DUMMY SEAL 217 DUMMY SEAL 218 DUMMY SEAL 219 DUMMY SEAL 220 DUMMY SEAL 221 ...

Page 126: ...g the pump inside the fuel tank is that it is less likely to start a fire Though electrical components such as a fuel pump can spark and ignite fuel vapours liquid fuel will not explode and therefore submerging the pump in the tank is one of the safest places to mount The pressure regulator maintains a constant pressure of 350 kPa cm by returning the surplus fuel back into the tank Specifications ...

Page 127: ...ne mode Idle Part Throttle Wide Open Throttle WOT Air fuel ratio correction Acceleration Deceleration correction 5 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR The Manifold Absolute Pressure sensor provides instantaneous manifold pressure information to the ECU This is necessary to calculate air density to determine the required fuel metering for optimum combustion and influence the advance or retard of ...

Page 128: ...nalheatingelement thusSensorheatingreduces the influence of the exhaust gas temperature on the sensor ceramic temperature and therefore the temperature dependent sensor Reliable signals working temperature from 300o C to 900o C maximum 6 CANISTER PURGE VALVE The purge valve is the part of the vehicle Evaporative Emission Control EVAP system The EVAP system prevents fuel vapors in the fuel tank fro...

Page 129: ...ir temperature sensors and operates the stepper motor in regulating the engine RPM This allows the engine s idle speed to be maintained constant It is mounted on throttle body as ref in photo 9 SECONDARY AIR INJECTION SAI SOLENOID Secondary air injection solenoid is used to reduce the tailpipe emissions by burning the unburnt fuel in the exhaust The solenoid is connected over the top of the air fi...

Page 130: ...t gives the information about ambient air temperature to the ECU for making corrections in the injection quantity ignition timing ItismountedonAirfilterboxtoprightcornerasshown in photo Specifications Operating Temperature 55 to250 C Supply Voltage 5 V Pin Out Voltage 2 7734 V 39 6 C across pins 215 106 Specifications Operating Temperature 55 to125 C Supply Voltage 5 V Pin Out Voltage 1 777 V 39 8...

Page 131: ...ilitycalculationsintheECU During neutral gear position a light will glow in instrument cluster Operating temperature 20o C to 150o C Specification Across pins 123 208 Neutral Gear 0 37 to 1 16V 1st Gear 1 22 to 1 50V 2nd Gear 4 30 to 4 80V 3rd Gear 3 63 to 4 12V 4th Gear 2 98 to 3 45V 5th Gear 2 30 to 2 80V 6th Gear 1 68 to 2 10V 13 SIDE STAND SWITCH Side stand switch prevents the vehicle from sta...

Page 132: ...hiftPositionSensorCircuitHigh Open P0917 3DC 53 18 Gear shiftposition sensor GearShiftPositionSensorCircuitLow P0916 3DC 53 19 Gear shiftposition sensor GearShift PositionSensorCircuit NonPlausible P0730 3DC 53 20 Vehiclespeedsensor VehicleSpeedSensor A Range Performance P0500 3DC 70 21 Evaporativeemissionsystem EVAPSystemPurgeControlValveCircuitHigh P0459 3DC 23 purgecontrolvalve 22 Evaporativeem...

Page 133: ...ircuitNonPlausible P1635 3DC 25 51 FuelPump FuelPumpControlCircuitOpen P0627 3DC 41 52 FuelPump FuelPumpControl CircuitLow P0628 3DC 41 53 FuelPump FuelPumpControlCircuitHigh P0629 3DC 41 54 Starterrelay StarterRelayCircuitHigh P0617 3DC 26 55 Starterrelay StarterRelayCircuitLow P0616 3DC 26 56 Battery ADC SystemVoltageLow P0562 3DC 31 57 Battery ADC SystemVoltageHigh P0563 3DC 31 58 Battery ADC S...

Page 134: ...perature 10o C to 160o C TBC Crank Position Sensor STARTER MOTOR The Starter motor is assembled on top of the crankcase behind the cylinder barrel Thestartermotorisactivatedbyasolenoid whenever thestarterbuttonispressedtostarttheengine While cranking when the crank speed attains 600 RPM the ECU commands the startersolenoidtodisconnect the power supply to the starter motor so that is will stop spin...

Page 135: ... accumulate in the fuel tank 1 they are transferred to charcoal canister 5 through a vacuum hose 3 Hydrocarbon vapors gas fumes are condensed by the charcoal canister and transferred back to throttle body 6 through a vacuum hose 4 Inspection Cleanandinspectanydamageorcrackoncanister housing inlet and outlet ports Inspect the canister weight on hand If it seems heavy there may be fuel flooding Repl...

Page 136: ...o ground EVAP Purge control valve struck open improper fuel mixture EVAP purge control valve to throttle body connection hoses are cracked or disconnected Charcoal canister damagedor cracked EVAP purge control valve damaged or cracked Hoses are dis connected cracked torn or pinched Refer the EVAP purge control inspection Check and replace if defective Check the EVAP Purge control circuit and repai...

Page 137: ...ordamage Replace if defective NOTE Remove mud dust or foreign material from the pipe and quick joint by blowing compressed air FUEL SYSTEM 1 Fuel Tank 2 FuelFilter 3 Fuel Pump module 4 Hose fuel feed 5 Hose fuel return 6 Plate retaining fuel pump 7 Fuel gauge assembly 8 Fuel gauge assembly gasket 9 O ring fuel pump lower 10 O ring fuel pump upper 11 Screw Fuel pump mounting 12 Screw Fuel gauge mou...

Page 138: ...y for leak lost off the bike Fuel tank EVAP canister Purge Valve Throttle Body Throttle Body 1 4 2 3 5 6 7 8 9 EVAP SYSTEM SCHEMATIC Figure2 Components the Evap system contains the following components NOTE During assemblytoensurethere are noleaks inany of the hoses or joints 1 2 4 3 5 6 7 8 9 Breather to atmosphere Figure1 EVAPSYSTEMLEAK TEST PROCEDURE 3 Test Procedure a Sub assembly test procedu...

Page 139: ...s Bolt Size Metal Plastic Interface Nm Interface Nm T20 Self Tapper N A 1 5 M5 5 3 M6 10 3 M8 25 N A M10 45 N A M12 70 N A TORQUE VALUE Sl Fixing Location Thread Torque No 1 Side stand switch M6 5Nm 2 Top yoke handlebar M8 20Nm riser pinch bolts 3 Stem special nut N A 8Nm 4 Rear Shock absorber Unit Top mounts M8 18Nm 5 Rear spindle nut M16 70 Nm 6 Swingarm Spindle M16 100 Nm 7 Front spindle nut M1...

Page 140: ...r unit top mounts 18 Nm 8 Air filter box SAI Solenoid Valve 2Nm 5 Rear spindle nut 70 Nm 6 Swingarm Spindle nut 100 Nm 7 Front spindle nut 70 Nm 2 Top yoke and handlebar riser pinch bolts 20Nm 3 Stem specialNut 8Nm 10 11 12 Upperframe swingarm lower frame adjusters 3Nm 1 Side stand switch 5 Nm TORQUE SETTINGS ...

Page 141: ...g rates give flexible and controlled feel Front fork pipe runout 0 2mm maximum Front fork main spring length 303 3mm 9 8 7 6 5 4 3 2 1 17 16 15 14 13 12 11 10 FRONT FORK LEG FRONT WHEEL SUSPENSION DESCRIPTION KEY NO QTY A1 Front Wheel Assembly 1 1 HexSocket HeadScrew M6 x12 1 2 Wheel Speed Sensor ABS 1 3 Flanged Hex Bolt M10x1 5x44 2 4 Front Caliper Assembly 1 5 Spindle Front Wheel 1 6 Spacer Disc...

Page 142: ...d replace if out of specification Inspect and replace spindle 1 if it has excess wear rust or bend 1 2 7 6 5 4 3 2 1 Floating disc 10 rivets 1 2 3 4 Å 5 6 7 8 INSPECTBRAKEPADTHICKNESS 1 Hex socket bolt 1 2 ABS sensor 1 3 ABS sensor shim as required qty 1 4 Front brake pads set 2 5 Brake pads sliding pin 1 6 Brake pads lock pin 1 7 Brake caliper mounting bolts 2 8 Brake caliper 1 KEY NO DESCRIPTION...

Page 143: ...s or damages andreplace if necessary Check and replace wheel hub bearing seated portion if there is any scoring Inspect wheel rim for run out If required adjust wheel truving STEERING SYSTEM DETAILS To maintain the vehicle specification dimension of wheelbase trail caster angle and headlight position It s necessary to control the dimension between the frontsuspensionandsteeringstem andsteeringstem...

Page 144: ...he Headstock on Frame Lock Nut Cover Headstock Seal Head stock Bearing Step 2 Place the Seal Headstock bearing and Cover Headstock on the steering stem Upper Yoke Subassembly Step 3 Pre fit the lock nut over the steering stem Apply 35Nm torque then loosen the stem nut and then set the required torque of 8Nm by using tightening tool NOTE After a set torque of 8 Nm do not turn the handlebar steering...

Page 145: ...T Continental 535 INTERCEPTOR 650 CONT GT 650 Small cantilever upperRSUmount ing method In consistent 2 10 Bar Gas pressure Inverted Piggy back reservoir Infinite preload adjustment Dia14mm UpperRSU mount solidly incorporated into frame Fixing method does not take any vertical load and only secures any lateral movement New RSU Gabriel 6 to 10 Bar Gas pressure is maintained to give consistent dampi...

Page 146: ... 1 2 Plain Washer 1 3 Spindle Long 1 4 Spacer Disc Side 1 5 Grease Seal 1 6 Deep Groove Ball Bearing 1 Double Side Sealed 7 Rear Wheel Assembly 1 8 Plain Washer 1 9 Spacer Wheel 17 20 2 1 10 Rear Brake caliper Assembly 1 11 Swing Arm 1 12 Flanged Hex Nut 8 x M1 25 4 13 Plate Chain Adjuster 2 14 Chain Adjuster LH RH Set 1 4 5 6 1 2 3 10 11 12 8 9 7 14 14 12 13 13 ...

Page 147: ... 17 x 25 x 29 1 7 Cush rubbers 4 8 Grease seal 1 9 Deep groove ball bearing 6203 2 17x40x12 double side sealed 10 Spacer wheel internal 1 11 Wheel rear assembly 1 12 Rear disc plate 1 13 Toner wheel rear 1 14 Hex socket button head screw M6x1x14 6 15 Grease seal 1 REAR WHEEL EXPLODED VIEW DESCRIPTION QTY 1 1 14 INSPECTION Inspect tyre condition and wheel rim for any damages or bend and replace if ...

Page 148: ...ng Specification Offset of the rear wheel rim is allowed 1 5 mm with respect to front wheel rim Below images only for reference 0 81 79 147 77 Vehicle Mid Plane Front Wheel Rear Wheel SWING ARM DESCRIPTION KEY NO QTY 1 Hex Nut M16 1 2 Washer Hardened 16 5 x 30 x 3 1 3 Frame adjuster special check nut 1 4 End Cup Swingarm 2 5 Bearing Sleeve Swingarm 2 6 Bearing NeedleRoller 22x28x20 2 7 Spindle Swi...

Page 149: ... 1 2 Hex Flanged Bolt M6x1x10 3 3 Tool Kit 1 4 Battery Strap 1 5 Pan Head Screw M6x12 Counter 1 6 Bracket Battery Strap 1 7 Battery 12V 12AH VRLA 3 BATTERY REMOVAL 1 Side Panel Lock RH 1 2 SidePanel RH 1 3 Side Panel LH 1 4 Panel FittingScrew LH 1 KEY NO DESCRIPTION QTY 1 7 4 3 2 5 6 SIDE PANEL RH LH BATTERY REMOVAL INSPECTION ...

Page 150: ...e torque specified Fig1 Batterytray boltfitmentandtighteningsequence NOTE The right hand lower fixing also mounts a bracket a different design is used for Conti GT 650 and Interceptor 650 models A washer is not required at this position Fig2 Rearmudguardinfill boltfitmentandtighteningsequence 1 Front Mudguard 1 2 Mud Flap Front 1 3 Hex Socket Button Head Screw M6 4 4 Mudguard Bracket Front 1 5 Hex...

Page 151: ...e 2 11 Front brake lever 1 12 Mirror rear view RH 1 13 Balancer mounting screw 2 14 Balancer Counter Weight 2 15 Grip RH Accelator Throttle 1 KEY NO DESCRIPTION QTY KEY NO DESCRIPTION QTY HANDLE BAR RH LH 13 14 15 12 6 5 1 2 3 4 11 9 8 10 7 16 18 19 20 13 14 23 22 21 17 24 4 4 16 Switch module LH 1 17 Clip on fabricated LH 1 18 Screw switch module LH 1 19 Mirror rear view LH 1 20 Grip LH 1 21 Clut...

Page 152: ...rafficator Assembly with Bulb Front RH 1 KEY NO DESCRIPTION QTY HEAD LAMP AND INSTRUMENT CLUSTER KEY NO DESCRIPTION QTY 10 Wire Guide Throttle Cable 1 11 Ignition cum steering combination lock 1 12 Ignition key 2 13 Bulb Headlight H4 Halogen 55 60W 1 14 Head lamp holder LH 1 15 Trafficator assembly with bulb front LH 1 16 Hex socket head cap screw m6 x 16 2 17 Hex socket hd cap screw m6 x 20 2 18 ...

Page 153: ...een Violet Blue Black Green Notused White Yellow Brown Red Red White Blue White Green White White Black CONNECTOR DETAILS FuelSignal Battery ve Neutral Ignition Ground Tacho Ground TachoSignal Wheel SpeedInput MIL ABSMIL NotUsed NotUsed 1 9 8 16 LowOil Pressure TurnLeft Right TurnLeft Right HiBeam ...

Page 154: ...BUTTON MANAGEMENT ManagementbyOne Set Reset PushButtonPlaced on bottom of cluster FUNCTION PRESSURE TIME Sec ACTION 0 2 t 1 Move to ODO ODO TRIP A TRIP B ODO 3 No Function 0 2 t 1 Move to TRIP A TRIP A TRIP B ODO TRIP A 3 TRIP A RESET 0 2 t 1 Move to TRIP B TRIP B ODO TRIP A TRIP B 3 TRIP B RESET SWITCH In ignition key off position FROM 10 2 LCD should be in ODO Mode KM MILE Long press and hold Se...

Page 155: ...cess needs an handling experience and also requires special riveting tool Separate spares have to be provided along with the chain Most preferable type of chain joint No implication on the chain life But careful handling has to be done during chain servicing tends to break if not fitted properly 5 No implications on chain life Extreme care to be taken while fitment of the chain using the riveting ...

Page 156: ...g Place the new chain on the U Holder Grease the connecting pin Link Place the connecting pin on the G R Position as shown in the figure PlacethesealringsinpositionandcloseitwithOP plateontheconnectingpin Insertgaugingblock on the pressure bolt Locate the pressure bolt holder as shown in the figure Ensure it is in the centre position By using the mentioned wrenches tighten the pressure bolt Now Ga...

Page 157: ... nuts in small increments evenly on both sides until the measured slack is as specifieddependent on condition Side Stand Centre Stand 4 Tightenthelocknutsandwheelspindle Re check the slack in the chain to confirm it if it is still not within specification repeat steps 1 4 A Specification Dimension A Chain Slack mm Side Stand 30 to 40mm Centre Stand 30 to 40mm Chain Assembly DRIVECHAINSLACKANDADJUS...

Page 158: ...A If the measured oil pressure is considerably lower than the standard inspect the oil pump and the relief valve if the oil pump and the relief valve do not exhibit any abnormal conditions inspect the remaining areas of the lubrication system B If the measured oil pressure is considerably higher than the standard inspect the oil filter and other areas of the lubrication system for contamination or...

Page 159: ...peed of the wheels in the vehicle ABS speed sensors are located at the Front fork lug and Swingarm mounting of the vehicle These sensors constantly monitor the rotation of each wheel to evaluate whether the ABS system needs to override manual braking of the vehicle in slippery conditions The speed sensor calculates revolutions as well as evaluates continuity between all wheels Any detection of dif...

Page 160: ...Normal Braking 4 Sensor detects when the wheel is about to lock The driver has pushed too hard 5 Control unit activates accumulator and pump 6 Fluid is bleed off to accumulator Reservoir this releases the brake pressure 7 Fluid is pumped back to reapply pressure 8 Process 6 7 happen approx up to 15 times Seconds Toner Ring Front M C Rear M C sRFP sRFP M RVR Acc AV EV EV Acc AV P U Front W C Rear W...

Page 161: ...Battery NABS_SLAMP 17 12V Lamp On 0V Lamp Off WSS_F 3 0 2V 0 6V WSP_F 12 12V Approx WSS_R 14 0 2V 0 6V WSP_R 13 12V Approx Connector Number Voltage ABS VOLTAGE WSSVOLTAGEMEASURE To test the wheel speed sensors measure the voltage whilst they are connected to the harness andthe ignition is on It is not possible tomeasure resistance of the wheel speed sensors as they are active sensors The following...

Page 162: ...el Airgap consistency WSS bracket C1032 Signal quality from the Rear WSS is not good Check the Rear toner wheel Airgap consistency WSS bracket C1024 Signal quality from the front Rear Check the front toner wheel Airgap consistency WSS is not good WSS bracket U2922 CAN Bus Off failure Diagnosis is not possible Check for CAN lines connection with tester when the failure is current U2921 CAN controll...

Page 163: ... R W 5 DUMMYSEAL 6 13B G W 7 DUMMYSEAL 8 DUMMYSEAL 9 305 R W The ABS Wheel Speed Sensor The ABSwheel speedsensor is locatedon theleft side of thefront wheel andthe rightside of therear wheel This sensor is initially assembled with a 0 5mm shim 9 18 8 17 2 11 1 10 MATING FACE VIEW Adjusting Clearance Loosentheboltfixingofthe wheel speed sensor a shim can be added or removed without the complete rem...

Page 164: ...ystem hoses shown in Fig 3 1 below are identified by different colours as described by the colour index on page 1 Fig 1 1 Secondary Air under tank routing Fig 1 2 Secondary air routing side view Fig 2 1 Map sensor hose The hose then connects directly to the LH throttle body inner spigot Fig 2 3 Map sensor hoses to throttle body The hose then connects directly to the LH throttle body inner spigot G...

Page 165: ... drain hose is fitted to the left hand fuel tank spigot as shown in Fig 4 4 Below the air box and battery bracket the three fuel system hoses are secured by the frame upper wire guide Afterpassingthroughtheupperwireguide the Evap to T joint hose red routes back up to connect to the purge valve see Fig 4 5 and Fig 4 7 Frame upperwire guide After passing through the upper wire guide the fuel tank dr...

Page 166: ... the rear brake hoses reach the airbox they are secured by two guide brackets as shown in Fig 5 3 These also guide the fuel system hoses described in section 4 The guide brackets 576316 and 576317 shouldonlybe fittedwhenall of thehose connections have been made Fig 5 3 Rear hose airbox and swingarm routing The brake hose 148049 connects the rear master cylindertotheabsmodulator On Conti GT 650only...

Page 167: ...lightly different brake hose routings due to different controlplates Thehosesareroutedsimilarly withthe exception of the brackets shown in Fig 5 4 and Fig 5 5 6 FRONTBRAKEHOSES The front brake hose 148048 connects to the master cylinder and is routed between the front forks headlampandtheinstruments asshownin Fig6 1 1 to Fig6 1 3 forConti GT 650 and Fig6 2 1 to Fig 6 2 2 for Interceptor 650 Clutch...

Page 168: ...ensorwireisclippedtothishosealongthelengthfrom the ABS modulator to the caliper ROUTING OF ALL CABLES 1 THROTTLE CABLE ROUTING The throttle cables are common between the Conti GT 650 and Interceptor 650 variants They leave the underside of the switch cube and route around the front of the RH fork leg above the headlamp mount bracket below the upper yoke They pass between the RH fork leg and the he...

Page 169: ...s is shown in Fig 1 5 Fig 1 2 Throttle cable routing to RHS of headstock Conti GT 650 Fig 1 3 Throttle cable routing to RHS of headstock Interceptor 650 Anidentificationmarker indicatesthefitment arrangementofthecables atthethrottlebody Fig 2 1 Clutch cable from lever Conti GT 650 Fig 2 2 Clutch cable from lever Interceptor 650 As the clutch cable routes around the front of the headstock onConti G...

Page 170: ...nti GT 650 Fig 2 4 Clutch cable routing through yokes Interceptor 650 Fig 2 7 Clutch cable Interceptor 650 frame fixings TheclutchcableissecuredtotheRHframedowntube and cradle tube with two omega clips The clip locations are different between Conti GT 650 and Interceptor 650 as shown in Fig 2 7 and Fig 2 8 below Fig 2 9 Clutch cable to engine fixing Fig 2 8 Clutch cable Conti GT 650 frame fixings ...

Page 171: ...en guided under the fuel tank from the LHS to the RHS by features in the ABS moulding shown in Fig 1 4 This moulding also provides locations for two zip ties as shown in Fig 1 5 Fig 1 6 The harness is fedunder the frame bridges andlies on top of the airbox as shown in Fig 1 2 and Fig 1 3 A cable tie is used for a second securing location to the LH seat rail immediately behind the cylinder head bra...

Page 172: ...eddowntheleft hand side of the battery tray and is secured by two additional fir tree cable tie clips as shown in Fig 1 8 These securing locations also help guide the harness underneath the battery tray Fig 1 8 Rear Harness Constraints Cabletie firtree clips The Hego connectors are mounted to the bottom of the ignition coil bracket as shown in Fig 2 1 which is positioned within the front end of th...

Page 173: ...tification purposes Fig 2 6 1 2 Wheel Speed Sensor Connector 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 Ziptie Fig 2 7 1 2 Horn Connectors The four horn connectors breakout from the intersectionofthemainharnessseenin Fig2 7 2 and are clipped to the secondary a...

Page 174: ...eeds from multiple connectors join into the main harness Fig 2 12 Fuel Pump Connector The fuel pump connector is the first connection stemming from the intersection with the main harness Fig 2 13 Idle Speed Stepper Motor Sensor Connector The idle speed sensor connector is forms part of the intersection mentioned in Fig 2 10 Fig 2 14 Oil Temperature Sensor Connector Fig 2 15 Throttle Position Senso...

Page 175: ...se Fig 2 17 Air Temperature Sensor The air temp sensor inserts into the LHS of the airbox Fig 2 18 1 2 Roll Over Sensor The rollover sensor breakout from the harness routes around the fuse box and to its fixed location on the rear mudguard infill on the RHS of the bike as shown in Fig 2 18 2 Fig 2 19 OBD Diagnostics Connector This connector is routes directly from the harness breakout to the frame...

Page 176: ...illpanel locatedbytworetainingfeaturesinthe panel Itconnectstothemainharnessabovethebattery Fig 2 25 Rear Sub harness Connector This allows for the rear light sub harness to connecttothemainharness andislocatedonthe RHS of the motorcycle next to the ECU Fig 2 26 Starter Solenoid Connectors These connectors are located underneath the batterytrayandareheldbyawireclip thesolenoid is mounted to the bo...

Page 177: ... in Fig 2 30 2 above This portion of harness runs down the back of the engine through an omega clip fixed to the regulator rectifier bracket and then through a wire guide over the gear position sensor until reaching the oil pressure sensor in the bottom of the engine In addition to the wire for the oil pressure sensor the omegaclipshownin Fig2 32 alsoprovidesretention for the gear position sensor ...

Page 178: ... sensor The brake and RH switch cube wires route around the side and front of the fork leg into the RH side of the headlamp bowl as shown in Fig 4 1 below Fig 4 1 Right side fly leads Fig 4 2 Front wheel speed sensor The front wheel speed sensor is secured in two locations The first is shown in Fig 4 2 above where a rubber grommet on the cable is secured in a wire guidesecuredtotheRHforkleg Thesec...

Page 179: ...nthelower rearportion of the headlamp bowl 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 STATOR COIL ASSEMBLY Specification Statorcoilphasetophaseresistance0 24 0 05Ohms Crank position sensor resistance 215 10 Ohms Stator coil is assembl...

Page 180: ...every1000kms orearlierandtopupasrequired 2 Engineoilfilterelement R R R R R R 3 InletandExhaustvalveclearance I A I A I A I A I A I A 4 SparkPlug C A C A C A C A R C A C A C A R C A C A 5 HTleadforcrack I I I I I I I I R I I 6 Rubberhose AirfiltertoThrottlebody I I I I I I I I I I I 7 Rubberhose Inletmanifold Adaptor I I I I I I I I I I I 8 Evaporative Emission Equipment rubber hoses I I I I I I I...

Page 181: ... Feeler Gauge LH VALVETAPPET CLEARANCESETTING Remove the Bolt Cover Cylinder Head Rubber Gaskets Carefully without damage respectively Ensure the L mark LH side in Camshaft Horizontally inline with Cylinder Head Cover joint face ToalignitRotatetheMagnetoAnticlockwise using special tool as per image Magneto Holder Fig 1 1 LocktheCamShaft RHside Slotusingspecialtool Cam TDC aligning plate Fig 1 2 Va...

Page 182: ...10 Nm Fig 1 3 To align the R mark LH side in Camshaft rotate the Magneto Assly in Anti clockwise Ensure the R mark LH side in Camshaft Horizontally inline with Cylinder Head Cover joint face LocktheCamShaft RHside Slotusingspecialtool Cam TDC aligning plate RH VALVETAPPETCLEARANCESETTING Insert the feeler gauge of the required specification as mentioned and Adjust the valve Tappet Screw to check b...

Page 183: ...mbled on the frame underneath the fuel tank The ignition coil provides the High tension voltage to the spark plugs and is controlled by the ECU IGNITION COIL ASSEMBLY Specification Primary resistance 2 0 Ohms 10 Secondary resistance 13 5 K Ohms 105 HT LEAD FOR CRACKS Inspect for cracks at Every service Maintenance Schedule Replace at every 40 000Km RECONFIRMATION OF TAPPET GAP After Tappet gap adj...

Page 184: ... 4 Air Filter Box Assembly 1 5 Breather Hose 1 6 Hose Idle Air Control Valve 1 7 Clip Bellow 2 8 Hose Secondary Air 1 9 Hex Socket Head Cap Screw M5X 0 8 22l 2 10 Washer M5 2 11 SAI Solenoid Switch 1 12 Vent Pipe 1 13 Hex Head Flange Bolt M10 2 14 Intake Air Temperature IAT Sensor 1 15 Hex Socket Head Allen Screw M5 2 KEY NO DESCRIPTION QTY Air cleaner is placed on right side of the vehicle It is ...

Page 185: ...t Pipe Locator Peg Replace air filter element every 10 000 kilometers or 1 year whichever is early incase of customer s motorcycle running in dirty dust condition replace as early as required Please inspect vent pipe in all services if found oil water drain and clean properly In all services remove air filter element tap it to remove dirt particles and then advised to blow compressed air distance ...

Page 186: ...utch lever for finer adjustment If proper freeplay can t be obtained or the clutch slipsduringtestdrivedisassembleandinspectthe clutch In case of technician adjusting free play at workshop please check if adjuster nut goes to end at handlebar and further adjustment as per above process is not possible Then clutchactuating arm serration position can be changed as per following procedure Check if th...

Page 187: ...etween 2 3mm If the arm position is not close to the line mark during service Change the arm position in serration ref image A B MICRO RELAYS LAYOUT NOTE The Arm clutch will be on the nearest possible serration near the marking on the LH side of the marking as per above illustration Arm Alignment Mark Image C Arm positioned inline with Alignment Mark Image D 1 Flasher Relay 1 2 Main Relay 1 3 Pump...

Page 188: ...mes Take the average mean reading to know actual compression pressure The above procedure need to repeated for RH cylinder Specified engine compression pressure 170 185 PSI Recommended tool Pressure gauge range 50 300 PSI b Connect the compression gauge repeat above said procedure as explained in the step A If compression pressure reading increases then check for Improper alignment of piston ring ...

Page 189: ...ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 188 WIRING HARNESS LIGHTING SYSTEM WIRING HARNESS CHARGING SYSTEM WIRING DIAGRAM ...

Page 190: ...ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 189 WIRING HARNESS ABS MODULATOR DOL Connector ...

Page 191: ...ING MANUAL 190 WIRING HARNESS HORN SYSTEM TOTAL WIRING COLOUR CODE Wiring Colour Code Wiring Colour Code B Black Br Brown Ch Chocolate Dg Dark Green G Green L Blue Lg Light Green O Orange P Pink R Red Sb Sky Blue V Violet W White Gr Grey ...

Page 192: ...ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 191 COMPLETE WIRING DIAGRAM CONTI GT 650 INTERCEPTOR 650 ...

Page 193: ...ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 192 WIRING HARNESS SIGNALLING SYSTEM ...

Page 194: ...ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 193 WIRING HARNESS ES STARTING SYSTEM ...

Page 195: ...ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 194 WIRING HARNESS EFI SYSTEM IGNITION ...

Page 196: ...ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 195 NOTES ...

Page 197: ...ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 196 NOTES ...

Page 198: ......

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