Royal Enfield Interceptor 650 2018 Owner'S Manual Download Page 5 | Manualshive

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Royal Enfield Interceptor 650 2018 Owner'S Manual Download Page 5

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CONTENTS

Parking ..........................................................................................................................................................................................

60

Tools Kit ........................................................................................................................................................................................

62

Minor Maintenance Tips .............................................................................................................................................................

63

Long Trip Precautions .................................................................................................................................................................. 100
Washing Procedure ..................................................................................................................................................................... 102
Storage Precautions .................................................................................................................................................................... 104
Trouble Shooting .......................................................................................................................................................................... 105
Wiring Diagram ............................................................................................................................................................................

113

Periodical Maintenance Chart ....................................................................................................................................................

116

Service Maintenance Record ......................................................................................................................................................

120

Warranty Terms and Conditions ................................................................................................................................................

123

Emission Warranty ...................................................................................................................................................................... 126
EVAP .............................................................................................................................................................................................. 132
Environment Care .......................................................................................................................................................................

134

Notes ............................................................................................................................................................................................. 136

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Summary of Contents for Interceptor 650 2018

Page 1: ...EURO IV ...

Page 2: ...dle chassisdevelopedatourstate of the arttechnologycentreintheUnitedKingdom wehopeyouenjoyridingyourmotorcycleas muchasweenjoyedbuildingitforyou This manual is your friend philosopher and guide when it comes to taking care of your motorcycle In the pages that follow you will ﬁnd ways of looking after your machine so that it remains a reliable partner in your travels and exploration for decades to ...

Page 3: ...shall be copied distributed or otherwise dealt without the express permission in writing from Royal Enﬁeld All images shown are for reference to explain and need not to be exactly the same on the model you own Technical speciﬁcations are subject to change without prior notice Avail further details on the products Repair and Maintenance Instructions at https serviceinfo royalenﬁeld com through paid...

Page 4: ...essories and Luggage 16 Technical Speciﬁcations 18 Recommended Lubricants 26 Motorcycle Identiﬁcation Numbers 28 Engine Number Details 30 Location of Key Parts 31 Operation of Controls 34 Warning Indications and Safety Systems 45 Pre Operational Checks 49 Running in Period 50 Starting 52 Gear Shifting Riding and Stopping 56 ...

Page 5: ... Trip Precautions 100 Washing Procedure 102 Storage Precautions 104 TroubleShooting 105 Wiring Diagram 113 Periodical Maintenance Chart 116 Service Maintenance Record 120 Warranty Terms and Conditions 123 Emission Warranty 126 EVAP 132 Environment Care 134 Notes 136 ...

Page 6: ...readthesecarefullyandifdisregardedmayresultininjurytoyourselforothersanddamages tothe motorcycle NOTE Indicates important and useful messagesfor better understanding CAUTION Thismessage if disregarded may result indamage to the motorcycle WARNING Indicates a potentially hazardoussituation Disregarding this message may result ininjury to rider or other persons ...

Page 7: ...EINFORMATION Name Door No Street Locality Town City Country Contact Res Oﬀ Mobile Email Licence No Valid till Model Color Engine No VIN No Tyre make Front Rear Tyre Nos Front Rear Battery make Battery No Sold by Date of Sale ...

Page 8: ...oil levels etc n Use onlygenuine Royal Enﬁeld spare partsandapproved accessories Use of other manufacturer spartsmayaﬀect the performance of your motorcycleand render themotorcycle void of warranty Visit your RoyalEnﬁeld Authorised ServiceCentre fordetails n Whenever refuelingyour motorcycle please exercise utmost cautionand carefullyobserve thefollowingguidelines Refuel ina well ventilated area w...

Page 9: ...edure mentioned inrespectivesection n Operate motorcycle only at moderate speeds and out of traﬃc until you have become thoroughly familiar with its operation and handling characteristics under all conditions n DO NOT exceed the legal speed limit or ride too fast for existing conditions Alwaysreduce speed when poor riding conditions exist High speed increases the inﬂuence of any other condition aﬀ...

Page 10: ...he following upsetting forces Wind blasts from passing vehicles Roughor uneven road surfaces Slippery road surfaces Theseforcesmayaﬀect thehandling characteristicsof your motorcycle If thishappens reduce speedof the motorcycle toa controlled condition Donot applybrakeabruptly n Operate your motorcycle defensively Remember that a motorcycle does not aﬀord the same protection as an automobile inan a...

Page 11: ...iduals under any circumstances to operate your motorcycle unless you know they are experienced licensed ridersand are thoroughly familiar with the operating conditionsof your motorcycle WARNING Regularlyinspectshockabsorbersand frontforksandlookfor leaks Replace wornoutparts Wornout partscanadversely aﬀect stability and handling WARNING Foryourpersonal welfare allthe listed serviceand maintenance ...

Page 12: ...gine isturned oﬀ Failure to wear proper or protective clothing could result in seriousinjury WARNING Exhaust gas contains poisonous carbon monoxide and chemicals known to cause cancer birth defects or other reproductivedefects WARNING Motorcycle batteries containlead acidsand chemicalsknowntocausecancer birthdefectsor other reproductiveharm Exercise extreme cautionwhile handlinga battery wash hand...

Page 13: ...RNING DO NOT tow a motorcycle The steeringand handling of the towed motorcycle will be impaired due to theforce of the towline If a motorcyclemust be transported usea truckor a trailer WARNING DO NOT pull a trailer behind a motorcycle Towing a trailer may causereduced braking eﬃciency tyre overloading and SAFERIDINGTIPS GUIDELINES unstable handling asit may cause loss of control of the motorcycle ...

Page 14: ...tasafe speed that isconsistent withthe typeof road surfaceyouare on Paystrict attentionwhile ridingonthe following surfaces Dusty Oily Icy Wet Sand n Watchforloose debris suchasleaves slippery substancesorgravelthat canhamper thestabilityofyour motorcycle n Keep to the correct sideof the road centre line whenmeeting oncoming vehicles ...

Page 15: ...als as well asother vehicles n All traﬃc signs includingmanual controlsat intersections should be obeyed promptly SLOWDOWN at traﬃc signs near schools and CAUTION signs at railroad crossings n When intending toturn signal at least 100 feet 30 5meters beforereachingthe turning Beclose to the centre line unlesslocal rulesrequire otherwise slowdownand then turncarefully n Never jump a traﬃc light Whe...

Page 16: ...anceof vehicles objectsseen inthese mirrors NOTE Toestablish the relative distance of vehicles objectsbehind your motorcycle throughthemirrors adjust eachmirror in sucha way that a small portionof your shoulder isvisible and alarge portionbehind your motorcycle isseen clearlywith RULESOFTHEROAD reference to your ridingposture n Whenparking themotorcycle parkona ﬁrm and ﬂat surface to prevent it fr...

Page 17: ...te weight evenly onboth sides of the motorcycle DO NOT exceed 110km h 70 mph when riding solo carrying a pillion or payload on an accessory equipped motorcycle n DO NOTload bulky itemsbehind the rider or add weight tothe handlebarsor front forks n DO NOT exceed 6 6 pounds 3 kgs maximum weight ineachRoyal Enﬁeld Genuinemotorcycleaccessory pannier n Re checkthe luggage periodicallytoensureit issecur...

Page 18: ...cle WARNING Royal Enﬁeld cautionsyou against use of nonstandard partssuchasaftermarket and custommade extended front forks which mayadversely aﬀect the performance and handling of the motorcycle Removing or altering original parts may adversely aﬀect the performance of the motorcycle causing an accident which could result in serious injury or loss of life WARNING DO NOT ignore model design speciﬁc...

Page 19: ...78mm Stroke 67 8mm Swept volume 648cc Compression ratio 9 5 1 Max Power 34 9 kw 7250 rpm Max Torque 52 3 Nm 5150 rpm Idle RPM 1200 80 RPM Starting E Start Air ﬁlter element Paper element Lubrication Forced lubrication Wet sump with pump driven oil delivery Gear Box 6 Speed Constant Mesh ...

Page 20: ...erial gallon Engine oil grade TOTAL ELF MOTO 4 TECH SAE 10W50 API SL JASO MA2 SYNTHETIC Fuel Supply Fuel Injection Cooling Air cooling IGNITION SYSTEM Ignition Digital Spark ignition o Ignition Advanced 11 25 BTDC Spark Plug BOSCH UR5CC Spark Plug Gap 0 7 to 0 8 mm TECHNICALSPECIFICATIONS ...

Page 21: ...ydrive Gear Primary ratio 2 05 1 Gear box 6 Speed Constant Mesh st Gear Ratio 1 2 615 1 nd 2 1 813 1 rd 3 1 429 1 th 4 1 190 1 th 5 1 040 1 th 6 0 962 1 Secondary drive Sprockets and Chain 5 8 Pitch Secondary Ratio 2 533 1 TECHNICALSPECIFICATIONS ...

Page 22: ...ks 88 mm travel Hydraulic Disc Brakes Front and Rear with ABS system Front 320 mm disc ABS Rear 240 mm disc ABS ABS BOSCH 9 1 Brakes Brake Fluid Grade DOT 4 Capacity Front 50 ml Rear 100 ml Tyre size Front Rear Dual Channel ABS 100 90 18 Pirelli Phantom Sports Comp 130 70 18 Pirelli Phantom Sports Comp TECHNICALSPECIFICATIONS ...

Page 23: ...1 RON Research Octane Number or Higher Induction Fuel Injected Fuel tank capacity 13 7 litre 3 imperial gallon Low Fuel Warning 2 9 litre 0 63 imperial gallon DeadStock 0 75 litre 0 16 imperial gallon The above values are approximate and the actual fuel ﬁlling capacitywill vary from the valuesmentioned 32 psi 2 20 kg cm 36 psi 2 53 kg cm With Pillion Steering Lock Combination Lock ...

Page 24: ...arenot approved byRoyal Enﬁeld may not only disqualify for warranty but will alsoaﬀectsthe performance of the motorcycle ELECTRICALS System 12V DC Generation Alternator Alternator Output 156 W 1100 rpm Battery 12V 12 Ah VRLA Head lamp 12V H4 60 55 W Brake Tail lamp 12V P21 5W Halogen Turn signal 12V R10W Instrument Cluster Digital Instrument Cluster withLCD Horn 320 Hz Low and 420 Hz High Tone Sta...

Page 25: ...TECHNICALSPECIFICATIONS DIMENSIONS Rake 24 degrees Front Wheel 18 M C xMT 2 50 Rear Wheel 18 M C x MT3 50 Length 2119 mm Width 857 mm with mirrors Height 1120 mm Wheel base 1398 mm Ground Clearance 174 mm ...

Page 26: ...kg Max payload 200 kg Inclusive of rider mass n Values dimensions given above only for your guidance n In view of continuous improvements being done on our products the speciﬁcations could change without prior TECHNICALSPECIFICATIONS NOTE notice ...

Page 27: ...usly aﬀect performance NOTE Recommendation subject to change without notice Front Fork Oil Brake Fluid Brake System Capacity Grade DOT4 TOTAL ELF MOTO 4 TECH SAE 10W50 API SL JASO MA2 SYNTHETIC 1st DryFill 3 9 litre 1 03 imperial gallons Grade Routine Oil Change 3 1litre 0 82 imperial gallons Capacity Grade 2W 25 HPCL 473 ml Fork Front 50 ml Rear 100 ml Dual Channel ABS ...

Page 28: ...horised Service Centrefor the safe disposal of the used oilsto prevent environmental pollution In case theoilsare replaced privately it isadvised toensure theold removed oilsare collected carefully and disposed through a certiﬁed disposal agency Similarly hazardous waste such as old discarded batteries tyres tubes cables gaskets oil ﬁlters etc should also be disposed oﬀ carefully and properly thro...

Page 29: ...t side steering head tube in the formof label Sample VIN ME3 X X XX X X J X X X X X X X Manufacturer scode Type of Frame Type of Engine Commercial Name Ignition System Transmission Type Production Year Assemblyfactory ProductionSerial No 2017 H 2018 J 2019 K C Chennai K Kanchipuram ...

Page 30: ...FICATIONNUMBERS Punched on the steering head tube right side VIN INFORMATION LABEL It isillegal totamper withthe VIN information label as it is the only meansof identiﬁcations of the motorcycle CAUTION M E 3 C N E H T 6 H K 0 0 0 0 0 1 ...

Page 31: ...n details It isillegal to tamper with the engine number as it is the only means of identiﬁcations of the engine Engine Family Engine Capacity Type of Cooling Transmission Fuel Feed Place of Manufacturing Production Month Year of Manufacturing 2017 H 2018 J 2019 K P 7 A 6 F K H 1 000086 A Jan h Aug K Sep N DEC 0 Chennai 1 Kanchipuram Production Serial Nos ...

Page 32: ... Cluster 7 Ignition Switch 8 Malfunction Indicator Lamp 9 RPM Tacho Meter 10 Engine Kill switch 11 Electric Start Switch 12 Fuel Tank Cap km h 00 2 0 00 4 0 00 6 0 00 80 00 100 00 120 00 14 0 00 16 0 00 18 0 00 20 0 00 E ODO 00 F km 00 OF F R P M x 1000 1 00 2 00 3 00 4 00 5 00 6 00 7 00 8 00 9 00 ABS N 45 2 1 3 89 7 6 10 11 12 ...

Page 33: ...LOCATIONOFKEYPARTS 1 Right Traﬃcator Rear 2 Right Traﬃcator Front 3 Horn 4 StarterMotor 5 BrakePedal 6 Brake LeverRear 7 Right Side Panel 8 Brake Lever Front 32 8 2 3 4 5 6 7 1 ...

Page 34: ...33 LOCATIONOFKEYPARTS 1 Left Traﬃcator Front 2 Left Traﬃcator Rear 3 Left Side Panel 4 SideStand 5 Centrestand 6 Gear Change Pedal 7 Spark plug 7 6 4 5 2 1 3 ...

Page 35: ...and remove the key n OPERATIONOFCONTROLS IGNITION SWITCH To unlock insert the key in steeringat lock position and turn clockwise direction NOTE n Key is common for ignition petrol tank lock steering lock and side panels n Key can be removed from fuel tank side panel only in locked position from the key slots OFF Steering unlock ignition OFF ON Steering unlock ignition ON ...

Page 36: ...ash plate n Over ﬁllingmay result ingasoline entering the EVAP canister and may damage the EvaporativeEmission System CAUTION Gasoline vapour ishighly explosive Please ensure there are noopen ﬂames or sparksnearby while refueling andﬁll fuel onlyina wellventilated area Pleaseensuregasolinedoesnotspillonpaintedsurfaces Incasefuelspillsoverthepaintedsurfaceswipeitoﬀ immediately as it mayleavea perma...

Page 37: ...2 Anti splashplate OPERATIONOFCONTROLS 3 Maximum fuel level ENGINE KILL SWITCH Engine OFF Engine ON CAUTION n Turn oﬀ ignition switchwhen engine is not running Failure to do sowill discharge the battery due tothe headlamp being continuously ON ...

Page 38: ... maximum of 5 seconds HI BEAM LOW BEAM SWITCH High beam Low beam HORN Pressthehorn button to sound horn n When the headlamp is in ON condition High Low beam will be selected by toggling the switch Highbeamindicator lamp located ininstrument cluster will glowwhen high beamisselected ...

Page 39: ...SIGNAL SWITCH OFF Push to cancel Right turn signal ON Left turn signal ON DAY FLASH Press theswitchfor Dayﬂash Pushthebuttonfrom OFF positiontoeither left orright before turning as neededand restore to OFF positiontostop blinking ...

Page 40: ...eleft side panel remove theseat andretainingscrew pulland disengage the side panel fromlocater and gentlyremove the side panel SIDE PANEL RIGHT n Turn keyclockwise tounlock the side panel n Pull the side panel along with keytogently remove the sidepanel ...

Page 41: ...3 Selection Button 4 Trip Meter A and B 5 Turn Signal Indicator 6 Hi beam Indicator 7 Engine Malfunction Indicator 8 BatteryLow Voltage Indicator 9 Fuel Level Indicator 10 ABS Indicator OPERATIONOFCONTROLS 11 Neutral Indicator 12 Low Oil Pressure Indicator 13 Tachometer 1 2 4 9 3 13 5 7 6 81011 12 ...

Page 42: ...torcycle hascovered 1 SPEEDOMETER The Speedometer indicates the speed at which motorcycle is travelling and has both kms OPERATIONOFCONTROLS miles calibration WARNING It isillegal totamper withthe odometer display or reset the total kms miles themotorcycle hascovered It isillegal to ride the motorcycle after disconnecting thespeed sensor of the motorcycle ...

Page 43: ...tton switch will change the display from odometer Trip A Again another press onthe select button switchwill change the display from Trip A toTrip B NOTE 1 Set the displayasTrip A or Trip B ascurrent mode 2 Presstheselect buttonfor more than3seconds 3 Automatically the display will become zero OPERATIONOFCONTROLS 3 SELECTOR BUTTON The selector knob will help toselect between odometer Trip A or Trip...

Page 44: ...in the tachometer Whenboththe ignitionandengine kill switchisin ON position and after vehicle isstarted the MILwill glowforfewsecondsandswitch OFF thisindicatesthat all thefunctionsofElectronic fuel injection EFI system is functioning normally In the event of any malfunction in the EFI system MIL will glow continuously Itisrecommended totakethemotorcycletoanearestRoyalEnﬁeldAuthorised ServiceCentr...

Page 45: ...cator turns OFF automatically Incase the batteryvoltageisbelow12 volt and thebatteryisnot charging when the engineis started the batterylow voltageindicator will continue to glow inthe instrument cluster CAUTION DO NOT ride the motorcycle if the battery low voltage indicator is glowing continuously and please get the charging systemchecked throughan Royal Enﬁeld Authorised Service Centre immediate...

Page 46: ...empty E whenthe fuelleveldecreases fromfulltank level F The last bar of thefuel level indication inthe instrument cluster will blinkcontinuously whenthe fuel is less than 3litre 0 8 imperial gallon Please do not ride the motorcycle with the low fuel indication blinking continuously as it may not only result in the motorcycle running out of fuel but will alsocause seriousdamagetothe fuel pump Pleas...

Page 47: ...he brakesfromlockingthewheelswhile reducingthespeed of the vehicle This will help the rider to control the motorcycle An ABS indicator lamp is provided inthe cluster as shown in the adjacent image to warn the rider in the event of any malfunction of the ABS When the ignition and engine kill switch are switched in ON position the ABS sign will glow and remain ON till the motorcycle attains a speed ...

Page 48: ...cornering ABS cannot estimatethe weightshifts and momentumof the motorcycle while negotiating a corner and therefore prevent skidding due tolossof traction Please anticipatethestopping distance requiredfor thespeedoftraveland applybrakeswellinadvanceso astobring the motorcycle toa safe stop Please applybothbrakes simultaneously to stop withbetter tractionand control of the motorcycle Failure toadh...

Page 49: ...cator glows ON and turnsOFF when the vehicle speed exceeds 5 km h 3 1mph n Please check thebrake ﬂuid at MAX level inthe front and rear brake reservoir and ensurethere isno leakinthebrake systems n Applyboth thebrakes simultaneouslyfor better eﬃciency n In the event of theABS indicator remaining continuously ON please takethemotorcycletoanearestAuthorisedRoyalEnﬁeldServiceCentre toinspect thebrake...

Page 50: ...m surface n Ensure gear is inneutral position and theneutral lamp isglowingin the instrument cluster n Turn OFF ignition andswitch OFF engine kill switch wait for a few secondsand turn ON the Ignitionand switch WARNINGINDICATIONSAND SAFETYSYSTEMS ON engine kill switch once again tostart the engine 13 TACHOMETER Thisindicates the engine speed inRPM CAUTION When the indicator glows continously and i...

Page 51: ...lyafter longperiodsof storageto determineif anyadditional maintenance is necessary 1 Adequate fuel inthe tankfor the journeyplanned 2 Tyresfor correct pressure abrasionsor cuts 3 Ensure chainfor proper tension and suﬃcient lubrication 4 Brakes clutch steeringand throttle for proper responsiveness 5 Handle bar controls for smooth operation 6 Engine oil level 7 Wheel spokes for proper tightnessand d...

Page 52: ...ding the motorcycle 3 Avoid full throttleoperation and donot ride at constant throttlecontinuously Vary thespeed by 10 while riding 4 It is recommended to use half clutch condition when commuting in the city traﬃc condition alone Engine RPM around idling to2000 RPM at 1st gear condition In Other gears and higher RPM avoid using half clutch which will proportionately reduce the clutchlife Duringacc...

Page 53: ...0 kms 501 2000 kms NOTE The belowtable indicates the recommended engine speed in rpmfor optimum performance of the engine DistanceCovered Max Engine Speed 0 to800 kms 0 to 500 miles 4000 rpm 800 to 1600 kms 500 to 1000 miles 6000 rpm 20 kmph 15 kmph 1 30 kmph 25 kmph 2 40 kmph 30 kmph 3 55 kmph 45 kmph 4 70 kmph 60 kmph 5 85 kmph 75 kmph 6 ...

Page 54: ...back and forth gently while simultaneously shifting the gear Ensure gear is in neutral position and the neutral lamp is glowing in the instrument cluster n Turn ignition key to ON position and engine kill switch on right hand side handle bar to RUN position ...

Page 55: ...m is functioning normally In the event of any malfunction in the EFI system the MIL will glow continuously CAUTION n In casethemalfunctionindicator DOES NOTturn OFF get the motorcyclechecked throughanRoyal Enﬁeld Authorised Service Centre for rectiﬁcation n Checkthefuellevel indicator intheclusterfor adequate fuelinthefueltank Incase the last bar is blinking continuously it indicates low fuel leve...

Page 56: ...ts for a maximum of STARTING n Disengage clutch by pulling in the clutch lever and hold it in depressed condition NOTE Incase theenginedoesnot startwithin5second releasestarter switchand waitfor about 5second before attempting to start the engine again 5 seconds ...

Page 57: ...tifyand correct the reasonfor not starting CAUTION NEVER accelerate assoon as the engine starts especially in cold condition The engine should be allowed to run in idle RPM for at least 2 minute for the engine oil to circulate and lubricate all the internal moving parts and for the engine temperature to raise Failure toadhereto thisimportant information will causeseriousdamage tothe engine interna...

Page 58: ... attempting a gear shift Failure to fully depress the clutchlever will cause a roughstart ORstalling of the engine besides causing damage totransmission parts n Whenthe vehicle isinNeutral position press gear shift lever downwithtoe toengage 1stgear GEAR SHIFT PATTERN 1 N 2 3 4 5 6 ...

Page 59: ...cletomovesuddenly which willleadtolossof control leading toanaccidentresultingininjuryand orlossoflife torider otherroad users passed by besidesdamage tothe motorcycle n Always exercise utmost caution while releasing clutch and riding the motorcycle n Lift gear shift lever up withtoeto shift to 2nd and subsequent gears n As soon asthemotorcycle reachesa speed of 20 kmph in1st gear position shift t...

Page 60: ... theengine fromstalling or straining topull n Always shift to lower gears asappropriate whenever slowingdown tostop thevehicle n Shift gearsto neutral position just before bringingthe vehicle toa complete stop always n Close throttle fullyand release the clutchlever slowlyensuringthemotorcycle isinneutral positionand neutral lamp is glowing n Stop the motorcycle in a safe place turn OFF ignition a...

Page 61: ...entre stand suchthat boththe legsof thestand are restingona ﬁrmground n Applypressureonthefulcrumleveronthecentrestandandpullthemotorcyclebackward n Lockthesteeringandensurethehandlebarislocked ﬁrmly beforeremovingthekeyfrom the ignitionbarrel PARKING MOTORCYCLE ON CENTRE STAND PARKING ...

Page 62: ...rking andensure it isparked ona ﬁrmand ﬂat surfacetoavoid themotorcyclefrom falling over and causing injury to you or to others and damage tothe motorcycle parts PARKING MOTORCYCLE ON SIDE STAND n Select a ﬁrm ﬂat surface n Extend side stand Tilt the motorcycle to the left side till it is supported ﬁrmly on the ground ...

Page 63: ...n the right side panel of the motorcycle S No Description Qty 1 C Spanner 1 2 Allen Key 6mm 1 3 Allen Key 5mm 1 4 Allen Key 4mm 1 5 ExtensionTube 1 6 Ring Spanner 24 x 14 Combination 1 7 Screwdriver 06 x160 1 8 Double End Spanner 10 x12 2 ...

Page 64: ...for an complete maintenance we recommend youto get in touch witha Royal Enﬁeld Authorised Service Centre HAND LEVERS CENTRE AND SIDE STAND PIVOTS n Cleanthe pivot pointsand ensure theyare free of anydirt grime rust etc n Lubricate thepivots NOTE Wipe oﬀ theexcess lubricant to prevent dirt and grime fromaccumulating ...

Page 65: ...etelycovered with the cleaning solvent If necessaryuse asuitable brushtoremovehard depositsfrom the chain n Wait fora few minutesand cleanthechainthoroughlyfromanydirt grime etc n Rotate rear wheel slowly and simultaneously apply recommended chain lubricant onthe chain links n MINORMAINTENANCETIPS Wipe oﬀ excess chain lubricant after a few minutes with a clean cloth ...

Page 66: ...e is inupright positionona ﬁrmandﬂat surfaceonits centre stand n Start theengine and allowit toruninidlingrpm for about 2 minute and switch oﬀ the ignition n Wait for 2 minute for the oil to settle down and check oil level through the window on RH cover of the engine n The level iscorrect onlyif the oil is found betweenthe MIN and MAX marksonthe cover RH n If necessarytop up ONLY withrecommended e...

Page 67: ...ic drain plug Remove it along withthe washer todrain oil completelyfrom the engine WARNING DO NOT spill theengine oil Store used oil in a separate container anddispose it Avoid skin or body contact with the oil Promptly wash the aﬀected areas with soap and water till it is cleaned thoroughly MINORMAINTENANCETIPS ...

Page 68: ...ﬁller cap n Start and warmup enginefor 2 to 3minutesand thenturnit oﬀ Check oil level MINORMAINTENANCETIPS NOTE through oil level window Ensure the engineoilisdrained completely Drain theoil completely and to avoid oil spilling ENGINE OIL FILLING CAUTION DO NOT over ﬁll engine oil as excess oil will spill over through the crankcase breathing systemand clog the air ﬁlter Reﬁll the engine oil recomm...

Page 69: ...spark plug cleaning machine MINORMAINTENANCETIPS Gap 0 7 to 0 8 mm n Remove spark plugfrom the cleaning machine checkand set electrode gap between 0 7 to 0 8 mm n Position spark plug in the spark plug testing machine and check for proper functioning of the spark plug n Always replacespark plugs ONLY as per recommended speciﬁcation n Apply a thin ﬁlm of anti seize on the sparkplug mounting and thre...

Page 70: ...ake ﬂuidishighlycorrosiveand cancause damage to painted parts Please ensure that brake ﬂuid doesnot spillonany part of the motorcycle Inthe event of a spill please clean the area immediately witha soft wet clothtoavoid damageto theaﬀected part DO NOT mix diﬀerent brake ﬂuid grades Use ONLY DOT 4 Brake ﬂuid Front Brake Rear Brake n Top up only withDOT 4 brake ﬂuiduntill level isbetween MIN and MAX ...

Page 71: ... rimfor wobblingor runout n Checkuniformseatingofthetyrebeadingontherimwheneverthetyreisreassembled n Useonlyrecommendedtyresandtubes inﬂatedtocorrectairpressureasgivenbelow n Inspect the tyresperiodicallyfor tread wear cracksand cuts Minimum tread depth Front tyre 1 mm Rear tyre 2 mm Front Rear Solo 32 psi 2 20 kg cm 36 psi 2 53 kg cm With Pillion 32 psi 2 20 kg cm 39 psi 2 74 kg cm ...

Page 72: ... the motorcycle and ensure front wheel is oﬀ the ground by minimum 2 inches n Fromwiring harness RH side disconnect the speedo drive coupler n Loosen thepinchbolt on the front fork bottomright side n Remove the axle nut alongwithwasher holdthe wheel axle onthe right side and loosen hex nut on theleft completely n Remove axle nut and washer from wheel axle ...

Page 73: ...akingsystemand ABS n Tap and remove the front wheel spindle gently tap axle from left side while supporting wheel at the bottomthenremove axle fromthe right side Do not pressthe brake lever when front wheel is removed as this will result in the brake pads coming too far out of the brake caliper CAUTION Take care to secure the wheel spacers and speed sensor while removing the axle from the forks n ...

Page 74: ...re the brake discislocated between thebrake pads n Supportfront wheel at thebottomand ensurethemountingholesarealigned toinsert thewheel axlealong theright side fork end Gentlytapaxleintowheeltillthethreaded portionof axle isfullyvisibleon the left side fork end n Assemble washer and nut on axle n Hold the wheel axle ﬁrmly on right side and tighten axle nut ﬁrmly on left side to a torque of 70Nm n...

Page 75: ... eﬃciency CAUTION Please exercise utmost caution while reassembling the frontwheel onthe motorcycle please ensure the wheel isﬁtted correctlybefore attempting to ride the motorcycle Failure to do so may result in the motrocycel not performing correctly may lead to an accident causing injury to you other road usersand maylead toloss of life MINORMAINTENANCETIPS ...

Page 76: ...right ona ﬁrmand ﬂat surface withthe rear wheel atleast 6 inchesraised above from thesurface n Observe and markthe alignment indexes onboth chain adjuster on left and right side swing arm n Loosenthe locknutsand adjusternutsfullyonthe left and right side chainadjuster ...

Page 77: ...Release the brake hose gently and remove caliper assembly from swing arm on MINORMAINTENANCETIPS right side n Ensure brake hose doesnot get damaged or kinked while removing n Support caliper assembly suitably and away from swing arm n Releasethechainfromthesprocketand ensure it doesnot getjammedordamaged when removingrear wheel n Remove supportfromwheelbottomand gentlyslideoutrear wheelfromtheswin...

Page 78: ...e thebrake padsto dislocate from thebrakecaliper CAUTION n Place a 4 mm thick wooden piece or cardboard sheet between the brake pads to avoid activation of brake pads if rear brake pedal is accidentally pressed DONOT pull up the rear brake pedal tolift or raise the motorcycle for anyreason CAUTION ...

Page 79: ... Locate rear wheelwiththe sprocket totheleft sideensuring the brake discin between the brake pads onright side n Lift up the rear wheel and ensure that theslotsintheswingarm brake caliper bracket holesin chainadjustersandthe centrehole in the hub are aligned n Support rear wheel suitably andinsert rearwheel spindle alongthe leftside swingarm intothe wheel hub n Ensure thatthelongsteppedspacer islo...

Page 80: ...el hubslot till the threadsare completelyvisibleonthe right side n Assemble the drivechain on the sprocket andensure it isseated correctly n Checkfor free and smoothrotationof the rear wheel n Assemble washer and hex nut on wheel spindle on right side ...

Page 81: ... side set torque to 70 Nm n Locate the brake hose inthe clips along the swing arm right side n Checkrear brake for proper operating eﬃciency CAUTION Pleaseexercise utmost caution while reassembling therear wheel onthe motorcycle Please ensurethewheel isﬁtted correctly before attemptingto ride the motorcycle Failure todosowill result in poor performance of motorcycle whichmaylead toanaccident causi...

Page 82: ...lockwise toincrease thefree play n Tighten lock nut after adjustment isdone n Check free play 2to3mmat clutchleverpivotonhandlebar end ifdesiredfree playisnot achieved readjust REAR BRAKE LIGHT The brake light glows once youpressthebrakelever If brake light isnot glowing check the brakelight switch wire for proper connection ...

Page 83: ...tral position n Measure the drive chainfree playas shown Thedrivechainfreeplayis20mm to 30 mm 1 If the drive chainfree playis found to be incorrect adjust as follows a Loosen the axle nut of the rear wheel axle b Loosen the lock nut ontheadjuster at bothend of the swingarm c To reduce thefree play tightentheadjuster nut onthe adjuster evenly n ...

Page 84: ...rmlyto the left side and tightenrear hex nut to a torque of 70 Nm h Tighten the adjuster locknut using a 24mm spanner MINORMAINTENANCETIPS WARNING Chain slackness beyond 30mm will lead to chain slippage and may also cause increased wear rates to chain and sprockets Maintaindrive chainslackness withinthespeciﬁed limitsat every1000 kmsinterval Please ensure thebothwheelsarealignedcorrectly afteradju...

Page 85: ...ust be periodicallychecked for cleanlinessand corrosionfree MINORMAINTENANCETIPS terminals NOTE The poor contact or loose ﬁtment of batteryterminalsmaycause ECU failure DISMANTLING n Switch OFF the engine and remove ignition keyfrom the key barrel n Disconnect battery negative ve terminal bolt ...

Page 86: ...85 MINORMAINTENANCETIPS n Remove 3Nos Hex head boltsfromtool box to access thebattery n Disconnect battery positive ve terminal frombattery ...

Page 87: ...86 n Pull batterystrap belt downwards and release strap lock from battery strap bracket n Loosenand remove hex ﬂangehead screw frombatterystrap bracket MINORMAINTENANCETIPS ...

Page 88: ...87 n Removebatterystrapbracket frombattery tray n Remove batteryfromtray MINORMAINTENANCETIPS ...

Page 89: ...waysdisconnect the black negative ve batterycable ﬁrst and thenthe red positive ve cable while removing the batteryconnections NOTE For checking the battery voltagecontact Royal Enﬁeld Authorised Service Centre or batteryservice centre ...

Page 90: ...89 ASSEMBLY n Assemble batteryin totray n MINORMAINTENANCETIPS Place batterystrap bracket into batterytray ...

Page 91: ...90 n Locate and tighten ﬂanged head screwinto batterystrap bracket n MINORMAINTENANCETIPS Pull batterystrap belt downwardstoﬁxstrap lockintobatterystrap bracket ...

Page 92: ...91 n Connectbatteryred positive ve terminalbolt n MINORMAINTENANCETIPS Locate and tighten3 nos hex head boltsintotool holder ...

Page 93: ...ative ve terminal bolt MINORMAINTENANCETIPS CAUTION Keepthered ve positiveterminal and ve negativeterminal cablesﬁrmlyconnectedtothe respectivebatteryterminals Failure to do so mayresult in damage to the motorcycleelectrical system CAUTION Connect the black ve negative terminal after connect red ve positive terminal only ...

Page 94: ...L COMPONENTS HEADLAMP BULB REPLACEMENT n Loosen the rim holdingscrew on top and take out the head lamp dome n Disconnect electrical connections n Thumb push and remove the bulb holding clamp gently n Remove the bulb usinga clean and soft cloth ...

Page 95: ...amp n Connect the electrical connections n Positionhead lamp dome onto thehead lampshell and tightenthe mounting screw on top NOTE Never touchthebulb withyour ﬁngers Finger printswill etchthe glassand decrease bulb life apart from causing burnsto your ﬁngers MINORMAINTENANCETIPS Always hold the bulb with gloves and clean dry cloth during handling ...

Page 96: ...seat lock cable n Remove the tail light cover by unscrewing its mounting screw n Hold the bulb press inside and rotate anticlockwise to removethetail lightbulb fromitsholderusingacleancloth n Replace the bulb 12V 21 5Wusing a soft clean cloth n Re assemblethetaillightinthereverseorderofdismantling process ...

Page 97: ...ing n Open the indicator housing n Remove the bulb holder with help of a screw driver n Removethe bulbandreplace the sameusinga softandclean cloth n Reﬁt the holder toitsproper position n Fix therubber gasket cover n MINORMAINTENANCETIPS Assemble the indicator housing cover ...

Page 98: ...nit ECU may fail due toloose electricalconnections loose battery terminals etc Hence it isvery important to keep all the electrical connections are intact n Thefuse carrier islocated under the seat n Unlock side panel RH n Release seat lock by pulling knob and remove the seat ...

Page 99: ...Please get the electrical system of your motorcycle checked thoroughlyand get the faults corrected immediatelyafter experiencing any fuse failure Failure todoso mayresult inrepeated fusefailure Usage of fuses other thanspeciﬁed rating will damage the complete electrical system Fuse ID Color Rating Remarks Number 6 R 15 A Lighting Fuse Head Lamp 7 R W 10 A Accessory Fuse 8 R 10 A ABS Fuse 9 R W 25 ...

Page 100: ...ovetheairﬁltercoverscrewsandthentakeout n Pulloutﬁlterelementandcheckfordirt Cleanﬁlterelementcarefully MINORMAINTENANCETIPS AIR FILTER NOTE Usage of highpressure compressed air is not recommended to cleanair ﬁlter element Fitment of air ﬁlter element isinthe reverse order of removal process airﬁlterboxcover ...

Page 101: ...ceCentre n Ensure suﬃcient quantityof fuel isalwaysavailable inthe fuel tankfor the journeyplanned n Checkandcorrect tyrepressureifnecessary CHECKS AFTER EVERY 1500 KMS OF RUN n Anyloosefasteners n Conditionof the tyres n Correct oillevel inengine n Working of all lights and horn n Proper drive chaintension n Clutchcable free play ...

Page 102: ...101 LONGTRIPPRECAUTIONS ITEMS TO BE CARRIED n Tools kit n Bulbsfor headlight traﬃcator light and mini blade fuses 10 and 15 A n Accelerator and clutchcable n Sparkplug spark plug cap n Sparetubes ...

Page 103: ...hengine area witha recommend noncorrosive solvent toremove dirt or grease n Use lowpressure water jet toclean n Neverspraywaterwithgreatforceonheadlamp meter clusterunit ﬂasher lights front andrearwheelhubs electrical connections and wires control cables EFIcomponents sparkplug battery side panels n Donot applyanycorrosive solvent onpainted surfacesor rubber parts n Use lukewarmwater and mild dete...

Page 104: ... linkages drive chainetc with lube oil n Polish the painted and plated surfaces using recommended automobile polishing wax n Start the engine and allowtorun at an idling speed for a fewminutes to warm up engine n WASHINGPROCEDURE Drive the motorcycle slowly applyboththebrakesintermittentlytodryup thewater inbrake pads n If possible use compressed air and blow oﬀ water particles from the obscure ar...

Page 105: ...ter 5 minutes of application n Removebatteryfromthe motorcycle Cleantheterminalstofreefromcorrosionandapplypetroleumjellytoterminals and cover boththemusing a plastic sheet n Storethebatteryina cool dry andwell ventilated place n Cover the silencer withsuitable bagsto prevent moisture entry Set the motorcycleon itscentre stand n Applyanti rust solutionson all plated parts Take care not toapply thi...

Page 106: ...ult in the motorcycle not functioning properlyor serious injury CAUSES REMEDIES Contact Royal Enﬁeld Authorised ServiceCentre I ENGINE FAILS TO START 1 Ignition switch in OFF position Turn Ignition switch ON 2 Engine kill switch in OFF position Kill switch to ON position WARNING Please get the electrical system of your motorcycle checked thoroughly and get thefaults corrected immediatelyafter expe...

Page 107: ...ne Malfunction indciator is glowing Get the motorcycle inspected through a Royal Enﬁeld Authorised continuously ServiceCentre 6 Sparkplug cap lead not connected Fix cap lead ﬁrmly 7 Spark plug electrode dirty fouled Cleansparkplug 8 Sparkplug insulationcracked Replace sparkplug 9 Main or EFI fuse blown out Replace with new fuse Contact Royal Enﬁeld Authorised ServiceCentre ...

Page 108: ...oose connections CheckMAPorEOTorTPSsensorwiring couplerlooseconnections 4 Water infuel tank Clean fuel tank Fill tank with fresh petrol 5 Engine startsbut shutsof immediately Check if the MIL indicator continuously is glowing If yes 6 Engine misﬁres and runs erratically Check if the MIL indicator continuously is glowing If yes Contact Royal Enﬁeld Authorised ServiceCentre ...

Page 109: ...4 Under inﬂated tyres Inﬂatetocorrectpressure 5 Accelerator cablefree playexcessive Adjust accelerator cable free play 6 Clutch slipping Adjust clutchcable free play 7 Faulty fuel supply fuelpump Remove fuel pump and clean ﬁlter injector blocked TROUBLESHOOTING CAUSES REMEDIES 8 Poor pickup Checkif the MIL indicator is glowing If yes Contact Royal Enﬁeld Authorised ServiceCentre ...

Page 110: ...and top up if necessary 2 Clutch slipping Check andcorrect 3 Cylinder ﬁns not clogged Cleanthecylinder ﬁnsat regular intervals V EXCESSIVE FUEL CONSUMPTION 1 Under inﬂated tyres Inﬂatetocorrect pressure 2 Choked air ﬁlter Clean Replace 3 Fuel leakage Check and rectify tankﬂoat unit drainpipe breather pipe fuel line pump EVAP system ...

Page 111: ...brake pads 2 Oil grease on disc Cleanand reﬁt 3 Spongybrake Fill brake ﬂuid and performbrake bleeding VII MOTORCYCLE WOBBLES 1 Under inﬂated tyres Inﬂatetocorrect pressure 2 Loose Brokenspokes Tighten Replace spokes 3 Wheels misaligned Ensure proper alignment 4 Wheel rim runout Rectify 5 Tyres not ﬁtted correctly Reﬁt tyrescorrectly ...

Page 112: ...use 3 Loose improper connection Check and correct Horn not working 1 Fuse blown Checkandcorrect 2 Loose connections Check andcorrect Traﬃcators not working 1 Loose improper connections Checkandcorrect TROUBLESHOOTING CAUSES REMEDIES 2 Bulb fused Replace Contact Royal Enﬁeld Authorised ServiceCentre ...

Page 113: ... connection Check for all EFI sensor coupler loose connection and correct them 2 Any EFI sensor failure Checkand replace thesame X ABS ANTI LOCK BRAKING SYSTEM TROUBLESHOOTING CAUSES REMEDIES 1 ABS indicator continuously ON Take the vehicle to servicecentrefor diagnosis Contact Royal Enﬁeld Authorised ServiceCentre ...

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Page 120: ...0 0 5 5 10 15 20 25 30 35 40 45 50 Months Miles x 1000 0 3 3 6 9 12 15 18 21 24 27 30 Check level at every 1000 Kms or earlier and top up as required R R R R R R The maintenance schedule detailed here will help you to maintain your interceptor INT 650 motorcycle meticulously to get a long trouble free service The schedule provided herein is based upon an average riding conditions and indicates the...

Page 121: ...Rubberhose Inlet manifold Adaptor I I I I I I I I I I I 8 EvaporativeEmissionEquipmentrubberhoses I I I I I I I I I I I 9 Fuel ﬁlter External R R 10 Airﬁlterelement C C R C R C R C R C R Clean replace more frequently ifoperated in dusty condition 11 Vent Pipeunder airﬁlter box I I I I I I I I I I 12 Hose Secondary Air I I I I I I I I I I I 13 Acceleratorand Throttlepulley cables free play 14 Clutc...

Page 122: ...Brake hose and Banjo Bolt Front and Rear 20 Front Fork oil leak I I I I I I I I I I I 21 Steering tapper roller bearing Play I I I I I I I I I I I 22 Rear Wheel Drive Chain Lubricateand Adjust every 1000 Kms Clean Lubricate and Adjust every serviceor earlier as required 23 RearwheelCush rubbers I I PERIODICALMAINTENANCE PERIODIC MAINTENANCE I Inspect Clean Adjust lubricate or replace if necessary ...

Page 123: ...lefortightness I I I I I I I I I I I After First service Engine oil and Engine oil ﬁlter replacement is a mandatory at every 12 months even the vehicle has not covered the speciﬁed kms After Firstservice Valveclearnace adjustment is a mandatory at every 12 months even the vehicle has not covered thespeciﬁed kms PERIODIC MAINTENANCE I Inspect Clean Adjust lubricate or replace if necessary L Lubrica...

Page 124: ...kms miles Royal Enﬁeld Authorised Dealer 120 ...

Page 125: ...121 SERVICE MAINTENANCE RECORD S No Date Brief detailsof work service 9 10 11 12 13 14 15 16 Job Card No Royal Enﬁeld Authorised Dealer kms miles ...

Page 126: ...122 SERVICE MAINTENANCE RECORD S No Date Brief detailsof work service 17 18 19 20 21 22 23 24 Job Card No Royal Enﬁeld Authorised Dealer kms miles ...

Page 127: ...ty 3 Record of all the regular servicesand periodical maintenance that have been carried out along with proof of servicehistory will be required to be veriﬁed by the Authorised Distributor s service facility OR their Authorised dealership s service facility prior to carrying out a warranty service 4 Proof of Ownership in the form of Sales Registration OR Proof of Purchase documentation of the moto...

Page 128: ... pads shoes clutch plates etc n Electrical items like bulbs wiring harness switches battery fuses electric start motor etc WARRANTYTERMSANDCONDITIONS 8 Warranty will become void under the following conditions n Damages due to lack of proper maintenance periodicservices not carried out asper Royal Enﬁeld recommendation etc n Damages caused by any unauthorised repairs carried out in any part of the ...

Page 129: ...nﬁeld authorised distributors and or their dealers are independently owned and operated They may hence deal with other aftermarket products for which Royal Enﬁeld is not responsible for the performance safety quality reliability and suitability of such products Defects if any in such parts OR that may arise in the motorcycle due to use of such parts is not liable to be covered by Royal Enﬁeld and ...

Page 130: ...free of charge componentsof the emission control system tomeet the required emissionstandards The method s of examination todetermine thewarranty conditionsof the emission warranty related componentswill be at the sole discretion of Royal Enﬁeld and or our Authorised Service Centre and results of suchexamination will be ﬁnal andbinding If onexamination the warrantyconditions of thepart s is are no...

Page 131: ...eserves the right to carry out necessary consequential repairs to the motorcycle or replace any part in additiontotherepair orreplacement of thecomponentscoveredunder emissionwarranty to establishcompliance toin use emissionstandards Suchrepairs replacementswill be chargeable to the customer All parts removed for replacement under warranty will become theproperty of Royal Enﬁeld Royal Enﬁeld will ...

Page 132: ...TY SHALL APPLY IF THE CUSTOMER n Observes all the important instructions and anyother precautions listed in theowner smanual n Under all circumstances uses lubricants and fuel asrecommended by Royal Enﬁeld n Regularly obtainsand carries out maintenanceinaccordance withRoyal Enﬁeld guidelines and enters the details in the Log book n Immediatelyapproachesthenearest RE Authorised Dealer Service Centr...

Page 133: ...e date of original purchase of the motorcycle n Produces valid certiﬁcate of Insurance and R TORegistration Certiﬁcate R C Book THE EMISSION WARRANTY SHALL NOT APPLY IF n A valid Pollution under control certiﬁcate isnot produced n Themotorcycleisnot serviced by RE Authorised Dealer Service Centre asper theservice schedule described inthe maintenance chart n The motorcycle has been subjected to abn...

Page 134: ...l Enﬁeld or its Authorised Dealer Service Centre if the motorcycle shows that any of the conditions stipulated in the Owner s manual with regard to use and maintenance have beenviolated n The motorcyclehasbeen runon adulterated leaded fuel or lubricant other thanthose speciﬁed by Royal Enﬁeld in the Owner smanual or anyother document given tothe customer at the time of sale of the motorcycle n The...

Page 135: ...able by law TIPS TO REDUCE POLLUTION n Ensure that the periodical maintenance is carried out as stipulated in the owner s manual through a Royal Enﬁeld AuthorisedServiceCentre n Use only Unleaded petrol 91 RON or higher from reputed fuel pumps n Ensure thefuel usedisnot adulterated n Use correct spark plug asrecommended in the owner s manual n EMISSIONWARRANTY Use lubricants asper recommendationsg...

Page 136: ... fromthe date of ﬁrst use of the motorcycle The Warranty periodshallbegineitheronthedatethemotorcycleisdeliveredtothe ﬁrst retail purchaserORfromtheﬁrst date the motorcycle isused asa demonstrator OR asa display and or trialmotorcycle THE FOLLOWING ARE NOT COVERED BY THE EVAPORATIVE EMISSION CONTROL SYSTEM WARRANTY 1 Failureswhichmayarise asa result of misuse alterations accidentsOR nonperformance...

Page 137: ... immediately due to whichthe exact distance covered cannot be determined 5 Normal aging of partssuch asfuel hoses vapor hoses gasketsand rubber components RECOMMENDATIONS FOR REQUIRED MAINTENANCE It is recommended that the routine maintenance of the motorcycle be carried out at speciﬁed intervals and any maintenance to the evaporative emission control systems should be performed only by an Authori...

Page 138: ...d in the soil down the sewers drains lakesor rivers around you The simplest wayto doit istohave themdrained into a container whichyou canhand over toyour local recyclingagent or at yournearest Royal Enﬁeld Authorised Service Centre Theywill followtheguidelineslaid downbythelocalauthoritiesto get rid of it BATTERY IfyourRoyalEnﬁeld sbatteryneedstobereplaced handitovertoanauthorisedrecyclingagentorR...

Page 139: ...dly manner CLEANING YOUR ROYAL ENFIELD Avoid aerosol sprays instead use a biodegradable detergent or drywashtocleanyour Royal Enﬁeld Also becautious while discarding the cleaningsolvents Hand them over to an authorised recycling agent or a Royal Enﬁeld Authorised Service Centre Theywill followthe local authority sguidelinestoget rid of theminanenvironmentallyfriendlymanner Thisnotedoes not constit...

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