Royal Enfield Interceptor 650 - Service manual > Clutch Cover

• Ensure the dowel pins (a) are seated properly on the upper and lower crankcases on RH side.

• Install gasket (a) on the crankcase if necessary smear engine oil and ensure it is properly seated on dowels. Do not use any sealant OR adhesive.

• Ensure racks on the clutch pull rod is facing towards the rear of the engine.
• Hold the clutch cover (a) in position, rotate the clutch actuating shaft to ensure it is engaged correctly with the pull rod and gently tap cover inside, till it seats fully on the dowels and crankcase.

• Locate 14 Nos. Hex socket bolts (M6) (a) on clutch cover and tighten them in crisscross pattern.

• Tighten bolts (M6) (a) evenly to specified torque.

Arm Clutch Actuating Lever

• Assemble clutch release spring (a) on shaft with the "L" bend positioned against the lug (b) in clutch cover.

• Rotate clutch shaft (b) clockwise till it stops.
• Ensure pinch bolt is sufficiently loose, position actuating lever on shaft at 11 'O' clock position and ensure the inner side of the lever is aligned to the reference mark (a) on the clutch cover.

• Tighten pinch bolt sufficiently such that the lever is firmly clamped on the shaft.
• Position the upper leg of the spring against the inside of the lever and check for proper spring action.

Clutch Cable on Clutch cover

• Assemble clutch cable assembly (a) on clutch lever (b). Refer clutch cable assembly procedure.

FD Sprocket

• Assemble spacer (a) on drive shaft (b) on the LH side.

• Locate oil seal (a) on the crankcase on LH side with its open end facing inwards and tap it in gently till the outer surface of the oil seal is flush with the crankcase(b).

• Assemble FD sprocket (a) on drive shaft (b).

• Install new tab washer (a) on drive shaft (b).

• Assemble FD Sprocket "U'' nut (M20) (a) on drive shaft.

• Locate special tool (a) over FD sprocket and tighten nut to specified torque.

• Gently bend the tab washer (a) outer, to seat against a flat surface of the hex nut (b) with a flat chisel to prevent the nut from loosening during use.

Rear Chain to FD Sprocket

• Locate drive chain (a) over the FD sprocket teeth (b).

• Ensure rear chain is properly seated on the rear wheel sprocket.
• Adjust rear chain tension as specified.

Gear Position Sensor (GPS)

• Assemble gear position sensor on the LH side of lower crankcase duly ensuring the lug (a) in the GPS is located into the hole (b) in gear selector drum.

• Position cable holder (a) over the GPS.

• Assemble 2 nos Hex flange head bolts (M6) (a) on the cable holder and tighten cable holder and GPS to the crankcase on the LH side to specified torque.

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