Royal Enfield Interceptor 650 - Service manual > Exhaust Pipes and Silencers

Dismantling

Hego/Oxygen Sensor Connectors

• Disconnect Hego/oxygen sensor connectors (a) from both LH and RH on the front side of engine.

Exhaust Pipe and Silencer LH

• Loosen and remove Hex flange head bolt (M8) (a) on clamp (b) (exhaust pipe to silencer) supporting outer end nut (M8) (c) suitably.

• Suitably support silencer.
• Loosen and remove Hex head flange bolt (M8) (a) from frame bracket (b) supporting the outer end nut (M8) (c).
• Disconnect silencer from exhaust pipe.

• Loosen and remove Hex head flange bolt (M8) (a) on mounting bracket (b). Ensure silencer is supported suitably.

• Loosen and remove 2 Nos. Hex head nuts (M8) (a) on engine LH side to disconnect LH exhaust pipe (b) from cylinder head (c).

• Gently remove the LH exhaust pipe (a) along with Hego/oxygen sensor (b) and gasket from cylinder head.

• Repeat the procedure to remove exhaust pipe and silencer RH.

Hego/Oxygen Sensor

• Loosen and remove sensor Hex stud (a) along with washer from exhaust pipe holding sensor.
• Gently loosen and remove the Hego/Oxygen sensor along with gaskets from the exhaust pipes LH & RH.

Assembly

Hego/Oxygen Sensor

• Locate new gaskets on the Hego/Oxygen sensor and assemble sensor on the exhaust pipes LH & RH and tighten firmly.

CAUTION DO NOT over tighten as it damage the sensor.

Exhaust Pipe and Silencer LH

• Locate exhaust pipe (a) into exhaust manifold on cylinder LH and ensure the exhaust pipe flange is properly located on the studs.

• Assemble 2 Nos. Hex nuts (M8) (a) on the studs and tighten exhaust pipe flange to cylinder head.

• Align exhaust pipe mounting hole with mounting hole on LH side.
• Assemble Hex flange head bolt (M8) (a) along with washer cup and Hex nut on mounting bracket (b) and tighten to specified torque.

• Ensure mounting clamp (a) on silencer (b) is sufficiently loose.
• Assemble new gasket on exhaust pipe (c) and locate silencer on exhaust pipe.
• Duly ensure rear mounting bracket of silencer is aligned to the mounting hole of frame LH.

• Align silencer mounting bracket hole to main frame mounting hole.
• Insert Hex head bolt (M8) (a) into mounting bracket (b) along with washer and nut (c). Hold nut and tighten bolt to specified torque.

• Hold Hex head bolt (M8) (a) on clamp (b) and tighten nut (c).

• Follow above procedure for assembling exhaust pipe and silencer RH.

Hego/Oxygen Sensor Connectors

• Ensure Hego/oxygen sensors are tightened fully on exhaust pipes LH and RH.
• Connect LH & RH Hego/Oxygen sensors connectors (a).
• Ensure connectors are locked properly. (There is a "click" sound when locked.)

Troubleshooting

NOTE

• The troubleshooting given in this section is only related to issues with noise/leak in the exhaust system. For complaints related to poor pickup, misfiring, etc., please refer to engine section.

See also: