Royal Enfield Interceptor 650 - Service manual > Oil Pump

• Locate oil pump mounting point below crankshaft gear in RH crankcase.
• Assemble 4 Nos. Hex flange head bolts (M6) (a) on oil pump (b) and tighten bolts to specified torque.

• Locate and fit oil pump drive chain (a) on crankshaft gear (b) and sprocket on oil pump.

• Locate Hex flange head bolt (M6) (a) on oil pump. DO NOT TIGHTEN FULLY.

• Tighten the bolt to specified torque.

NOTE

• Lock the crank shaft by using special tool to prevent rotation while tightening bolt.

Clutch Assembly

• Ensure collar on bush (a) is facing inward and assemble it on countershaft (b). Ensure it is seated properly.

• Assemble needle bearing (a) on countershaft (b).

• Locate clutch housing (a) on counter shaft, with its lugs (b) facing outside.
• Ensure the clutch housing gear is correctly meshed with the gear on crankshaft.

• Assemble thrust washer (a) on countershaft.

• Locate bell assembly (a) on the splines on counter shaft (b).

• Locate the anti-judder steel washer-plain, in the groove in the clutch bell.
• Assemble Belleville washer over judder washer in the clutch bell. ENSURE THE "HUMP" OF THE BELLEVILLE WASHER IS FACING INSIDE AND SEATED AGAINST THE JUDDER WASHER.
• Assemble 1 st friction plate with larger ID (less friction area) ensuring the splines of the plate are correctly positioned and located on the clutch housing.
• Assemble 1 st steel plate ensuring the splines on the plate are correctly positioned and located on the clutch bell.
• Assemble 2 nd friction plate on the clutch housing and ensure it is seated against the 1 st steel plate.
• Assemble 2 nd steel plate on clutch bell.
• Assemble 3 rd friction plate on clutch housing.

• Assemble washer (a) on countershaft.

• Locate the Hex "U" nut (M17) (a).

CAUTION Hex U nut is left hand thread. Turn anticlockwise to tighten nut on shaft.

• Locate and hold special tool on clutch assembly and tighten clutch hub nut to specified torque.

• Remove special tool and further assemble the following
  • 3 rd steel plate on clutch bell.
  • 4 th Friction plate on clutch housing.
  • 4 th steel plate on clutch bell.
  • 5 th Friction plate on clutch housing.
  • 5 th steel plate on clutch bell.
• Locate 6 th friction plate (a) with larger ID (less friction area) on clutch hub (b) and ensure it is seated properly against the inner face of the clutch hub.

• Locate 6 th steel plate (a) on the splines in clutch hub (b) and ensure it is properly seated against the 6 th friction plate.

• Locate 7 th friction plate (a) with larger ID (less friction area) on clutch hub (b) such that its lugs are offset and between 2 lugs of the 6 th friction plate.

• Locate clutch hub (a) into clutch bell duly ensuring the following
• Insert pull rod (b) into clutch housing from the inside, such that the serrations on the pull rod are facing outside.
• Ensure pull rod is fully and properly seated against the bearing on the inside.

• The outer lugs of 7 th friction plate are correctly located in the INNER slots of the clutch housing.
• The outer lugs of 6 th friction plate are correctly located in the OUTER slots of the clutch housing.
• The 3 lugs of the clutch hub are correctly positioned between the 3 slots in the clutch bell (Gently rotate clutch hub back and forth, to match the slots of the clutch bell).
• The three mounting studs of the clutch bell are central to the slots in the clutch hub.
• Insert 3 Nos. compression springs (a) in hub.

• Locate pressure plate (a) on clutch hub with the words "OUT" and "FR" facing outside.
• Assemble 3 Nos. Hex bolts (M6) (b) and tighten pressure to clutch hub, sequentially to specified torque.

Oil Level Window on Clutch Cover

• Locate new oil window (a) on clutch cover with the window facing towards clutch cover outer and gently press till it is seated fully inside.

• Assemble circlip (a) in the groove in clutch cover and ensure it is correctly locked in the clutch cover.

Clutch Actuating Lever Assembly

• Ensure needle bearings (a) are assembled in the clutch cover.

• Insert clutch actuating shaft (a) into clutch cover (b) with the gear facing inside and the splines facing outside.

• Assemble washer (b) on the shaft bottom inside the clutch cover.
• Assemble E-clip (a) in the slot in shaft bottom inside clutch cover.

• Assemble oil seal (a) in clutch cover at the top with the lips facing down.
• Assemble washer (b) above oil seal.

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