Royal Enfield Interceptor 650 - Service manual > Clutch Cover

• Loosen and remove 14 Nos. Hex socket head screws (M6) (a) in a crisscross to remove clutch cover (b) from motorcycle RH.

• If the cover is jammed in the engine, gently tap on the tabs (a) provided on the cover using a plastic/ rubber mallet.

• Remove gasket (a) and 2 Nos. dowel pins (b) from clutch cover/engine.

CAUTION Do not use a sharp tool to scrap the gasket material from the joint faces.

If required scrap only with a soft and blunt tool.

Clutch Actuating Shaft

• Gently remove the E clip (a) and washer (b) from the bottom of the clutch actuating shaft inside clutch cover.

• Remove oil seal (a) along with washer (b) from outer clutch case.

• Gently pull out clutch actuating shaft (a) from clutch cover (b).

• Remove needle roller (a) top from clutch cover with special tool.
• Remove needle roller bearing (b) bottom from clutch cover with special tool.

Oil Level Window

• Remove the circlip (a) on the oil level window inside clutch cover.

• Gently press oil window (a) from outer side to remove from clutch cover.

Clutch Plates

CAUTION Bolts are under spring tension. Loosen bolts progressively and slowly until spring tension is completely released.

• Loosen 3 Nos. Hex flange head bolts (M6) (a) on the pressure plate evenly and slowly until tension is released completely.

• Hold pressure plate (a) and remove the bolts (b).
• Remove pressure plate and spring (c) from clutch hub.

• Remove clutch hub (b) along with 2 friction plates, 1 steel plate and pull rod (a) from the clutch bell.

• Remove the pull rod from the inner side of clutch bell.
• Remove 1 st friction plate (a), steel plate (b) and 2nd friction plate (c) from clutch hub (d).

• Locate special tool (a) on clutch center (b) and ensure it is seated fully on the splines.
• Hold the clutch center firmly and remove Hex "U" nut (M17) (b) by rotating clockwise.

CAUTION Hex "U" nut is a left hand thread. Wrong rotation may damage the threads.

• Remove Hex U nut and washer from counter shaft.

• Remove special tool and pull out clutch bell assembly (a) from the counter shaft along with the remaining 6 plates (b) (3 each friction and steel plates) from the clutch housing.

NOTE

• If the plates are to be reused, suitably mark the plates so that they can be reassembled in the same sequence as it was before dismantling.

 

• Remove thrust washer (a) from counter shaft.

• Remove clutch housing (a) from counter shaft.

• Remove the needle bearing (a).

• Remove collar bush (a) from counter shaft.

Oil Pump

• Loosen and remove Hex flange bolt (M5) (a) on oil pump sprocket.

• Gently pull out the sprocket (a) from oil pump shaft.
• Release and remove chain (b) from the teeth on crankshaft sprocket (c).

• Loosen and remove 4 Nos. Hex flange head bolts (M5) (a).

• Remove the oil pump (a) along with O-ring (b).

NOTE

• Inspect O-ring for any deformation OR damage and replace if required.
• The oil pump does not have any serviceable parts, hence as to be replaced only as a complete assembly.

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