Royal Enfield Interceptor 650 - Service manual > Fuel Pump Connector and Fuel Level Sensor

• Gently lift the fuel tank upwards to access the fuel pump connector.
• Disconnect the fuel pump connector (a) from fuel tank (b).

• Disconnect fuel level sensor connector (a) from fuel tank (b).

Fuel Hose (Fuel Pump to Injector)

• Locate the fuel feed hose connector (fuel pump to injector rail) (a) under the fuel tank.

• Disconnect quick joint connector (a) from pipe (b) by pressing the lock button (c).

WARNING Fuel pressure may still in line; crank engine to release pressure in the fuel line.

EVAP Connections on Fuel Tank

• Disconnect EVAP connection hose (a) from fuel tank (b).

Drain Hose

• Disconnect drain hose connection (a) from fuel tank (b).

Throttle Body Covers on LH and RH

• Loosen and remove 2 Nos. Hex socket bolts (M5) (a) from RH and LH throttle body cover (b).

Throttle Cable

(Connection on Throttle Body)

• Loosen 2 Nos. Hex head nuts (M6) (a) on RH throttle body (b) to release the tension in throttle cable.

• Gently pull throttle cable (a) out from bracket to release the adjuster and lock nuts (b) from throttle body.
• Repeat the procedure to release the other throttle cable.

Injector, TPS, MAPS, ISC Connections

Throttle Position Sensor (TPS), Manifold Absolute Pressure (MAP) Sensor and Idle Speed Controller (ISC)

• Disconnect throttle position sensor connector (a) from LH throttle body (b).

• Gently press connector lock to disconnect fuel injector connectors (a) from LH and RH of throttle body (b).

• Disconnect idle speed control sensor connector (a) from throttle body (b).

Reed Valve Connection

• Disconnect Reed valve hose (a) from front side of engine cylinder head.

Air Filter Housing to Throttle Body

• Locate LH and RH worm clips on throttle body to air filter box.
• Loosen both LH and RH worm clip screws (M5) (a) and separate the air filter housing (b) from throttle body (c).

Throttle Body

• Ensure throttle position sensor, manifold absolute pressure sensor and idle speed controller wiring connectors are disconnected.
• Disconnect the hoses (a) from canister purge valve.
• Loosen LH and RH worm clip screws (M5) (b) to disconnect throttle body from inlet manifolds.

Engine Steady Bracket

• Support the bottom of engine suitably.
• Locate steady bracket (a) on center of main frame (b).
• Loosen and remove Hex socket head bolt (M8) (c) on LH side and hold hex nut on RH.

• Remove Hex nut (M8) (a) and washer from RH side.

Engine Cylinder Head Steady Bracket

• Remove 4 Nos. Hex flange head bolts (M8) (a) from  LH and RH steady brackets (b) located on center of main frame (c).

• Remove the LH and RH steady brackets (a) from frame (b).

Hego/Oxygen Sensor Connectors

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

Exhaust Pipe and Silencer LH

• Locate LH silencer bracket attached on rear end of the frame/near to shock absorber.
• Loosen and remove Hex head flange bolt (M8) (a) from frame bracket (b). Locate and support the outer end Hex nut (M8) (c) suitably.

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

• Loosen and remove Hex head flange bolt (M8) (a) on frame (b) located below the front bottom of LH cover.

• Loosen and remove 2 Nos. Hex 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) from cylinder head.

Exhaust Pipe and Silencer RH

• Loosen and remove Hex flange head bolt (M8) (a) from frame bracket (b). Locate and support the outer end Hex nut (M8) (c) suitably.

• Loosen and remove Hex head flange bolt (M8) (a) from clamp (b) (exhaust pipe to silencer). Locate and support the outer end Hex nut (M8) suitably.

• Loosen and remove Hex head flange bolt (M8) (a) from main frame (b) located on bottom of clutch cover/below to rear brake lever (c).

• Loosen and remove 2 Nos. Hex nuts (M8) (a) from cylinder head (b).

• Gently remove the RH exhaust pipe (a) along with Hego/oxygen sensor (b).

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