Royal Enfield Interceptor 650 - Service manual > Headlamp and Cluster Dismantling

Headlamp Reflector from Housing

NOTE

• Ensure ignition switch and stop switch in off condition

CAUTION Support the Headlamp assembly carefully.

• Loosen and remove Phillips screw (a) on headlamp.

• Gently remove front rim (a) along with reflector (b) from housing (c).

WARNING The headlamp and bulb can be extremely hot. Do not remove while headlamp/bulb are hot.

• Hold headlamp head carefully and disconnect headlamp connector (a) from headlamp bulb.

Pilot Bulb from Reflector

• Disconnect wires (a) from pilot bulb main (b) and ground (c) carefully.

• Gently pull out pilot bulb (a) along with bulb holder (b) from headlamp reflector.

CAUTION Do not remove headlamp/bulb while they are hot.

• Gently depress bulb (a) to holder and turn counter- clockwise to remove bulb from holder (b).

Headlamp Bulb from Reflector

• Depress wire clip (a) and release from slot (b) in headlamp reflector.

• Remove wire clip (a) from reflector (b) and gently pull out headlamp bulb (c) from reflector.

CAUTION Do not touch glass of bulb. Any strains or finger prints will affect the luminosity. Ensure pointed tip of bulb does not get damaged Whenever handling the bulb, hold it firmly at terminal end and not at glass end.

Connectors and Sensors from Headlamp Housing

• Disconnect LH module connector (a) from headlamp housing.

• Disconnect clutch switch connector (a).

• Disconnect front brake lamp switch connector (a).

• Disconnect RH module connector (a).

• Disconnect wheel speed sensor connector (a).

• Press the lock to disconnect LH trafficator sensor connector (a).

• Disconnect RH trafficator sensor connector (a).

• Disconnect ignition switch connector (a).

• Disconnect cluster connectors (a) and (b).

Headlamp Housing from Holder LH & RH

• Ensure all electrical connectors are removed.
• Support and loosen Hex flange holder bolts (M8) (a) RH and LH and remove headlamp housing.

Direction Trafficators from Headlamp Holder

Dismantling

• Loosen and remove Hex nut (M12) (a) from LH direction trafficator.

• Remove LH direction trafficators (a) nut (b) and washer (c) from headlamp holder.

• Similarly remove RH direction trafficator.

Cluster Assembly

• Remove 2 Nos. Hex socket head bolts (M6) (a) located below key set on LH and RH.

• Gently remove ignition key set (a).

• Remove 2 Nos. Hex socket head bolts (M6) (a) located below cluster bracket on LH and RH.

• Detach cluster bracket (a) from motorcycle and keep it aside safely.

Headlamp Housing Holders from Fork Legs

• Loosen and remove Hex socket head bolt (M8) (a) from top yoke RH.

• Gently pull out upper yoke (a) from steering stem.

• Remove handlebar clip-on LH and RH.
• Pull out headlamp housing holders (a) LH & RH from front fork legs LH & RH (b).

Tail Lamp Dismantling

Tail Lamp

NOTE

• Handle tail lamp assembly with care. Avoid over tightening of lens screws.

 

• Loosen and remove 2 Nos. screws (a) from tail lamp lens (b).

• Gently remove lens (a) from tail lamp assembly (b).

• Gently push bulb (a) and turn in anti-clockwise direction to remove bulb from holder (b).

Brake Lamp Connectors Dismantling

Brake Lamp Connector - Rear

• Remove RH side panel.
• Disconnect rear brake lamp connector (a) located near rear mudguard infill.

Brake Lamp Connector - Front

• Remove the following parts:
  • Headlamp assembly.
  • Front brake lamp switch.
• Disconnect front brake lamp connector (a).

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