Royal Enfield Interceptor 650 - Service manual > Injector, TPS, MAPS, ISC Connections

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

• Connect the LH and RH injector connectors (a) located on throttle body (b).

• Connect TPS connector (a) to sensor (b) at bottom of throttle body.

• Connect idle speed sensor connector (a) on throttle body (b).

• Connect purge valve hoses (a) to the inlet pipes on the top of the throttle body.

Throttle Body Covers on LH and RH

• Locate throttle body covers (b) on both LH and RH of throttle body.
• Insert and tighten 2 Nos. Hex Allen bolts (M5) (a) into LH throttle body cover (b).
• Insert and tighten 2 Nos. Hex Allen bolts (M5) (a) into RH throttle body cover (b).

• Position ABS modulator with bracket on frame and tighten with bolts.
• Assemble the following parts:
  • Horn and electrical connections.
  • Connect HT cable.
  • Fuel tank.
  • Side panels LH.
  • Rider seat assembly.
  • Assemble RH side panel.

Spark Plugs

• Locate and tighten spark plug (a) to RH cylinder head.

• Repeat the procedure to assemble LH spark plug.

Spark Plug Suppressor Caps

Spark Plug Suppressor Caps on LH and RH Cylinder Heads

• Locate spark plug suppressor cap (a) on spark plug in LH cylinder head (b).

• Locate spark plug suppressor cap (a) on spark plug in RH cylinder head (b).

Star Index

• Locate and tighten 2 Nos. Hex head bolts (M6) (a) on selector fork shaft stopper plate.

• Locate and tighten Hex socket head stepped bolt (M6) (a) on gear shift cam drum.

Star Index Stopper

• Locate spring and stopper plate support (a) on RH lower crankcase and assemble Hex head flange bolt (M6) (b).

NOTE

• Handle stopper plate tension spring carefully else it may damage supporting components.

Shifter Selector Shaft Assembly

Shifter Selector Shaft

• Assemble inner spring (a) from the longer side of shifter shaft (b).
• Ensure the legs of the spring are correctly located in the plate on the shifter shaft.

• Assemble inner circlip (a) on longer end of shifter shaft (b). Ensure it is properly seated on shifter shaft groove near the spring.

• Assemble 1 st inner washer (a) from the longer end of shifter shaft (b).

• Assemble outer plate (a) from smaller end of shifter shaft with its projection facing towards the longer end of the shaft.
• Ensure the peg on the shifter shaft is located correctly in the hole on the outer plate (a).

• Assemble outer spring (a) from smaller end of shifter shaft.

• Assemble outer washer (a) from the smaller end of shifter shaft.

• Assemble outer circlip (a) from smaller end of shifter shaft.

• Insert longer end of the shifter shaft (a) into the hole in the lower crankcase from the RH side.
• Ensure the shifter plate is correctly seated over the star index.

• Assemble washer (a) on the shifter shaft on the LH side.

• Assemble circlip (a) on the shifter shaft at the LH side and ensure it is correctly seated and locked in the groove on the shifter shaft.

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