Royal Enfield Interceptor 650 - Service manual > Magneto Cover Sub Assembly

Stator coil with CPS in Magneto cover

• Position stator coil (a) inside magneto cover such that.
  • The Crank position sensor is seated at its mounting location.
  • Magneto wires and grommet are aligned to the slot on the top of the cover.
  • The stator mounting holes are aligned to the mounting holes in magneto cover.
• Locate 3 Nos. Hex socket head bolts (M6) (b) in the stator coil mounting holes and tighten evenly to specified torque.

• Locate guide plate (b) over the CPS (a), ensure the mounting holes of the guide plate, CPS are aligned to the mounting holes in magneto cover.
• Locate 2 Nos. Hex socket head screws (M5) (c) on the guide plate and tighten evenly to specified torque.

• Locate dowel pins (a) and (b) into crankcase.

• Install gasket (a), if necessary smear engine oil and ensure it is properly seated on dowels. Do not use any sealant or adhesive.

• Align the magneto cover such that the stator coils are located into the magneto rotor and ensure proper seating of the cover against the gasket.

CAUTION Magnetic force from the rotor may cause misalignment of the cover during assembly. please ensure cover is centralized and seating properly before tightening the screws.

• Locate 12 Nos. Hex socket bolts (M6) (a) on magneto cover (b) and tighten it in a crisscross pattern.
• Tighten the bolts evenly to specified torque.

• Locate O-ring (a) on plug (b).

• Assemble plug (M34) (a) on center of magneto cover and tighten it to specified torque.

• Ensure the magneto and gear position sensor wiring is correctly routed through the crankcase assembly.

Starter Motor

NOTE

• Do not tap on the starter motor. It may damage the internal parts.
• Inspect the starter driveshaft teeth for any wear- out or damages.

 

• Locate starter motor (a) into the upper crankcase housing (b) LH.

• Locate and install 2 Nos. Hex head flange bolts (M6) (a) on starter motor (b).

Breather Box

• Locate gasket (a) on breather box cover (b) and assemble breather box cover on engine.

• Install and tighten 5 Nos. Hex-head flange bolts (M6) (a) to specified torque.

• Fit breather hose (a) into intake manifold and install clamp.

Oil Filter

• Ensure O-ring (a) is seated properly over the oil filter (b).
• Apply thin layer of fresh engine oil over O-ring.
• Locate oil filter into crankcase.

• Tighten oil filter (a) using special tool (b) to specified torque.

 

Engine Troubleshooting

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