Royal Enfield Interceptor 650 - Service manual > Oil Pressure Switch

• Assemble oil pressure switch (a) along with washer (b) on crankcase. Do not TIGHTEN FULLY.

• Tighten oil pressure switch (a) to specified torque.

Oil Bypass

• Ensure O-rings (a) are located properly.
• Install oil bypass pipe (b) into lower crankcase oil gallery.

• Tighten 2 Nos. Hex socket head screw (M6) (a) to specified torque.

Oil Strainer

• Ensure O-ring is located properly.
• Install oil strainer (a) into lower crankcase oil gallery and tighten with 2 Nos. Hex flange head bolts (M6) (b) to specified torque.

Oil Pan

• Locate oil pan gasket (a) on crankcase and assemble oil pan (b).

• Assemble and tighten 13 Nos. Hex flange head bolts (M6) (a) in crisscross pattern to specified torque.

NOTE

• Rotate the crankcase so that the connecting rods are facing upwards for further assembly.
• Support timing chain suitably to ensure it does not fall into the crankcase while rotating.

Drain Plug

• Assemble magnetic drain plug (M14) (a) along with washer (b).

• Tighten drain plug (a) to specified torque.

Pistons and Rings

NOTE

• Rings should be assembled with proper orientation (top marking should be always towards 1 st ring end gap should be 45º before "EX" mark on piston crown).
• Middle 2 nd ring end gap should be 180º from 1 st ring end gap.
• Oil ring 3 rd top rail end gap should be 180º from 2nd ring end gap (45º before "EX" on piston crown).
• Oil ring spacer end gap should be 45º before 3 rd ring top rail end gap (90º before "EX" on piston crown).
• Oil ring (3 rd ) bottom rail end gap should be 180º from 3 rd ring top rail end gap.
• One of the circlip should be assembled on the inner side of piston.

Piston Rings

Orientation Pattern

• Top ring (1 st ) and oil ring (3 rd ) top rail end gap positions.

• Middle (2 nd ) ring and oil ring (3 rd ) bottom rail end gap positions.

• Oil ring spacer end gap position.

Cylinder Barrel Dowels on Crankcase

• Install 2 Nos. dowel pins (a) and (b) on upper crankcase.

Cylinder Barrel Gasket on Crankcase

• Ensure the gasket seating area in crankcase is clean.
• Ensure cam chain is routed through a new cylinder base gasket (a) and locate the gasket on crankcase (b).
• Ensure proper seating of the gasket on the dowels on the crankcase.

Piston LH in Cylinder Barrel

• Ensure piston LH is at its top most position by rotating crankshaft clockwise.
• Locate special tool (a) on piston LH.

• Position and hold cylinder barrel above crankcase, route cam chain through cylinder barrel bottom and ensure it is supported firmly and suitably at the top.
• Ensure cylinder barrel LH is well lubricated, LH piston is held firmly and straight.
• Gently lower cylinder barrel (a) over the special tool piston LH, till the piston is halfway into the cylinder barrel.

• Hold cylinder barrel firmly in suspended position and remove the special tool (a) from piston LH.

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