Royal Enfield Interceptor 650 - Service manual > Throttle Body End

• Gently open throttle at handlebar end and identify the cable in which the inner cable retracts.
• Insert this cable into the front slot in the bracket in the throttle body and ensure the adjuster is fully into the bracket on throttle body.
• Assemble lock nut on the inner cable.
• Position inner cable (a) to the front slot of the rotor on throttle body, insert inner cable into the eyelet and route the cable in the groove in the rotor of the throttle body.

• Repeat above steps to locate the other cable in the rear slot of the rotor on throttle body.

• Ensure both inner cables are seated properly in the eyelets at throttle body end and handlebar end. Gently rotate throttle rotor at handlebar and ensure they are operating properly.

Throttle Cables Free Play Adjustment

• Gently pull adjusters out of the bracket on throttle body end till the inner cables have NO SLACK.
• Tighten the outside nuts on the adjusters till they are resting against the bracket on throttle body.
• Hold handlebar straight and check for free rotation of 3 to 4 mm. (The rotor on the throttle body should not rotate).
• Loosen/Tighten the outer nuts to achieve the correct free play.
• Check both cables are correctly positioned and clamped to the frame, turn handlebar to both left and right sides to ensure the free play is maintained.
• Tighten inner lock nuts on the adjusters till they are firmly locked on the inside of the bracket.

NOTE

• To carry out finer adjustments to maintain the free play, turn the adjusters on the cables at the handlebar end, in or out.

 

• Locate throttle body cover RH (a) against the bracket and ensure holes are aligned and tighten with 2 Nos. Hex socket screws (M5) (b).

• Assemble fuel tank assembly.

Clutch Cable

Handlebar End

• Ensure adjuster on lever bracket LH is in midway position and the slot in the adjuster is correctly aligned to the slot in the lever bracket LH.

• Locate inner cable into the eyelet on clutch lever and ensure it is aligned.
• Route inner cable into the slot in the clutch bracket and adjuster and lock the outer cable into adjuster.

• Route clutch cable between headlamp holder LH and frame towards the RH side.
• Locate 2 holding clips on the clutch cable and frame near RH exhaust pipe.

Clutch cover End

• Insert inner cable into the cable guide (b) in clutch cover assembly and ensure the adjuster (a) is fully inside the guide in clutch cover assembly.

• Assemble adjuster nut (a) on the adjuster and tighten by a few threads.

• Assemble protective rubber boot (a) on clutch cable inner (b).

• Gently locate inner cable (a) into clevis (b) in clutch lever (c).

Clutch Cable Free Play Adjustment

• Gently pull clutch cable adjuster (a) out of the clutch cover till the inner cable has NO SLACK and tighten the outer lock nut (b) against the guide in clutch cover.

• Hold handlebar straight and check clutch lever free play of 2 to 3 mm (The lever on clutch cover should not move).
• Loosen/Tighten outer nut at clutch cover end to achieve the correct free play.
• Check for proper clamping of clutch cable to frame, turn handlebar to both left and right sides to ensure the free play is maintained.
• Tighten inner lock nut on the adjuster till it is firmly locked against the cable guide on cover RH.

NOTE

• To carry out finer adjustments to maintain the free play, turn the adjuster on the lever bracket LH at the handlebar end, in or out.

Troubleshooting

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