ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 3
1 Technical Specification .................................... 4
2 General Vehicle Information .......................... 7
3 Salient Technical Features............................... 8
4 Power Flow
a) Power Flow - Piston to Rear Wheel............ 14
b) Power flow in Electric start ....................... 14
c) Gear box (transmission) power flow .........15
d) 6 Speed Transmission ............................... 16
5 Oil lubrication ................................................. 17
6 Single Over Head Cam Shaft Mechanism ...... 22
7 Assist and slipper clutch ................................ 22
8 Valve timing ................................................... 24
9 Screw type silent cam chain tensioner .......... 24
10 Engine Overhauling ....................................... 25
11 Engine Job List .............................................. 25
12 Special Tools Application
(ENGINE & VEHICLE)..................................... 26
13 Dismounting Engine from the Frame ............. 31
14 Engine Mounting into frame ......................... 35
15 Engine Exploded Views................................. 36
16 Engine dismantaling process ......................... 51
CONTENTS
SL.NO. DESCRIPTION PG.NO. SL.NO. DESCRIPTION PG.NO.
17 Service / Wear Limits...................................... 67
18 Torque Values - 650 Twin .............................. 75
19 Engine Assembly Process ............................. 78
20 EFI system..................................................... 121
21 Emission System.......................................... 134
22 Fuel System .................................................. 136
23 Front Wheel & Suspension .......................... 140
24 Rear Wheel ................................................... 145
25 Instrument Cluster ....................................... 152
26 Drive Chain Adjustment .............................. 154
27 Engine Oil Pressure Checking Procedure .... 156
28 ABS system .................................................. 158
29 Control Cables ............................................. 163
30 Periodical Maintenance Chart ..................... 179
31 Tappet Checking / Adjustment
(Valve Clearance)......................................... 180
32 Fuse Identification List ................................ 183
33 Clutch Lever Play Checking & Adjustment .. 185
34 Compression test process ........................... 187
35 All Wiring Diagrams...................................... 188
ROYAL ENFIELD 650 TWIN SERVICE TRAINING MANUAL 03
