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INTERCEPTOR 1965
Royal Enfield INTERCEPTOR 1965 User Manual
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WORl{SHOP
MAINTENANCE
MANUAL
FOR
THE
736
c.c.
''INTERCEPTOR''
MOTOR
CYCLE
TRADE
lt#AR/C
•
1
M,ADI'
LIKE
A
GIIN
1
THE
ENFIELD
CY
-
CLE
CO
-
MP
-
ANY
LIMITED
HEAD
OFFICE
AND
WORKS:
REDDITCH,
WORCESTERSHIRE,
ENGLAND
Telephone:
Redditch
4222
(9
lines)
S.T.D.
RE9.
4222
Telegrams
:
"
Cycles,
Redditch
"
2
Table of Contents
Table of Contents
3
Technical Data
5
Engine Specification
6
Engine
6
Cylinder Heads
6
Cylinders
6
Pistons
6
Connecting Rods
6
Crankcase
6
Crankshaft and Flywheel
6
Main Bearings
6
Camshafts
6
Ignition and Lighting System
7
Timing Drive
7
Valve Gear
7
Valves
7
Air Filter
8
Breather
8
Carburetters
8
Gearbox
8
Oil Pump Diagrams
9
Lubrication System
8
Clutch
10
Removal of the Timing Cover
10
Service Operations with Engine in Frame
10
Tappet Adjustment
10
Valve Timing
10
Ignition Timing
11
Removal of the Camshafts
11
Magneto Chain Adjustment
12
Primary Chain Adjustment
12
Removal of the Dual Seat and Rear Mudguard
12
Removal-Of the Petrol Tank
12
Removal and Refitting of the Cylinder Head
13
Timing Chain Adjustment
12
Reniovai of the Valves
13
Decarbonising
14
Removal of Pistons
14
Removal of Sparking Plugs
14
Removal of the Cylinders
14
Removal of the Rockers
14
Removal of the Valve Guides
14
Grinding-In Valves
15
Reassembly after Decarbonising
15
Cleaning the Oil Filters
16
Overhaul of Oil Pumps
16
Dismantling the Breathers
17
Removal of Camshaft Sprockets
17
Removal of the Clutch
17
Removal of the Engine and Clutch Sprockets
17
Removal of the Magneto
17
Removal of the Timing Chains
17
Timing Sprocket
17
Fitting the Alternator
18
Oil Pipe Unions
18
Oilsealbehindenginesprocket
18
Removal of Final Drive Sprocket
18
Rocker Oil Feed Relief Valve
18
Dismantling the Crankcase
19
Main Bearings
20
Fitting the Connecting Rods
20
60. Reassembly of Crankcase
20
61 . Crankshaft Plugs
21
62. Pump Worm Threads
21
Gearbox and Clutch
21
Description of the Clutch
21
Description of the Gearbox
22
Removal of the Gearbox
22
To Dismantle the Gearbox
22
Removal of the Ball Races
22
Operation of Gears
23
Change-Gear Menchanism
24
Reassembling the Gearbox
24
Dismantling and Reassembling the Clutch
24
Adjustment of Clutch Control
24
72. Adjustment of Neutral Finder
26
Gearbox Oil Level
26
Amal Monobloc Carburetter
27
General Description
27
Tuning the Carburetter(S)
28
Exploded View of Monobloc
29
Carburetter
30
Tuning Sequence with Two Carburetters
30
Causes of High Petrol Consumption
31
Lucas Twin-Cylinder Magneto
31
General
31
Lubrication
31
Adjustments
32
Cleaning
32
High Tension Cables
32
Renewing Timing Control Cable (Manual Control)
32
Contact Breaker Springs
32
Automatic Advance Mechanism
33
Removal of the Engine Gear- Box Unit from the Frame
19
Removal of the Gearbox
19
Service Operations with Engine Removed
19
General (6-Volt Sets)
34
Maintenance
36
Filling and Soaking Batteries
37
General
37
Technical Data
37
Head and Tail Lamps
38
Headlamp
38
Lucas Light Unit
38
Parking Lights (Early Models with Casquettes)
39
Tail Light
39
Description of Frame
40
Frame
40
100. Removal of Rear Suspension
41
101. Servicing Rear Suspension Units
41
Steering Head Races
41
104. Wheel Alignment
42
Front Fork
43
Operation of the Fork
44
108. Dismantling the Fork to
44
111. Steering Head Races
45
Front Wheel
47
Replacing Brake Linings
47
Removal of Brake Operating
47
Bearings
53
Hub Bearings
53
Removal of Ball Bearings
53
139 Removalofhubdrivingpins
54
144. Wheel Rims
54
5
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Royal Enfield INTERCEPTOR 1965 Specifications
General
Brand
Royal Enfield
Model
INTERCEPTOR 1965
Category
Motorcycle
Language
English
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