Royal Enfield Himalayan Service Manual
  1. Manuals
  2. Brands
  3. Royal Enfield Manuals
  4. Motorcycle
  5. Himalayan
  6. Service manual

Royal Enfield Himalayan Service Manual

Hide thumbs Also See for Himalayan:
Table of Contents

Advertisement

Quick Links

Carburettor Version Model

Advertisement

Table of Contents
loading

Related Manuals for Royal Enfield Himalayan

Summary of Contents for Royal Enfield Himalayan

  • Page 1 Carburettor Version Model...
  • Page 2 “FIRST TIME RIGHT” is a very important element for enhancing Customer Satisfaction. Royal Enfield is committed to upgrade the skills and knowledge of technicians so that they follow scientific repair techniques to ensure “FIRST TIME RIGHT” practices and carry out repairs accurately so that customers will enjoy trouble free performance at all times.
  • Page 3 HIMALAYAN – VEHICLE VIEWS VEHICLE VIEW LH ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 4 VEHICLE VIEW RH ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 5 VEHICLE VIEW FRONT ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 6 VEHICLE VIEW BACK ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 7 VEHICLE VIEW TOP ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 8: Table Of Contents

    11. Front Suspension 11.1 Front Mudguard ..........17. Wiring Harness ............206 11.2 Front Wheel ........... 11.3 Front Fork ............18. Trouble Shooting ............ 210 11.4 Handle Bar ............11.5 Steering Stem ..........ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 9: Technical Specifications

    . Tank capacity 15+0.5 litres approx.* Reserve 3.0 + 0.5 Litres approx.* Low fuel warning - Fuel Gauge (Red zone) 5.5+0.50 litres approx.* Dead stock (unusable fuel) 0.5 litre approx.* ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 10 LCD Indication DIMENSIONS: Length 2190mm Width 840mm Height 1360mm Wheel base 1465mm Ground clearance 220mm Saddle Height 800mm WEIGHTS: Kerb weight with (90% fuel & oil) 182 Kg. Max. permissible load. 183 Kg. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 11: Periodical Maintenance

    If in case the motorcycle is used frequently in very dusty environment / severe climatic conditions / Poor Roads / stagnant water etc., the maintenance will need to be done earlier as may be required. Contact a nearest Royal Enfield Authorised Dealer / Service Center to carry out the periodical maintenance and for any expert advice.

  • Page 12: Special Tools Usage List

    Allen bolt on bottom tube. ST-26485-3 Front Fork Oil Seal Driver To drive slide bush and fork oil seals into bottom tube ST-25244-4 Special spanner adjuster To adjust rear shock absorber spring pre tension ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 13: Engine Dismantling From Frame & Reassembly

    Flanged Hex Bolt, M6 X 1 X 14 Skid Plate Grommet Cradle Frame Stud Bracket Assy-Oil Cooler Crossbar Assy Flanged Hex Bolt, M10 X 1.25 X 75 Dust Cap-Frame Top Flanged Hex Bolt M6 X1 X 27 Dust Cap-Frame ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 14 Flanged Hex. Bolt M8 X 1.25 X 45 Steady Bracket Black Saddle Bag Mtg- RH Hex Socket Head Screw M8 X 1.25 X 25 Flanged Hex. Nut M8 X 1.25 Flanged Hex Bolt M8 X 1.25 X 20 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 15 Rear top engine mounting on frame (support engine Magneto rotor assembly including Starter clutch from bottom suitably)   Starter idler gears with bush & spindles Four mounting studs of Engine to cradle frame  ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 16  Remove oil cooler along with inlet & outlet pipes. (Ensure the Oil pipe No 2 on RH side between engine & frame is taken out carefully, while dismantling the oil cooler.) ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 17 LH & RH sides.  Gently pull out Cover cockpit LH & RH from the rubber grommets in the top frame LH & RH. Hex socket hd. Screw: M5 Allen key: M4 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 18 LH & RH, to fuel tank while rotating & connector tube. removing the side support  Gently rotate & pull out brackets. top frames LH & RH from connector tube. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 19  Slide fuel tank towards damage to the front rear to release front end of the fuel tank. clamp from frame - Prevent damage to  Remove tank along with EVAP hose overflow tube carefully. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 20 Double End Spanner: down and loosen hex 13mm nuts completely.  Gently pull throttle cable from bracket to release the threaded position from the bracket.  Remove inner cable from the Carburetor. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 21  Release inner cable from adjuster while removing the clevis in the clutch nut. shaft  Remove rubber grommet & outer lock nut & remove clutch cable from the bracket. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 22  Remove 3 Hex socket Hex. Socket Button Hd Button head screws Screw M6X12 (except right bottom Allen Key: M5 one).  Gently pull out to release locater from frame rubber Grommet. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 23 Ensure Ignition switch & and remove the wire. engine stop switch are in  Remove flanged hex position before bolt securing the earth disconnection battery & wire eyelet to crankcase. wiring couplers. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 24 (Pulsar wire connections from LH Side. I. Gear position switch coupler  Disconnect BIG & SMALL Black coupler from LH side. J. Side stand switch coupler  Disconnect Red coupler from LH side. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 25  Gently pull out the exhaust pipe from the cylinder head remove exhaust pipe Hex bolts: M8 X 1.25X45 with silencer from the Hex Nuts: M8 X1.25 vehicle. Socket spanner -12mm Double End Spanner: 12mm ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 26 LH & RH sides of the swing arm and push the rear wheel inside, to create sufficient slack in the rear chain  Remove chain link lock and remove chain from the engine sprocket. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 27 & cradle frame to main frame.  Gently remove the support from the bottom of the cradle frame / engine simultaneously remove cradle frame with crankcase from main frame. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 28 Flanged U nut on the Socket Spanner: 14mm cradle frame rear LH Ring Spanner: 14mm side.  Remove the 3 studs from the cradle frame & gently lift up the engine away from the frame. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 29 Apply suitable thread locking liquid as appropriate on non precoated fasteners before assembling and tightening  to torque. Always tighten fasteners diagonally and evenly to the correct specified torque values  Clean, and repaint rusted areas in frame and other parts before assembly  ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 30: Torque Values

    Head Lamp Mtg to Support Hex Soc. Hd. screw 1.0  0.9  11.5 Brackets M8X1.25X25 Trafficators Mtg to Support Button Head M6X1X20 0.5  0.4  Brackets Windshield Mtg to Support Hex Socket Head Screws M5X16 0.5  0.4  Brackets ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 31 - 2 mounting holes at the rear bottom of cradle frame with 2 holes in main frame.  Insert flanged Hex Bolt M10X 183 at rear top of engine and assemble U nut. TIGHTEN FULLY. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 32  Route rear chain through final drive sprocket and locate it on rear wheel sprocket  Ensure ‘O’ rings are located on the chain link and Insert link from the inside of the chain. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 33 Torque: 10Nm(1.0Kg.M) shift pedal is parallel to rider footrest LH.  Assemble Hex bolt on gear shift lever short from the front side and tighten to torque. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 34 12mm rear and insert flanged Torque: 25Nm (2.5Kg.M) hex bolt. Assemble hex nut over bolt.  Tighten the 2 hex nuts at the cylinder head, first and then the silencer bracket nut. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 35 M6. Hex nut : M6  Slide rubber Double end spanner : grommets over the 10mm threaded sleeve on outer cable.  Adjust the throttle cable free play correctly. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 36 Socketspanner: 8mm motor & tighten with Torque: 8-12Nm flanged hex bolt. (.8-1.2Kg.M)  Locate Relay starter cable on the starter motor terminal & tighten with Hex nut. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 37  Connect BIG & SMALL Ensure Protection Black coupler to wiring couplers are correctly slid harness on LH side. over the coupler after connecting. Ensure wiring harness correctly strapped to frame after connecting couplers. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 38  Connect Red coupler to wiring harness on LH side. J. Battery Connections  Connect Positive terminal (Red) to the positive terminal of the battery.  Connect negative terminal (Black) to negative terminal of the battery. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 39 Hex. Soc Button Hd Screw: side panel in the rubber M6X12 grommet in frame and press in gently. Allen Key: M5  Assemble 3 Hex socket Torque: 5Nm(0.5Kg.M) Button head screws over the panel and tighten. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 40 Socket Spanner: 14mm. mounting bracket is on Torque: 50 Nm (5.0 Kg.M) the RH side.  Align mounting holes with upper mounting hole in Frame. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 41  Ensure the dust caps are fitted on the connector. Horn 4.35  Locate horn in the bracket and tighten.  Connect horn terminals ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 42 NOTE: top frame with hex Couplers are color coded as: socket button head screw & hex nut. LH side: Green RH side: Red  Connect the wiring coupler to the wiring harness ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 43 Philips screw driver  Locate wind shield on Torque: 5Nm.(0.5Kg.M.) the top frame, ensure the mounting holes are aligned on both sides and tighten using 4 Pan head screws with plastic washers.. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 44  Ensure 2–3 mm clutch lever free play at handle bar end by suitably turning inner lock nut on cable cable.  Tighten outer lock nut against cable bracket. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 45: Oil Cooler

     Position each Banjo Union Bolts: M14 aluminum washer on Socket spanner: 19mm. either sides of the hose banjo union of Hose no.1 Torque: 38Nm.(3.8Kg.M.) tighten crankcase LH with Banjo union bolt. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 46 Skid plate.  Assemble 2 Flanged Hex Bolts, M6 X 1 X 14 at the front of the skid plate.  Tighten all the 6 bolts evenly and diagonally. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 47 SECTION 05 - RIDER & PILLION SEAT EXPLODED VIEWS RIDER & PILLION SEAT S. NO. QTY. S. NO. QTY. DESCRIPTION DESCRIPTION Pillion Seat Assy Rubber Support - Rear Rider Seat Assy Tool Kit Strap Rubber Support - Front ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 48: Rider & Pillion Seat

     Unlock pillion seat by turning key clockwise & lift pillion seat from front end to release rear tab & remove.  Lift rider seat from rear end to release front tab & remove. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 49  Locate rear seat tab in the frame, align lock pin with the seat latch and gently press on seat to lock.  Remove after locking pillion seat. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 50: Control Cables

    SECTION 06 - CONTROL CABLES EXPLODED VIEWS CONTROL CABLES S. NO. QTY. DESCRIPTION Clutch Cable Assy. Throttle Cable Assembly Seat Latch Cable Assy ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 51 Removal from Handle bar  Remove the outer cable from the clutch lever holder assembly at the handle bar end.  Remove clutch cable inner from the clutch lever  Remove the clutch cable ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 52  Lower the housing and release the inner cable from the eyelet on the throttle rotor  Remove the inner cable on the throttle rotor housing bottom ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 53 Free movement of the inner cable inside outer cable.  Carefully inspect the outer cables for cuts / damages.  Brittleness of the cables and no flexibility.  ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 54  Check clutch lever free Hex Nut: M8 play is between 2-3 mm and tighten /loosen D E Spanner: 12mm inner lock nut.  Tighten outer locknut against clutch bracket. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 55 Philips head screw driver handle bar.  Locate throttle cable stop plate on outer cable and tighten to bottom housing with screw.  Route the throttle cable below fuel tank and strap properly to frame. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 56 3mm at the throttle rotor at the handle bar end and adjust top lock nut accordingly.  Tighten bottom lock nut Hex Nut: M6 against the bracket at D E Spanner: 10mm carburetor end ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 57 Air Filter Box Assembly Clip Pan Head Screw M5 X12 Hex Flange Bolt, M6 X 1 X 14 Inlet Cover Rear Damper - Tank Seal Lid – Battery Carrier Element Air Filter Clamp Pipe Outlet ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 58: Air Filter

     Loosen & Remove the 3 Pan head Screw M5 Pan head screws from Allen Key 4mm the air filter cover.  Remove Cover.  Remove air filter element from housing. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 59  Loosen flanged Hex bolt, holding bracket air filter to frame and remove the bolt and bracket air filter.  Remove air filter housing from rear side of the frame. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 60 Flanged Hex Bolt M6 X 1 X 20 Crossbar Assy Flanged Hex Bolt, M6 X 1 X 14 Piece mudguard Flanged Hex Bolt, M6 X 1 X 20 Lid battery carrier Flanged Hex Bolt, M6 X 1 X 14 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 61  Assemble battery, Flanged Hex Bolt: M6 connect terminals, locate lid battery carrier in Socket spanner: 8mm housing and tighten with Torque: 8-12Nm(0.8-1.2 hex bolts. (Refer electricals KgM.) section for battery assembly) ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 62: Air Filter Element

    Philips head screw driver  Locate side panel with its bottom leg located in the rubber grommet  Tighten side panel with 2 hex socket button head screws Pan head screw M5 Allen Key 4mm ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 63 Braided Hose assy Damper - Oil Cooler SS Hose Clip Spacer - Oil Cooler Hex Socket Head Cap Screw M6 X 20 Hex flange bolt M6 X 30 Clip - PAV air filter hose ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 64: Pulse Air Valve

    Hex bolts & nuts: M6 inside, loosen remove the 2 flanged Double end spanner: hex bolts from frame  Remove pulse air valve from frame, taking care not to drop the spacers and dampers ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 65 Max. Torque Aggregate Fastener Kg.M (Nm) (Kg.M) (Nm) (Kg.M) Braided hose mtg to cyl head Hex Socket Head Cap Screw M6 X 20 PAV mtg to frame Hex flange bolt M6 X 30 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 66 (1.0-1.2 Kg.M) two hex socket head cap screws  Tighten worm clip over the braided hose.  Connect the rubber hoses from airfilter and inlet manifold respectively and slide the clips in place. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 67: Exploded View

    Front Damper-Tank Rear Damper-Tank O Ring-Fuel Gauge Fuel Hose Fuel Level Sensor Unit Drain Hose Hex Flange Nut M5 X 0.8 Fuel Tap Assy Hex socket head cap screw M5X16 Plain Washer ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 68: Fuel Tank

     Slide fuel tank towards damage to the front rear to release front end of the fuel tank. clamp from frame. - Prevent damage to  Remove tank along with EVAP hose overflow tube carefully. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 69 Do not smoke or allow open flame or sparks in the vicinity.  Store the fuel carefully to avoid spillage.  TORQUE VALUES Torque Range Aggregate Component Fastener Kg-M Fuel Tank Fuel tank Mounting Flanged Hex Bolt M6 * 1*27 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 70 Socket Spanner 10 mm tighten to torque. Torque 5 NM (0.5 Kg.M)  Connect fuel hose to fuel tap and carburetor and lock the clips in place. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 71 Exhaust Pipe Assy Damper Bush Guard, Cat Pipe Silencer Assy Philips Pan Head Screw M6 X 6 Hex Flange Bolt M8 X 1.25 X 55 Guard Exhaust Pipe Guard Silencer Clamp Silencer ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 72: Exhaust Pipe & Silencer

     Support the silencer and Socket spanner - 12mm remove the bolt. Double End Spanner: 12mm  Gently pull out the exhaust pipe from the cylinder head remove exhaust pipe with silencer from the vehicle. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 73 Copper gasket between exhaust pipe and cylinder head whenever exhaust pipe is dismantled from cylinder  head. Torque Range S No. Aggregate Fastener Kg-M Exhaust Pipe Mounting to Cyl.head Flanged Hex Bolt M8 X 1.25 X 16 Silencer Mounting to Frame Hex Socket M8X1.25X25 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 74  Tighten the 2 hex nuts at Hex bolts: M8 X 1.25X45 the cylinder head, first Hex Nuts: M8 X1.25 and then the silencer bracket nut. Socket spanner -12mm Double End Spanner: 12mm Torque: 25Nm (2.5Kg.M) ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 75 SECTION 11 - TOP BRACKET, HANDLE BAR, FRONT MUDGUARD, FRONT WHEEL FRONT SUSPENSION & STEERING STEM ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 76 Hex Socket Head Cap Screw M8 X 45 Rubber Nut-M5 Top frame RH with Decal Cover Cockpit Top Cover Cockpit RH Decal RH Hex.Socket Button Head Screw M6X1 Hex Socket Head Cap Screw-M6 Washer Plastic ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 77: Front Mudguard

    Front Mudguard - Bottom Front Mudguard with sticker assy - Black Hex. Socket Button Head Screw M6 X 1 Flanged Hex Bolt M6 X 1 X 27 Hex. Socket Head Cap Screw- M6 X 20 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 78: Front Wheel

    Spacer - Front Hub Disc- Front Front Hub Assy Hex Flanged Bolt M8 X 1.25 X 25 Wheel Speed Sensor Assy Spokes Front Spindle - Front Wheel Nipple Hex U Nut M16 X1.5 Washer ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 79: Front Fork

    Lock Washer, M6 Hex Socket Head Screw M8 X 1.25 X 25 Plain Washer Spindle Taper Hex. Bolt M6 X 12 Piston - Front Fork Bellow Fork Spring - 2 (Short) Fork Gaiter Clip ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 80 Mountable Strap- Handle bar Handle Bar Complete Bracket - Lever, Clutch LH Rear View Mirror LH Clutch Lever Lever & Holder Assy- LH Screw - Clutch Switch Clutch Switch Screw Brake lever fixing ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 81: Steering Stem

    Ring Nut Number Plate – Front Clip Holder Assy - Wiring Harness Cross Recessed Pan Head Screw M5 X 0.8 X 12 Flanged Hexagonal Bolt M6 X 1 X 10 Clamp-Wheel Speed Sensor ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 82 LH & RH sides. Hex Nut: M6 Double end spanner:10mm  Gently pull out Cover cockpit LH & RH from the rubber grommets in the top frame LH & RH. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 83  Gently rotate & pull out CAUTION: top frames LH & RH from Take care not to damage fuel connector tube. tank while rotating & removing the side support brackets. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 84: Instrument Cluster

    Allen key: 4mm screws beneath switch and remove switch.  Remove 2 Allen screws Hex soc. Hd. cap Screw: mounting Instrument cluster Allen key: 6mm bracket to frame head tube. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 85: Front Mudguard

    Allen key: 4mm  Remove 4 Allen screws Hex soc. Hd. cap Screw: inside front mudguard bottom to separate mudguard from fork Allen key: 4mm brace. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 86: Front Wheel

    Place a suitable spacer of 4 sensor and spacer. mm thickness, between the brake pads to prevent them  Remove wheel speed from coming out too far, sensor from the hub. incase brake lever is depressed accidentally. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 87: Front Fork

    LH & RH side on steering stem assy. Allen key: 6mm  Rotate main tube & simultaneously pull out from fork crown plate steering stem assembly.  Repeat same process with other fork assembly. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 88  Invert the fork assembly to drain out the oil from the fork.  Gently pump main tube Fork oil capacity: into the bottom tube to 455ml/leg drain completely. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 89  Separate fork tubes by sharply pulling inner tube out of the outer tube along with the guide bush, seat pipe assembly, rebound spring and cap oil lock. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 90: Handle Bar

     Remove 4 Hex socket Hex soc hd. cap screw: M8 screws mounting top Allen key: 6mm raiser to steering stem top bracket & remove handle bar with top raiser. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 91: Steering Stem

    - Fork assemblies LH & RH  Loosen top nut on steering stem and remove  Support steering stem from bottom and remove adjuster nut at the top Hex nut : M24 Double end Spanner : 30mm ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 92: Royal Enfield

    NOTE: bearing from the frame head tube. The bottom taper roller bearing will be tight in the steering stem and will have to be pulled out of the stem using suitable puller. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 93 Hex Socket head screw M8X1.25X30 8.50 0.85 11.50 1.15 15 Front Caliper Mtg Hex Flange Bolt M8X1.25X55 21.25 0.21 28.75 0.29 16 Front Disc Plate Mtg Hex Flange bolt M8X1.25X25 21.25 0.21 28.75 0.29 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 94 Fork spring long  Spring Length ------ mm Short Pitch Long Pitch Fork spring short  Length New Spring: --------mm Service Limit: -------mm Main tube straightness Service Limit: 0.15 mm Guide Bush ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 95 & smooth rotation on both LH & RH.  Locate top yoke over the steering stem  Assemble top nut over the top yoke. Do not tighten fully. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 96 / or sticky movement of Socket Spanner - 30m steering assembly. Torque - 70 Nm (7.0 Kg.m)  Tighten top nut stem to torque on steering. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 97 5)  Connect clutch switch wiring coupler.  Connect wiring couplers of LH and RH switch assemblies from the wiring harness  Assemble rear view mirrors LH & RH from handle bar. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 98 – front fork  Insert special tool into inner tube assembly, from top to hold piston – front fork. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 99 Fork oil capacity:  Locate thrust washer 455ml/leg and tube spacer inside inner tube.  Assemble plain washer over spacer and tighten with the special hex cap nut.  Repeat process assemble other fork. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 100 Allen head socket : 6mm sufficiently. Torque : 22.5 Nm (2.25  Assemble front Kg.m) mudguard and brace  Locate front wheel caliper on fork Lh and tighten with 2 Hex flange bolts. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 101  Tighten front mudguard Hex. Socket Head Cap top to steering stem screw : M5 using 4 hex bolts from inside of mudguard. Allen key : 4mm ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 102  Tighten the pinch bolt on Hex. Soc. Head Cap fork end LH. Screw : M8  Remove the support Allen Key : 6mm provided under the vehicle. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 103  Assemble 3 washers on Hex cap nuts: M6 the studs and tighten Socket Spanner: 10mm with 3 cap nuts Torque :  Connect instrument cluster wiring coupler. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 104 LH & RH and tighten with 2 hex socket head screws.  Assemble 2 dust caps in the mounting holes in top frame LH & RH.  Connect head lamp wiring coupler below head lamp. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 105 Hold the rubber mounted  Assemble plastic washers nuts from behind while on the 4 Hex socket head Tightening screws. cap screws and tighten to top frame LH & RH. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 106 SECTION 12 - REAR WHEEL, CHAIN & SPROCKET, SAREE GUARD, CHAIN GUARD, REAR GUARDS, SHOCK ABSORBER, DRAG & DROP LINKS, SWING ARM, REAR CHAIN ADJUSTMENT AND WHEEL ALIGNMENT ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 107 Rear Number Plate Assy Mudflap - Rear Hex.Socket Button Head Screw M6 X 1 X 16 Hex socket head cap screw M5X16 Reflector Spacer- Oil Cooler Hexagonal Nut M6 X 1 Grommet ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 108 Spindle - Long Hex U Nut M16X1.5 Washer Nipple Spacer - Sprocket Side Rear Spokes Rear Rear Hub Grease Seal FD Sprocket comp Ball Bearing 6005 (25 X 47 X12) [Double Side Rubber Sealed] ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 109 Flanged Hex Bolt M6 X 1 X 27 Spacer - Swing Arm Chain – Guide Saree Guard Hex Nut With Nylock M12 X 1.5 Hex socket head screw M6X1X14 Rear Chain-Pad Washer-Chain Pad ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 110 Inner Race- Drag Link Back Flanged Hex. Bolt M10X1.25 X 47 Inner Race- Drag Link Front Inner Race- Drop Link Flanged Hex. Bolt M10 X 1.25 X 66 Swing Arm with bearing-Assy ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 111: Rear Wheel

    LH and RH side 12mm completely to increase chain slack.  Remove Chain Link Lock.  Remove Chain link plate, Small Nose pliers. ‘O’ rings and link to disconnect rear chain from sprocket. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 112  Gently pull out sprocket with adaptor from the wheel hub.  Holding Hex Nylock nut at the sprocket adaptor end, loosen and remove six Hex socket head cap screws.  Separate sprocket from the adaptor. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 113  Remove saree guard and chain guard from swing arm. 12.3 Piece mudguard  Remove 4 Hex bolts (2 at Hex Bolt: M6 the top & 2 at the bottom) Socket spanner:10mm  Remove piece mudguard ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 114: Rear Mudguard

     Support rear mudguard Hex Soc. Hd cap screws: and remove 2 hex socket head cap screws on LH & Allen key:4mm RH side and remove rear mudguard. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 115: Mono Shockabsorber

    U nut at Ring spanner: 14mm shock absorber bottom mounting to drag link.  Hold hex bolt and loosen hex U nut at shock absorber Top mounting to frame  Remove shock absorber. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 116: Drag & Drop Links

    2 drop links to swing arm bottom.  Remove the 2 hex bolts one after the other to release drop links along with dust seals and inner race from swing arm. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 117: Swing Arm

    In case of bearing worn out  Remove swing arm or damaged, the entire assembly along with the swing arm assembly should spacers, dust seals and be replaced. inner race from the frame assembly. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 118 Button Head M6X1 4.25 0.43 5.75 0.58 15 Tail Lamp Bkt Mtg Hex Flange M6X1X20 10.0 8.50 0.85 11.50 1.15 16 Rear Mudguard Mtg Hex Flange M6X1X20 10.0 8.50 0.85 11.50 1.15 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 119 Torque: 50Nm(5 KgM) frame.  Assemble hex nut on bolt.  Tighten all fasteners of drag and drop links to torque.  Ensure free movement of swing arm, drag and drop links. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 120  Position saddle bag Hex Soc. Hd cap screws: mounting LH & RH on frame and tighten with 2 each hex socket head Allen key: 5mm cap screws to torque. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 121 Spindle: M12 the spindle RH side and tighten to torque. Socket spanner: 17mm  Ensure free and smooth Torque: 70Nm(7 KgM) up and down movement of swing arm. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 122 Torque: 50Nm(5 KgM) frame.  Assemble hex nut on bolt.  Tighten all fasteners of drag and drop links to torque.  Ensure free movement of swing arm, drag and drop links. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 123  Position saddle bag Hex Soc. Hd cap screws: mounting LH & RH on frame and tighten with 2 each hex socket head Allen key: 5mm cap screws to torque. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 124 Hex Soc. Hd cap screws: mudguard bottom. Allen key:4mm Piece mudguard 12.13  Locate piece mudguard Hex bolt: M6 and tighten with 4 Hex Socket spanner:10mm bolts (2 at the top & 2 at the bottom) ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 125 Allen screw: M10  Tighten the 6 bolts diagonally and evenly to Allen key: M8 torque following the Hex nut: M10 sequence shown. Ring spanner: 12mm Torque: 50Nm (5Kg.M) ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 126 Ensure brake hose is  motorcycle. correctly positioned on the clips, without any twist, sharp kinks or damage as it will seriously affect brake efficiency. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 127: Chain Tension

    AXLE NUT IS TIGHTENED while ensuring they are Hex nut: M16 held firmly. Socket Spanner: 24mm  Tighten the rear wheel Torque: 70Nm (7.0Kg.M.) axle nut for torque. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 128 SECTION 13 - HYDRAULIC DISC BRAKES ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 129 Pad Pin Kit Front Caliper Diaphragm Kit Front M/C Wear pad Reservoir Cover Kit Front M/C Primary Pin Kit Front Caliper Lever Kit Front M/C Flanged Hex. Bolt M8 X 1.25 X 55 Front Brake Switch ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 130 Brake Pad Kit Rear Caliper - BBI Minor Kit Rear Caliper Pad Pin Kit Rear Caliper A8 Banjo Bolt Kit Wear pad Reservoir Kit Rear M/C Threaded Banjo Bolt Reservoir Tube Kit Rear M/C Washer ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 131  Remove protective rubber cap on bleeder nipple on the caliper.  Loosen bleeder nipple Ring Spanner: 10mm by about 2 turns. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 132  Gently depress brake lever slowly and release to drain the brake fluid through the bleeder screw. Repeat this process several times till the fluid is completely drained from the brake system. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 133  Remove the brake hose from vehicle.  Remove 2 slotted screws Philips screw driver from the top cover.  Remove cover diaphragm plate and rubber diaphragm from master cylinder. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 134  Remove 2 hex bolts on Hex nut: M6 the clamp. Ring spanner: 8mm  Remove clamp and master cylinder from the handlebar ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 135 Screw Driver  Loosen and remove 2 Allen screws : 4mm socket headed Allen key : M5 screws from the caliper body.  Remove the brake pad from Caliper Assembly. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 136  Gently remove the seals from caliper using a blunt and soft tool. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 137 Repeat this process several times till the fluid is completely drained from the brake system.  Remove the brake hose with rubber grommets from the swing arm. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 138 NOTE: from vehicle. Remove the sealing washers from either side of the brake hose banjo. Master cylinder 13.2.2 reservoir  Unscrew lid from master cylinder reservoir and remove lid along with diaphragm. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 139  Remove disconnect brake pedal from the link rod in master cylinder.  Loosen 2 socket head Hex soc Hd screw : M4 screws holding master Allen key : 5mm cylinder to frame. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 140 Pull gently with minimum force. 13.2 Front Disc Brake Brake pads from 13.2.4. wheel caliper  Remove 2 locking clips from the brake pad pivot in wheel caliper ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 141  Loosen and remove rear wheel axle nut.  Pull out the pivot pin from the inside of the caliper.  Separate the Mounting Bracket from the Caliper Assembly by gently pulling them apart. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 142 Ensure piston outside bore. surfaces does not get  Gently remove the scored or damaged. piston with seal from caliper using a blunt and soft tool. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 143 In case of any brake fluid contamination in the brake system, the contaminated brake fluid must be flushed out  completely from the entire system, the internal parts cleaned well, filled with fresh brake fluid and the brake system bleeding must be carried out. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 144 Thickness of the Minimum disc thickness disc plate as engraved on the disc Rear Disc Brake Disc Flatness of the disc 0.1 mm plate plate Runout of the disc 0.3 mm plate ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 145 0.15 Brake pad pin bolts Socket pin bolts 20.0 Grub screw, brake pad in bolts Grub screw Bleeder nipple Hex nipple Wheel caliper mounting on fork end LH Hex Nut M8X1.25 30.0 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 146  Smear fresh brake fluid on the caliper boot and bellow and assemble them on the caliper body. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 147 Caliper body.  Assemble Bleed screw Ring Spanner: 8 mm with the dust cap on the Torque: 10Nm (0.1Kgm) caliper body.  Assemble the Mounting Bracket on the caliper Body. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 148  Tighten the pins to the Brake pad pins caliper body. Allen key: 5mm Torque: 20Nm (2.0Kgm)  Assemble Grub screws Grub screws on the pins and tighten. Screw driver Torque: 3Nm (0.3Kgm) ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 149 NOTE: Ensure the circlip is seated correctly inside the groove. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 150 Torque: 6Nm(0.6 KgM) pivot screw from the top and tighten to bracket.  Assemble lock nut below and tighten.  Assemble the Brake Switch on the bracket.  Connect the brake light switch. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 151  Fill fresh brake fluid in the Master cylinder till Slotted screws “MAX” mark Screw driver  Assemble the diaphragm, Torque: 15Nm(.15KgM) plate and cover.  Tighten screws gently. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 152  Insert the closed end of the piston into the caliper bore and gently press it into caliper fully till the open ends of the piston are flush with the caliper bore outer edge. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 153 Torque: 10Nm (0.1Kgm) caliper body.  Position the guides on Caliper mounting bracket correctly on the rubber boot and assemble caliper body in the mounting bracket ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 154  Locate the pivot pin from the inside of the caliper correctly.  Assemble the 2 locking clips on the brake pad pivot pin. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 155  Assemble Circlip in the Circlip master cylinder body Circlip pliers and ensure it is locked properly in the groove  Assemble the protective rubber boot on the master cylinder. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 156  Insert link rod in master cylinder align mounting eyelet with brake pedal eyelet correctly.  Insert lock pin from Split pin outside and assemble Nose pliers split pin on lock pin on the inside. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 157: Brake Hose

    Ensure proper routing of brake hose before  Assemble Banjo bolt tightening. with brake switch on the brake hose banjo, and tighten banjo to master cylinder.  Connect brake light switch coupler to main harness. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 158 Ring spanner: 12mm and tighten with banjo bolt.  Fill fresh brake fluid in the Master cylinder till “MAX” mark  Bleed the air out of the hydraulic brake system. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 159  When a slight firmness is felt on the lever / pedal and travels only up to halfway, hold the lever/ pedal firmly depressed in that position. DO NOT RELEASE THE LEVER. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 160 / pedal movement is minimal and locks firmly without sponginess applied position.  Also check and ensure there are no more air bubbles being carried out by the fluid while bleeding the system. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 161 Check for any leaks at the banjo or the bleeding screw  Tighten the cover firmly areas and ensure all on the reservoir in the tightness of all fasteners. rear brake master cylinder. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 162: Carburetor

    Jet Holder (JH) ‘O’ Ring (Drain) Screw Assy. (FCB) Bowl Mtg. Float Body Assy. Screw (Float) Packing (Idle Screw) Clip (Needle Valve) Screw (DH. Cover) ‘O’ Ring Plunger Assy. Choke Bracket (TH Cable) ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 163 NOTE:  Tilt carburetor towards Ensure the vent and drain RH side and remove hoses are free from the frame from air filter connection when removing carburetor. tube. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 164 Ensure Needle jet does not and remove main jet fall out of the body while removing jet holder.  Loosen and remove jet holder from carburetor Remove needle jet after body. removing jet holder. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 165 – unless there is a defect in these components.  Remove Pilot screw Screw Driver assembly along with O Rings, washer and spring from the carburetor body. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 166 Aggregate to Dismantle / Fastener, Size, Tool Usage, Precautions, Photos Instructions 14.2 Carburetor internals  Loosen Hex nut and D.E spanner: 14 mm remove Starter plunger assembly along with “O” ring from the carburetor body. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 167 DO NOT alter the locking position of the E ring on the jet needle or use under / over sized jets to improve the  performance AND/ OR fuel efficiency. Use of non specified jets can seriously affect the performance of the vehicle and also cause major harm to the engine internals. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 168 Float Pin Fixing Screw 20 kgf-cm Bowl Fixing Screw 35 + 10 kgf-cm Drain Screw 20 + 5 kgf-cm Starter Choke Guide Holder 25 + 5 kgf-cm Diaphragm Top Cap Screw 35 + 10 kgf-cm ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 169  Locate main jet holder in D.E Spanner : 8 mm carburetor body and tighten. Torque: 18 + 5 Kgf  Assemble Main jet on Screw driver holder Torque: 18 + 5 Kgf ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 170  Recheck and ensure the CAUTION : correct float height is Exercise utmost caution maintained at both float while adjusting the float ends after height to prevent damage adjustments are carried to the floats. out. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 171  Loosen pilot air screw by 1 ½ TO 2 FULL TURNS. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 172  Assemble bottom lock Double end spanner: nut on the cable adjuster 10mm and thread in by a few threads. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 173  Hold top lock nut and tighten bottom lock nut firmly against bracket  Connect TPS (black) coupler to carburetor on LH side.  Connect fuel hose to carburetor and fuel tank. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 174: Carburetor Tuning

    Check engine idling improperly adjusted or stability drive wrongly routed. Correct the vehicle to check for same before test ride. smooth operation (no misfiring or flat spot). ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 175 Clogging of fuel inlet nipple Remove the dust with small needle and clean with air Clogging of pilot jet. Clean with carburetor Cleaner MISFIRE Part missing Check the presence of Ball plugs and Air jets ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 176: Electrical Components

    SECTION 15 - ELECTRICAL COMPONENTS ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 177: Starter Motor

    Solenoid Switch Magnetic Relay type INSPECTION Ensure earth terminal is located on the outside hex flange bolt of the starter motor before tightening both bolts. RELAY STARTER WIRING LAYOUT Schematic Diagram - Relay ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 178 Multimeter. If the Multimeter indicates 0Ù with a beep sound, the contacts have got closed. If the Multimeter indicates as open (OL) ,contacts have not closed and hence the Relay starter has to be replaced. Starter motor +ve eyelet terminal Energised the relay Battery +ve terminal using battery ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 179 If the diode is good, then the multimeter will show a voltage drop of 0.4~0.7V. If diode has failed, multimeter will show either open or short with beep sound, then Replace the RR unit. 3 Phase AC Terminals ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 180 All the three diodes to be checked by keeping the multimeter negative probe on all the 3 phase terminals one by one. If the RR Unit is not working, replace with good working RR Unit. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 181 Keep the positive(Red) and negative (Black)probes of the multimeter on two ends of the suppressor cap. Resistance shall be 3.75 to 6.25 Kilo Ohms 4. If resistance deviates from the specification or open, Suppressor cap to be replaced. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 182: Flywheel Magneto

    ~ 50 ohms) with a beep sound. If insulation failure is observed, failed magneto to be replaced with new magneto.  2. During visual inspection, if stator coil has burnt, magneto shall be replaced with new magneto. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 183 At higher current application large amount of heat is Higher current capability can be achieved generated and component life will be reduced. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 184 ID No. Function Rating CHARGING FUSE MAIN FUSE IGNITION - EFI FUSE INSTRUMENT CLUSTER/ SIGNALLING FUSE HORN FUSE LIGHTING FUSE SPARE-1 SPARE FUSE 1 SPARE-2 SPARE FUSE 2 SPARE-3 SPARE FUSE 3 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 185: Electricals

     Remove Hex screw from Hex head screw: M6 battery strap front. Socket Spanner: 10mm  Release battery strap from the slot in the rear and remove strap.  Remove battery from the housing. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 186 Instrument Cluster 16.3 Assy  Disconnect Instrument Hex Cap nut: M6 cluster wiring coupler T spanner: 10mm  Remove 3 Hex cap nuts along with washers.  Remove instrument cluster from mounting bracket. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 187 Tail Lamp & Number 16.6 plate illuminator  The tail lamp has a LED lighting system. In the event of failure, the entire tail lamp assembly should be replaced. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 188  Locate side panel on the right side by installing 2 hex socket button head screws.  Lock (turn the key Anti- clockwise) and locate the pillion seat.  Locate the front seat ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 189 Assy  Locate instrument Hex Cap nut: M6 cluster on its mounting bracket. Allen Key: 5 mm  Install 3 Hex cap nuts along with washers.  Connect Instrument cluster wiring coupler. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 190 LH& RH  Locate the bulb by pushing and turning clockwise.  Locate outer lens  Install the screw on the trafficator housing back side.  Connect Trafficator couplers red & green ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 191 RH. Clutch Switch 16.14  Release coupler lock from the switch on Handle bar LH, bottom.  Loosen 2 screws holding clutch switch to switch module LH and remove clutch switch ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 192 Allen key: 5 mm housing and remove switch. Side stand switch 16.17 coupler  Remove strap to frame  Pull the bellow down  Disconnect Red coupler from LH side. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 193 Clutch Switch 16.20  Install 2 screws holding clutch switch to switch module LH and locate clutch switch  Locate coupler lock on the switch on Handle bar LH, bottom. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 194 Allen key: 5 mm  Connect ignition switch wiring coupler. Side stand switch 16.23 coupler  Connect Red coupler from LH side.  Push bellow upwards.  Locate strap to frame ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 195 Finger prints the reflector. will etch the glass and decrease bulb life. Always hold the bulb with clean dry cloth during handling. Don’t disturb the vent cap provided in the inner body mould. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 196  Push the bulb and turn clockwise direction to lock the bulb in the holder.  Refit the trafficator cover with reflector and tighten the screw. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 197 Do Not over tighten the bottom of the rim are mounting screw as it can aligned. Tighten with 2 cause damage to the Philips head screws threads in the lens firmly. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 198  Locate bulb correctly in the reflector, gently press bulb and turn clockwise to lock bulb inholder.  Refit trafficator cover with reflector into the housing and tighten the screw. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 199 HT coil.  Loosen the 2 Hex flange Hex Flange Bolt : M6 bolts mounted on the Socket Spanner : 10 mm welded nut in frame.  Remove HT Coil assy from frame. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 200  Tighten the bolts using 8 mm socket spanner to a Torque : 10 Nm torque of 10-12 Nm (1.0- 1.2 KgM)  Connect white coupler on the main wiring harness HT coil. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 201 ID No. Function Rating LIST CHARGING FUSE MAIN FUSE IGNITION - EFI FUSE INSTRUMENT CLUSTER/ SIGNALLING FUSE HORN FUSE LIGHTING FUSE SPARE-1 SPARE FUSE 1 SPARE-2 SPARE FUSE 2 SPARE-3 SPARE FUSE 3 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 202: Clock Setting

    6. Side Stand indication potential accident, resulting in serious injury to both rider and other road users, besides causing severe 7. Gear position indication damage to the motorcycle. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 203 TEMPERA- hold MODE TURE button for period > MODE > 10 secs UNIT 10 secs to reset temperature units CHANGE from degree Celsius OVER to Fahrenheit and vice versa. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 204 5.5+0.5 lts. in the fuel tank so that the rider can plan fuel filling accordingly based on his trip SIDE STAND requirements, Trip “F” will get activated when INDICATOR needle on fuel gauge enters the red zone. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 205  Eg. if heading Northwest, text will display NW and battery. arrow will be in top right corner to indicate North. High Beam Indication: Head lamp high beam ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 206 Refuel at the earliest. Failure to do so may cause the motorcycle to run out of fuel and get stranded, in addition to causing serious damage to the fuel pump. ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

  • Page 207: Wiring Harness

    SECTION 17 - WIRING HARNESS ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 208 WIRING DIAGRAM COMPLETE - LS 410 COMPLETE DIAGRAM - LS 410 (HIMALAYAN) ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 209 STARTING, CHARGING & IGNITION - HIMALAYAN THROTTLE POSITION SWITCH MODULE RH SENSOR TCI UNIT IGNITION COIL MAIN LIGHTING SWITCH E-START KILL SWITCH SWITCH BATTERY POSITIVE TACHOMETER Gr/B NEUTRAL BR/B STARTER MOTOR IGNITION R/BR SWITCH STARTER BR/G SOLENOID BR/L R/BR CRANK...
  • Page 210 CIRCUIT DIAGRAM LIGHTING SYSTEM - HIMALAYAN SWITCH MODULE RH MAIN LIGHTING SWITCH BATTERY POSITIVE HIGH BEAM INDICATOR LED TAIL LAMP Y/Gr LICENSE PLATE HEAD LIGHT ILLUMINATOR Y/Gr 60/55 W Y/Gr POSITION LAMP IGNITION R/BR SWITCH R/BR FUSE DETAILS SWITCH MODULE LH BATTERY 1.

  • Page 211: Trouble Shooting

    Repair and maintenance operations not listed in this Owner’s Manual should be performed by your Royal Enfield Authorized Dealer only. Improper repair / maintenance could result in the motorcycle not functioning properly or injury seriously.
  • Page 212 Check and correct Trafficators not working Loose / improper connections Check and correct Bulb fused Replace Brake light remains on Switch not adjusted properly * Adjust connecting links properly Switch sticky * Replace switch ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...
  • Page 213 NOTES ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL...

Table of Contents