Royal Enfield HIMALAYAN BS VI 2021 Owner's Manual
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Royal Enfield HIMALAYAN BS VI 2021 Owner's Manual

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  • Page 3 FOREWORD Thank you for choosing the Royal Enfield Himalayan. Your new motorcycle is the product born from Royal Enfield’s vast experience of riding in the Himalayas since decades, from exhaustive testing in all conditions, and our continuous striving for superior reliability and performance. Please read this Owner’s Manual carefully before riding so that you will be thoroughly familiar with the proper operation of the Himalayan’s controls, its features and capabilities.
  • Page 4 NOTICE All information in this manual is based on the latest product Disclaimer information available at the time of publication. Due to Wash the motorcycle only with plain water. Do not use continuous improvements, there may be discrepancies any cleaning ag ents or detergents, especially on between the information in this manual and your motorcycle.
  • Page 5 CONTENTS Personal and Motorcycle Information ......... Environment Care ............. 70 Technical Specifications ............Periodical Maintenance Chart ......... 71 Recommended Lubricants ........... Tools Kit ................78 Safety Definitions ..............First Aid Kit ................. 79 Motorcycle Identification Numbers ........Minor Maintenance Tips ........... 80 Location of Key Parts ............
  • Page 6 PERSONAL & MOTORCYCLE INFORMATION Name Door No./Street Locality/Town City Country Res: Off: Contact Mobile : Email : Licence No. Valid Till : Model Color : Engine No. Vin No. Tyre make Front : Rear : Tyre Nos. Front : Rear : Battery make Battery No.
  • Page 7 TECHNICAL SPECIFICATIONS Air filter element ..Paper element ENGINE Lubrication ....Forced Lubrication, Wet sump Engine Type ..... Single Cylinder, 4 Stroke, SOHC, ......... Air cooled, Fuel Injection Engine oil capacity ... 2.3 l (Initial fill only), Bore ......78 mm ........
  • Page 8 TECHNICAL SPECIFICATIONS TRANSMISSION 3rd Gear ....3 1.428:1 Clutch ....... Wet Multi Plates 4th Gear ....4 1.173:1 Primary drive .... Gear 5th Gear ....5 1.000:1 Primary ratio ..... 2.312:1 Secondary Drive ..5/8” Chain & Sprocket Gear box ....5 Speed, Constant Mesh Secondary Ratio ..
  • Page 9 TECHNICAL SPECIFICATIONS CHASSIS Front Disc ..300 mm Dia disc. Frame ......Half duplex split cradle Rear Disc ... 240 mm Dia disc. Suspension Front ....Telescopic, Hydraulic Damping, Tyre size ......Front wheel travel : 200 mm Front ....90 / 90 - 21 Rear ....
  • Page 10 TECHNICAL SPECIFICATIONS Tyre Pressures CAUTION Solo The use of petrol containing more than the specified Front ....25 psi / 1.75 kg/cm ethanol may cause the fuel tank corrosion & paint Rear ..... 32 psi / 2.25 kg/cm damage and may also damage the rubber tubes in the fuel line as well.
  • Page 11 TECHNICAL SPECIFICATIONS Minimum Octane ..91 RON (Research Octane ELECTRICALS rating Number) or Higher Flywheel magneto ..221 W @ 1500 rpm Fuel tank capacity* ... 15 + 0.5 l approx * Generation ....Alternator, III Phase System ......12 V - DC Low fuel warning ..
  • Page 12 TECHNICAL SPECIFICATIONS Hi beam indicator ..12 V - LED WARNING Neutral lamp telltale ..12 V - LED Using bulbs / electrical gadgets other than specified Turn signal telltale ..12 V - LED rating may lead to overloading / erratic behaviour / Turn signal .....
  • Page 13 TECHNICAL SPECIFICATIONS DIMENSIONS WEIGHTS Length ......2190 mm Kerb weight (90% fuel & oil) ..199 kg Width ......840 mm Gross Vehicle Weight ....365 kg Height ......1370 mm Wheel base ..... 1465 mm Ground clearance ... 220 mm Saddle Height ....
  • Page 14 RECOMMENDED LUBRICANTS ENGINE OIL FRONT FORK OIL BRAKE FLUID SAE 15 W 50 API SL Grade JASO MA 2 Grade 10 W/Fork Oil Grade DOT 4 Grade Semi Synthetic (Viscosity range 35) 2.3 l (First Fill only ) 1.6 - 1.8 l Approx. Front / Rear : Capacity (during oil &...
  • Page 15 SAFETY DEFINITIONS The information given under the titles : Warning, Caution and Note are for your safety and for the care and safety to your motorcycle and others. Please read these carefully and if disregarded may result in injury to yourself or others and damages to the motorcycle.
  • Page 16 MOTORCYCLE IDENTIFICATION NUMBERS FRAME NUMBER ENGINE NUMBER Punched on steering head tube right side. Punched on crankcase top side. CAUTION It is illegal to tamper with OR alter the VIN / Engine numbers of the motorcycle as it will not only against the law BUT will render the vehicle registration and warranty VOID.
  • Page 17 LOCATION OF KEY PARTS 1. Horn Button 2. Turn Signal Switch 3. Head Lamp Dip Switch 4. Rear View Mirror Left Side 5. Instrument Cluster 6. Wind Shield 7. Tripper 8. Rear View Mirror Right Side 9. Engine Stop Switch 10.
  • Page 18 LOCATION OF KEY PARTS 1. Front Trafficator Right Side 2. Horn 3. Oil Level Window 4. Rear Brake Pedal 5. Rider Foot rest Right Side 6. ABS Module 7. Pillion Foot rest Right Side 8. Rear Trafficator Right Side Royal Enfield Himalayan...
  • Page 19 LOCATION OF KEY PARTS 1. Front Trafficator Left Side 2. Head Lamp 3. Tail Lamp 4. Rear Trafficator Left Side 5. Licence plate illuminator 6. Pillion Foot rest Left Side 7. Side Stand 8. Center Stand 9. Rider Foot rest Left Side 10.
  • Page 20 OPERATION OF CONTROLS CAUTION STEERING LOCK LOCK ING: Do not force or attempt to lock / unlock steering if the handle bar is not in extreme left or right side. Failure to Turn handle bar to extreme adhere to this caution will damage the lock and also cause left or right position.
  • Page 21 OPERATION OF CONTROLS CLOSING: FUEL TANK CAP Gently depress cap till it is firmly locked in place and OPENING: key can be removed. Lift flap and insert key. Remove key and close flap. Turn key clockwise to enable cap to unlock and WARNING spring up.
  • Page 22 OPERATION OF CONTROLS Please ensure petrol does not spill on painted surfaces. Wipe IGNITION SWITCH immediately incase fuel spills over as otherwise it will leave a permanent stain on the painted surfaces. Anti splash plate NOTE Key can be removed only if ignition is in “OFF” or 1.
  • Page 23 OPERATION OF CONTROLS E-START SWITCH WARNING Press & hold till engine DO NOT switch “OFF” ignition while riding the starts. motorcycle. Doing so can cause a potential accident, resulting in serious injury to both rider and other road users, besides causing severe damage to the motorcycle. ENGINE STOP SWITCH HAZARD LIGHT SWITCH Engine “OFF”...
  • Page 24 OPERATION OF CONTROLS DIMMER SWITCH WARNING High beam Turn signals do not work when the hazard light switch is on. Low beam All the trafficator lamps will flash simultaneously. HORN DAY FLASH Press Press for Head Light Flash. Royal Enfield Himalayan...
  • Page 25 OPERATION OF CONTROLS TURN SIGNAL SWITCH DOCUMENT HOLDER Left turn signal “ON” Useful for storing motor- cycle documents and “OFF” (Push to cancel) owners manual. Right turn signal “ON” Remove the pillion Seat. Gently press on top to RIDER & PILLION SEAT release the tabs from the frame and open slightly.
  • Page 26 OPERATION OF CONTROLS INSTRUMENT CLUSTER 1. Main LCD 2. Speedometer (km major) 3. Tell tales 4. Tachometer 5. Mode button 6. Select button 7. Gear position indication 8. Fuel gauge 9. ABS Switch 10.ABS Indicator Lamp Royal Enfield Himalayan...
  • Page 27 OPERATION OF CONTROLS A. MAIN LCD 1. Clock 2. Ambient Temperature 3. Service reminder 4. Odometer 5. Trip Value (A/B & F), AVG speed A/B 6. Side Stand indication Royal Enfield Himalayan...
  • Page 28 OPERATION OF CONTROLS CLOCK Display in 12 hour format with AM/PM indication. Will reset to 12:00 AM when battery is disconnected. Royal Enfield Himalayan...
  • Page 29 OPERATION OF CONTROLS CLOCK SETTING Pressure Action Function Switch time (s) SELECT & MODE pressed In ignition key ‘ON’ position (when vehicle not running) Enters into clock setting > 3 s with No Speed input mode and hour digits starts to blink SELECT <...
  • Page 30 OPERATION OF CONTROLS AMBIENT TEMPERATURE INDICATION Ambient temperature display can be changed from Celsius to Fahrenheit and vice versa. The temperature indication may increase during vehicle riding / engine “ON” condition due to increase of engine temperature. Ambient temperature indication tolerance is + 2°C. NOTE The ambient temperature valve should be referred to only when the engine is switched “OFF”...
  • Page 31 OPERATION OF CONTROLS TEMPERATURE UNIT CHANGEOVER Temperature sensor push button management. Required button Mode Pressure Function Button Action time (s) In ignition key “ON” position, long press and TEMPERATURE hold “MODE” button for period > 10 s to MODE > 10 s UNIT CHANGE reset temperature units from degree Celsius to OVER...
  • Page 32 OPERATION OF CONTROLS Dual Channel ABS mode (Default): ABS will work on both I. ABS SWITCH - ACTIVATION PROCEDURE wheels. Ignition switch “ON” condition *Ignition key Reset: Turning ignition switch from “OFF” to “ON”. 2. Vehicle stationary 3. Press ABS switch for (3-5 s) CAUTION Single Channel ABS mode is If Single channel ABS mode enabled, ABS only controls...
  • Page 33 OPERATION OF CONTROLS followed by ABS tell tale J. ABS INDICATOR LAMP continuous “ON”, once indicator lamp the vehicle is ride more continuously “ON” during than 5 kmph, ABS tell tale initial check up (until or will blink continuously. after vehicle running for a ABS Indicator lamp lights particular distance / speed) Single channel Activation...
  • Page 34 OPERATION OF CONTROLS Service reminder can be reset ONLY by authorised SERVICE REMINDER personnel at service centre after service is completed. Service reminder is provided to remind about service Service reminder symbol will flash on as per below due. distance input from odometer. Spanner symbol will flash till vehicle is serviced at 1st service –...
  • Page 35 OPERATION OF CONTROLS 4. ODOMETER TRIP A/B & AVG SPEED A/B Displays the cumulative kilometers the vehicle has Trip A/B indicates distance travelled in particular trip. covered. Avg A/B indicates average speed of vehicle in particular trip mode. Royal Enfield Himalayan...
  • Page 36 OPERATION OF CONTROLS Function Switch Pressure time (s) Action SELECT < 1 s In ignition key “ON” position, Move to: AVA A TRIP A SELECT > 2.5 s TRIP A/AVG A RESET SELECT < 1 s Move to: TRIP B AVG A SELECT >...
  • Page 37 OPERATION OF CONTROLS Trip “F” mode would come into function TRIP “F” MODE automatically. The word, Trip “F” will flash when the Trip “F” mode is active. Trip “F” mode would de-activate automatically if fuel Trip “F” is provided to measure distance travelled by is filled above 5.5 + 0.5 l the vehicle when fuel level in the vehicle is 5.5 + 0.5 l During Trip “F”...
  • Page 38 OPERATION OF CONTROLS 6. SIDE STAND INDICATOR WARNING Indicates when side stand is extended. NEVER attempt to operate the select or reset buttons while riding the motorcycle. Doing so may cause loss of concentration and unstable riding, leading to a potential accident, resulting in serious injury to both rider and other road users, besides causing severe damage to the motorcycle.
  • Page 39 OPERATION OF CONTROLS GEAR POSITION INDICATION C. TELL TALES Turn Left : Left turn signal “ON”. Displays the gear position in which the vehicle is traveling. "G" represents the Gear and "1" represents Turn right : Right turn signal “ON”. the gear position.
  • Page 40 OPERATION OF CONTROLS Lo w Ba tt er y In di ca ti on : Indicator will glow ABS MIL : Will be continuously “ON” during initial continuously if ignition switch is “ON” & engine is not check up (until or after vehicle running for a particular running.
  • Page 41 OPERATION OF CONTROLS D. TACHO METER WARNING Indicates the rpm at which engine is working. Do not run engine with gears in neutral as rpm will go beyond red zone. Useful for right selection of gear with respect to engine rpm.
  • Page 42 OPERATION OF CONTROLS H. FUEL GAUGE WARNING Indicates fuel level in Do not use the motorcycle for long duration with the fuel tank. indication in red zone. Refuel at the earliest. The fuel pointer enters Failure to do so may cause the motorcycle to run out of red zone, if the fuel level fuel and get stranded, in addition to causing serious in the fuel tank is...
  • Page 43 OPERATION OF CONTROLS - TRIPPER Device is capable of showing turn by turn navigation on a TRIPPER custom designed round color TFT with uniquely designed arrow font designed intuitively for ease of riding. Background display can be switched between day mode and night mode which can be selected by riders from RE Mobile app.
  • Page 44 OPERATION OF CONTROLS - TRIPPER Features: Turn by turn navigation with primary turn, secondary Secondary direction Primary direction or next to next turn turn. or next turn Distance to next turn, distance to destination or Estimated Time of Arrival (ETA). Clock display (in case of no connectivity, no navigation input or after destination is reached).
  • Page 45 OPERATION OF CONTROLS - TRIPPER Smartphones compatible version to use RE Mobile Primary direction or next turn: Indicates the next turn app: to be taken along with the distance. Compatible with Android and iOS. Distance to next turn: Shows the distance to next turn. Android support: Current version - 2.
  • Page 46 OPERATION OF CONTROLS - TRIPPER TRIPPER - DISPLAY FLOW SEQUENCE If pairing is initiated (one time) PIN no Green Tripper display helmet Ignition Orange Built with In case of RE logo SW version helmet Google connection lost / no input in paired mode tripper will Clock show clock...
  • Page 47 OPERATION OF CONTROLS - TRIPPER the device, after that auto-pairing will happen if same NOTE device is connected. After every Ignition "ON" cycle tripper will be in discoverable mode for 120 s Everytime the tripper is paired the clock time will sync with mobile time after which it will continue to run Incase there is no connection established within 120 s with internal clock even in case of disconnection, there...
  • Page 48 OPERATION OF CONTROLS - TRIPPER CAUTION Disable battery optimisation settings / low battery cut- off setting of smartphone for Navigation to work in Ensure ignition is "ON" and display is in powered while low battery mode. establishing connection. Ensure fi rst time pairing is done in isolated RE Mobile app works only with Android (Current environment to avoid cross connections (one time).
  • Page 49 OPERATION OF CONTROLS - TRIPPER RE Mobile app works with bluetooth version 4.2 and N+1.0, for other lower versions performance lag can be expected. Check for network signal strength in case of navigation lag. Check for data speed in case of navigation lag, Navigation system performance is better in 4G band compared to other lower versions.
  • Page 50 PRE OPERATIONAL CHECKS 11. Head lamp, tail lamps, brake lamps and indicator Adequate fuel in fuel tank for the journey planned. lamps working correctly. 2. Tyres inflated to correct pressure. 12. Front and rear wheel axle nuts tightened properly to 3.
  • Page 51 SAFE & HAPPY RIDING Ride only at moderate speeds and out of traffic until Please read this manual carefully to get to know the motorcycle and its maintenance schedules. you have be come familiar with the handling characteristics of your motorcycle under all Please exercise utmost caution while refueling.
  • Page 52 SAFE & HAPPY RIDING know they are experienced, licensed riders and are Never ride under the influence of alcohol or other thoroughly familiar with the operating conditions of drugs that might affect your riding skills reflex. your motorcycle. When carrying a pillion rider, it is your responsibility to instruct them on proper riding procedures and RIDING GEAR riding gear.
  • Page 53 SAFE & HAPPY RIDING Never wear loose-fitting clothes; otherwise they could SITTING POSTURE catch on the control levers, footrests, or wheels and Correct sitting posture is a must for stable and safe riding. cause injury or an accident. Sit with your shoulders completely relaxed. Always wear protective clothing that covers your legs, ankles and feet.
  • Page 54 SAFE & HAPPY RIDING BRAKING WARNING Apply front and rear brakes gently and simultaneously Brake pad wear will be increased if the motorcycle is used for maximum braking efficiency. frequently off-road. Always inspect the brake pads more Please use utmost caution while applying brakes, frequently if the motorcycle is used off-road &...
  • Page 55 CARGO & ACCESSORIES The maximum permissible weight of the pannier box LOADING is 5 kg each side. Please do not fit Non OE or Non genuine accessories as they may cause damage to the motorcycle and also Do not hang any items on the handle bar and luggage affect the riding and handling of the motorcycle.
  • Page 56 CARGO & ACCESSORIES CAUTION WARNING Exhaust gases contains poisonous carbon monoxide and Please exercise utmost caution while carrying cargo or chemicals, known to cause Cancer, Birth defects or other luggage on the motorcycle. Failure to adhere to the above reproductive defects. Please park the motorcycle only in a well ventilated area and do not stay in the same place precautions can cause loss of control on the motorcycle, where the motorcycle is parked, especially when the engine...
  • Page 57 CARGO & ACCESSORIES WARNING WARNING Max load on grab rail not DO NOT attach a trailer to the motorcycle Attaching a trailer to exceed 7 kg can cause loss of control on the motorcycle, leading to a potential accident, resulting in serious injury to both rider and other road users, besides causing severe damage to the motorcycle.
  • Page 58 RULES OF THE ROAD DO NOT exceed the legal speed limit or drive too fast Be sure your number plate is installed in the position for existing conditions. Always reduce speed when specified by law and is clearly visible at all times. poor driving conditions exist.
  • Page 59 RULES OF THE ROAD (unless local rules require other-wise), slow down and When parking the motorcycle, park on a firm and flat then turn carefully. surface to prevent it from falling over. Protect your motorcycle against theft. After parking Never jump a traffic light. When a change is imminent your motorcycle, ensure that the steering head is from GO to STOP (or vice versa) at intersections, slow locked and then remove the ignition key.
  • Page 60 RULES OF THE ROAD Use care when judging the size or distance of vehicles / SIDE VIEW MIRRORS objects seen in these mirrors. NOTE To establish the relative distance of vehicles / objects behind your motorcycle through the mirrors, adjust each mirror in such a way, that a small portion of your shoulder is visible and a large portion behind your motorcycle is seen clearly with reference to your riding posture.
  • Page 61 RUNNING IN PERIOD The Himalayan Motorcycle is capable of consistent high Avoid sudden accelerations and racing starts. speeds. However as with any new motorcycle, a 6. Avoid prolonged full-throttle operation. Vary speed “RUNNING-IN PERIOD” procedure is essential to help in occasionally.
  • Page 62 WARNING INDICATIONS & SAFETY SYSTEMS In the event of any malfunction in the EFI System the MIL 1. ENGINE MALFUNCTION INDICATOR LAMP will glow continuously. It is recommended to take the A Malfunctioning Indicator motorcycle to a nearest Royal Enfield Authorized service Lamp (MIL) is provided in the station for a detailed inspection and correction of the EFI small meter.
  • Page 63 WARNING INDICATIONS & SAFETY SYSTEMS brakes from locking the wheels while reducing the speed 2. ANTI-LOCK BRAKING SYSTEM (ABS) of the vehicle. This will help the rider to control the Anti-Lock Braking System motorcycle. (ABS) will help prevent the An ABS indicator lamp is provided in the console (as shown brakes from locking the in adjacent image) to warn the rider in the event of any wheels,...
  • Page 64 WARNING INDICATIONS & SAFETY SYSTEMS Please apply both brakes to stop - front brake momentarily CAUTION (ABS) earlier, followed by rear brake, to have better traction and ABS is a safety feature to help prevent locking of wheels control of the motorcycle. during sudden application of brakes.
  • Page 65 WARNING INDICATIONS & SAFETY SYSTEMS DO’S & DON’TS : (ABS) DO’S DON’TS While starting the engine do check the ABS indicator comes DO NOT RELEASE the brake lever / pedal when “ON” and switches “OFF” when the vehicle speed exceeds pulsations are felt during hard application of the 5 kmph (3.1 mph).
  • Page 66 STARTING Depress Clutch Lever Ensure Gear is in Neutral position and the Neutral lamp fully. is glowing in the Instrument Cluster. To shift into neutral, move the motorcycle back and forth gently, while simultaneously shifting the gear. CAUTION Do not attempt to shift gears when engine is “OFF” and rear wheel is stationary as it will cause damage to gear shift Press starter button and mechanism.
  • Page 67 STARTING CAUTION NOTE In case engine does not start, do not keep starter button It is recommended to switch off the engine when the pressed continuously as it will drain the battery. Release engine is in idling condition for long time. button and restart after a few minutes to allow battery to It is recommended not to accelerate by giving recoup.
  • Page 68 GEAR SHIFTING, RIDING & STOPPING War m up eng ine for 2 min - unti l idling is Press clutch lever towards the hand grip. consistent. Press gear pedal with toe to engage 1st gear. G E A R S H I F T PAT T E R N Gently open throttle and release clutch simultaneously.
  • Page 69 GEAR SHIFTING, RIDING & STOPPING Lift gear lever with toe to engage 2nd and subsequent NOTE gears. Always start the engine with gear in neutral position. Always move the motorcycle in first gear position only. The motorcycle may begin to slow down and show lack of power while climbing steep hills.
  • Page 70 PARKING PARKING MOTORCYCLE ON SIDE STAND CAUTION Select a firm, flat surface. When Side stand is in “ON” position. Extend side stand. Tilt the motorcycle to the left, till it Engine will start if vehicle is in neutral, but will cut-off is supported firmly.
  • Page 71 PARKING over and causing injury to you or to others and damage NOTE to the motorcycle parts. The Side stand is only designed for the weight of the Do not ride motorcycle with the side stand extended. motorcycle. Do not sit on the motorcycle when it is resting Doing so can cause the side stand to touch the ground on the side stand.
  • Page 72 Engine oil, oil filter, petrol, Battery (batteries shall be CLEANING OR WASHING YOUR ROYAL ENFIELD disposed only with an authorised service centre or battery Please ensure that the effluents are not discharged into the recycler), tyres, tubes, electrical & electronic parts environment.
  • Page 73 PERIODICAL MAINTENANCE The Periodical maintenance schedule detailed below is based upon average riding conditions and indicates the intervals at which regular inspections, adjustments, replacements and lubrications must be carried out to help maintain your Himalayan motorcycle meticulously. 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.
  • Page 74 PERIODICAL MAINTENANCE FREE SERVICE DESCRIPT ION PAID SERVICE whichever is earlier km (x 1000) Months 6 Oil cooler inlet & outlet pipes Spark plug C&A C&A C&A C&A C&A C&A C&A C&A 8 HT leads for crack 9 Fuel Hose & Clip 10 Fuel Pump (under tank) Mounting Check for screw tightness in all services 11 Air filter element...
  • Page 75 PERIODICAL MAINTENANCE FREE SERVICE DESCRIPT ION PAID SERVICE whichever is earlier km (x 1000) Months 13 Rubber Hose, Air fitler to Throttle body 14 PAV pipes & Hose clip Evaporative Emission Equipment rubber hoses Throttle body should be removed from the vehicle and cleaned with a dry Microfibre cloth, Usage of throttle body cleaners or any 16 Throttle body similar solvent or alcohol based liquids for cleaning is strictly...
  • Page 76 PERIODICAL MAINTENANCE FREE SERVICE DESCRIPT ION PAID SERVICE whichever is earlier km (x 1000) Months 18 Clutch free play Adjust every 1000 km or earlier as required 19 Clutch no slippage Inspect, adjust & lubricate for every 5000 km or earlier as 20 Steering head bearings # I &...
  • Page 77 PERIODICAL MAINTENANCE FREE SERVICE DESCRIPT ION PAID SERVICE whichever is earlier km (x 1000) Months 26 Hydraulic brake hose & Washers - Front & Rear # 27 Brake Pads - Front & Rear # 28 Tyre wear pattern (Front & Rear) # (1) 29 Spokes tightness / Wheel rim run out front &...
  • Page 78 PERIODICAL MAINTENANCE FREE SERVICE DESCRIPT ION PAID SERVICE whichever is earlier km (x 1000) Months Inspect & If required lubricate for every 5000 km or earlier 32 Rear Suspension Linkages # as required. Replace if necessary 33 Rear Brake Pedal Pivot 34 Rear Brake Pedal free play Adjust every 1000 km or earlier as required 35 Rear wheel cush rubbers #...
  • Page 79 PERIODICAL MAINTENANCE FREE SERVICE DESCRIPT ION PAID SERVICE whichever is earlier km (x 1000) Months 39 Starter motor & Starter relay connections 40 Side stand switch operation A : Adjust C : Clean I : Inspect (Clean, Adjust, Lubricate or Replace if necessary) T : Re-tighten (2) L : Lubricate R : Replace...
  • Page 80 TOOLS KIT The tool kit is strapped underneath the Pillion seat. S.No. Tool Description Purpose Qty. Allen Key 4 mm To remove side panels LH & RH To Loosen / tighten pinch bolt Allen Key 6 mm on fork end Tool Spark Plug To Loosen / tighten Spark plug To Loosen / tighten screws...
  • Page 81 FIRST AID KIT A first aid kit is provided with the motorcyle for any emergency requirements. Please inspect the kit regularly and replace materials upon expiry. S.No. Description Qty. Antiseptic cream 5 gms Wash proof plaster 1.9 cm x 7.2 cm Gauze bandage 5 cm x 2 cm Sterilized Gauze Swab 5 cm x 5 cm Sterilized elastic plaster 7 cm x 6 cm...
  • Page 82 MINOR MAINTENANCE TIPS The following simple maintenance activities will help in SIDE STAND PIVOTS maintaining your motorcycle. However if you are in experienced or feel it is best done by an experienced person, Apply a few drops of oil on we recommend you to get in touch with a Royal Enfield the pivots after cleaning the Authorised Dealer / Service Centre.
  • Page 83 MINOR MAINTENANCE TIPS PERIODICAL MAINTENANCE DRIVE CHAIN Lubricate the center stand pivot periodically for Clean the drive chain smoother operation of center stand. carefully. Apply chain lubricant while simultaneously rotating the rear wheel. Wipe off the excess lubricant. Lubricate Royal Enfield Himalayan...
  • Page 84 MINOR MAINTENANCE TIPS CAUTION OIL LEVEL INSPECTION Using Non Recommended / In-correct oils, can cause Place motorcycle serious damage to the moving parts, affect performance on its center stand of the motorcycle AND void the warranty. on a firm surface. Warm up engine for a few minutes &...
  • Page 85 MINOR MAINTENANCE TIPS SPARK PLUG BRAKE FLUID Check fluid level is between “MIN & MAX”. CLEANING AND ADJUSTING PLUG GAP Top up with DOT 4, if required. Remove the spark plug cap from the spark plug. Remove spark plug using the plug spanner and Do not overfill.
  • Page 86 MINOR MAINTENANCE TIPS Replace tyres if CAUTION - Side wall cracks, Brake fluid is highly corrosive and can cause damage to cuts or damages, painted parts. Please ensure brake fluid does not spill on uneven lugs wear any part of the motorcycle. In the event of a spill, please etc.
  • Page 87 MINOR MAINTENANCE TIPS FRONT WHEEL REMOVAL WARNING Support front end of Dismantling and reassembly of the wheel should be done engine suitably such that ONLY by an experienced technician. the front wheel is off the Failure to do so may cause loss of control on the ground.
  • Page 88 MINOR MAINTENANCE TIPS Remove wheel along with wheel speed sensor and Support wheel and pull out spindle from right spacer. side. CAUTION Do not press the brake lever when wheel is removed as this will result in the brake pads coming out too far from the Remove the wheel brake caliper.
  • Page 89 MINOR MAINTENANCE TIPS (Follow below procedure FRONT WHEEL REASSEMBLY if vehicle have a wheel Remove the spacer speed sensor assembly). placed between the Position wheel along brake pads. with wheel speed sensor and spacer on left side Locate wheel speed between the front fork sensor lugs on the hub legs, ensuring the brake...
  • Page 90 MINOR MAINTENANCE TIPS side spacer aligned properly. REAR WHEEL REMOVAL Ensure the motorcycle (Follow below procedure if vehicle have a wheel is on a firm, flat surface speed sensor assembly). and the rear wheel is off the ground. Position wheel speed sensor such that it is parallel to ground.
  • Page 91 MINOR MAINTENANCE TIPS Remove the brake caliper assembly from the slot in Loosen rear axle nut on the swing arm along with ABS wheel speed sensor the right side and and support it suitably to avoid damage to the brake remove al ong with hose and ABS wheel speed sensor.
  • Page 92 MINOR MAINTENANCE TIPS Locate the caliper bracket slot on the lug in the swing REAR WHEEL REASSEMBLY arm. Ensure the cush rubbers are in Position the respective spacers on the left and right place in the wheel hub. side of the wheel hub. Insert the wheel assembly Ensure the axle mounting hole in the swing arm, wheel between the swing arms and...
  • Page 93 MINOR MAINTENANCE TIPS Assemble washer and CAUTION wheel axle nut on right side Do not force the spindle and tighten to correct through as it will cause torque. damage to the threaded Fix the brake hose pipe in end. swing arm clips properly. CAUTION Ensure correct...
  • Page 94 MINOR MAINTENANCE TIPS Tighten / loosen the adjuster nut on left swing arm end, DRIVE CHAIN TENSION (FREE PLAY 20-30 mm) to reduce / increase chain tension. Measure the drive chain free play on the top run of the Ensure the ground is level & firm and place the chain. ...
  • Page 95 MINOR MAINTENANCE TIPS Tighten / loosen adjuster WARNING nut on right side to align the front and rear wheels Chain slackness beyond 30 mm will lead to chain and also to align the slippage. reference marks on both left and right side of the Maintain drive chain slackness within the specified limits swing arm.
  • Page 96 MINOR MAINTENANCE TIPS ADJUSTMENTS - CLUTCH LEVER FREE PLAY ADJUSTMENT - REAR BRAKE PEDAL FREE PLAY Clutch Lever (free play 2 - 3 mm) Rear brake pedal free play 7 to 11 mm. Loosen the cable outer lock Loosen the lock nut in nut (A).
  • Page 97 MINOR MAINTENANCE TIPS BRAKE PAD WEAR Brake pad wear depends upon the severity of usage, the type of riding and road condition. Check the wear indicator mark on each pad. If either pad is Check the wear indicator mark on each pad. If either pad is worn to the wear indicator mark.
  • Page 98 MINOR MAINTENANCE TIPS BATTERY & MAINTENANCE REMOVAL OF BATTERY FROM THE MOTORCYCLE The Motorcycle is Remove the side panel provided with 12 V - on the right sight by 8 AH MF battery. unscrewing the hex socket button head The battery must be screws.
  • Page 99 MINOR MAINTENANCE TIPS Unlock (turn the key Take out the clockwise) and battery. remove the pillion seat. Remove front seat. Remove the Battery carrier bracket by loosening the hex bolt. WARNING Disconnect both the Always disconnect the Black negative (-) battery cable first Battery terminals wires (negative first and then the Red positive (+) cable while removing the...
  • Page 100 MINOR MAINTENANCE TIPS Place the terminal boot / cap properly. REASSEMBLY OF BATTERY ON MOTORCYCLE Refit the battery bracket. Position the battery in the battery carrier such Reconnect the harness connector to the respective that the terminals are couplers on the battery located area. facing inside.
  • Page 101 MINOR MAINTENANCE TIPS Your Battery is a maintenance free type and can be WARNING permanently damaged if the cap strip is removed. Battery terminals and internals contain lead and lead CAUTION components, known to cause cancer and birth defects or other reproductive harm.
  • Page 102 MINOR MAINTENANCE TIPS Gently press the bulb holding CHANGING ELECTRICAL COMPONENTS clip and release it from the HEADLAMP BULB slot in the reflector. DISMANTLING Remove the bulb from the Remove the 2 screws reflector. holding the head lamp rim to NOTE the housing.
  • Page 103 MINOR MAINTENANCE TIPS Connect head lamp HEAD LAMP BULB REPLACEMENT coupler on the bulb Locate the 3 lugs in the bulb terminals correctly. correctly in the reflector. Locate the head lamp rim Locate the bulb holding clip in the housing correctly over the bulb and lock it in the such that it locks in place slot in the reflector.
  • Page 104 MINOR MAINTENANCE TIPS TAIL LAMP & LICENSE PLATE ILLUMINATOR TRAFFICATOR BULB REPLACEMENT Remove the screw from the The tail lamp & license plate trafficator housing back side. illuminator has a LED lighting Remove outer lens. system. In the event of failure, Remove the fused bulb by pushing turning...
  • Page 105 MINOR MAINTENANCE TIPS FUSE RELAY STARTER - FUSE BOX Remove the RH side panel. Replace the required fuse with the spare fuse available in the fuse carrier. The blade fuses are located in the carrier. F0 - Main Fuse - 40A NOTE Spare Fuse - 40A Please ensure to replace a spare fuse in the holder at the...
  • Page 106 MINOR MAINTENANCE TIPS FUSE & CARRIER The fuse carrier is located under the rider seat. Remove pillion seat & rider seat. Open the fuse carrier lid & replace fuse as indicated inside the lid. Replace the required fuse with the spare fuse available in the fuse carrier.
  • Page 107 MINOR MAINTENANCE TIPS BLADE FUSE USAGE LIST ID No. Function Rating ID No. Function Rating CHARGING FUSE 25 A ABS MAIN 1 15 A DEVICE Bt+ FUSE 10 A ABS MAIN 2 10 A IGNITION FUSE (EFI) 15 A ABS IGNITION SIGNALLING FUSE 15 A SPARE FUSE...
  • Page 108 MINOR MAINTENANCE TIPS products, solvents and alcohol based material will WINDSHIELD CLEANING seriously affect the windshield transparency. Wipe the windshield with a soft cloth. Do not wipe Scratches, cloudiness, cuts and abrasions on the vigorously as it will cause windshield cannot be polished or r emoved. The scratches on the windshield.
  • Page 109 LONG TRIP PRECAUTIONS Working of all lights and horn. CHECKS PRIOR TO THE COMMENCEMENT OF LONG JOURNEY Proper drive chain tension. Service the motorcycle at a Royal Enfield Authorised ITEMS TO BE CARRIED Dealer / Service Centre. Tool kit. Ensure sufficient quantity of petrol in the fuel tank for the journey planned.
  • Page 110 SHOCK ABSORBER INCREASING THE PRELOAD SPRING PRELOAD & SHOCK ABSORBER SETTINGS To increase spring preload, turn preload adjuster in the clockwise direction. REDUCING THE PRELOAD To decrease the spring preload, turn preload adjuster in the anti-clockwise direction. CAUTION It is recommended to visit Authorised Dealer for adjusting spring preload and shock absorber settings.
  • Page 111 OFF ROADING Apply the brakes in good time until the brakes have AFTER OFF ROADING been cleaned. It is recommended to check the following after off roading : RIMS TYRE PRESSURE It is recommended to check the rims & wheels for damage after off...
  • Page 112 OFF ROADING SPRING PRELOAD & SHOCK ABSORBER AIR FILTER ELEMENT SETTINGS Cleaning of air filter element is recommended for effective utilisation of air filter element in returning to The off road settings of spring & shock absorber surfaced roads. settings will impair the motorcycle’s handling characteristics on surfaced roads.
  • Page 113 WASHING PROCEDURE Never spray water with great force on head lamp, PRECAUTIONS speedometer, flasher lights, front and rear wheel hubs, Wash motorcycle when the engine is cold. electrical connections and wires, control cables, cables, sparkplug, battery, ABS ECU, EMS ECU, side Cover the silencer, tail pipe, horn, Control switches, mirrors, steering stem etc.
  • Page 114 WASHING PROCEDURE No direct jet at the edges of decal, electrical parts, AFTER WASHING coupler joints, silencer tail pipe, radiator lubrication Ensure, the motorcycle is thoroughly dry by wiping points like steering cone kit, brake pedal, wheel with a clean soft absorbent cloth or chamois leather. bearings, chain, brake cam &...
  • Page 115 WASHING PROCEDURE Location Do’s Don’ts Wipe Steering area with Cotton Cloth WARNING Do not spray high pressure water on top & bottom dust seal area, as shown. Steering Wet a small piece of cloth and gently rub ‘T’ Stem on required areas, to clean the steering tube area.
  • Page 116 WASHING PROCEDURE Location Do’s Don’ts Don’t use High Oil Cooler protector pressure water jet on Fins Oil Cooler to cover Damage the fins Location Wipe Head Don’t use High pressure lamp glass Water on Head lamp Instrument with Front & back Cluster Cotton Cloth...
  • Page 117 WASHING PROCEDURE Location Note High Stickers pressure on Front water Jet Mudguard, should Rear Mudguard directly & Side Shown Panel on these Locations. Royal Enfield Himalayan...
  • Page 118 STORAGE PRECAUTIONS In case your Motorcycle is not going to be used for a month Remove battery from the motorcycle. Clean the or more, the following precautions should be taken. terminals free of corrosion and apply petroleum jelly to terminals. Get the motorcycle serviced through a Royal Enfield Authorised Dealer / Service Centre.
  • Page 119 STORAGE PRECAUTIONS For re-use after storage, it is preferable to get the motorcycle prepared through a Royal Enfi eld Authorised Dealer / Service Centre to ensure the motorcycle is restor ed to its peak operating conditions. If the motorcycle is not used for a month or longer, It is advised to disconnect battery terminals and remove the battery.
  • Page 120 TROUBLE SHOOTING We have listed below a few basic checks in case your motorcycle is not functioning. If in case the problem is not rectified after these checks, it is necessary to get the motorcycle checked by a Royal Enfield Authorised Dealer / Service Centre to rectify the problem and to ensure trouble free performance.
  • Page 121 TROUBLE SHOOTING Symptom Observations Check for / Remedy Spark plug Cap / wire disconnected. Reconnect. Check if SIDE STAND is ON / SIDE STAND SWITCH Engine Does MALFUNCTION. 5. Engine Cranking but not starting not start Check if gear is engaged and the side stand is down. If the ambient Temperature is low use Manual Bi-starter.
  • Page 122 TROUBLE SHOOTING Symptom Observations Check for / Remedy 1. Typically happens after a Refill / Drain out entire fuel and Refill with fresh fuel from a Adulterated / Water in Fuel. reputed filling station. Engine Misfires & Runs Erratically / 2.
  • Page 123 TROUBLE SHOOTING Symptom Observations Check for / Remedy Engine rpm raises disproportionately to Clutch is Slipping. Check for sticky clutch / clutch motorcycle speed. not having any free play. Poor Pickup Adjust Rear chain to correct tension. Rear Chain excessively loose causing chain to slip on Sprocket.
  • Page 124 WARRANTY TERMS & CONDITIONS Royal Enfield Motorcycles are manufactured by following best Quality practices in respect of the material and workmanship. Royal Enfield (RE) warrants its motorcycle to be free from manufacturing and material defect under normal use subject to following conditions. RE will replace or repair defective part(s) at their Dealerships and Authorised Service Centre, free of charge within a period of 3 Years / 30,000 km from the date of sale, whichever is earlier.
  • Page 125 WARRANTY TERMS & CONDITIONS Consumables like Oil, Oil Filter, Fuel etc. used during warranty repair / replacement are not covered and chargeable to the customer. 6. Claims on proprietary items like tyres, tubes, spark plug, battery etc. should be taken up with the respective manufacturer or their authorised agents in the area directly by the customer.
  • Page 126 WARRANTY TERMS & CONDITIONS (c) Failures occurred due to use of non recommended grade lubricants, fuel or improper level. (d) Damages due to use of non-genuine parts, lack of proper maintenance, incorrect riding habits. (e) Damages to engine management system parts (like ECU, Throttle body, Sensors, etc.) due to tampering which affects the performance of the motorcycle.
  • Page 127 WARRANTY TERMS & CONDITIONS (k) Motorcycle used for competitions / racing / Stage Rallying etc. (l) Electrical component like bulbs, fuses etc. and electronic components failure due to repairs by arc welding. (m) Normal maintenance operations like adjustment of brakes, cleaning fuel system, engine tune-up and other such adjustments.
  • Page 128 EMISSION WARRANTY In compliance with the provisions of Rule 115(2) of the Central Motor Motorcycle Rules, 1989, Royal Enfield certifies that the following warranty is applicable to those components liable to affect the emission of the gaseous pollutants in its range of motorcycle, in normal use to which it may be subjected to.
  • Page 129 EMISSION WARRANTY In case any of the components covered under emission warranty or the associated parts are not independently replaceable. Royal Enfield will have the sole discretion to replace either the entire assembly or parts of the assembly through suitable repairs.
  • Page 130 EMISSION WARRANTY THE WARRANTY SHALL APPLY IF THE CUSTOMER Observes all the important instructions and any other precautions listed in the owner’s manual. Under all circumstances uses lubricants and fuel as recommended by Royal Enfield. Regularly obtains and carries out maintenance in accordance with Royal Enfield guidelines and enters the details in the Log book.
  • Page 131 EMISSION WARRANTY THE EMISSION WARRANTY SHALL NOT APPLY IF A valid “Pollution under control” certificate is not produced. The motorcycle is not serviced by RE Authorised Dealer / Service Centre as per the service schedule described in the maintenance chart. The motorcycle has been subjected to abnormal use, abuse, neglect and improper maintenance or has met with an accident.
  • Page 132 EMISSION WARRANTY The emission related components are tampered with. All service and parts related bills and vouchers incurred during the tenure of the emission warranty is not produced. All maintenance activities carried out on the motorcycle during the tenure of the emission warranty are not entered in the log book.
  • Page 133 SERVICE / MAINTENANCE RECORD Job Card Type of Service Sc hedule Date Dealer Code Brief details of service 1st Free Service* 500 km / 45 Days 2nd Free Service* 5000 km / 6 Months 3rd Free Service* 10000 km / 12 Months 4.
  • Page 134 NOTES 132 Royal Enfield Himalayan...

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