Royal Enfield HIMALAYAN EURO IV 2017 Service Manual
  1. Manuals
  2. Brands
  3. Royal Enfield Manuals
  4. Motorcycle
  5. HIMALAYAN EURO IV 2017
  6. Service manual

Royal Enfield HIMALAYAN EURO IV 2017 Service Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

EURO IV - HIMALAYAN VEHICLE SERVICE MANUAL
HIMALAYAN
HI

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the HIMALAYAN EURO IV 2017 and is the answer not in the manual?

Questions and answers

Related Manuals for Royal Enfield HIMALAYAN EURO IV 2017

Summary of Contents for Royal Enfield HIMALAYAN EURO IV 2017

  • Page 1 EURO IV - HIMALAYAN VEHICLE SERVICE MANUAL HIMALAYAN...
  • 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 4 VEHICLE VIEW RH ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 5 VEHICLE VIEW TOP ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 6: Table Of Contents

    20. Trouble Shooting 11.2 Front Wheel ........... 20.1 Vehicle Trouble Shooting ......11.3 Front Fork ............20.2 EMS Trouble Shooting ........289 11.4 Handle Bar ............21. Notes ................ 11.5 Steering Stem ..........ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 7 Wet Multi Plate Primary drive Gear Primary ratio 2.312:1 Gear box 5 Speed, Constant Mesh Gear Ratios 1st Gear 2.916:1 2nd Gear 1.833:1 3rd Gear 1.428:1 4th Gear 1.173:1 5th Gear 1:000:1 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 8 Alternator, III Phase System 12V - DC Battery 12V - 8 AH MF Head lamp 12V, H4-60/55W - BULB Tail lamp / Brake lamp 12V- 4/1W LED Licence Plate illuminator 12V- LED ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 9 Turn signal 12V, 10W * 4 Nos. Modifications or fitments which are not approved by Horn 12V, 2.5 Amp. Royal Enfield, will seriously Starter Motor 12V, 0.7 KW affect the performance of the vehicle and will render the Instrument Cluster Digital cluster with main warranty void.

  • Page 10: 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 11 # Check every time after vehicle is used for off road riding NOTE: For maintenance after 50,000 Kms. , please repeat same frequency specified above, in consultation with a Royal Enfield Authorised Dealer / Service Center. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • 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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 13: Engine Dismantling From Frame & Reassembly

    Flanged Hex Bolt M6 X 1 X 20 Side Stand Assy Plain Washer Hex Nylock Nut M8 X 9.5 Hex nut with nylon insert Spring Piece Mudguard Bracket Assy-Oil Cooler Grommet Flanged Hex Bolt M6 X1 X 27 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 14 Flanged Hex Bolt M6 X 1 X 10 Steady Bracket Black Bracket Assy- Solenoid Valve Flanged Hex. Nut M8 X 1.25 Bracket Assy- Roll Over Sensor Brake Pedal Comp - RH Dummy cap- Frame ROYAL ENFIELD HIMALAYAN EURO IV 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 16 Socket spanner: 8mm. 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 EURO IV 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 18 Take care not to damage top frames 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 19 Disconnect rubber hose from fuel tank to cannister. Slide fuel tank towards rear to release front clamp from frame Remove tank along with overflow tube carefully. ROYAL ENFIELD HIMALAYAN EURO IV 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 throttle body rotor eyelet. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 21 12 x 13 mm starter & slide out cable from the guide. At handle bar end Loosen switch holding screws at the bottom & seperate the switch. Disconnect cable from lever & remove. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 22 4.14 Side Panel RH 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 23 Disconnect black coupler from fuel injector at LH side. F. EOT Disconnect EOT Sensor coupler (white) on RH side. G. Oxygen Sensor Disconnect black coupler from Oxygen sensor as exhauste pipe top. ROYAL ENFIELD HIMALAYAN EURO IV 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 25 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 26 Gently pull out fuel injector along with fuel hose and spacer tube. B. Throttle body Ensure TPS & MAP Sensor coupler are disconnecting. Remove Bi starter from throttle body after loosening plastic nut. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 27 4.18 Gear shifter/ linkage Loosen Hex bolt on small Hex flange bolt: M6 gear lever mounted on gear shaft on LH side of Socket spanner: 10mm engine. Slide out small lever from shaft. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 28 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 29 & 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 30 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 31 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 32 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 33 - 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 34 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 35 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 36 Take care not to damage silencer bracket nut. the oxygen sensor while Connect the Oxygen locating exhaust pipe on sensor coupler to the cylinder head. sensor. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 37 10mm inlet manifold adaptor. Torque : 10Nm (1.0 Kg.M) Insert valve - Bi Starter plunger into throttle body are tighten the plastic hex nut to throttle body sufficiently. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 38 Positon Cap, injector Torque : 10Nm (1.0 Kg.M) assembly with fuel hose on injector and stud - injector correctly. Tighten cap, injector assembly to stud using hex nut M6. Connect fuel injector coupler. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 39 Hex nut : M6 bracket using the hex nut M6. Double end spanner : 10mm Slide rubber grommets over the threaded sleeve on outer cable. Adjust the throttle cable free play correctly. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 40 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 41 Connect black coupler to fuel injector. E. Engine Oil Temperature (EOT) Sensor Connect white coupler to EOT sensor wires. F. Oxygen Sensor Connect Black coupler to sensor wires on the exhaust pipe top. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 42 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 43 Lift rear end of the tank slightly and - Route the drain hose between the frame without any kinks. - Connect blue coupler of Low fuel sensor to wiring harness ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 44 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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 45: Rider & Pillion Seat

    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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 46 LH & RH to assembling the top frames. clamp them against the connector tube. Ensure the dust caps are fitted on the connector. Horn 4.37 Locate horn in the bracket and tighten. Connect horn terminals ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 47 Tighten trafficator to the 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 48 LH & RH. 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 49 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 50 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 51 Hex Bolts M6 X1 X 35 at the bottom of the 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 52 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 53 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 54 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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 55: Control Cables

    SECTION 06 - C C ONTROL CABLES EXPLODED VIEWS CONTROL CABLES S. NO. QTY. DESCRIPTION Clutch Cable Assy. Throttle Cable Assembly Seat Latch Cable Assy ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 56 Inspect Cables for any fraying or damage Remove protective rubber cover & nut completely from cable & remove cable from bracket. Disconnect cable inner from clutch lever on handle bar LH& remove clutch cable. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 57 & slide out the strap plate from the cable Separate rotor housing from the handle bar and remove the inner cable from the rotor. Remove outer cable from rotor housing. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 58 Remove spring & valve bi starter & slide out cable from the guide. At handle bar end Loosen switch holding screws at the bottom & seperate the switch. Disconnect cable from lever & remove. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 59 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 60 & valve bi starter on the cable. Insert Valve bi starter into throttle body and tighten cable guide to throttle body. Assemble fuel tank on frame as detailed in section ... ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 61: Air Filter

    Inlet Cover HEX SOCKET HEAD CAP SCREW M5 X 16 Seal Hex Flange Bolt, M6 X 1 X 14 Element Air Filter Rear Damper - Tank Clamp Lid – Battery Carrier Pipe Outlet ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 62 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 63 Remove cross assembly 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 64 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 65 Assemble battery, connect terminals, locate Flanged Hex Bolt: M6 lid battery carrier in Socket spanner: 8mm housing and tighten with hex bolts. (Refer electricals Torque: 8-12Nm(0.8-1.2 section for battery KgM.) assembly) ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 66 Locate side panel with its bottom leg located in the rubber grommet Tighten side panel with Pan head screw M5 2 hex socket button Allen Key 4mm head screws ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 67: Pulse Air Valve

    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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 68 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 69 Kg.M (Nm) (Kg.M) (Nm) (Kg.M) Braided hose mtg to cyl head Hex Socket Head Cap Screw M6 X 20 1 1 0 PAV mtg to frame Hex flange bolt M6 X 30 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 70 (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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 71: Fuel Tank

    Hex Flange Nut M5 X 0.8 Flanged Hex Bolt M6 X 1 X 27 O Ring- Fuel pump Cap - Fuel Tank Fuel Pump Assy Hex socket head cap screw m5x15 Clamp Plate (FPM) ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 72 - Prevent damage to Slide fuel tank towards EVAP hose rear to release front clamp from frame Remove tank along with overflow tube carefully. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 73 Do not smoke or allow open flame or sparks in the vicinity. Store the fuel carefully to avoid spillage. TORQUE VALUES Torque Range A A ggregate Component Fastener Kg-M Fuel Tank Fuel tank Mounting Flanged Hex Bolt M6 * 1*27 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 74 Locate 2 washers on the flange bolts, Socket Spanner 10 mm assemble the bolts and Torque 5 NM (0.5 Kg.M) tighten to torque. Connect fuel hose to fuel pump using quick fix adaptor. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 75 Hex Flange Bolt M8 X 1.25 X 55 Flanged Hex Bolt M6 x 1 x 7 Guard Silencer Guard Exhaust Pipe Gasket (Exhaust Pipe & Silencer) Clamp Silencer Oxygen sensor Hex Flange Bolt M8 X 1.25 X 38 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 76: 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 77 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 1 1 0 Silencer Mounting to Frame Hex Socket M8X1.25X25 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 78 Deep Groove Socket: along with copper 21mm washer on the exhaust down pipe near the cylinder head. Ensure Ignition switch and stop switch are in OFF position. Connect wiring harness coupler on the sensor. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 79 SECTION 11 - T T OP BRACKET, HANDLE BAR, FRONT MUDGUARD, FRONT WHEEL FRONT SUSPENSION & STEERING STEM ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 80 Hex Socket Head Cap Screw M8 X 45 Grommet Top frame RH with Decal Rubber Nut-M5 Cover Cockpit RH Cover Cockpit Top Decal RH Hex.Socket Button Head Screw M6X1 Hex Socket Head Cap Screw-M6 Washer Plastic Connector Complete Black ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 81: Front Mudguard

    Hex. Socket Button Head Screw M6 X 1 Lock washer- Internal teeth Flanged Hex Bolt M6 X 1 X 27 Hex. Socket Head Cap Screw- M6 X 20 Sticker - Front mudguard ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 82: 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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 83: 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 84 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 85 Hex. Socket Head Cap Screw - M6 X 20 Cross Recessed Pan Head Screw Ring Nut M5 X 0.8 X 12 Clip Holder Assy - Wiring Harness Clamp-Wheel Speed Sensor Flanged Hexogonal Bolt M6 X 1 X 10 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 86 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 87 Socket Spanner: 10mm connector tube. 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 88 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 89 Hex soc. Hd. cap Screw: securing fork brace to fork legs. 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 90 Remove wheel along with wheel speed sensor and spacer. Remove speedo sensor. Place a suitable spacer of thickness, between the brake pads to avoid accidental compression of the brake lever. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 91 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 92 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 93 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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 94: 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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 95: 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 96 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 97 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 98 WEAR LIMIT 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 99 & smooth rotation on both LH & RH. Locate top yoke over the steering stem Assemble top nut over the top yoke. D D o not tighten fully. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 100 / 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 101 (refer section 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 102 – front fork Insert special tool into inner tube assembly, from top to hold piston – front fork. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 103 Fill 455ml of fork oil per leg 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 104 RH sides of the top yoke 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 105 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 106 Tighten pinch bolt on right fork end. Rotate wheel and check for smooth rotation. Press brake lever and check front brake for efficiency. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 107 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 108 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 109 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 110 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 111 Spacer - Oil Cooler Hex socket head cap screw M5X16 Grommet Rear Number Plate Assy Spacer - Rear mudguard Hex.Socket Button Head Screw M6 X 1 X 16 Sticker - Rear mudguard ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 112: Rear Wheel

    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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 113 Spacer - Swing Arm Flanged Hex Bolt M6 X 1 X 27 Hex Nut With Nylock M12 X 1.5 Chain – Guide Rear Chain-Pad Saree Guard Washer-Chain Pad SS Hex socket head cap screw (M6X25) ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 114 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 115 Slide out the rear wheel from the swing arm, taking care not to drop the spacers on the wheel hub. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 116 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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 117: Rear Mudguard

    LH to prevent damage to seat latch cable. 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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 118: 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 119 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 120 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 121 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 122 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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 123: Drag & Drop Links

    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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 124 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 125 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 126 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 127 Insert the wheel axle the performance of the from the left side of the rear brake. swing arm and gently tap it in. Check rear brake for effectiveness correct functioning before using motorcycle. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 128 NOT RELEASE TILL REAR against the inner nuts AXLE NUT IS TIGHTENED while ensuring they are held firmly. Hex nut: M16 Socket Spanner: 24mm Tighten the rear wheel Torque: 70Nm (7.0Kg.M.) axle nut for torque. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 129 Sleeve- ABS Modulator Master Cylinder - Front Master Cylinder - Rear Brake hose - Caliper Front Rubber Hose- Reservoir Front Caliper ABS Modulator Reservoir Kit Rear M/C Threaded Brake hose- Master Cylinder Rear ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 130 Anti-Lock Braking System (ABS) fitted in Royal Enfield motorcycles, is a safety system to help the front and rear wheels maintain traction with the road surface in the event of sudden application of brakes by the rider at high speeds.
  • Page 131 1. ABS INDICATOR Located inside the Instrument Cluster. 2. MODULATOR Located inside panel RH. 3. . ABS ECU Located adjacent to Modulator 4. FRONT BRAKE MASTER CYLINDER. Located on Handle bar RH side ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 132 Located on the fork end LH side 7. TONER RING - FRONT WHEEL. Located on front Hub centre (below brake disc) 8. REAR BRAKE MASTER CYLINDER Located on the frame bottom on RH side. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 133 10. . REAR WHEEL CALIPER Located on swing arm RH side 11. WHEEL SPEED SENSOR - REAR Located on the rear caliper assembly mounting bracket 12.TONER RING – REAR WHEEL Located on Rear wheel right side. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 134 IF FOR ANY REASON THE BRAKE HOSES OR THE MODULATOR HAS TO BE SERVICED, THEN THE ENTIRE HYDRAULIC FLUID SYSTEM BLEEDING HAS TO BE CARRIED OUT AND THE ECU HAS TO BE REPROGRAMMED. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 135 Head cap Screw : M6 RH by loosening 2 Socket head cap screws on the Allen Key : 5 mm sides. Loosen and remove the 4 banjo bolts holding 4 brake hoses to the modulator. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 136 Remove 2 hex bolts on Hex Bolt: M6 the sides and 1 hex bolt at the bottom, holding Double end spanner: modulator to the mount- 10mm ing bracket. Remove modulater from the bracket. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 137 10mm ing bracket Connect wiring coupler to the ABS ECU and gently locate out ECU. Locate and install the 4 banjo bolts holding 4 brake hoses to the modulator. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 138 13.3 ABS Modulator & Locate the side panel RH Head cap Screw : M6 on the RH side by installing 2 socket head Allen Key : 5 mm cap screws on the sides. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 139 5223 H VarCode EEPROM Out Of Range 5331 H Front Wheel Pressure sensor ohmic fault 5332 H Front wheel pressure sensor offset/Test Pulse/POT fault 5333 H External Supply for Pressure sensor failure ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 140 SECTION 14 - H H YDRAULIC DISC BRAKES ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 141 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 142 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 143 Remove protective rubber cap on bleeder nipple on the caliper. Loosen bleeder nipple Ring Spanner: 10mm by about 2 turns. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 144 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 145 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 146 Spring loaded. Remove and piston with seals with care. from master cylinder housing. Remove 2 hex bolts on Hex nut: M6 the clamp. Ring spanner: 8mm Remove clamp and master cylinder from the handlebar ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 147 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 148 Gently remove the seals from caliper using a blunt and soft tool. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 149 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 150 Remove the brake hose 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 151 Nose pliers 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 152 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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 153: Swing Arm

    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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 154 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 155 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 156 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 157 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 158 Check periodically whether the Disc has been contaminated with oil, brake fluid or grease and clean contaminated Disc with a high quality brake-degreasing agent. Always keep the disc clean and dry at all times for the brakes to work at peak efficiency. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 159 Smear fresh brake fluid on the caliper boot and bellow and assemble them on the caliper body. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 160 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 161 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 162 NOTE: Ensure the circlip is seated correctly inside the groove. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 163 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 164 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 165 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 166 Ring Spanner: 8 mm with the dust cap on the 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 167 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 168 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 169 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 170 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 171 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 172 “MAX” 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 173 / 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 174 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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 175: Evap

    Hose- Canister to T Connector Canister Assy Bracket Assy- Purge Valve Clip T Connector Hose- Air vent Hose- T Connector to Purge Valve Hose- Purge Valve to Throttle body Hose- Fuel tank to Purge Valve Hose-Clip ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 176 LOCATION OF EVAP IN MOTORCYCLE The canister is connected to the fuel tank to trap all the fuel vapours that build up in the fuel tank . HIMALAYAN Location : Located on Skid Plate. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 177 As soon as the engine is started, these vapours are purged from the canister, into the combustion chamber. The system consists of a canister, purge valve, rubber hoses, connectors and a sealed fuel tank cap. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 178 Allen Key : 5 mm assy. & Purge valve. Gently remove the 2 canister bracket assy along with rubber strap Gently remove the canister from the skid plate assy.with the hoses. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 179 Inspect Canister periodically for any damage to its body cuts or cracks. Replace all rubber hoses and connectors every 12,000 Kms. TORQUE CHART Torque Range Aggregate Component Fastener Kg-M Canister Canister Assembly Bracket Hex. Flange bolt M6 X 1 X 20 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 180 & purge Allen Key : 5 mm valve. Install 6 hex bolts on skid plate LH, RH & Top Hex Bolt : M6 portion. Socket Spanner : 8mm Torque : 10 Nm ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 181: Engine Management System (Ems)

    S S ECTION 15 - ENGINE MANAGEMENT SYSTEM (EMS) ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 182 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 183 Royal Enfield NACS II diagnostic tool is connected to the socket in the wiring harness of the motorcycle. Once the defect is diagnosed and corrected, the history of the defect can be erased using the Royal Enfield NACS II diagnostic tool.
  • Page 184 Crank Pulse Sensor GND Engine Temp. Sensor SSTAND Side Stand Switch ROLL Roll Sensor Manifold Pressure Sensor EXAJ Exhaust Air Injection NLSW Neutral Switch K-LINE Diagnostic Tool HEGO HT HEGO Sensor Heater ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 185 It senses the oil temperature and provides the input to the ECU on a real time basis. The ECU can then determine the fuel injector operating time to provide the required amount of vaporized fuel into the combustion chamber for optimum performance of the motorcycle and also to meet the emission norms. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 186 In addition to the Hego sensor, the EXAI gets inputs from the ECU to supply filtered air into the exhaust end of the cylinder head, primarily during idling RPM so as to meet exhaust emission specifications. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 187 ECU. This helps the ECU to regulate the fuel injector opening duration to provide the required amount of vaporized fuel into the combustion chamber for optimum performance of the motorcycle. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 188 The ambient temperature input is provided to the ECU on a real time basis, based on which the ECU determines the fuel injector operating time to provide the required amount of vaporized fuel into the combustion chamber for optimum performance of the motorcycle. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 189 The fuel injector operation and duration to deliver vaporized fuel is controlled by the ECU based on the critical operating inputs received from the crank position sensor, EOT sensor, ambient air temperature sensor, throttle position sensor, manifold pressure sensor and HEGO sensor. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 190 To re activate the system, the motorcycle should be made upright in its centre stand position, the ignition switch and stop switch must be switched OFF and switched back ON after a few seconds. This will help to RESET the rollover sensor. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 191 In the event of any malfunction the MIL will glow continuously. The EMS should be checked using either the test pin method OR the Royal Enfield NACS II diagnostic tool connected to the socket in the wiring harness of the motorcycle.
  • Page 192 Gently pull out the ECU from the rubber housing located in the frame. Gently release lock and disconnect the wiring coupler from the ECU. Remove ECU. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 193 Remove 2 Hex Flange Bolt M5 X 0.8 X 16, holding Pulsar coil to cover RH inside. Remove 3 Hex Socket Head Cap Screw M5 X 30, holding stator coil to cover RH inside. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 194 Ensure Ignition switch and stop switch are in OFF position Disconnect wiring harness coupler from the sensor. Gently Loosen engine temperature sensor and remove along with ‘O’ ring. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 195 Ensure Ignition switch and stop switch are in OFF position. Disconnect wiring harness coupler from the sensor. Loosen Hego sensor and remove along with copper washer from the exhaust down pipe. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 196 EXAI solenoid. Remove socket head cap NOTE: screw holding the EXAI solenoid to the reed Ensure spacer between the valve bracket. EXAI solenoid & bracket is removed. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 197 (MAP) are not serviceable cylinder head. and hence should not be Remove throttle body removed from the throttle by gently sliding it out of body. the inlet bellow and adaptor. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 198 Philips Screw driver Using a long reach Philips head screw driver, loosen and remove the 2 screws, holding TA sensor to pipe outlet. Remove TA sensor along with gasket, from pipe outlet. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 199 Pull out fuel pump from fuel pump. the fuel tank. Take care to remove the Hex Soc Button Hd Cap O ring from the fuel tank. Screws: M6 X 12 Socket spanner: 8mm ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 200 Remove hex nut from top of injector cap assembly and remove injector cap along with “O” ring. Remove the spacer from the stud. Gently pull out the Injector from cylinder head. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 201 Ensure Ignition switch and stop switch are in OFF position. Remove side panel LH. Gently pull out relay from the rubber holder and electrical socket. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 202 OFF position. Disconnect the wiring coupler from the sensor. Loosen and remove the hex socket screw holding the sensor to the frame and remove the sensor. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 203 Indicator Lamp Himalayan Located in the RPM meter in the instrument cluster. Ensure Ignition switch and engine stop switch are in OFF position. The instrument cluster does not have any individual serviceable parts. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 204 The ECU is located under the seat. Locate seat on the frame and push it for proper seating. Locate the side panel LH and lock side panel LH. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 205 RH, top, centre and bottom. Install and tighten 2 Hex Flange Bolt M6 X 1 X 85 on cover RH front. Connect Magneto wiring coupler in the electrical harness. Fill engine oil. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 206 17mm along with ‘O’ ring on the cylinder head right side below the inlet manifold. Ensure Ignition switch and stop switch are in OFF position, Connect wiring harness coupler on the sensor. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 207 Deep Groove Socket: along with copper 21mm washer on the exhaust down pipe near the cylinder head. Ensure Ignition switch and stop switch are in OFF position. Connect wiring harness coupler on the sensor. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 208 EXAI Ensure spacer between the solenoid. EXAI solenoid. & bracket is removed. Ensure Ignition switch and stop switch are in OFF position, Connect wiring harness coupler in the EXAI solenoid. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 209 OFF position. NOTE: Connect TPS and MAP wiring couplers. The throttle position sensor (TPS) Manifold Absolute Pressure Sensor (MAP) are not serviceable and hence should not be removed from the throttle body. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 210 2 screws, holding TA sensor to pipe outlet. Ensure Ignition switch Philips head screws and stop switch are in OFF position. Philips Screw driver Connect the wiring coupler in the TA sensor. Assemble seat assembly ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 211 Socket spanner: 8mm Assemble Seat assembly and fuel tank NOTE : In three times operation of kill switch in ignition on condition, 210 ml to 240ml of fuel should get collected. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 212 Ensure Ignition switch and stop switch are in OFF position. Connect the wiring coupler from the fuel injector. Assemble Seat assembly and fuel tank. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 213 OFF position. Gently push the two identical relays in the rubber holder electrical socket. Locate in a rubber holder on the side of the battery carrier. Locate side panel LH. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 214 Connect the wiring coupler from the sensor. Ensure Ignition switch and engine stop switch are in OFF position. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 215 Indicator Lamp Himalayan Ensure Ignition switch and engine stop switch are in OFF position. Locate the RPM meter in the instrument cluster. The instrument cluster does not have any individual serviceable parts. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 216 / electrical connection that caused the malfunction. LEVEL 3 GENERIC SCAN TOOL (NACS II DIAGNOSTIC TOOL) A generic scan tool supplied by Royal Enfield will help identify the exact cause of the malfunction in the EMS, when connected between the motorcycle and a computer.
  • Page 217 Switch ON ignition and engine stop switch and observe the MIL keenly for a series of short and long blinks at different intervals, to identify the defective sensor / wiring connection as detailed in the table below, ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 218 It can also be used to capture engine data for future reference for saving data regarding issues of engine malfunction before in the process of resolving engine malfunction. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 219 Vehicle / Wheel speed sensor The Sensor circuit malfunction P0500 AIR System Switching Valve EXAI Short circuit to ground or open circuit P0412 “A” Circuit (low or open) Crankshaft position sensor The Sensor circuit malfunction P0335 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 220 7) DO NOT use high pressure water jet to clean the ECU / Throttle Body / any of the sensors. Keep them well protected while washing the vehicle. NOTE : Since this BS IV vehicle has AHO function, while using NACS II tool thehead lamp fusecan be removed to avoid the battery drain. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 221: Electrical Components

    SECTION 16 - ELECTRICAL COMPONENTS ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 222 Starter Motor 0.9 KW 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 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 223 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 224 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 225 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 226 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 227 ~ 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 228 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 229 IGNITION - EFI FUSE SIGNALLING FUSE HORN FUSE LIGHTING FUSE ABS MAIN-1 FUSE ABS MAIN-2 FUSE ABS ECU SPARE-1 SPARE FUSE 1 SPARE-2 SPARE FUSE 2 SPARE-3 SPARE FUSE 3 SPARE-4 SPARE FUSE 4 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 230: 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 231 Instrument Cluster 17.3 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 232 Tail Lamp & Number 17.6 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 233 Socket Spanner: 10mm 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 234 Instrument Cluster 17.9 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 235 RH side: Red Trafficator Rear 17.11 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 236 RH. Clutch Switch 17.14 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 237 Hex Cap Screw: M6 from bottom of switch Allen key: 5 mm housing and remove switch. Side stand switch 17.17 coupler Remove strap to frame Pull the bellow down Disconnect Red coupler from LH side. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 238 Screw driver the wiring harness. Clutch Switch 17.20 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 239 Hex Cap Screw: M6 switch. Allen key: 5 mm Connect ignition switch wiring coupler. Side stand switch 17.23 coupler Connect Red coupler from LH side. Push bellow upwards. Locate strap to frame ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 240 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 241 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 242 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 243 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 244 HT coil. Loosen the 2 Hex flange Hex Flange Bolt : M6 bolts mounted on the welded nut in frame. Socket Spanner : 10 mm Remove HT Coil assy from frame. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 245 Socket Spanner : 10 mm 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 246 IGNITION - EFI FUSE SIGNALLING FUSE HORN FUSE LIGHTING FUSE ABS MAIN-1 FUSE ABS MAIN-2 FUSE ABS ECU SPARE-1 SPARE FUSE 1 SPARE-2 SPARE FUSE 2 SPARE-3 SPARE FUSE 3 SPARE-4 SPARE FUSE 4 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 247 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 248 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 249 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 EURO IV VEHICLE SERVICE MANUAL...
  • Page 250 ECU & Sensors. Please visit the nearest When in neutral the indication will be “0”. autorise Royal Enfield dealer to diagnose & rectify the defect in the EMS. When in gear the appropriate number between 1 to 5 will be displayed.
  • Page 251 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 EURO IV VEHICLE SERVICE MANUAL...

  • Page 252: Nacs Ii Diagnosis

    5. Cigarette 6. SD memory cable lighter cable Card Reset Button SD memory card Diagnostic connector 7. SD card reader 8. Carrying Box 9. Installation CD 10. User Manual (Included on CD) ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 253 The warranty will become void if NACS II is disassembled or altered. We recommend you to back up the SD-card data to avoid data loss due to various reasons. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 254 USB driver. First, you need to disable “User Account Control (UAC)” before installing our software. The way to disable UAC is as follows. Click ‘Start button’ and select ‘Control Panel’. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 255 ROYAL ENFIELD NACS II DIAGNOSIS 9. SOFTWARE INSTALLATION 8 8 .2. 9.1. Start the computer. Click ‘User Accounts’ 9.2. Insert installation CD to CD-ROM drive and install following software. a. Main software: NACSII_ROYAL_V0.03_install.exe b. Recording data analyzing software: NACSII- RECORD_ROYAL-V0_01_setup 8.3.
  • Page 256 ROYAL ENFIELD NACS II DIAGNOSIS 9.4. 9 9 .7. Click ‘Finish’ to exit installation Click ‘Finish’ to complete the installation 10. SOFTWARE REMOVAL 9.5. 10.1. After installing Firmware program, USB high speed driver will start installation. Click ‘Extract’ to install.
  • Page 257 ROYAL ENFIELD NACS II DIAGNOSIS 1 1 0.3. 11. DIAGNOSTIC SOFTWARE FOR Find ‘NACSII_ROYAL’ and click ‘Change / Remove’ . HANDHELD TOOL 11-A. Diagnosis 11-A1. Please connect your NACSII-ROYAL diagnostic tool kit with your motorcycle. NACSII-ROYAL interface- maincable Diagnostic cable...
  • Page 258 ROYAL ENFIELD NACS II DIAGNOSIS 1 1 1-A3. 11-A6. Select ‘Royal Enfield Press to exit 534 EFI’ . Press ‘Vehicle Info’ page. The page continue. will return to the main menu. 11-A4. 11-A7. NACS II will Using automatically detect move the cursor.
  • Page 259 ROYAL ENFIELD NACS II DIAGNOSIS 1 1 1-A9. 11-A11. Press to view Erace DTC. It’s the function to erace ‘History ‘ DTC. Diagnostic Trouble Press to view next Code in both ‘Current’ and page and press ‘History’. to view last page.
  • Page 260 ROYAL ENFIELD NACS II DIAGNOSIS 1 1 1-A13. 11-A16. Back to the main Press to view all the content. menu, move the cursor to ‘Special Function’ and Press ‘Special function’ is customized functions provided to specific vehicles. 11-A17. Select “CO 11-A14.
  • Page 261 ROYAL ENFIELD NACS II DIAGNOSIS 1 1 1-B2. 11-C. ABS Functions Press to view System Information. 11-C1. Select ‘BOSCH ABS System’ . Press to continue. 11-C2. Select ‘Special Function’ . Then, select ‘Repair Air Bleed’. 11-B3. Press to set Date and Time.
  • Page 262 ROYAL ENFIELD NACS II DIAGNOSIS 1 1 1-C3. 11-C6. Read the warning first before start operating air Front Channel bleeding. Activation 11-C7. 11-C4. Follow the instructions on screen to finish the Follow each step on thescreen to finish the activation.
  • Page 263 ROYAL ENFIELD NACS II DIAGNOSIS 12-3. 1 1 2. Diagnostic software for PC base When the first time you use software, 12-1. the software will Before diagnosis, please connect your NACSII- enter register ROYAL diagnostic took kit with your motor cycle.
  • Page 264 ROYAL ENFIELD NACS II DIAGNOSIS 1 1 2-6. 12-9. There are various Click to show Interface info and green buttons on Contact info of I.C.M. the right. button is for displaying all the vehicle info. 12-7. 12-10. Click to switch Click to read the language.
  • Page 265 ROYAL ENFIELD NACS II DIAGNOSIS 12-15. 1 1 2-12. To erase the The window will pop Diagnostic Trouble up for selecting Code, click printer. Note : if you click the erase button, all Diagnostic Trouble Code in ‘Current’ and ‘History’ will be erased! 12-13.
  • Page 266 ROYAL ENFIELD NACS II DIAGNOSIS 1 1 2-17-A. 12-17-D. Click to erase ALL selected live data. If you want Click to view selected data values. to erase only one item, please press and hold ‘Shift’ key and select the item that you want to delete.
  • Page 267 ROYAL ENFIELD NACS II DIAGNOSIS 1 1 2-20. 13-2. Adjust CO value Select Record Date by clicking and File name, then and click click save adjusted value. 13-3. 13. RECORD ANALYZING SOFTWARE Select the items This software is for reading NACS II handheld which used often.
  • Page 268 ROYAL ENFIELD NACS II DIAGNOSIS 13-8. 1 1 3-5. For example, setting Engine speed grater than 3150, To slow down the playing speed of wave chart, enter 3150 in the right block. Click to confirm please drag the slider down.
  • Page 269 ROYAL ENFIELD NACS II DIAGNOSIS 13-14. 1 1 3-11. Back to Live data selection page, click to view Click to quickly find matched point of setting value. wave chart of the 2 setting values. 13-12. Sometimes, setting only one value still can not find the 13-15.
  • Page 270 ROYAL ENFIELD NACS II DIAGNOSIS 1 1 3-17. 13-18. The 3 setting items will be listed in ‘All value match’ block. To analyze conditions and differences of Click to quick find matched conditions. values, it’s necessary to select match items. Select...

  • Page 271: Wiring Harness

    SECTION 19 - WIRING HARNESS ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 272 WIRING DIAGRAM COMPLETE - LS 410 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 273 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 274 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 275 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 276 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 277 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 278: Vehicle Trouble Shooting

    Inflate to correct pressure Accelerator cable free play excessive Adjust cable free play Clutch Slipping Adjust clutch cable free play Faulty fuel supply Remove fuel pump & clean. Fuel pump, filter / injector blocked ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 279 Loose / improper connection Check and correct H H orn not working Fuse blown Check and correct Loose connections Check and correct Trafficators not working Loose / improper connections Check and correct Bulb fused Replace ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 280 Check for any EFI sensor coupler loose connection and correct them Any EFI Sensor Failure Check & replace the same XII. ABS (ANTI LOCK BRAKING SYSTEM) ABS lamp continuously ON. Take the vehicle to service center for diagnosis ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 281 Valve stem bent, seating area Check & replace burnt, excess carbon deposit on seating area, Valve springs broken Piston rings sticky / worn-out Check & replace Cylinder barrel / Piston excess Check & replace clearance. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 282 Investigate cause of seizure, pin / connecting rod big end check & correct as required Crankshaft bearings in LH / RH Investigate cause of seizure, crankcases seized check & correct as required ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 283 Valve not seating properly (stem Check & replace bent. Heavy carbon deposit on seating surface) Piston rings worn out/ broken / Check & replace stuck in ring groove Cylinder / piston worn Check & replace ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 284 Clutch plates worn out / warped / Check & correct sticky release / burnt Front / rear brakes jamming Check & correct E. Others Front / rear wheel bearing jammed Check & correct ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 285 Excessive Carbon in combustion Check & Clean chamber Piston ring bad (worn, weak, Check & Replace broken, or sticking) Piston rings clearance excessive Check & Replace Cylinder, piston worn Check & Replace ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 286 C. Bluish / White smoke Excess clearance between valve Check & correct stem & guide Oil scrapper ring worn out Check & correct Cylinder barrel / piston clearance Check & replace high ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 287 Oil cooler fins dirty / blocked Check & clean oil cooler fins Clutch slipping Check & correct Front / Rear brakes jammed Check & correct Engine oil pressure less Check & correct Silencer choked Check & clean ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 288 F. Transmission noise Drive / counter gears backlash Check & replace Drive / Countershaft bearings worn out Check & replace Gears / bushes seized in drive / counter shaft Check & replace ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 289 Check & replace F. Gears overshifts Sliding Gear dogs worn out Check & replace Drive shaft/counter shaft splines worn out Check & replace Drive / counter shaft bearings wornout Check & replace ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 290: Ems Trouble Shooting

    Fuel dripping through Fuel Pump Check for Pressure Lock in tank, if pressure lock is not there Pump Nipple replace the pump If Pressure Lock is there check for Tank Cap and EVAP Purge valve. ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 291 * Check for Supply Voltage MIL distance not Vehicle Speed Sensor * Check for Connector loose fitment, terminal back out or wire showing in diagnostic cut etc. tool * Check for Supply Voltage ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

  • Page 292: Notes

    NOTES ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...
  • Page 293 NOTES ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL...

Table of Contents

Save PDF