Royal Enfield HIMALAYAN LS410 2021 Service Manual
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Royal Enfield HIMALAYAN LS410 2021 Service Manual

Royal Enfield HIMALAYAN LS410 2021 Service Manual

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Summary of Contents for Royal Enfield HIMALAYAN LS410 2021

  • Page 2 Royal Enfield Service Manual This page is intentionally left blank...
  • Page 3 GENERAL AND SPECIAL TOOLS ..................... ENGINE ............................. CHASSIS ............................FUEL SYSTEM ........................... EVAPORATIVE EMISSION CONTROL SYSTEM (EVAP) ..............BRAKES AND ABS ..........................ENGINE MANAGEMENT SYSTEM (EMS) ..................ELECTRICAL SYSTEM ........................EURO V ADDON CONTENT ......................10 13 SERVICE MANUAL ROYAL ENFIELD HIMALAYAN...

  • Page 4: Table Of Contents

    CONTENTS PAGE 1. General Information ..........................11 1.1 About this Manual ..........................11 1.2 How to Use this Manual ........................12 1.3 Important Information ........................13 1.4 General Precautions ........................13 1.5 Prior to Service ..........................14 Technical Specifications ........................24 2.1 Engine .............................23 2.2 Ignition System ..........................23 2.3 Transmission ..........................23 2.4 Chassis ............................24...
  • Page 5 9.2. Brake - Rear ........................... 312 9.3 Anti-lock Braking System (ABS)....................330 9.4. Preparation ( Front Disc Brake) ....................347 9.5. Reassembly ..........................349 9.6. Preparation ( Rear Disc Brake) ....................350 9.7. Reassembly ........................... 351 9.8. Brake Bleeding ..........................353 SERVICE MANUAL ROYAL ENFIELD HIMALAYAN...
  • Page 6 CONTENTS PAGE 10. Engine Management System (EMS) ....................361 10.1 Engine Management System (EMS) ..................363 11. Electrical System ..........................388 11.1 Headlamp and Cluster Dismantling .....................391 11.2 Connectors behind Headlamp Housing ..................392 11.3 Tail Lamp Dismantling ........................395 11.4 Brake Lamp Connectors Dismantling ..................396 11.5 Trafficators Dismantling ......................

  • Page 7: General Information

    General Information GENERAL INFORMATION...
  • Page 8 CONTENTS PAGE 1.1 About this Manual ..........................11 1.2 How to Use this Manual ........................12 1.3 Important Information ........................13 1.4 General Precautions ..........................13 1.5 Prior to Service .............................14...

  • Page 9: About This Manual

    Lastly, we would recommend and insist that the periodic maintenance and overhauling of the Royal Enfield motorcycles be carried out ONLY through authorized Royal Enfield service stations where factory trained and experienced service technicians are always available.

  • Page 10: How To Use This Manual

    This service manual is divided into several chapters as detailed below. This will help the technical personnel to easily refer to the particular section of interest, for carrying out the correct maintenance and repair procedure as recommended by Royal Enfield. Click and explore on the blue icons to refer individual chapters. Chapter No.

  • Page 11: Important Information

    1.3 Important Information To enhance customer satisfaction and to improve the performance of the motorcycle, Royal Enfield will carrying out modifications and changes in the motorcycles in the years to come. Such changes will be intimated periodically and continuously through service bulletins and notifications to the authorized Royal Enfield dealers and service stations and will also be included in the future editions of this service manual.

  • Page 12: Prior To Service

    1.5 Prior to Service Proper preparation is very important before commencing any maintenance or repair on a motorcycle. This will not only result in an efficient and accurate repair job but will also save time and result in “FIRST TIME RIGHT” and help the customer gain confidence in the technician’s capability.
  • Page 13 Place tools handy before beginning the Do a test ride wherever required to reconfirm issues service or maintenance. mentioned by customer. This will also help to identify other issues if any. 1.5.3. Service Records Check the service records. SERVICE MANUAL ROYAL ENFIELD HIMALAYAN...
  • Page 14 Do not use a screwdriver for punching, chiseling or scraping, or as a lever to lift another object. Use Ramp Royal Enfield recommends the use of a suitable ramp to hold the motorcycle vertically in a convenient position for easy repairs.
  • Page 15 Lubrication During assembly, ensure that all rotating and/or sliding parts are lubricated to minimize wear and tear during initial operation. Use Royal Enfield recommended oil and lubricants only. All brake system parts should be cleaned and lubricated with recommended brake fluid only (e.g., piston, MC, etc.).

  • Page 16: Electrical Connectors

    (+) terminal to avoid short circuit. While connecting, first connect the Royal Enfield does not recommend welding on the positive (+) and then the negative (−) terminals. frame or any other parts of the motorcycle. Welding will make the frame weak and can also affect the balance of the motorcycle.

  • Page 17: Protective Covers

    Use only Use proper covers on the motorcycle to avoid Royal Enfield Genuine parts. scratching/damaging paint during service. 1.5.11. Inspection Reuse of worn or damaged parts may lead to serious malfunction and/or unsafe operation of the motorcycle.

  • Page 18: Final Inspection

    Hazardous Substances Yet, if you are using any after-market part that is not supplied by Royal Enfield, do ensure that it does not interfere with the functioning of any of the Many liquids and other substances like fuel, motorcycle parts.

  • Page 19: Technical Specifications

    Technical Specifications TECHNICAL SPECIFICATIONS...
  • Page 20 CONTENTS PAGE Technical Specifications ........................23 2.1 Engine .............................23 2.2 Ignition System ..........................23 2.3 Transmission ..........................23 2.4 Chassis ............................24 2.5 Electrical System ...........................24 2.6 Dimensions ............................25 2.7 Weights ............................25...

  • Page 21: Engine

    Wet multiplate Gear Primary Drive 2.312:1 Primary Ratio 5 Speed Constant Mesh Gear Box 2.916:1 1.833:1 1.428:1 Gear Ratio 1.173:1 1:000:1 5/8” Chain & Sprocket Secondary Drive 2.533:1 Secondary Ratio 110 links Drive Chain links SERVICE MANUAL ROYAL ENFIELD HIMALAYAN...

  • Page 22: Chassis

    Using bulbs/other electrical gadgets other than specified rating may lead to over loading/erratic behavior/premature failure of electrical system. Modifications on the motorcycle which are not approved by Royal Enfield may not only disqualify for warranty, but will also affects the performance of the motorcycle.

  • Page 23: Dimensions

    174 Kgs. (Inclusive of rider mass) • Values/Dimensions given above are for your guidance only. • In view of continuous improvements being done on our motorcycles, the specifications are subject to change without prior notice. SERVICE MANUAL ROYAL ENFIELD HIMALAYAN...
  • Page 24 Periodic Maintenance Schedule PERIODIC MAINTENANCE SCHEDULE (PMS)

  • Page 25: Periodical Maintenance Schedule (Pms)

    The frequency of the maintenance must be shortened depending upon the severity of the driving condition or if the motorcycle is used in a very dusty environment. Contact the nearest Royal Enfield Authorized Dealer/Service Center for expert advice and to carry out the required maintenance.
  • Page 26 (#) - After First service, Engine oil and Engine oil filter replacement is a mandatory at every 12 months even the vehicle has not covered the specified kms. NOTE • For Maintenance after 50,000 kms, Please repeat the same frequency specified above, in consultation with a Royal Enfield Authorized Dealer/Service Center.
  • Page 27 The frequency of the maintenance must be shortened depending upon the severity of the driving condition or if the motorcycle is used in a very dusty environment. Contact the nearest Royal Enfield Authorized Dealer/Service Center for expert advice and to carry out the required maintenance.

  • Page 28: Periodic Maintenance

    (#) - After First service, Engine oil and Engine oil filter replacement is a mandatory at every 12 months even the vehicle has not covered the specified kms. NOTE • For Maintenance after 50,000 kms, Please repeat the same frequency specified above, in consultation with a Royal Enfield Authorized Dealer/Service Center.
  • Page 29 EMS ADAPTATION PROCEDURE SERVICE MANUAL ROYAL ENFIELD HIMALAYAN...
  • Page 30 The following procedure to be followed when if any change in the EMS sensors or fuel type Step 1 - Check for Engine Oil Temperature (EOT) at start is less than 40˚C. Step 2 - Allow the engine to idle and leave it undisturbed till the Engine Oil Temperature reaches 115˚C.(Time required for the EOT to reach 115˚C will be 30 minutes approximately) Step 3 - Once Engine Oil Temperature reaches 115˚C, turn “OFF“...

  • Page 31: General And Special Tools

    General and Special Tools General and Special Tools GENERAL AND SPECIAL TOOLS...
  • Page 32 CONTENTS PAGE 4. General and Special Tools ........................33 4.1 General Tools ............................33 4.2 Measurement Tools ........................36 4.3 Special Tools ............................38 4.3.1. Engine ..............................38 4.3.2. Vehicle ..............................40...

  • Page 33: General Tools

    Size Part Description Illustration 100 - 225mm Screw Driver 100 - 225mm Screw Driver Phillips Screw Driver (Torx) Chisel Flat Chisel Pointed 6-7 to 26-27mm Spanner (Double End/Open End) 8-9 to 24-25mm Spanner (Ring) Hammer SERVICE MANUAL ROYAL ENFIELD HIMALAYAN...
  • Page 34 Sl. No. Size Part Description Illustration Plastic Hammer Mallet Tommy Bar Spring Puller 4 - 14mm Allen Key 4 - 14mm Allen Socket 8 to 30mm Hex Socket 12mm Bi-hexagonal 5” & 10” Extension...
  • Page 35 Sl. No. Size Part Description Illustration Ratchet T-handle 10 - 50N-m & Torque Wrench 22 - 100N-m Cutting Plier Nose Plier Circlip Plier Adjustable Plier Pinch Plier Spoke Adjuster SERVICE MANUAL ROYAL ENFIELD HIMALAYAN...

  • Page 36: Measurement Tools

    Sl. No. Size Part Description Illustration Scissor Jack V-block 10 N-m - 200 N-m Digital Torque Wrench 1.2 Measurement Tools Vernier Caliper 0 - 25mm, 25 - 50mm, Micrometer 50 - 75mm, 75 - 100mm Bore Gauge Dial Gauge with Magnetic Stand Tyre Depth Gauge Steel Ruler...

  • Page 37: Special Tools

    General and Special Tools SPECIAL TOOLS...

  • Page 38: Special Tools

    1.3 Special Tools 1.3.1. Engine l. No. Part Number Part Description Illustration ST30274/a Magneto Puller Assembly ST275332 Crank Gears Locking Tool ST30259/a Adapter - Compression Checking ST30266/a Clutch Holder Gear Shifter Shaft NRB and Oil Seal ST30271/a Installer ST30296/a Piston Ring Compressor ST30294/a Oil Filter Wrench...
  • Page 39 Clutch Activating Shaft Top Bearing ST-27540-1 Puller Clutch Activating Lever Bottom Bearing ST30261/a Installer ST30263/a Clutch Act Shaft Bottom Bearing Puller ST30270/a Gear Shifter Drum NRB Installer ST30293/a Oil Filter Union Wrench ST-27527-2 Tappet Adjusting Tool SERVICE MANUAL ROYAL ENFIELD HIMALAYAN...

  • Page 40: Vehicle

    SL. No. Part Number Part Description Illustration ST-27534-2 FD Sprocket Holding Tool ST-27528-2 Valve Spring Compressor Magnet Holder Oil Pressure Adapter Oil Pressure Gauge 1.3.2. Vehicle Sl. No. Part Number Part Description Illustration Frame Adjuster OD 14.8/ ID 10.8 mm- ST30267/a Engine ST30268/a...
  • Page 41 Headstock Bearing Puller-Assembly ST30273/a Headstock - Frame Cone Installer ST30298/a Bearing Puller, T -Stem ST30299/a T Stem Taper Roller Bearing Installer ST30297/a Swing Arm NRB Installer ST26461-2 Fork Damper Tube Holder ST26485-3 Fork Oil Seal Installer SERVICE MANUAL ROYAL ENFIELD HIMALAYAN...

  • Page 42: Engine

    Engine ENGINE...
  • Page 43 Engine CONTENTS PAGE 5.1. ENGINE REMOVAL FROM FRAME ..............5.2. ENGINE DISMANTLING ..................5.3. ENGINE ASSEMBLY .................... X 5.4. ENGINE ASSEMBLY TO FRAME ................ X 5.5. ENGINE INSPECTION ..................X SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 44: Engine Removal From Frame

    Engine Removal from Frame ENGINE REMOVAL FROM FRAME...
  • Page 45 Engine Removal from Frame CONTENTS PAGE 5.1 Engine Removal from Main Frame....................47 5.1.1. Engine Oil ................................47 5.1.2. Oil Filter ................................47 5.1.3. Side Panel RH ..............................48 5.1.4. Side Panel LH ..............................48 5.1.5. Pillion and Rider Seat from Frame ........................48 5.1.6.
  • Page 46 Engine Removal from Frame CONTENTS PAGE 5.1.25. Rear Wheel (Increasing chain slack) ........................ 58 5.1.26. Remove Rear Chain from FD Sprocket ......................58 5.1.27. Gear Position Sensor ............................59 5.1.28. Cradle Frame Mountings ..........................59 5.1.29. Engine from Main Frame ..........................60...

  • Page 47: Engine Removal From Main Frame

    Place a tray under engine oil drain plug (M6). • • Gently remove oil filter cap (a) along with O-ring Remove bolt (a) along with cap (b) and O-ring (c). (b). Fig. 5.3.2 Fig. 5.3.5 8 mm Socket with Ratchet SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 48: Side Panel Rh

    • Gently remove oil filter (a). • Gently pull the LH cover (a) to remove. Fig. 5.3.1 Fig. 5.3.6 1.1.3. Side Panel RH 1.1.5. Pillion and Rider Seat from Frame • Remove 3 Nos. Hex socket button head screws (a) •...

  • Page 49: Grab Rail From Frame

    Disconnect battery negative (-) terminal bolt (a). • side from the grab rail. Fig. 11.5.1 Fig. 5.3.5 10 mm Double end spanner 10 mm Socket with Ratchet Remove the 2 Nos. allen bolts (a) from the • mudguard. Fig. 5.3.6 SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 50: Clutch Cable

    • Disconnect battery positive (+) terminal (a) from • Loosen outer locknut (M8) (a) completely on the battery (b). clutch cable adjuster at RH cover end and push clutch cable (b) into cable guide in cover RH to increase the free play of the inner cable. Fig.

  • Page 51: Fuel Tank

    Gently lift fuel tank (a) upwards and pull backwards slightly. • Disconnect fuel pump connector (b) from fuel tank. CAUTION DO NOT lift the tank too much to prevent damage to connectors and brake hoses. Fig. 5.3.2 SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 52: Fuel Hose (Fuel Pump To Injector)

    1.1.11. Fuel Hose (Fuel Pump to Injector) 1.1.13. Drain Hose • Clean quick fix adapter area and disconnect by • Disconnect drain hose connection (a) from fuel pressing lock button (a). Remove fuel hose (b). tank (b). Fig. 5.3.3 Fig. 5.3.6 1.1.14.

  • Page 53: Air Filter Housing To Throttle Body

    • 4 mm Allen key (b). 1.1.17. Hego/Oxygen Sensor Connectors Disconnect Hego/oxygen sensor connectors (a) • from both LH and RH located on front side of engine. Fig. 5.3.9 4mm Allen Socket and Ratchet Fig. 5.3.11 SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 54: Exhaust Pipe And Silencer

    1.1.18. Exhaust Pipe and Silencer • Remove the silencer guard along with bolts. Silencer • Loosen and remove 2 Nos. hex socket bolts (M6) (a) from the silencer guard at muffler end. Fig. 5.3.15 • Remove the heder pipe mounting bolt (a). Fig.

  • Page 55: Magneto/Gear Position/Side Stand

    (b). 14 mm socket with ratchet Remove the exhaust header pipe (a). • Fig. 5.3.22 Fig. 5.3.20 CAUTION Perform any action in exhaust pipe only after the exhaust pipe cools down. SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 56: Starter Motor Connection

    • Disconnect wiring coupler (a) of stator from main • Loosen and remove 2 Nos. Hex flange head bolt wiring harness. (M6) (a) to disconnect starter motor (b) negative (-) terminal. Fig. 5.3.23 Fig. 5.3.26 • Disconnect side stand connector (a) from wiring harness located behind engine .

  • Page 57: Gear Shift Linkage

    5 mm Allen socket with Ratchet • Gently pull out FD sprocket cover (a). Fig. 5.3.30 14 mm Socket with Ratchet 17 mm Ring Spanner Fig. 5.3.32 Unlock and release washer holder (a). • Fig. 5.3.33 Chisel and Hammer SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 58: Rear Wheel (Increasing Chain Slack)

    • Apply rear brake (a). 1.1.25. Rear Wheel (Increasing chain slack) Loosen rear wheel axle nut (M16) (a) to increase • the chain slackness/tension. Fig. 5.3.34 • Loosen and remove FD sprocket U nut (a). Fig. 5.3.37 24 mm Socket with Ratchet Loosen chain adjuster lock nut (M8) (a) on LH and •...

  • Page 59: Gear Position Sensor

    Loosen and remove 1 Nos. Hex socket head long bolts (M10) (a) on LH on cradle frame (b). Fig. 5.3.43 14 mm socket with Ratchet • Remove cradle frame (a) from engine. Fig. 5.3.41 14 mm socket with Ratchet Fig. 5.3.44 SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 60: Engine From Main Frame

    1.1.29. Engine from Main Frame • Loosen and remove Hex flange head bolt (M10) (a) along with nut (M10) (b) and washers (c) from rear • Support engine with flat jack (a) so that it will not upper bottom of engine. fall off when mounting bolts are removed.

  • Page 61: Engine Dismantling

    Engine Dismantling ENGINE DISMANTLING...
  • Page 62 Engine Dismantling CONTENTS PAGE 5.2 Engine Dismantling .......................... 64 5.2.1. Oil Cooler ................................64 5.2.2. Drain Plug ................................. 64 5.2.3. Oil Filter ................................65 5.2.4. Cover crankshaft center ........................... 66 5.2.5. Throttle Body ..............................66 5.2.6. Injector ................................66 5.2.7. Spark Plugs ................................ 67 5.2.8.
  • Page 63 Engine Dismantling CONTENTS PAGE 5.2.25. FD Sprocket ..............................76 5.2.26. Cylinder Head Cover ............................77 5.2.27. Auto Chain Tensioner ............................79 5.2.28. Rocker Arms from Rocker Carriers .........................80 5.2.29. Center Cover LH .............................80 5.2.30. Cover LH ................................81 5.2.31. Idler Gear .................................81 5.2.32.

  • Page 64: Engine Dismantling

    1.2 Engine Dismantling 1.2.2. Drain Plug Loosen and remove oil filler cap (a) from the • NOTE crankcase top on the RH side. • Ensure the engine is properly clamped on the • Use an adjustable plier with soft jaws to unscrew holding fixture on a worktable.

  • Page 65: Oil Filter

    • Ensure the engine oil is drained completely. • Gently shake and remove the oil filter (a) from • After draining the oil suitably cover the oil filler cover RH cap hole to prevent debris. Fig. 5.5.4 SERVICE MANUAL ROYAL ENFIELD...

  • Page 66: Cover Crankshaft Center

    5.2.4 Cover crankshaft center For EURO V Model • Loosen and remove 1 No (M5) (a) allen bolt from • Remove the 2 Nos. allen bolts (a) along with the the clamp (c). crankshaft center cover (b) and O-ring (c). Gently pull out the throttle body (b) along with •...

  • Page 67: Spark Plugs

    • DO NOT tap on the starter motor while removing it. Tapping may damage the internal components. Fig. 5.5.10 18mm Open End Spanner • Gently pull out the engine oil temperature sensor along with the O-Ring SERVICE MANUAL ROYAL ENFIELD...

  • Page 68: Breather Hose

    5.2.10 Breather Hose CAUTION Do not use a sharp tool to scrap the gasket • Remove the Circlip (a) on the breather (b) and material from the joint faces. gently pull it to remove. If required scrap only with a soft and blunt tool.

  • Page 69: Clutch Actuating Lever Assembly

    Remove the circlip (a) on the oil level window • inside clutch cover. 5mm Allen Socket with Ratchet Gently remove the oil seal (a) from the cover RH • using a screw driver. Fig. 5.5.20 Circlip plier Fig. 5.5.23 Screw Driver SERVICE MANUAL ROYAL ENFIELD...

  • Page 70: Balancer Shaft Bolt

    5.2.16 Balancer Shaft Bolt 5.2.17 Crankshaft Nut CAUTION CAUTION • Refer section 5.2.30 to remove cover LH Crank nut is a left hand thread. Wrong rotation and to loosen magneto rotor bolt. may damage the threads. • It is not be possible to remove the •...

  • Page 71: Oil Jet

    Loosen and remove Hex flange bolt (M6) (a) on oil • Fig. 5.5.29 pump sprocket along with washer. Remove the washet (a) and crankshaft gear (b). • Fig. 5.5.32 Fig. 5.5.30 10 mm Socket with Ratchet SERVICE MANUAL ROYAL ENFIELD...

  • Page 72: Clutch Assembly

    5.2.20 Clutch Assembly • Remove oil pump sprocket (b) along with the washers (a) and (c). CAUTION Ensure gearbox in neutral position. Remove the bearing (a) from the clutch housing. • Fig. 5.5.33 • Remove 4 Nos. Hex flange head bolts (M6) (a) in crisscross pattern.
  • Page 73 Remove 2 Nos. Hex bolts along with washers from clutch assemby. Loosen and remove uniformly 2 Nos. Hex bolts (a) • and remove the special tool (b). Fig. 5.5.40 Fig. 5.5.43 10 mm Socket with Ratchet SERVICE MANUAL ROYAL ENFIELD...

  • Page 74: Gear Shifter Shaft

    • Remove the pressure plate (a) slowly from the • Remove the thrust plate (a) and steel plate (b) springs. from the clutch housing. Fig. 5.5.47 Fig. 5.5.44 Remove the clutch housing (a) from the crankshaft. • Remove six springs (a) from the clutch. •...

  • Page 75: Star Index Stopper

    10 mm Socket with Ratchet Fig. 5.5.51 Remove stopper (b) along with bolt (a) washer (c) • and spring (d). • Expand spring legs and pull out spring (a) from shorter end of shifter shaft (b). Fig. 5.5.54 Fig. 5.5.52 SERVICE MANUAL ROYAL ENFIELD...

  • Page 76: Star Index

    5.2.23 Star Index 5.2.24 FD Sprocket cover Remove 2 Nos. hex bolt (M6) (a) from the FD • • Loosen and remove Hex socket head stepped bolt sprocket cover. (M6) (a) on star index. Fig. 5.5.58 Fig. 5.5.55 Gently remove the FD sprocket cover (a). •...

  • Page 77: Cylinder Head Cover

    Remove lock tab washer (a) from shaft. • Fig. 5.5.65 10 mm Socket with Ratchet Remove the valve cover (a) along with the O-ring. • Fig. 5.5.62 (b). • Remove FD sprocket (a) from drive shaft. Fig. 5.5.66 Fig. 5.5.63 SERVICE MANUAL ROYAL ENFIELD...
  • Page 78 Loosen and remove 2 Nos .hex bolts (M6) (a) from • Loosen and remove 2 Nos. Hex flange head bolts • (M6) (a) along with rubber seals and washers LH side. from RH side. Fig. 5.5.70 Fig. 5.5.67 Loosen and remove 2 Nos .hex bolts (M6) (a) from •...

  • Page 79: Auto Chain Tensioner

    Before dismantling ensure piston at TDC. • Remove 1 No. Hex bolt (a) from the timing adjuster Loosen and remove center Hex flange bolt (a) from • cover. chain tensioner. Fig. 5.5.75 Fig. 5.5.78 12 mm Socket with Ratchet SERVICE MANUAL ROYAL ENFIELD...

  • Page 80: Rocker Arms From Rocker Carriers

    Remove the rocker carrier assembly (a). • Loosen and remove 2 Nos. Allen bolts (M6) (a) • from cylinder barrel (b). Fig. 5.5.82 Fig. 5.5.79 Remove 2 Nos rocker arms (a) rocker carrier • 5 mm Allen Socket with Ratchet assembly.

  • Page 81: Cover Lh

    If required scrap only with a soft and blunt Hex head bolt (M6) (a) • Loosen and remove 1 tool. from cam sprocket. Remove dowel pin (a) from the crankcase. • Fig. 5.5.90 Fig. 5.5.87 8 mm Socket with Ratchet SERVICE MANUAL ROYAL ENFIELD...
  • Page 82 • Rotate magneto rotor only in anti-clockwise CAUTION direction, till the other Hex head bolt on cam chain Support timing chain suitable so that it does sprocket appears at the top most position. not fall into the crankcase. Remove “C” washer (a) from groove in cylinder •...

  • Page 83: Stator Assembly

    Part Name: Crank Gears locking tool • Remove the sensor (a) and guide plate. • Loosen and remove Hex flange head bolt (M12) (a). Fig. 5.5.98 Fig. 5.5.101 4 mm Allen socket with Ratchet 17 mm Socket with Ratchet SERVICE MANUAL ROYAL ENFIELD...

  • Page 84: Starter Clutch From Magneto Rotor

    5.2.35 Starter Clutch from Magneto Rotor • Assemble puller (b) on magneto rotor (a) and thread in fully. Loosen 6 Nos. Hex socket head screws (M6) (a) • • Tighten center bolt onto puller till magneto rotor from inside magneto rotor. Do not LOOSEN AND gets released from crankshaft.

  • Page 85: Cylinder Head

    Loosen and remove 2 Nos. Hex head bolts (M6) • (a) on cylinder head. Fig. 5.5.111 Remove 2 nos dowel pins (a) on cylinder head. • Fig. 5.5.109 Fig. 5.5.112 8 mm Socket with Ratchet Nose Plier SERVICE MANUAL ROYAL ENFIELD...

  • Page 86: Components From Cylinder Head

    5.2.37 Components from Cylinder Head • Remove the retainer, valve spring (a) from the top of the valve spring (b). Valves and Springs Compress valve spring (a) with valve spring • compressor (b). Fig. 5.5.115 • Remove valve spring (a) from valve stem (b). Fig.

  • Page 87: Cylinder Barrel

    Remove the guide pad bolt (a) from the guide pad. Fig. 5.5.122 • Slightly tilt and gently remove the cylinder barrel Fig. 5.5.119 (a) from crankcase (b). Remove cam chain (a) from cylinder barrel. • Fig. 5.5.123 Fig. 5.5.120 SERVICE MANUAL ROYAL ENFIELD...

  • Page 88: Piston

    Remove 2 nos dowel pin (a) from cylinder barrel • 5.2.40 Crankcase Fasteners Description Quantity M6 x 1.25 x 35 • Support crankcase assembly on suitable wedges such that the fasteners on the crankcase can be removed. • Slackening sequence. Fig.

  • Page 89: Balancer Shaft

    Match the punch mark (a) in balancer shaft and • crankshaft. Fig. 5.5.132 5.2.44 Gear Selector • Gently pull to remove transmission selector drum (a) with selector forks (b) and spindles (c). Fig. 5.5.130 Fig. 5.5.133 SERVICE MANUAL ROYAL ENFIELD...

  • Page 90: Countershaft

    • Remove spindle (a) from forks (c) from selector • Remove circlip (a) from the countershaft. drum (b). Fig. 5.5.137 Fig. 5.5.134 Circlip Expander 5.2.45 Countershaft • Place countershaft separately. Remove the third and fourth drive gear (a) from • the countershaft.

  • Page 91: Driveshaft

    Remove thrust washer (a) and first driven gear (b) • Circlip Expander from driveshaft. Remove thrust washer (a) and second drive gear • from the countershaft Fig. 5.5.143 • Remove circlip (a) from groove in the driveshaft. Fig. 5.5.141 Fig. 5.5.144 Circlip Expander SERVICE MANUAL ROYAL ENFIELD...
  • Page 92 • Remove thrust washer (a) and fifth driven gear (b) • Remove the third driven gear (a) from the drive shaft. Fig. 5.5.145 Fig. 5.5.149 Remove splined washer (a) from driveshaft. • • Remove collar (a) along with thrust washer (b) and circlip (c) from the drive shaft.
  • Page 93 • Remove circlip (a) and bush (b) from driveshaft. Fig. 5.5.152 Remove second driven gear (a) from driveshaft. • Fig. 5.5.153 SERVICE MANUAL ROYAL ENFIELD...

  • Page 94: Engine Assembly

    Engine Assembly Engine Assembly ENGINE ASSEMBLY...
  • Page 95 Engine Assembly CONTENTS PAGE 5.3 Engine Assembly ..........................97 5.3.1. Components Sub Assembly in Crankcase ......................97 5.3.2..................................... Countershaft Components ............................97 5.3.3. Driveshaft Components ............................ 98 5.3.4. Transmission Selector Drum ........................... 100 5.3.5. Crankshaft Assembly ............................100 5.3.6. Balancer Shaft ..............................100 5.3.7.
  • Page 96 Engine Assembly CONTENTS PAGE 5.3.25. Clutch Assembly (LH thread) ..........................114 5.3.26. Crank gear (LH Thread) ..........................116 5.3.27. Balancer Shaft Bolt ............................117 5.3.28. Oil Pump ................................. 117 5.3.29. Oil Jet ................................118 5.3.30. Oil Level Window ............................118 5.3.31. Oil Bypass seal ..............................118 5.3.32.

  • Page 97: Engine Assembly

    • (a) on countershaft. expanding to ensure it is properly seated. NOTE • While installing the circlip, ensure the circlip is opened only upto the outer diameter of the shaft. Fig. 5.8.2 Fig. 5.8.5 Circlip Expander ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 98: Driveshaft Components

    • Install the second drive gear (a) and .washer (b) on • Install slide bush (a) on the drive shaft. the countershaft. Fig. 5.8.9 Fig. 5.8.6 • Install collar (a) along with thrust washer (b) and 5.3.3. Driveshaft Components circlip (c). Install second driven gear (a) on the driveshaft.
  • Page 99 Circlip Expander • Install thrust washer (a) on the drive shaft. • Install first gear (b) and thrust washer (a) on the driveshaft. Fig. 5.8.14 Fig. 5.8.17 ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 100: Transmission Selector Drum

    5.3.4. Transmission Selector Drum 5.3.5. Crankshaft Assembly NOTE NOTE • Lubricate selector drum and forks with engine oil • Lubricate crankshaft big end bearing with before installation. engine oil before installation • Gently install crankshaft assembly (a) on LH • Install driveshaft and countershaft in LH crankcase.

  • Page 101: Dowel Pins

    Crankcase bolts and washers are non reusable • Tighten the crankcase bolts in the following se- quence mentioned below, Fig. 5.8.24 NOTE • Ensure the mating space both the crankcase are clean and dry. Fig. 5.8.26 ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 102: Piston And Piston Rings

    5.3.10. Piston and Piston Rings NOTE • Lubricate piston rings with engine oil before installation Fig. 5.8.30 Fig. 5.8.27 Piston Top Ring Second Ring Fig. 5.8.31 Oil Ring Rings Orientation Pattern Fig. 5.8.32 Fig. 5.8.28 Fig. 5.8.33 Fig. 5.8.29...

  • Page 103: Cylinder Barrel

    • Apply a thin coat of engine oil around the cylinder • barrel before installing piston Install new cylinder barrel gasket (a) on the • crankcase by aligning to the two dowel pins. Fig. 5.8.35 Connector Fig. 5.8.37 ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 104: Valves And Springs

    • Install the cylinder barrel (a) on the crankcase (b). • Lubricate and install the corresponding valve (a) in the cylinder head (b) valve guide from bottom. Fig. 5.8.38 Fig. 5.8.41 • Install the 2 Nos.cylinder barrel bolts (a). • Support the valve from bottom and install valve spring seat and spring (a) on valve stem (b) from top.

  • Page 105: Cylinder Head

    Cylinder Head Bolts and washers M10 are NON • Fig. 5.8.45 REUSABLE. • Apply engine oil to the threads of the bolt before Gently unscrew special tool (a) screw and remove • installation. from the valve spring (b). Fig. 5.8.46 ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 106: Timing Chain On Crankshaft

    5.3.14. Timing chain on Crankshaft • Install the cylinder head (a) over cylinder barrell. • Install the tensioner pad (a) on the crankcase groove using a bolt (M6). Fig. 5.8.49 Install cylinder head bolts (M10) (a) 4 Nos. along • with washers.

  • Page 107: Magneto Rotor On Crankcase

    Fig. 5.8.56 Install hex flange bolt (M6) on magneto rotor. • Fig. 5.8.60 17 mm Socket with Ratchet Fig. 5.8.57 Torque 45-55 N-m/4.5-5.5 kgf-m 5 mm Allen Socket with Ratchet Torque 10-12 N-m/1.0-1.2 kgf-m ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 108: Camshaft Assembly

    • Install C washer (a) on cylinder head (b). NOTE • Ensure Crankshaft & Magneto taper free from oil & foreign particles. • Taper surfaces has to be cleaned with Isopropyl solution before assembly 5.3.17. Camshaft Assembly NOTE • Lubricate camshaft lobe and journals with Fig.

  • Page 109: Rocker Carrier In Cylinder Head

    & M6 tap should be facing outside Fig. 5.8.69 CAUTION • Lock the crank gear using special tool (a). Ensure rocker shaft is assembles in the corresponding inlet and exhaust sides as dismantled. Fig. 5.8.70 ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 110: Tappet Clearance Adjustment

    • Gently rotate the crankshaft and insert the special • Loosen tappet adjuster locknut with special tool. tool (a) on crankcase RH to lock the crankshaft. Fig. 5.8.74 Fig. 5.8.71 • Insert a screwdriver into the tappet adjusting tool • Install 4 Nos.

  • Page 111: Cylinder Head Cover

    Ensure the cylinder head cover surface and gasket seating groove are clean. • Ensure sealant is applied in the head gasket before assembly. Install the cylinder head (a) after applying sealant • and ensure it is seated properly. Fig. 5.8.80 Fig. 5.8.77 ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 112: Spark Plug

    • Install 2 Nos .hex bolts (M6) (a) from LH side. Install 2 Nos. Hex flange head bolts (M6) (a) along • with rubber seals and washers from RH side Fig. 5.8.81 Fig. 5.8.84 • Install 4 Nos .hex length bolts (M6) (a) from LH side.

  • Page 113: Star Index

    Locate washer (b) and Install circlip (a) on shifter • shaft (a). Locate spring (a) washer (b) and stopper arm (c) • above spring. • Ensure spring is seated on the groove provide in the stopper arm. Fig. 5.8.92 Circlip plier Fig. 5.8.89 ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 114: Clutch Assembly (Lh Thread)

    5.3.25. Clutch Assembly (LH thread) • Install six springs (a) from the clutch. Locate spacer primary gear (a) on the clutch • housing assembly. Fig. 5.8.96 • Install pressure plate (a) on the clutch assembly. Fig. 5.8.93 • Install the steel plates (a) and thrust plates (b) in •...
  • Page 115 Install 2 Nos. Hex bolts (a) along with washers from clutch assemby. Fig. 5.8.103 Part No: ST275332 Part Name: Crank Gears Locking Tool 24 mm Socket with Ratchet Torque 110-130 N-m/11.0-13.0 kgf-m Fig. 5.8.101 8 mm Socket with Ratchet Torque 8-12 N-m/0.8-1.2 kgf-m ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 116: Crank Gear (Lh Thread)

    • Install bearing (a). • Install the oil pump chain (a) from the sprocket. Fig. 5.8.104 Fig. 5.8.107 5.3.26. Crank gear (LH Thread) Install the crankshaft nut (a) on the oil pump drive • sprocket by locking the gear using the special tool. CAUTION Ensure metal grading of crank gear and clutch housing gear are the same.

  • Page 117: Balancer Shaft Bolt

    • Oil pump does not have any servicable parts hence has to be replaced as an entire assembly. Fig. 5.8.113 • Oil pump metal gasket & O ring is one time use only. DO NOT reuse. ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 118: Oil Jet

    5.3.30. Oil Level Window • Install circlip (a) on the oil pump. • Locate oil level window inside cover LH (a). Fig. 5.8.114 Fig. 5.8.116 5.3.29. Oil Jet Locate circlip (a) in the grove provided. • NOTE • Ensure gearbox is in neutral condition Locate and tighten oil jet (a) into crankcase.

  • Page 119: Clutch Actuating Lever Assembly

    Locate and tighten Hex head bolt (M6) (a) in clutch Install 2 nos dowel pins (a) on RH crankcase • actuating lever assembly (b). Fig. 5.8.122 Fig. 5.8.120 10 mm Socket with Torque Wrench Torque 10-12 N-m/01.0-1.2 kgf-m ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...
  • Page 120 • Install the clutch cover (b) on the crankcase along • Install O-Ring (a) on the oil filter cover (b). with gasket (a) and tighten the 18 Nos. bolts (M6) NOTE in the given sequence. Oil filter O-Ring is one time use only. DO NOT •...

  • Page 121: Starter Idler Gear

    Install collar (a) on each shaft. • sequence mentioned below. Fig. 5.8.129 Fig. 5.8.132 5.3.36. Cover LH 8 mm Socket with Ratchet • Install dowel pin (a) into the grooves provided in Torque 10-12 N-m/1.0-1.2 kgf-m the crankcase LH. Fig. 5.8.130 ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 122: Gear Position Sensor

    5.3.37. Gear Position Sensor • Install retainer-Gear Position Sensor Wire (a) using 2 nos bolts. NOTE • Apply BONDERITE S-O240 around the O-Ring before installation. Install new O-ring (a) over Gear Position Sensor (b) • on the crankcase using 2 Nos. bolts (c) (M6) (for EURO IV Model).

  • Page 123: Oil Strainer

    Apply engine oil on o-ring before assembly Dry Fill 2.5 Liters / 0.55 Imperial gallon SAE 15W50 APISL, JASO MA2, SEMI Grade SYNTHETIC 8 mm Socket with Ratchet Fig. 5.8.141 Torque 8-12 N-m/0.8-1.2 kgf-m Nose Plier ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 124: Fd Sprocket

    5.3.41. FD sprocket • Lock using tab washer holder (a). • Install the tab washer (a) and “U” nut (c) (M20). Fig. 5.8.145 Fig. 5.8.142 Chisel and Hammer • Install the FD sprocket (a). 5.3.42. Throttle Body • Install throttle body (b) in inlet manifold using 2 Nos.

  • Page 125: Engine Oil Temperature/Eot Sensor

    17 mm Open end spanner Torque 15-20 N-m/1.5-2.0 kgf-m 5.3.44. Oil Cooler Align the oil cooler inlet & outlet pipes (a) on RH • and LH crankcase. • Install the 1 No. banjo bolt (a) on LH and RH crankcase. ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 126: Engine Assembly To Frame

    Engine Assembly to Frame ENGINE ASSEMBLY TO FRAME...
  • Page 127 Engine Assembly to Frame CONTENTS PAGE 5.4 Engine Assembly to Frame ......................129 5.4.2. Engine Mounting Final Torque ........................130 5.4.3. Cradle Frame Mountings..........................130 5.4.4. Gear Position Indicator Sensor ......................... 131 5.4.5. FD Sprocket ..............................132 5.4.6. FD Sprocket Cover ............................133 5.4.7.
  • Page 128 Engine Assembly to Frame CONTENTS PAGE 5.4.26. Side Panel LH ..............................141 5.4.27. Side Panel RH ..............................141 5.4.28. Drain Bolt and Engine Oil Re-fill ........................142...

  • Page 129: Engine Assembly To Frame

    Insert Hex flange bolt long (M10) (a) into mounting • holes on the main frame rear top, insert washer (b) and nut (c) on other side. Fig. 5.4.4 14 mm Ring spanner and 14 mm Hex socket with Ratchet Fig. 5.4.2 SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 130: Engine Mounting Final Torque

    5.4.2. Engine Mounting Final Torque • Tighten Hex socket bolts (M10) (a) with nut (b) on top rear frame (c) to engine. • Hold Hex nut (M10) and tighten the bolt to specified torque. Fig. 5.4.7 Fig. 5.4.5 14 mm Ring spanner and 14 mm Hex socket with Torque wrench Torque 45-55 N-m/4.5-5.5 kgf-m...

  • Page 131: Gear Position Indicator Sensor

    5.4.4. Gear Position Indicator Sensor bottom to frame (b). DO NOT TIGHTEN FULLY. Connect gear position sensor (a) to connector • located behind engine. Fig. 5.4.10 Fig. 5.4.12 12 mm Hex socket with Torque wrench Torque 22-28 N-m/2.2-2.8 kgf-m SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 132: Fd Sprocket

    Locate FD sprocket U nut (a) along with tab washer 5.4.5. FD Sprocket • and tighten it. CAUTION Ensure gear is in NEUTRAL position before assembling. Locate FD sprocket (a) to drive shaft. • Fig. 5.4.16 30 mm socket and Torque wrench Torque 130-160 N-m/13.0-16.0 kgf-m Fig.

  • Page 133: Fd Sprocket Cover

    Locate Hex bolt (M10) (a) on gear lever and • tighten to specified torque. Fig. 5.4.19 5 mm Allen socket and Torque wrench Torque 8-12 N-m/0.8-1.2 kgf-m Fig. 5.4.21 14 mm socket with Torque wrench and 17 mm Ring SPanner Torque 21-29 N-m/2.1-2.9 kgf-m SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 134: Breather Hose Connection

    5.4.8. Breather Hose Connection 5.4.10. Starter Motor Connections • Insert breather hose (b) on the tube into crankcase • Connect starter motor negative (-) cable (a) to plug (c). Position the clip (a) on hose correctly. terminal. • Assemble 2 Nos. Hex flange head bolts (M6) (b) into starter motor tighten firmly.

  • Page 135: Exhaust Pipe On Cylinder Head

    Fig. 5.4.30 • Locate the mounting hole in the frame and insert (M8) bolt (a) and tighten it. Fig. 5.4.28 14 mm socket with ratchet Fig. 5.4.31 12 mm socket with ratchet Torque 21-29 N-m/2.1-29 kgf-m SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 136: Hego/Oxygen Sensor Connectors

    5.4.14. Throttle Body • Locate the silencer guard back plate (a) and fix it in the silencer with 3 Nos (M6) (b) hex socket bolts.. • Insert throttle body (b) into intake manifold flange Fig. 5.4.32 Fig. 5.4.34 10 mm socket with ratchet Torque 10-12 N-m/1.0-1.2 kgf-m •...

  • Page 137: Injector Connections

    Assemble lock nut on the inner cable. • Ensure inner cables is seated properly in the eyelets at throttle body end and handlebar end. Gently rotate throttle rotor at handlebar and ensure they are operating properly. Fig. 5.4.41 SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 138: Evap Connections To Fuel Tank

    5.4.20. EVAP Connections to Fuel Tank • Gently lower the fuel tank into frame. • Locate and tighten 1 No. Hex head bolts (M5) (a) on Connect EVAP connection hose (a) to fuel tank • rear end of fuel tank (b). (b).

  • Page 139: Clutch Cable Free Play Adjustment

    10-12mm. Adjust if required. • Check gap of 3-6mm at adjuster nut at cable end. If found to be irregular, adjust at engine end. Fig. 5.4.50 12 mm Double end spanner Fig. 5.4.53 SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...

  • Page 140: Battery Connections

    • • Position steering in straight position. Acutate Connect battery negative (-) terminal (a) and clutch lever three times and check for free play of tighten Hex head bolt (M6) in battery. 10-16 mm. Fig. 11.8.2 Fig. 5.4.54 10 mm Double end spanner •...

  • Page 141: Pillion Backrest And Seat Assembly On Frame

    5 mm Allen Key • Insert the bolts (a) and tighten it. 5.4.27. Side Panel RH • Locate side panel RH into frame and lock in its position. Fig. 5.4.58 6 mm Allen Socket with Ratchet Fig. 5.4.61 SERVICE MANUAL ROYAL ENFIELD-HIMALAYAN...
  • Page 142 • Install 3 Nos. Hex socket button head screws (a) • Align and tighten the 2 Nos.bolt (a) (M6) (except left bottom one) Fig. 5.4.65 Fig. 5.4.62 Dry Fill 2.5 Liters / 0.55 Imperial gallon 5 mm Allen Key SAE 15W50 APISL, JASO MA2, SEMI Grade SYNTHETIC 5.4.28.

  • Page 143: Engine Inspection

    Engine Inspection ENGINE INSPECTION ROYAL ENFIELD METEOR 350-SERVICE MANUAL...
  • Page 144 Engine Inspection CONTENTS PAGE 5.5 Engine Inspection ..........................145 5.5.1. Cylinder Head ..............................145 5.5.2. Cylinder Barrel ..............................148 5.6.3 Crankcase ................................. 149 5.5.3. Clutch Components ............................150 5.5.4. Shifter Forks ..............................151 5.5.5. Selector Drum ..............................152...

  • Page 145: Engine Inspection

    • Insert pointed feeler gauge of 0.05 mm thickness between straight edge and cylinder head. Inspect and ensure 4 locations (a, b, c, d) on • cylinder head are at same level. Fig. 5.6.4 Fig. 5.6.2 ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 146: Rocker Cover

    Camshaft Journal OD • Ensure feeler enters properly at marked places. Measure camshaft journal OD (a). • Fig. 5.6.5 Fig. 5.6.7 Thick straight edge and Feeler gauge Micrometer Service limit: 0.01 mm Service Limit: 23.930 mm Rocker Cover Camshaft Lobe •...

  • Page 147: Valve Inspection

    0.010 mm Service Limit Intake 6.070 mm Service Limit Exhaust: 6.100 mm Exhaust Valve Stem Measuring Service Point Limit Stem OD Top 5.920 mm Stem OD middle 5.920 mm Stem OD bottom 5.920 mm Bend 0.010 mm ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 148: Cylinder Barrel

    5.5.2. Cylinder Barrel Piston OD • Measure and record both LH and RH cylinder piston Cylinder Barrel Bore ID OD at three levels - Top, Middle, and Bottom using Micrometer. • Check cylinder bore to piston working area for scoring, seizure marks and/or excessive wear. •...

  • Page 149: Crankcase

    Position the piston rings at their respective locations at the top of the cylinder barrel and ensure they are seated “squarely” inside the cylinder barrel. Fig. 5.6.19 Inside Micrometer Service Limit 20.042 mm V-Blocks and Dial gauge. Fig. 5.6.17 ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 150: Clutch Components

    5.5.3. Clutch Components Spring • Measure the length of the spring in decompressed Friction plate condition using a vernier caliper.. • Inspect the clutch plates visually for uneven wear, seizure and discoloration. Measure the thickness of the friction plate (a) at 4 •...

  • Page 151: Shifter Forks

    Visually inspect the shifter fork machined lugs (a) • for damage, excessive wear out scoring and replace if damaged. Fig. 5.6.25 Pressure Plate • Visually inspect pressure plate for any, wear, bends, lug breakage, heat marks or damages. Fig. 5.6.28 Fig. 5.6.26 ROYAL ENFIELD-HIMALAYAN SERVICE MANUAL...

  • Page 152: Selector Drum

    5.5.5. Selector Drum • Inspect the shifter fork working grooves in the selector drum for any damages, chipped ends etc. Measure the grooves in their working area for excessive wear out. Fig. 5.6.29 Vernier caliper Service Limit: 7.90 mm...

  • Page 153: Chassis

    Chassis CHASSIS...
  • Page 154 6.CHASSIS CONTENTS PAGE 6.1. AIR FILTER BOX ASSEMBLY ................6.2. CONTROL CABLES ..................... X 6.3. HANDLEBAR ...................... 6.4. EXHAUST PIPES AND SILENCERS ..............6.5. FOOTRESTS/STANDS/SAREEGUARD .............. X 6.6. MUDGUARD AND NUMBER PLATES ..............X 6.7. SIDE PANELS AND RIDER SEAT ................. 6.8.

  • Page 155: Air Filter Box

    Air Filter Box AIR FILTER BOX...
  • Page 156 Air Filter Box CONTENTS PAGE 6.1 Air Filter Box ............................157 Dismantling .............................. 157 6.1.1. Air Filter Element from housing ..........................157 6.1.2. Air filter Housing from frame ..........................158 Inspection ..............................158 Assembly ..............................159 6.1.3. Air filter housing on frame ..........................159 6.1.4. Air filter Element into housing .......................... 160...
  • Page 157 Allen Key 4mm • Remove Cover (a). Fig. 6.1.1 Allen Key 4mm Pull out the canister hoses (a) and (b) from the • calmps. Fig. 6.1.4 • Remove air filter element from housing. Fig. 6.1.2 Fig. 6.1.5 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 158 6.1.2. Air filter Housing from frame Remove cross bar (a) from bottom of the frame. • • Remove the canister. (Refer caniser dismantling) • Disconnect battery terminals and remove from air filter housing. (refer electricals section for disman- tling battery) Remove 2 flanged hex bolts (a) (M6) and remove •...
  • Page 159 • Replace air filter element every 20,000 Kms 12,000 Miles) or earlier if motorcycle is used in dusty/off road conditions. Fig. 6.1.13 10 mm Socket with Ratchet 10-12Nm(1.0-1.2 KgM.) Torque SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 160 • Align mudguard and install using 2 flanged hex bolt • Locate cover on the air filter housing by aligning (a) (M8) at bottom. three mounting holes. Fig. 6.1.14 Fig. 6.1.16 • Install air filter cover with 3 screws (a). 10 mm Socket with Ratchet Torque 10-12Nm(1.0-1.2 KgM.)
  • Page 161 • Locate the side panel (a) on the air filter assembly. Fig. 6.1.19 • Install side panel using 3 hex socket button head screws. Fig. 6.1.20 Allen Key 4mm SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 162: Control Cables

    Control Cables CONTROL CABLES...
  • Page 163 6.2 Control Cables ...........................164 Dismantling ..............................164 6.2.1. Clutch Cable ..............................164 6.2.2. Throttle Cable ..............................165 Inspection ..............................167 Assembly ..............................168 6.2.3. Throttle Cable ..............................168 6.2.4. Throttle Cables Free Play Adjustment .......................170 6.2.5. Clutch Cable ..............................170 Troubleshooting ............................173 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 164: Control Cables

    6.2 Control Cables • Gently push inner cable (a) into clevis (b) in clutch shaft (c) and remove cable through the slot in the clevis. Dismantling 6.2.1. Clutch Cable Cover RH End CAUTION Ensure the motorcycle is upright on a firm and flat surface.

  • Page 165: Throttle Cable

    Rotate and align adjuster with slot in • clutch bracket and release inner cable (b) from throttle cable bracket (b) to increase inner cable (c) free play. lever eyelet. Fig. 6.2.8 Fig. 6.2.10 10 mm Double end spanner SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 166 Loosen and remove 2 Nos. Phillips head screws (a) • Push cable adjusters fully into the bracket and • loosen the 2 inner hex nuts (M6) on the throttle from the bottom of the throttle rotor housing and cable adjusters. separate the halves.

  • Page 167: Inspection

    Inspect throttle rotor for any damages/wear out. • Inspect cable seating eyelets in the throttle rotor for any damages, fraying etc. • Inspect the throttle rotor movement slots in the top and bottom housing for any damages/wear out. Fig. 6.2.18 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 168: Assembly

    Assembly • Ensure the adjusters on cable is set at their center for finer adjustments later. Insert throttle cable (a) into the hole of the throt- • 6.2.3. Throttle Cable tle rotor housing and locate inner cable in the eyelet on the throttle rotor. Route the cable (a) between the top yoke and •...
  • Page 169 Position inner cable to the slot of the rotor on Fig. 6.2.25 throttle body, insert inner cable into the eyelet and route the cable in the groove in the rotor of the throttle body. Fig. 6.2.28 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 170: Throttle Cables Free Play Adjustment

    • Ensure inner cables is seated properly in the eyelets • Tighten inner lock nuts on the adjusters till they at throttle body end and handlebar end. Gently are firmly locked on the inside of the bracket. rotate throttle rotor at handlebar and ensure they NOTE are operating properly.
  • Page 171 Assemble protective rubber boot (a) on clutch • cable inner (b). 12 mm Double end spanner • Hold handlebar straight and check gap of 3-6 mm between adjuster and check nut. Fig. 6.2.35 Fig. 6.2.38 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 172 • Achieve 10-16 mm of clutch play in handle bar • Toque check nuts to recomemded value. straight position Fig. 6.2.42 Fig. 6.2.39 12 mm Open End Spanner • If free play found to be out of range, adjust clutch cable at engine end.

  • Page 173: Troubleshooting

    RH/ Check and replace clutch hard in cover RH uneven wear-out of clutch shaft/cover RH shaft/cover RH Clutch plates burnt and Clutch plates burnt/hard/ Check and replace clutch hard clutch housing damaged plates/clutch assembly SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 174 Recommended Symptom Possible Cause Diagnosis How to Fix Specification Throttle cables are Throttle cables stuck/ Check cable routing and stuck between frame jammed between frame proper strapping to frame and fuel tank and fuel tank Throttle rotor Throttle rotor area in the Check and lubricate throttle movement in housing housing is dry/heavy dirt...

  • Page 175: Handlebar

    Handlebar HANDLEBAR SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 176 Handlebar CONTENTS PAGE 6.3 Handlebar ............................177 Dismantling .............................. 177 6.3.1. Aggregates of Handlebar ...........................177 6.3.2. Mirrors ................................177 6.3.3. Bar End ................................177 6.3.4. LH Switch Assembly ............................177 6.3.5. Clutch lever bracket ............................177 6.3.6. RH switch cube ..............................178 6.3.7. Master cylinder ..............................179 6.3.8.
  • Page 177 Wrap a cloth soaked in hot water on LH grip (a) and • allow the grip to become free on the handle bar. Ro- tate the grip and pull it outwards to remove from handlebar. Fig. 6.1.2 14 mm open end spanner Fig. 6.1.5 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 178 Loosen and remove 1 Nos hex socket bolts (M6) (a) • • Remove 2 nos. Philips head screws from the RH to remove the clutch lever bracket along with the switch cube from handle bar. lever. Fig. 6.1.9 Fig. 6.1.6 Philips screw driver 10 mm Allen socket with Ratchet Gently separate the top (a) and bottom (b) of the...

  • Page 179: Master Cylinder

    Fig. 6.1.16 Fig. 6.1.13 10 mm Socket with Ratchet 6.3.8. Handlebar Loosen and remove 4 nos allen bolts (M8) (a) from • top clamps. Fig. 6.1.14 6 mm allen key SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 180 6.3.10. Clutch lever bracket Assembly 6.3.9. Handlebar • Position the clutch lever bracket past the hole pres- ent in the handlebar. Locate the handlebar (a) on the handlebar raiser • Fig. 6.1.20 Fig. 6.1.17 • Locate and tighten 1 no hex soc bolt (M6) (a) •...
  • Page 181 Philips screw driver • Connect the clutch switch wires. Fig. 6.1.27 Insert throttle cable (a) into the bottom housing (b) • of the switch cube and connect it to the throttle grip. Fig. 6.1.25 Fig. 6.1.28 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 182 Assemble switch mounting top (a) and bottom (b) Insert Philips head screw (a) and tighten sufficiently. • • are on handlebar. Fig. 6.1.32 Fig. 6.1.29 6.3.13. Master Cylinder • Insert 2 Nos Philips head screws (a) and (b) on the •...
  • Page 183 Rotate anti clockwise till the Fig. 6.1.36 mirror comes to a stop. • Locate the thread portion of rear view mirror stem on master cylinder bracket. Rotate clockwise till the mirror comes to a stop. Fig. 6.1.40 Fig. 6.1.37 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 184 • Rotate mirror clockwise for adjusting the view and tighten locknut against bracket. Fig. 6.1.41 14 mm open end spanner...

  • Page 185: Exhaust Pipe, Silencer

    Exhaust Pipe, Silencer and Catalytic Converter EXHAUST PIPE, SILENCER AND CATALYTIC CONVERTER SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 186 Exhaust Pipe, Silencer and Catalytic Converter CONTENTS PAGE 6.4 Exhaust Pipe, silencer........................187 Dismantling ..............................187 6.4.1. Silencer ................................187 6.4.2. Exhaust Header Pipe ............................188 6.4.3. O2 Sensor ................................. 188 Assembly ..............................188 6.4.4. O2 Sensor ................................. 188 6.4.5. Exhaust Header Pipe ............................189 6.4.6.

  • Page 187: Exhaust Pipe, Silencer

    Fig. 6.4.4 Fig. 6.4.1 • Remove the heder pipe mounting nut (a). 10 mm socket with ratchet • Remove silencer guard (a) along with bolts (b). Fig. 6.4.5 12 mm socket with ratchet Fig. 6.4.2 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 188: Exhaust Header Pipe

    Remove silencer mounting bolt (a) and from frame. • • Remove the exhaust header pipe along with 2 nos mounting fins. Fig. 6.4.6 Fig. 6.4.9 6.4.3. O2 Sensor 12 mm socket with ratchet • Refer headlamp dismantling section to remove O2 •...

  • Page 189: Assembly

    (b) is properly located on the studs (c). Fig. 6.4.14 • Locate the mounting hole in the frame and insert (M8) bolt and tighten it. Fig. 6.4.12 Fig. 6.4.15 12 mm socket with ratchet Torque 21-29 N-m/2.1-29 kgf-m SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 190 Tighten the mounting clamp (a) at the header pipe • Locate the silencer guard front plate and fix it on the • silencer with 2 nos (M6) hex socket bolts. end. Fig. 6.4.18 Fig. 6.4.16 12 mm socket with ratchet 10 mm socket with ratchet Torque 20-25 N-m/2.0-2.5 kgf-m...

  • Page 191: Footrests, Stands And Saree Guard Footrest

    Footrests, Stands and Saree Guard Footrest Dismantling FOOTRESTS, STANDS AND SAREE GUARD FOOTREST DISMANTLING SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 192 Footrests, Stands and Saree Guard Footrest Dismantling CONTENTS PAGE 6.5 Footrests, Stands and Saree Guard Footrest ..................193 Dismantling ..............................193 6.5.1. Rider LH and RH ..............................193 6.5.2. Pillion LH and RH ...............................193 6.5.3. Side Stand ................................. 194 6.5.4. Saree guard (For Indian market only) ........................195 Assembly ..............................195 6.5.5.

  • Page 193: Footrests, Stands And Saree Guard Footrest

    Push the pin (a) on the upward direction. Fig. 6.4.5 • Remove footrest (b) from mounting bracket careful- ly along with ball and spring (a). Fig. 6.4.2 Remove the footrest along (b) with ball and spring • (a). Fig. 6.4.6 Fig. 6.4.3 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 194: Side Stand

    Side Stand Dismantling Remove the hex nut (a) from the back side of the • stand. 6.5.3. Side Stand • Ensure the vehicle is on the main stand and is placed in a firm and flat surface. • Loosen and remove 2 Nos. M6 bolt (a) from the side stand switch.

  • Page 195: Saree Guard (For Indian Market Only)

    12 mm socket with ratchet Insert the pin (a) along with washer. • Remove the saree guard (a). • Fig. 6.4.16 Fig. 6.4.14 Install the cotter pin (a) at the bottom of the pin. • Fig. 6.4.17 Nose Plier SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 196: Pillion Lh And Rh

    Side Stand Assembly 6.5.6. Pillion LH and RH 6.5.7. Side Stand Install spring (a) in the grove provided (b). • Apply grease on the inner surface of the stand (a). • Fig. 6.4.18 Fig. 6.4.21 Install pin (a) along with washer. •...

  • Page 197: Saree Guard (For Indian Market Only)

    LH side of the frame. Fig. 6.4.25 Fig. 6.4.28 Screw Driver 12 mm socket with ratchet Install side stand swith using 2 Nos. hex bolts (a) in • Torque 10-12 N∙m/1.0-1.2 kgf-m the side stand. Fig. 6.4.26 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 198: Mudguards/Number Plates/Grab Handle

    Mudguards/Number Plates/Grab Handle MUDGUARDS/NUMBER PLATES/GRAB HANDLE...
  • Page 199 6.6.6. Rear Number Plate Lamp..........................203 6.6.7. Rear Fender and Mudguard ..........................203 6.6.8. Rear Number Plate (For Indian Market) ......................204 6.6.9. Front Mudguard ............................... 204 6.6.10. Front Number Plate (For Indian Market) ......................204 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 200: Mudguards/Number Plates/Grab Handle

    6.6 Mudguards/Number Plates/Grab Mudguard Removal Handle Loosen and remove 4 Nos. Hex flange bolts (M6) • (a) from fork brace. Dismantling 6.6.1. Front Number Plate (For Indian Market) • As per Government norms high security number plates will be provided which are riveted with the vehicle and cannot be removed.

  • Page 201: Rear Number Plate (For Indian Market)

    Loosen and remove 1 No. Allen bolts (a) from • both LH side. Fig. 6.6.9 • Seperate the fender from mudguard. • Disconnect the electrical couplers. • Remove the mudguard from the frame. Fig. 6.6.7 4 mm Allen with Ratchet Fig. 6.6.10 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 202: Rear Number Plate Lamp

    Inspection 6.6.5. Rear Number Plate Lamp Mudguard/Reflector/Grab handle • Loosen and remove 2 Nos. allen bolts (a) along with washer from rear fender bottom (b). • Clean Mudguard. Inspect for any scratches, cracks, damages on mudguard and replace if required. •...

  • Page 203: Assembly

    Install 2 Nos. Hex bolts (a) on the bottom of the • mudguard. Fig. 6.6.14 • Install the 2 Nos. Allen bolts (a) and 1 No. Hex bolt (b) (M5) along with washer on the mudguard bottom. Fig. 6.6.18 Fig. 6.6.15 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 204: Rear Number Plate (For Indian Market)

    6.6.8. Rear Number Plate (For Indian Market) Beak Removal • Align the beak (a) between the fork. • As per Government norms high security number plates will be provided which are riveted with the vehicle and cannot be removed. 6.6.9. Front Mudguard Mudguard Removal •...

  • Page 205: Side Panels And Rider Seat

    Side Panels and Rider Seat SIDE PANELS AND RIDER SEAT...
  • Page 206 Side Panels and Rider Seat CONTENTS PAGE 6.7 Side Panels and Rider Seat .......................207 Dismantling ..............................207 6.7.1. Side Panel RH ..............................207 6.7.2. Side Panel LH ..............................207 6.7.3. Pillion and Rider Seat from Frame ........................208 6.7.4. Grab Rail from Frame ............................208 Assembly ..............................

  • Page 207: Side Panels And Rider Seat

    Gently pull the LH cover (a) and remove. Fig. 6.7.1 5 mm Allen Key • Gently pull the LH cover (a) and remove. Fig. 6.7.1 Fig. 6.7.1 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD SERVICE MANUAL SERVICE MANUAL ROYAL ENFIELD ROYAL ENFIELD...

  • Page 208: Pillion And Rider Seat From Frame

    6.7.3. Pillion and Rider Seat from Frame 6.7.4 Grab Rail from Frame Remove the 1 No. allen bolt (a) on both RH and LH • • Insert ignition key and turn clockwise to unlock. side from the grab rail. Fig. 6.7.2 Fig.

  • Page 209: Assembly

    Install 1 No. allen bolt (a) on both LH and RH side. • Fig. 6.7.11 Fig. 6.7.9 6.7.7. Side Panel LH 6 mm Allen Socket with Ratchet • Align LH panel to fit into frame (a) and lock it. Torque Fig. 6.7.12 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 210: Side Panel Rh

    • Install 3 Nos. Hex socket button head screws (a) (except left bottom one). Fig. 6.7.13 5 mm Allen Key 6.7.8. Side Panel RH • Locate side panel RH into frame and lock in its position. Fig. 6.7.14 Install 3 Nos. Hex socket button head screws (a) •...

  • Page 211: Wheels

    Wheels WHEELS...
  • Page 212 6.8.9. Rear Wheel into Swing Arm ..........................228 6.8.10. Drive Chain Free Play Adjustment ........................229 6.8.11. Tyre Assembly on Wheel Rim ..........................231 6.8.12. Front Wheel and Front Brake Disc ........................231 6.8.13. Front Wheel into Front Fork Assembly ......................232 Troubleshooting ............................234 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 213: Wheels

    6.8 Wheels • Remove the Hex nut (a), washer (b) from the spindle RH (c). Dismantling 6.8.1. Front Wheel Assembly CAUTION Ensure the motorcycle is upright on a firm and flat surface. Locate a scissor jack (a) under the cradle frame (b) •...

  • Page 214: Front Wheel And Brake Disc

    Remove toner wheel front (a) from hub and store carefully. Remove spacer (a) from wheel hub (b) on LH. • CAUTION Avoid any bends or damages to the toner wheel as it will affect the functioning of ABS. Fig. 6.8.8 Fig. 6.8.10 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 215 Remove front brake disc (a) from hub and store • • Insert a punch into hub from LH side and drive out carefully. bearing RH (a). CAUTION Ensure the brake disc does not get damaged as it will affect the brake efficiency. Fig.

  • Page 216: Rear Wheel From Swing Arm

    RH and hold other side LH with tommy bar (a). Fig. 6.8.18 6 mm Allen Key • Push rear wheel forward to increase chain slack on rear sprocket. Fig. 6.8.16 24 mm Ring spanner and Tommy bar Fig. 6.8.19 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 217 Remove chain adjuster assembly (a) from swing Slide out and remove brake caliper (a) with bracket. • • arm RH (b). Fig. 6.8.23 Fig. 6.8.20 CAUTION Remove spindle (a) from rear wheel RH along with • Support the caliper carefully and ensure it washer (b).

  • Page 218: Rear Wheel And Brake Disc

    Loosen and remove 6 Nos. Hex head button socket screws (M6) (a) to remove ABS toner. • Remove chain drive sprocket (a) from sprocket carrier (b). Fig. 6.8.31 Fig. 6.8.28 5 mm Allen socket with Ratchet SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 219 • Remove ABS toner wheel (a) from rear wheel RH. • Insert a punch (a) into hub (b) from LH side and drive out bearing RH (c). Fig. 6.8.32 Fig. 6.8.35 • Remove rear brake disc (a) from the rear wheel hub RH (b).

  • Page 220: Inspection

    Gently remove grease seal (a) from the sprocket • carrier (b). Fig. 6.8.41 • Inspect and replace spindle (a) if it has excess wear, rust or bends. Fig. 6.8.39 Connector Fig. 6.8.42 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 221 • Check tyres for any uneven wear out and the sipes • Check if wheel hub assembly is cracked or damaged on the center of the tyre is above the TWI index. and replace. • Check and replace wheel hub bearing seated portion if there is any scoring.
  • Page 222 Replace if it is out of specifications. Fig. 6.8.52 Service limit: 0.10 mm NOTE • Run-out of brake disc should be checked only when brake disc is assembled on wheel hub. Fig. 6.8.50 Feeler gauge Standard: 0.00mm Service limit: 0.10mm SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 223: Rear Wheel And Brake Disc

    6.8.6. Rear Wheel and Brake Disc • Check and replace spacer if it has excess wear-out. • Inspect tyre condition and wheel rim for any damages or bends and replace if doesn’t meet the specifications. Fig. 6.8.56 • Inspect ABS toner wheel (a) for any bends or damages.
  • Page 224 Run-out of brake disc should be checked only when brake disc is assembled on wheel hub. Feeler gauge Standard: 0.00 mm Service limit: 0.10 mm • Inspect wheel hub assembly for any cracks or damages. Replace if out of specifications. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 225: Assembly

    Assembly • Check rear wheel hub cushion rubbers for any wear-out or damages. 6.8.7. Tyre Assembly On Wheel Rim • Ensure the tyre is assembled on the wheel rim with the arrow on the tyre side wall is facing towards the front.
  • Page 226 Assemble rear brake disc (a) into rear wheel hub • 5 mm Allen socket with Ratchet Torque 21-29 N-m/2.1-2.9 kgf-m NOTE • Apply Loctite 243 on the threads of the bolt before installation. Fig. 6.8.68 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 227 • Clean cushion rubbers seating area and insert 4 • Locate and gently tap the spacer (a) into sprocket Nos. cushion rubbers (a) into rear wheel hub LH carrier (b). and gently tap with mallet . Fig. 6.8.74 Fig. 6.8.71 Mallet Mallet Assemble rear sprocket carrier (a) over cushion...

  • Page 228: Rear Wheel Into Swing Arm

    • Apply Loctite 243 on the threads of the bolt before installation. 6.8.9. Rear Wheel into Swing Arm Fig. 6.8.80 Gently locate rear wheel (a) into swing arm (b). • Slide the caliper assy (a) into the swingarm. • Fig. 6.8.78 Fig. 6.8.81 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 229: Drive Chain Free Play Adjustment

    Assemble chain adjuster assembly (a) into swing Assemble Hex nut (M16) (a) and tighten into • • arm LH (b). swing . Fig. 6.8.82 Fig. 6.8.85 Insert spindle (a) with tommy bar into rear wheel • 24 mm Socket with Ratchet hub LH along with washer (b).
  • Page 230 5 mm Allen Key and Tommy bar Torque 63-77 N-m/6.3-7.7 kgf-m • Ensure the lines are matched with the lines punched in swing arm on both LH & RH side for proper wheel alignment. Fig. 6.8.89 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 231: Tyre Assembly On Wheel Rim

    6.8.11. Tyre Assembly on Wheel Rim • Apply thread sealant on the 5 Nos Hex socket head bolts (M6) (a) and allow it to dry for a few minutes. • Ensure the tyre is assembled on the wheel rim with •...

  • Page 232: Front Wheel Into Front Fork Assembly

    Insert spindle (a) into front fork assembly RH and • wheel hub (b). 6.8.13. Front Wheel into Front Fork Assembly • Carefully align front wheel (a) into front fork assembly (b). Fig. 6.8.103 Fig. 6.8.100 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 233 • Insert Hex nut (M16) (a) along with washer (b) into spindle bolt on LH. • Hold spindle with Tommy bar from RH and gently tighten Hex nut (M16) (a). Fig. 6.8.104 24 mm Socket with Ratchet and Tommy bar Torque 63-77 N-m/6.3-7.7 kgf-m •...

  • Page 234: Troubleshooting

    Wheel rims are bent/ Remove tyre and Wheel rims have a have excessive run carry out proper defect. out. wheel truing. Wheel bearings Remove and Rims have excessive worn-out/excessive replace wheel side play. play. bearings. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 235: Recommended Specification

    Recommended Symptom Possible Cause Diagnosis How To Fix Specification 2. Wheel Rims Related Tyre seating on rims Tyre bead is uneven Remove tyre and is improper at the rim surface reset correctly Wheel rims are bent/ Remove tyre and Wheel rims are out have excessive run true the wheel rim Motorcycle Is...

  • Page 236: Suspension

    Suspension SUSPENSION...
  • Page 237 6.9.17. Steering Stem on Frame Head Tube ......................... 252 6.9.19. Front Fork Sub Assembly LH and RH ....................... 253 6.9.20. Front Fork LH and RH Assembly on Motorcycle..................... 256 6.9.21. Steering Stem Play Adjustment ........................258 Troubleshooting ............................. 260 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 238: Suspension

    6.9 Suspension Loosen fork cap bolts (a) just sufficiently on both • LH and RH fork assemblies. Dismantling 6.9.1. Front Fork LH and RH Removal from Motorcycle CAUTION Ensure the motorcycle is upright on a firm and flat surface. Fig. 6.9.2 Locate a scissor jack (a) under cradle frame (b) and •...

  • Page 239: Front Fork Sub Assembly Lh And Rh

    Fig. 6.9.5 CAUTION Support headlamp holder while removing fork assembly. Fig. 6.9.8 • Repeat above steps to remove the fork assembly RH (a). Gently pull out the spacer tube (a). • Fig. 6.9.9 Fig. 6.9.6 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 240 • Gently invert fork assembly (a) into a clean tray to • Hold fork (a) inverted and pump main tube into collect the fork oil coming out of main tube. fork end several times till oil in the fork end drains out completely.
  • Page 241 Remove wire clip (a) from bottom tube. • Fig. 6.9.19 Remove spacer (a) from main tube (b) from top. • Fig. 6.9.17 Chisel pointed Fig. 6.9.20 Remove aluminum split bush (a) from main tube • (b) bottom. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 242: Steering Stem Assembly From Frame Head Tube

    • Remove damper spring (a) from piston (b). Fig. 6.9.21 Fig. 6.9.24 • Remove tapper oil lock (a) from piston bottom (b) inside fork end. 6.9.3. Steering Stem Assembly from Frame Head Tube CAUTION Ensure the motorcycle is upright on a firm and flat surface.
  • Page 243 • Hold steering stem from bottom and remove cover • Loosen and remove top yoke nut (a) along with head stock (a). washer. Fig. 6.9.30 Fig. 6.9.27 27 mm Hex Socket with Ratchet SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 244: Shock Absorber

    • Hold steering stem from bottom and remove seal • Remove the stem (a) from the bottom yoke. head stock (a). Fig. 6.9.34 • Remove the bearing (a) from bottomof the stem. Fig. 6.9.31 • Gently remove the roller bearing (a) from the frame headstock.

  • Page 245: Swingarm

    Remove the top bolt (a) by holding the nut (b). • Gently pull and remove the bolt along with the nut. Fig. 6.9.40 screw driver Fig. 6.9.38 • Gently pull and remove the mono shock absorber (a) from the top. Fig. 6.9.39 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 246 • Hold spindle bolt (M16) in frame LH side and loosen • Rotate swingarm slightly and release drive chain (a) and remove hex nut (M16) (a) with washer (b) from from swingarm (b). RH side. Fig. 6.9.44 Fig. 6.9.41 • Remove end cup (a) from swingarm LH and RH.

  • Page 247: Inspection

    303 ±3.0 mm. reduction in free length and replace. Service limit • Inspect damper spring for any coil breakage/ Main spring free length 303 ±3.0 mm. reduction in free length and replace. • Fig. 6.9.49 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 248: Front Fork Air Gap Setting

    6.9.8. Front Fork Air Gap Setting • Measure the height of the oil (Air Gap) using a fork Vernier calliper. Fig. 6.9.51 Fig. 6.9.52 • Remove fork leg (LH & RH) assembly from the • Make verrnier “zero”, unlock the screw and move vehicle.

  • Page 249: Steering Stem

    • Inspect if swingarm end cup is worn-out or damaged. Fig. 6.9.56 • Inspect spindle for any wear-out or bend. Fig. 6.9.58 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 250: Top Yoke

    6.9.12. Top Yoke • Assemble end cup (a) into swingarm LH and RH. • Inspect top yoke for any cracks or damages in seating area. Replace if damaged. Replace • Replace oil seals, dust seals, washers, chain guides whenever removed from the front fork/swingarm. •...

  • Page 251: Shock Absorber

    • spindle. • Hold spindle from LH side suitably and tighten nut. Fig. 6.9.68 6 mm Allen socket and Ratchet Torque 25-35 N∙m/2.5-3.5 kgf-m Fig. 6.9.66 24 mm Socket with Ratchet Torque 66-74 N-m/6.6-7.4 kgf-m SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 252: Steering Stem Assembly Into Frame Head Tube

    Align bottom mounting hole of shock absorber (a) to swingarm bracket LH (b) and tighten with button head bolt (M8) (c). • Apply Royal Enfield recommended grease on the bearing cups inner surface. • Insert steering stem (a) into frame head tube from the bottom.

  • Page 253: Front Fork Sub Assembly Lh And Rh

    Check axial play of steering stem at center, extreme left and right positions. Part No: ST26461-2 • Check lateral play of steering stem at center, extreme left and right positions. Part Name: Fork damper tube holder SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 254 • Assemble slide bush (a) into main tube (b) from • Assemble bottom tube top (a) over main tube (b). fork top. Ensure it is seated on taper oil lock. Fig. 6.9.79 Fig. 6.9.82 Assemble fork main tube (a) on piston (b) with the •...
  • Page 255 Remove special tool from fork inner tube. Quantity: 453 ml/fork Assemble seal clip (a) over oil seal and ensure it is • Oil grade: 2w25 seated properly on the grove in bottom tube. Fig. 6.9.87 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 256: Front Fork Lh And Rh Assembly On Motorcycle

    • Replace with new oil whenever the oil drained from • Locate O-ring (a) on cap nut (b), position it over fork. washer correctly, gently push down cap nut till threads engage in main tube (c) and tighten fully. • Check oil quantity and fill with recommended fork oil with specified grade.
  • Page 257 (section 6.8.13). • Support motorcycle underneath cradle frame such that front wheel is off the ground by minimum 6 inches/15 cm. Fig. 6.9.96 6 mm Allen socket with Ratchet Torque 21-29N-m/2.1-2.9 kgf-m Fig. 6.9.97 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 258: Steering Stem Play Adjustment

    • Turn handlebar to extreme left and right position • Loosen 4 Nos. Pinch bolts (M6) (a) on top yoke LH and check for free and smooth rotation. and RH side (fork main tube area). • Hold the front wheel straight ahead, check for any play.
  • Page 259 Tighten 4 Nos. pinch bolts to specified torque 20 N-m/2.0 kgf-m. Fig. 6.9.102 6 mm Allen socket with Ratchet • TIghten top nut (a) on top yoke. Fig. 6.9.103 27 mm Allen socket with Ratchet Torque 32-38 N-m/3.2-3.8 kgf-m SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 260: Troubleshooting

    Recommended Symptom Possible Cause Diagnosis How to Fix Specification 1. Front Fork/Steering Stem Related Royal Enfield front Dismantle fork legs, fork oil 2W 25. Excessive oil is filled in fork Excessive oil is filled. drain oil and fill correct legs.
  • Page 261 Steering stem bearings rollers have sticky Dismantle steering stem and movement/is rusted/bearing replace bearings. is damaged/uneven seating. Steering stem is bent. Steering stem is bent. Replace steering stem. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 262 Wheels alignment is Front and rear wheels are Align front and rear wheels not proper. not aligned. correctly. Royal Enfield front Dismantle fork legs, drain Oil quantity is Oil quantity is mismatched fork oil 2W 25. out the oil and fill with...
  • Page 263 Rear swingarm axle nut is mounting to frame is alignment to frame and swingarm loose. loose. tighten swingarm mountings. excessive Rear swingarm Rear swingarm bushes are Replace swingarm bushes side play bushes are defective rusted/jammed. and axle. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 264 Tyres found to have bulges/ Front tyre: Internal defect/poor Replace with Royal Enfield cracks in side wall. Threads quality tyre. recommended tyres. Tyre are separated from the tyre. Rear tyre:...

  • Page 265: Subframe

    Subframe SUBFRAME...
  • Page 266 Subframe CONTENTS PAGE 6.10 Subframe ............................267 Dismantling ..............................267 6.10.1. RH Subframe ..............................267 6.10.2. LH Subframe ..............................268 6.10.3. Center Subframe ............................. 269 Assembly ..............................270 6.10.4. Center Subframe ............................. 270 6.10.5. LH Subframe ..............................270 6.10.6. RH Subframe ..............................271...
  • Page 267 Remove the 1 No. Hex mounting bolt (a) from the • frame. Screw Driver (-) Loosen and remove 1 No. allen bolt (a) from RH • subframe near head lamp. Fig. 6.10.5 5mm Socket and Ratchet Fig. 6.10.2 4 mm Allen socket with Ratchet SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 268 • Gently pull and remove the RH subframe (a). • Loosen and remove 1 No. allen bolt (a) from LH subframe near fuel tank. Fig. 6.10.6 Fig. 6.10.9 6.10.2. LH Subframe 4 mm Allen socket with Ratchet Remove two cap (a) from the LH subframe. •...
  • Page 269 • the instrument cluster cover. Gently pull and remove the center subframe (a). • Fig. 6.10.13 Fig. 6.10.16 Phillip Screw Driver Gently remove the instruent cluster cover (a) from • the center subframe. Fig. 6.10.14 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 270 Assembly • Install 2 Nos. Phillip screws (a) on the instrument cluster cover. 6.10.4. Center Subframe Align the center subframe (a) to the mounting • holes. Fig. 6.10.20 6.10.5. LH Subframe Align the LH subframe (a) to the mounting points. •...
  • Page 271 Install 1 No. Hex mounting bolt (a) on the frame. 4 mm Allen socket with Ratchet Install 1 No. allen bolt (a) on LH subframe near head • lamp. Fig. 6.10.28 Fig. 6.10.25 4 mm Allen socket with Ratchet SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 272 Locate the RH trafficator cover (a) and Lock on LH Install two cap (a) to the RH subframe. • • subframe. Fig. 6.10.32 Fig. 6.10.29 Install the 1 No. Allen bolt (a) on RH subframe near • fuel tank. Fig. 6.10.30 4 mm Allen socket with Ratchet Install 1 No.

  • Page 273: Vehicle Troubleshooting

    Vehicle Troubleshooting VEHICLE TROUBLESHOOTING...
  • Page 274 Vehicle Troubleshooting CONTENTS PAGE 6.11. Troubleshooting ..........................275 6.11.1. Air Filter ................................275 6.11.2. Control Cables ..............................276 6.11.3. Handlebar ................................ 278 6.11.4. Exhaust Pipes and Silencers ..........................279 6.11.5. Wheels ................................280 6.11.6. Suspension ............................... 282...

  • Page 275: Troubleshooting

    Acv not sealing properly damaged/mounting gasket/sensor screws loose Engine oil Clean breather chamber accumulation Check and maintain Excessive oil in sump and hose leading to air inside air filter correct engine oil level filter box assembly box assembly SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 276: Control Cables

    6.11.2. Control Cables Recommended Symptom Possible Cause Diagnosis How to Fix Specification Clutch lever, bracket and pivot screw at handlebar Clean and lubricate clutch Clutch lever operation end is dry without lever, bracket and pivot at is sticky lubrication/excessive dirt screw at handlebar end accumulation Clutch lever excessive...
  • Page 277 Throttle cables inner strands broken Inner cables movement Check and replace throttle Teflon coating in between sticky in outer cable cables inner/outer throttle cables damaged SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 278: Handlebar

    6.11.3. Handlebar Recommended Symptom Possible Cause Diagnosis How to Fix Specification Solo: Front tyre: 32 psi/2.2 kg/cm Tyre pressures Rear tyre: 32 psi/2.2 kg/cm Improper front and Ensure correct tyre are more than rear tyre pressures. pressures. With Pillion: recommended. Front tyre: 32 psi/2.2 kg/cm Rear Tyre: 36 psi/2.54 kg/cm Balancer mountings...

  • Page 279: Exhaust Pipes And Silencers

    Gaskets are burnt/ Gaskets are Replace exhaust Exhaust leak from missing. burnt-out due to pipe/silencer cylinder head joint/ loose clamping gasket. silencer joint. of exhaust pipe/ silencer. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 280: Wheels

    Tyres found to have bulges/cracks in side Replace with Front tyre: 100/90-19, Internal defect/poor wall. Royal Enfield quality tyre. Threads are recommended Rear tyre: 140/70-17, separated from the tyres. tyre. Tyre/S Wearing Tyre seating on rims...
  • Page 281 Replace with royal Wheel rims have a cracked/damaged enfield genuine crack/heavy damage due to impact wheel rims 3. Others Wheels have Motorcycle Is Wheel bearings are Remove bearing excessive axial/side unstable/Wobbling worn-out and replace play SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 282: Suspension

    Symptom Possible Cause Diagnosis How to Fix Specification 1. Front Fork/Steering Stem Related Royal Enfield front Dismantle fork legs, drain oil fork oil 2W 25. Excessive oil is filled in fork Excessive oil is filled. and fill correct recommended legs.
  • Page 283 Steering stem bearings rollers have sticky Dismantle steering stem and movement/is rusted/bearing replace bearings. is damaged/uneven seating. Steering stem is bent. Steering stem is bent. Replace steering stem. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 284 Wheels alignment is Front and rear wheels are not Align front and rear wheels not proper. aligned. correctly. Royal Enfield front Oil quantity is Oil quantity is mismatched Dismantle fork legs, drain out fork oil 2W 25. mismatching in LH...
  • Page 285 Rear swingarm axle nut is mounting to frame is alignment to frame and swingarm loose. loose. tighten swingarm mountings. excessive Rear swingarm bushes Rear swingarm bushes are Replace swingarm bushes side play are defective rusted/jammed. and axle. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 286 Front tyre: Tyres found to have bulges/ 100/90-19 Internal defect/poor Replace with Royal Enfield cracks in side wall. Threads quality tyre. recommended tyres. Tyre/s are separated from the tyre. Rear tyre: wearing out...

  • Page 287: Fuel System

    Fuel System FUEL SYSTEM...
  • Page 288 Fuel System CONTENTS PAGE 7.1. Fuel System Components ......................... 289 Dismantling ............................. 289 7.1.1. Fuel Tank ................................289 7.1.2. Fuel Pump Connector and Fuel Level Sensor ..................... 289 7.1.3. Fuel Hose (Fuel Pump to Injector) ........................289 7.1.4. EVAP Connections to Fuel Tank ..........................290 7.1.5.

  • Page 289: Fuel System Components

    • Remove seat assembly Loosen and remove 2 Nos. Hex head bolts (M6) • (a) from rear end of fuel tank on frame (b). Fig. 7.1.3 Fig. 7.1.1 10 mm Socket with Ratchet SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 290: Evap Connections To Fuel Tank

    7.1.4. EVAP Connections to Fuel Tank 7.1.7. Fuel Pump Disconnect EVAP connection hose (a) from fuel • • Loosen and remove 4 Nos. Hex socket head bolts tank. (M6) (a) holding fuel pump (b) to tank (c). Fig. 7.1.4 Fig. 7.1.7 7.1.5.

  • Page 291: Fuel Level Sensor

    Fig. 7.1.11 Remove float assembly (a) from fuel pump(b). • • Remove the fuel level sensor (a) Fig. 7.1.15 Fig. 7.1.12 CAUTION Make sure the dust in the stainer does not enter the fuel pump. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 292: Inspection

    Inspection 7.1.11. Fuel Filter • Replace fuel filter for every 30,000 Kms. 7.1.9. Fuel Float • Check resistance at float unit pins at lower position. • Check the resistance at float unit pins at higher position. • Inspect float assembly for fuel ingress. Replace if fuel float assembly is punctured.

  • Page 293: Assembly

    7.1.13. Fuel Level Sensor Align the slot (a) with frame key provided in the • • Assemble fuel pump (a) into tank with outlet pipes cover (b). facing towards rear of the tank. Fig. 7.1.21 Fig. 7.1.24 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 294: Fuel Tank

    7.1.16. Drain Hose • Locate and tighten 4 Nos. Hex socket head bolts (M5) (a) to assemble fuel pump on fuel tank. • Gently lift fuel tank and connect drain hose connection (a) to fuel tank (b). Fig. 7.1.25 Fig. 7.1.27 10 mm Socket with Ratchet 7.1.17.

  • Page 295: Fuel Pump Connector

    Torque 10-12 N-m/1.0-1.2 kgf-m NOTE • Switch ON and OFF the ignition twice and visually check for any fuel leakage or wet on the tank and components, If anything found, inspect and rectify the issue. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 296: Evaporative (Evap) Emission Control System

    EVAP EVAPORATIVE (EVAP) EMISSION CONTROL SYSTEM...
  • Page 297 8.1.5. Hoses ................................. 301 8.1.6. Hose Connectors ............................... 302 8.1.7. EVAP System Leak Test Procedure ........................302 8.1.8. EVAP Service hose ............................. 302 Assembly ..............................302 8.1.9. EVAP Purge Valve .............................. 302 8.1.10. Canister ................................303 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 298: Evaporative (Evap) Emission Control System

    8. Evaporative (EVAP) Emission Control System 8.1. Evaporative (EVAP) Emission WARNING Control System Before dismantling any part of the EVAP system, ensure the engine and exhaust systems are at ambient temperature. Evaporative fuel Dismantling vapors are highly inflammable and explosive, which can result in serious injury and or fatal 8.1.1.
  • Page 299 Disconnect inlet (a) hose from canister. • Fig. 8.1.7 • Loosen 2 hex. bolts (a) mounting the canister from the skid plate assy. Fig. 8.1.4 Disconnect outlet (a) hose from canister. • Fig. 8.1.8 Fig. 8.1.5 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 300: Evap Purge Valve

    • Gently remove the canister (a) from the skid plate. • Remove the canister (a) by removing the 1 No. Hex bolt. Fig. 8.1.9 Fig. 8.1.12 For EURO V Models 8.1.2. EVAP Purge Valve • Remove the following parts • Remove the following parts: •...

  • Page 301: Inspection

    If suspected replace canister (weight 385± 5gms). • Blow very low pressure air (5 psi) through the inlet port and check for the free flow of outlet side. If restricted or no air, replace the canister. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 302: Hose Connectors

    8.1.6. Hose Connectors 8.1.8. EVAP Service hose • Check for any damages or cracks and replace if • Gently Pull the Plug from the service hose. defective. • Allow to drain the accumulated fuel (if any) during splashing. Do’s & Don’ts •...

  • Page 303: Canister

    Connect the outlet hose (a) to the canister. • Fig. 8.1.23 Locate 2 Nos. bolt (a) on the canister mounting. • Fig. 8.1.27 Fig. 8.1.24 10 mm Socket with Ratchet Torque 10 N∙m/1.0 kgf m SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 304 For EURO V Model • Connect the inlet hose (a) to the canister. • Install the canister on the bracket using the 1 No. Hex bolt (a). Fig. 8.1.28 Locate and lock the skid plate assy. (a) to the fame. •...

  • Page 305: Brakes And Abs

    Brakes and ABS BRAKES AND ABS...
  • Page 306 Brakes and ABS CONTENTS PAGE 9. Brakes and ABS ............................ 308 Dismantling ............................. 308 9.1. Brake - Front ............................. 308 9.1.1. Master Cylinder Assembly - Front ........................308 9.1.2. Brake Caliper - Front ............................310 9.1.3. Brake Disc - Front ..............................311 9.2.
  • Page 307 9.8.1. Front Brake Bleeding ............................353 9.8.2. Front Brake Fluid Leakage ..........................356 9.8.3. Front Brake Fluid Top up ........................... 357 9.8.4. Rear Brake Bleeding ............................358 9.8.5. Rear Brake Fluid Leakage ..........................360 9.8.6. Rear Brake Fluid Top Up .............................361 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 308: Brake - Front

    9. Brakes and ABS 9.1.1. Master Cylinder Assembly - Front • Remove the following part: Dismantling • Rear view mirror from handlebar RH (section 6.3.1). 9.1. Brake - Front CAUTION CAUTION Ensure master cylinder assembly is supported Ensure the motorcycle is upright on a firm and carefully while disconnecting.
  • Page 309 Fig. 9.1.7 Fig. 9.1.5 Circlip plier Screw driver and 10 mm Double end spanner • Remove the conical spring (piston compression spring) (a) from piston (b) . Fig. 9.1.8 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 310: Brake Caliper - Front

    9.1.2. Brake Caliper - Front • Suitably support caliper and correctly tap brake pad pin (a) from inner side to outside. • Gently remove hose from caliper assembly (section 9.3.1). • Support the front brake caliper assembly suitably. • Loosen and remove upper and lower Hex flange head bolts (M10) to remove front brake caliper assembly (a) from LH fork.

  • Page 311: Brake Disc - Front

    Fig. 9.1.17 6 mm Allen socket with Ratchet Fig. 9.1.16 WARNING DO NOT place/store the wheel with disc facing downward. It will cause bends and damages and change warpage. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 312: Brake - Rear

    9.2. Brake - Rear • Remove toner wheel (a) and keep it aside safely. CAUTION CAUTION Avoid any bends or damages to the toner Ensure the motorcycle is upright on a firm and wheel as it will have serious effects on ABS flat surface.
  • Page 313 (a) to remove master cylinder from frame. Fig. 9.2.4 Loosen and remove 1 No. Allen bolts (a) to remove • oil reservoir (b) from frame. Fig. 9.2.7 10 mm Socket with Ratchet Fig. 9.2.5 4 mm Allen socket with Ratchet SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 314 Dismantling Rear Brake Master Cylinder CAUTION • Remove protective rubber boot from master Do not use any sharp tool to pull out the piston cylinder. from the master cylinder. Pull out gently with minimum force. Rear Brake Pedal • Loose and remove 1 No.Allen bolt (a) (M10) along with brake pedal (b) from motorcycle.

  • Page 315: Brake Caliper Assembly - Rear

    • from rear wheel hub. • Remove brake pad outer clip (a) from brake pad lock pin. Fig. 9.2.16 Slide out and remove brake caliper (a) with holder. • Fig. 9.2.14 Nose plier Fig. 9.2.17 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 316: Brake Disc - Rear

    Dismantling Rear Brake Caliper • Remove ABS toner wheel (a) from rear wheel hub • Position caliper body with pistons down and apply small squirts of air pressure to the fluid inlet hole to remove pistons. Fig. 9.2.20 • Remove rear disc plate (a) from rear wheel hub RH Fig.
  • Page 317 Place toner wheel front on a flat surface and check warpage. Replace if out of specifications. • Place brake disc rotor on a flat surface and inspect warpage. Replace if it is out of specifications. Front brake disc. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 318 • After assembly of brake disc (a) into front wheel, insert spindle into rim, fix on wheel balance frame (b) and rotate rim to check the disc run-out with dial gauge (c). Ensure run-out is within specified limits. Fig. 9.2.26 •...
  • Page 319 Inspect brake lever front (a) free play and brake pedal rear (b) free play. If free play is spongy, check brake pads for wear or tear and replace and follow brake bleeding procedure. Front Fig. 9.2.35 Fig. 9.2.32 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 320: Assembly

    Assembly • Assemble drive chain and rear wheel into swing arms (section 6.8.8). Brake - Rear 9.2.5. Brake Caliper Assembly - Rear 9.2.4. Brake Disc - Rear Assembling Rear Brake Caliper Assemble rear disc plate (a) into rear wheel hub RH •...
  • Page 321 Fig. 9.2.45 Fig. 9.2.42 Install the pad tension spring plate (a) in the Caliper • Rear Brake Pads in Wheel Caliper body. Gently locate brake pads (a) into brake caliper. • Fig. 9.2.43 Fig. 9.2.46 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 322: Master Cylinder Assembly - Rear

    • Locate brake pad lock pin (a) into brake caliper (b). • Locate and tighten Hex socket head screw (M5) (a) located below brake caliper on rear wheel RH. Fig. 9.2.47 Fig. 9.2.50 • Install brake pad inner clip (a) into brake pad lock pin.
  • Page 323 (b) and brake hose (c) in the master cylinder Assemble the protective rubber boot (a) on the • assembly. master cylinder. Fig. 9.2.55 Fig. 9.2.53 12 mm Allen socket with Ratchet Screw driver Torque 10-12 N-m/1 kgf-m SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 324: Rear Brake Pedal

    Rear Brake pedal • Locate and assemble rear brake fluid reservoir (b) with allen bolt (a) . Insert the rear end of the brake pedal (a) into the • master cylinder (b). Fig. 9.2.56 Fig. 9.2.58 5 mm Allen socket with Ratchet Locate and tighten brake pedal mounting bolt (a).

  • Page 325: Brake - Front

    Install piston seals in inner groove (a) and dust seals in outer groove (b) in the bore in caliper assembly. Fig. 9.2.60 Fig. 9.2.62 • Coat the caliper cylinders and pistons with fresh brake fluid. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 326 • Insert closed end of the pistons into caliper bores • Assemble bleeder valve (a) with dust cap on the and gently press it into caliper fully till open ends caliper body. of the piston (a) are flush with caliper bore outer edge.

  • Page 327: Master Cylinder - Front

    Fig. 9.2.70 • Locate the conical spring (a) on the piston (b). Pin punch and Mallet Assemble brake pad lock clip (a) into the brake pad • pin (b). Fig. 9.2.73 Fig. 9.2.71 Nose plier SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 328 • Smear piston seals and cylinder bore with fresh • Assemble the rubber Boot (a) in the master brake fluid and assemble piston (a) subassembly cylinder (b). into master cylinder (b) by gently pushing it into the bore. Fig. 9.2.76 Fig.
  • Page 329 (M5) (a) into clamp and fix the master cylinder Torque 10-12Nm/1.0-1.2 kg/f assembly. • Refill fluid, inspect and diagnose if there are any leakages (section 9.8). Fig. 9.2.79 8 mm Socket with Ratchet Torque 10-12Nm/1.0-1.2 kg/f SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 330: Anti-Lock Braking System (Abs)

    Working Principle The Royal Enfield Meteor 350 motorcycle is equipped with the state of the art Anti-Lock Braking System (ABS). The ABS is a safety system which constantly receives inputs about the speed of rotation of the front and rear wheels on a real time basis and modulates the braking force for each wheel when brakes are applied by the rider.

  • Page 331: Functions And Specifications Of The Abs Aggregates

    In the event the lamp does not switch OFF and remains continuously ON at higher speeds, it is recommended not to drive the motorcycle and get the brake system inspected and corrected through a nearest authorized Royal Enfield Dealer / Distributor.
  • Page 332 The ECU also records and stores data on the performance of the ABS on a real-time basis. This will help in diagnos- ing any braking related disorders, whenever the Royal Enfield NACS II diagnostic tool is connected to the socket in the wiring harness of the motorcycle.
  • Page 333 4. Toner Rings, Front and Rear The toner rings are assembled on the front and rear brake hubs inside the brake discs. The toner rings assists the wheel speed sensors to assess the speed of rotation of the wheels. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 334 5. Master Cylinders, Front and Rear The front brake master cylinder is assembled on the handlebar RH and activated by the front brake lever. The rear brake master cylinder is assembled on the frame RH side and activated by the brake pedal Whenever the front brake lever/rear brake pedal are activated, the piston inside the master cylinder applies force on the brake fluid to activate the brakes.
  • Page 335 Do’s and Don’ts for ABS • Use only approved Brake fluid recommended by Royal Enfield. ( DOT4 ) • Whenever the modulator is removed from the motorcycle, please ensure it is stored upright with the ports facing upwards. • Whenever the modulator is removed from the motorcycle for any reason, please ensure the front and rear brake system bleeding is carefully done and no air is trapped in the brake system.

  • Page 336: Dismantling

    Dismantling WARNING Ensure brake fluid does not get in contact 9.3.1. Modulator with eyes and skin. In-case of exposure wash affected area thoroughly with water. Seek medical attention immediately if any CAUTION irritation persists. Before dismantling the modulator, ensure Keep out of reach of children. ignition switch and engine stop switch are in Dispose drained brake fluid carefully and OFF position.

  • Page 337: Wheel Speed Sensor - Front

    Disconnect holding straps (a) of the brake hoses • • Release sensor coupler wire from the brake hose to the frame/fork end/swing arm. clip on fork end LH and from the bracket on the frame. Fig. 9.3.5 Fig. 9.3.8 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 338: Wheel Speed Sensor - Rear

    • Disconnect sensor coupler (a) from harness. • Release sensor coupler wire from the routing in mudguard (a) and brake hose clip on swing arm Fig. 9.3.9 • Loosen and remove hex socket head bolt (M6) (a) Fig. 9.3.11 holding sensor to fork end LH. •...

  • Page 339: Assembly

    • Gently locate sensor onto fork end LH. • Locate and tighten hex flange bolt (M6) (a) WARNING holding sensor (b) to fork end LH. DO NOT interchange ABS unit/ECU from one motorcycle to another. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 340: Modulator

    9.3.10. Modulator • Repeat the above process to other brake hoses. • RED - Modulator to rear brake caliper hose. • Brake hose color tags: • a) BLUE - Front Master Cylinder Assembly • b) GREEN - Front Brake Caliper •...
  • Page 341 Locate brake hose mounting clamp rear (a) into • Locate and tighten hex bolt (M6) (a) at the both • RH side. sides of bracket (b). Fig. 9.3.27 Fig. 9.3.24 10 mm Socket with Ratchet SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 342 • Locate brake hose mounting clamps front (a) • Locate and assemble banjo bolt (a) and connect hose (b) into front master cylinder on handlebar into frame. Fig. 9.3.28 Fig. 9.3.31 Locate and assemble banjo bolt (a) along with • washers (b) and connect hose (c) into rear 12 mm Double end spanner master cylinder assembly.
  • Page 343 • Wiring couplers to fuel pump and low fuel sensors are properly connected. • EVAP hose pipes are properly connected. WARNING Gasoline is extremely flammable and highly explosive. Improper handling can lead to fatal accident or serious injury. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 344: Dtc Codes

    9.3.11 ABS DTC Codes DTC (P code) Failure type Failure Description Query Remedy C1021 ABS ECU Internal fault ABS Microcontroller Failure Change ABS unit C1019 ABS ECU Relay Fault Failure in the ABS valve relay Change ABS unit (EV) ABS Apply Solenoid C1054 Circuit Open or high Failure in the front Inlet Valve Change ABS unit...
  • Page 345 High Speed CAN Check for CAN U2922 CAN BusOff failure BUSOFF Communications Bus Fault lines connection CAN controller failure. CAN_ U2921 CAN Generic monitoring Diagnosis is not possible with Change ABS unit GENERIC tester in this case. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 346: Bleeding The Hydraulic Brake System

    Bleeding the Hydraulic Brake System With DOL Tool (Front & Rear)

  • Page 347: Preparation ( Front Disc Brake)

    • Select – Royal D1. fluid during the bleeding process). Fig. 9.4.4 Fig. 9.4.1 • Select – Bosch ABS. • Connect the DOL tool switch “ON” the ignition. Fig. 9.4.5 Fig. 9.4.2 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 348 • Default Screen. • Default Screen. Fig. 9.4.6 Fig. 9.4.10 • Press C. • Default Screen. Fig. 9.4.7 Fig. 9.4.11 • Select – Spl Function. • Loosen the bleeder nipple. Loose Fig. 9.4.8 Fig. 9.4.12 • Select – Repair Air Bleed. •...

  • Page 349: Reassembly

    Refit the diaphragm with diaphragm plate of the master cylinder. • Operate the brake lever till the next window open in DOL. • Refit the master cylinder cap taking care that the vent slot in the cap is facing rider. Fig. 9.4.16 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 350: Preparation ( Rear Disc Brake)

    9.6. Preparation ( Rear Disc Brake) • Loosen the bleeder nipple. • Remove the reservoir cap of the rear disc brake. • Remove the Diaphragm Plate with diaphragm. • Remove the dust cap and place the suitable ring spanner on the bleeding nipple. •...

  • Page 351: Reassembly

    Remove the vinyl pipe and remove the ring spanner. • Refit the dust cap ( make sure that there is no leak from the bleeder nipple). • Refit the diaphragm with diaphragm plate of the reservoir. Fig. 9.6.8 • Refit the reservoir cap. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 352: Manual Method

    BRAKE BLEEDING (Front & Rear) Manual Method...

  • Page 353: Brake Bleeding

    Ensure fluid reservoirs caps are closed properly. Fig. 9.8.3 If moisture in the brake system may cause damage to brake parts and fluid, causing reduction in braking efficiency; which in turn may lead to fatal accidents. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 354 • Remove reservoir diaphragm (a) from front brake • Remove rubber cap (a) from bleeder valve (b) reservoir tank (b). from front caliper on front wheel RH. Fig. 9.8.4 Fig. 9.8.7 • Gently top up fresh brake fluid (a) into reservoir •...
  • Page 355 • Whenever bleeding the brake system, it is always recommended to bleed both the front and rear brakes. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 356: Front Brake Fluid Leakage

    • Remove bleeder hose (a) from bleeder valve (b). • Locate and tighten 2 Nos. screws (a) into front brake reservoir tank (b). Fig. 9.8.13 Fig. 9.8.16 • Close rubber cap (a) on bleeder valve (b). • Ensure cap is locked properly to avoid exposure Screw driver to dust or mud.

  • Page 357: Front Brake Fluid Top Up

    Loosen and remove 2 Nos. screws (a) from front • brake reservoir tank. Fig. 9.8.19 • Inspect leakage on brake disc from caliper piston. Fig. 9.8.22 Screw driver • Remove reservoir cap (a) from front brake reservoir tank (b). Fig. 9.8.20 Fig. 9.8.23 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 358: Rear Brake Bleeding

    9.8.4. Rear Brake Bleeding • Remove reservoir diaphragm (a) from front brake reservoir tank (b). CAUTION Ensure the motorcycle is upright on a firm and flat surface. Support motorcycle with suitable equipment below cradle frame. • Rear brake reservoir is located near rear wheel on cradle frame.
  • Page 359 (c) on front caliper to drain used oil. fluid as necessary. • Gently tap brake hose for proper bleeding performance. • Check brake fluid level after completion of brake bleeding. Fig. 9.8.30 11 mm Ring spanner SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 360: Rear Brake Fluid Leakage

    • Remove bleeder hose (a) from bleeder valve on • Inspect fluid level visible on rear reservoir tank. rear caliper. • Ensure brake fluid level in rear reservoir tank is always between ‘MIN’ and ‘Max’ marks. Fig. 9.8.33 Fig. 9.8.35 •...

  • Page 361: Rear Brake Fluid Top Up

    Locate the reservoir cap (a) on the tank and ensure it is seated properly. Fig. 9.8.39 9.8.6. Rear Brake Fluid Top Up Fig. 9.8.42 Open rear brake reservoir cap (a) from reservoir (b). • Fig. 9.8.40 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 362: Engine Management System (Ems)

    Engine Management System ENGINE MANAGEMENT SYSTEM (EMS)
  • Page 363 Engine Management System CONTENTS PAGE Engine Management System (EMS) .....................365 EMS Components ..........................365 Functional Specifications......................366 1. Electronic Control Unit (ECU) Integrated with Throttle Body ..............366 Functional Diagram ........................366 2. Fuel Injector ............................367 3. Fuel Supply Module ..........................367 4.
  • Page 364 Engine Management System CONTENTS PAGE 10.1.12. Side Stand Switch ..........................379 10.1.13. Starter Motor Solenoid ........................380 Assembly ............................380 10.1.14. Engine Control Unit (ECU) ......................380 10.1.15. Fuel Pump ............................381 10.1.16. Fuel injectors...........................381 10.1.17. Engine Oil Temperature Sensor (EOT) .....................382 10.1.18.

  • Page 365: Engine Management System (Ems)

    Engine Management System (EMS) Engine Management System is responsible for controlling the amount of fuel being injected and for adjusting the ignition timing. Optimum functioning of EMS assures maximum engine power with the lowest amount of exhaust emissions and lowest fuel consumption. EMS Components •...

  • Page 366: Functional Diagram

    Functional Diagram Functional Specifications 1. Electronic Control Unit (ECU) Integrated with Throttle Body Electronic Control Unit integrated with throttle body and makes a single module. Electronic control unit is any embedded system that controls one or more electrical system or subsystems in a vehicle. Engine Control Unit is a type of Electronic Control Unit that controls a series of actuators on an internal combustion engine to ensure optimal engine performance.

  • Page 367: Fuel Injector

    2. Fuel Injector Fuel injector use pintle valves are operated by electromagnetic components called solenoids. The solenoid is activated, or “pulses” by an ECU which causes it to undergo linear movement. Since the solenoid is mechanically connected to a pintle valve within the fuel injector, the linear movement causes the pintle to move away from its seat.

  • Page 368: Manifold Absolute Pressure Sensor (Map)

    5. Manifold Absolute Pressure Sensor (MAP) The Manifold Absolute Pressure sensor provides instantaneous manifold pressure information to the ECU. This is necessary to calculate air density to determine the required fuel metering for optimum combustion and influence the advance or retard of ignition timing. This sensor is in built in the ECU. 6.

  • Page 369: Clutch Switch

    8. Idle Air Control Valve (IAC) Idle Air Control Valve is basically a stepper motor controlling the bypass air to the engine and helps to idle and cold start the engine without difficulties. The ECU accordingly collects the data from the engine oil temperature and intake air temperature sensors and operates the stepper motor in regulating the engine RPM.

  • Page 370: Side Stand Switch

    12. Side Stand Switch Side stand switch prevents the vehicle from starting when the side stand is down and not in neutral gear. It is rotary type switch, which is directly connected to ECU. Specification: (Across Pins 17 & 1) Side stand down: 0 V Side stand up: 12 V 13.

  • Page 371: Starter Motor Relay

    15. Crank Position Sensor (CPS) It provides an alternating electrical pulse to the ECU, to determine crankshaft speed and TDC position of the piston in compression stroke. This input will help the ECU to optimize both fuel injection as well as Ignition advance required to suit the crankshaft rotation speed (RPM).
  • Page 372 Idling Adaptation procedure CAUTION Idling adaptation should be done only if any changes in ECU, EMS sensors or in fuel type of the vehicle. Step 1 - Check the Engine Oil Temperature (EOT) at start is less than 35°C. Step 2 - Start and allow the engine to idle and leave it undisturbed till the engine oil temperature reaches 115°C.
  • Page 373 10.1 Engine Management System (EMS) CAUTION Ensure locks are fully lifted up and released Dismantling before disconnecting wiring connectors from ECU. Ensure locks are handled with care and do not 10.1.1. Engine Control Unit (ECU) get damaged or broken. Damaged or broken locks will result in loose CAUTION connections and cause the ECU to fail.
  • Page 374 Remove O-rings (a) and (b) from fuel pump (c). • CAUTION Ensure the following: Fuel is drained completely from fuel tank. Fuel feed and return hoses are disconnected from the fuel rail. Wiring couplers to fuel pump and low fuel sensor are disconnected.

  • Page 375: Fuel Injectors

    10.1.5. Engine Oil Temperature Sensor (EOT) • Ensure vacuum hose is removed. • Loosen wire clips on air filter connection tubes • The EOT (a) is located on cylinder head below the (section 5.1.10). exhaust pipe. • Loosen worm clip screw on inlet manifold. (section 5.3.19).
  • Page 376 10.1.6. HEGO/Oxygen (O2) Sensor 10.1.7. Purge Valve • Remove the following parts: CAUTION • Side panel RH (section 6.7.1). Do not loosen/remove HEGO (O2) sensor when the exhaust pipes are hot. • Rider seat (section 6.7.2). • Side panel LH (section 6.7.4).

  • Page 377: Ignition Coil

    10.1.8. Ignition Coil 10.1.9 Crank Position Sensor • The crank position sensor is located inside the • The Ignition coil is located on the frame under fuel engine cover LH and attached to the stator coil. tank. • Ensure Ignition switch and Engine stop switch are •...

  • Page 378: Gear Position Sensor

    10.1.10. Gear Position Sensor • Loosen and remove 2 Nos. Allen socket head bolts (M5) (a) holding crankshaft position sensor guide plate to cover LH. • The gear position sensor is located on the crankcase LH before FD sprocket. • Ensure Ignition switch and engine stop switch are in OFF position.

  • Page 379: Side Stand Switch

    10.1.12. Side Stand Switch • Remove cable bracket (a) and gently pull out gear position sensor from crankcase LH. • Place the vehicle in main stand. Disconnect side stand connector (a) from wiring • harness located behind engine . Fig. 10.1.17 10.1.11.

  • Page 380: Starter Motor Solenoid

    Assembly 10.1.13. Starter Motor Solenoid 10.1.14. Engine Control Unit (ECU) • Remove the following parts: • Rear wheel (section 6.8.3). CAUTION • Rear mudguard in fill cover (section 6.6.7). Before assembling any part of the EMS, the • Locate solenoid connectors below battery tray, Ignition switch and Engine stop switch MUST ensure ignition off.

  • Page 381: Fuel Pump

    • Connect wiring harness coupler (a) to ECU (b). CAUTION • Connect battery terminals. Ensure the following: • Assemble rider seat (section 6.7.7). Fuel is refilled into fuel tank. Fuel feed and return hoses are connected into • Assemble side panel RH (section 6.7.8).

  • Page 382: Engine Oil Temperature Sensor (Eot)

    10.1.18. HEGO (O2) Sensor CAUTION Ensure the following: • The HEGO sensor are located on the exhaust pipes Fuel is refilled into fuel tank. near the cylinder head. Fuel feed and return hoses are connected into WARNING fuel rail. The engine and exhaust systems get extremely Wiring couplers to fuel pump and low fuel hot during normal operation and can result sensor are connected.

  • Page 383: Purge Valve

    10.1.19. Purge Valve 10.1.21. Crank Position Sensor • Locate and install EVAP purge control valve into • The crank position sensor is located inside the frame. engine cover LH and attached to the stator coil. • Connect the inlet (a) and outlet (b) hoses to EVAP •...

  • Page 384: Gear Position Sensor

    • Locate crank shaft position sensor and wiring • Connect gear position sensor connector (a) to harness behind engine on RH, near RR module. wiring harness connector located on rear side of engine (b). • Connect crank position sensor connector to harness connector.

  • Page 385: Side Stand Switch

    10.1.24. Side Stand Switch 10.1.25. Starter Motor Solenoid • Locate solenoid connectors below battery tray CAUTION Ensure ignition off. Ensure the motorcycle is upright on a firm and • Gently slide and locate solenoid coil into battery flat surface. tray bracket. •...
  • Page 386 Test Procedure • Method of verification • Entry Conditions 4. For fuel pump, when actuated, an audible sound can be heard for 5 seconds . 1. Actuator tests can be carried out when the ignition key and kill switch are ON and engine speed is 0.
  • Page 387 To check O2 sensor heater, the sensor has to be 10. When CPV is actuated, a pulsating sound can be removed from the exhaust pipe. When actuation is observed. If not, the canister purge valve has to be requested, the sensor will get heated up and this manually touched to feel actuation.

  • Page 388: Electrical System

    Electrical System ELECTRICAL SYSTEM...
  • Page 389 11.10.1 Direction Trafficator Bulb - Front ........................401 11.10.2 Direction Trafficators - Rear ..........................401 11.11 Brake Lamp Connectors Assembly ....................403 11.11.1 Brake Lamp Connector - Rear ..........................403 11.11.2 Brake Lamp Connector - Front .......................... 403 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 390 Electrical System CONTENTS PAGE 11.12 Tail Lamp Assembly ........................403 11.12.1 Tail Lamp ................................403 11.12.2 Cluster Assembly ..............................404 11.12.3 Connectors and Sensors into Headlamp Housing ....................404 11.12.4 Headlamp Bulb into Reflector ..........................406 11.12.7 Pilot Bulb into Reflector ...........................406 11.12.8 Headlamp Reflector into Housing ........................406...

  • Page 391: Headlamp And Cluster Dismantling

    Phillips screw driver Gently remove front rim (a) along with reflector (b) • from housing (c). Fig. 11.1.5 Fig. 11.1.2 WARNING The headlamp and bulb can be extremely hot. Do not remove while headlamp/bulb are hot. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 392: Connectors Behind Headlamp Housing

    11.1.2 Headlamp Bulb from Reflector • Depress wire clip (a) and release from slot (b) in headlamp reflector. Fig. 11.1.9 11.2 Connectors behind Headlamp Housing Fig. 11.1.6 Disconnect LH module connector (a) from rubber • boot. Remove wire clip (a) from reflector (b) and gently •...
  • Page 393 Disconnect RH module connector (a). Phillips screw driver Disconnect RH Trafficator connector (a). • Fig. 11.1.13 • Disconnect wheel speed sensor connector (a). Fig. 11.1.16 Disconnect ignition switch connector (a). • Fig. 11.1.14 Fig. 11.1.17 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 394 11.2.3 Instrument Cluster Dismantling • Remove 3 Nos. Hex socket nut (M6) (a) located below Instrument cluster. • Remove the 2 Nos. Philip screw (a) from LH wind shield. Fig. 11.1.21 Fig. 11.1.18 5 mm Allen socket with Ratchet Remove the 2 Nos. Philip screw (a) from RH wind •...

  • Page 395: Tail Lamp Dismantling

    Fig. 11.2.1 4 mm Hex socket with Ratchet • Gently remove the tail lamp assembly (a). Fig. 11.1.25 5 mm Socket with Ratchet • Gently remove navigation unit (a) along with . Fig. 11.2.2 Fig. 11.1.26 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 396: Brake Lamp Connectors Dismantling

    11.5 Trafficators Dismantling • Remove the 4 Nos. Allen screw (a) from the tail lamp cover. 11.5.1 Direction Trafficators - Rear Remove the 1 No Hex bolt (a) from the LH side • inside. Fig. 11.2.3 • gently remove the tail lamp cover (a) and bracket (b) from the tail lamp.

  • Page 397: Battery Dismantling

    Fig. 11.4.5 Gently remove the front LH direction trafficator (a) • Fig. 11.5.1 • Disconnect battery negative (-) terminal bolt (a). Fig. 11.4.6 Fig. 11.5.2 10 mm Double end spanner SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 398 • Disconnect battery positive (+) terminal (a) from • Remove battery (a) from tray. battery (b). Fig. 11.5.6 Fig. 11.5.3 11.6.2 RR Unit 10 mm Double end spanner CAUTION Ensure motorcycle is placed on a flat surface, • Loosen and remove Hex flanged head screw (M6) resting it on center stand/ramp.
  • Page 399 Gently slide RR unit (a) out from frame. • approximately. Fig. 11.6.2 Fig. 11.5.11 Windshield • Check rubber nut while assemble & dismantle the Windshield. • Ensure the rubber nut is not damaged before fitment. Replace if damaged. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...

  • Page 400: Battery Assembly

    11.8 Assembly • Connect RR unit connector (a) into wiring harness and ensure they are locked properly. 11.9 Battery Assembly 11.9.1 RR unit Assembly Gently slide the RR unit (a) behind engine. • Fig. 11.5.15 11.9.2 Battery Assembly Install battery (a) into tray (b). •...

  • Page 401: Trafficators Assembly

    11.10 Trafficators Assembly tighten Hex head bolt (M6) (b). 11.10.1 Direction Trafficator - Front Gently align the front RH direction trafficator (a) on • the bracket. Fig. 11.8.4 10 mm Double end spanner Fig. 11.9.1 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 402 11.10.2 Direction Trafficators - Rear • Install the RH direction trafficator using the hex bolt (a). • Gently instal the RH direction trafficator (a) on the bracket.. Fig. 11.9.2 • Gently align the front LH direction trafficator (a) on Fig. 11.9.5 the bracket.

  • Page 403: Brake Lamp Connectors Assembly

    • After assembling front brake switch. Check front brake operation at Tail lamp Fig. 11.11.3 4 mm Socket with Ratchet NOTE • After assembling tail lamp assembly, check tail lamp operation & brake light operation. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 404 11.12.2 Cluster Assembly • Connect the instrument cluster connector (a). For EURO V model • Install the navigation unit using 2 Nos. Hex socket Head bolt (M5) along with washer on the Bracket. Fig. 11.12.4 Install instrument cluster using 3 Nos. Hex nut M6 •...
  • Page 405 Ensure it is properly seated/locked. Fig. 11.12.8 Fig. 11.12.11 Connect clutch switch connector (a). Ensure it is • Locate and connect wheel speed sensor connector • (a). Ensure it is properly seated/locked. properly seated/locked. Fig. 11.12.9 Fig. 11.12.12 SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 406 • Locate and connect LH module connector (a) into • Depress wire clip (a) and lock into slot (b) in headlamp housing. Ensure it is properly seated/ headlamp reflector. locked. Fig. 11.12.15 Fig. 11.12.13 11.12.2 Pilot Bulb into Reflector 11.12.1 Headlamp Bulb into Reflector Gently depress bulb (a) to holder and turn clockwise •...
  • Page 407 (a) into housing (c). Fig. 11.12.19 Insert and tighten 2 No. Phillips screw (a) on Both • the sides of the headlamp. Fig. 11.12.20 Phillips screw driver • Inspect and test all electrical functions after completing assembly. SERVICE MANUAL HIMALAYAN ROYAL ENFIELD...
  • Page 408 ADDON SERVICE MANUAL HIMALAYAN -2021...
  • Page 409 PERIODIC MAINTENANCE SCHEDULE (PMS) SERVICE MANUAL ROYAL ENFIELD...
  • Page 410 The frequency of the maintenance must be shortened depending upon the severity of the driving condition or if the motorcycle is used in a very dusty environment. Contact the nearest Royal Enfield Authorized Dealer/Service Center for expert advice and to carry out the required maintenance.
  • Page 411 (#) - After First service, Engine oil and Engine oil filter replacement is a mandatory at every 12 months even the vehicle has not covered the specified kms. NOTE • For Maintenance after 50,000 kms, Please repeat the same frequency specified above, in consultation with a Royal Enfield Authorized Dealer/Service Center. SERVICE MANUAL ROYAL ENFIELD...
  • Page 412 EMS ADAPTATION PROCEDURE...
  • Page 413 115˚C.(Time required for the EOT to reach 115˚C will be 30 minutes approximately) Step 3 - Once Engine Oil Temperature reaches 115˚C, turn “OFF“ the ignition key and DO NOT turn it back ON for the next 30 seconds. SERVICE MANUAL ROYAL ENFIELD...
  • Page 414 ENGINE...

  • Page 415: Throttle Body Removal

    Gently locate the throttle body (b) along with the • rubber manifold on to the clamp (c). Install the throttle body (b) using 1 No, allen bolt (a) • (M5). Fig. 8.1.2 4 mm Allen socket with Ratchet SERVICE MANUAL ROYAL ENFIELD...
  • Page 416 EVAPORATIVE (EVAP) EMISSION CONTROL SYSTEM...

  • Page 417: Canister Installation

    Connect the drain hose, outlet hose and inlet hose (a) to the canister. Fig. 8.1.3 • Loosen and remove the hex bolt (a) from the canister. Fig. 8.1.7 Fig. 8.1.4 Remove the canister (a) by removing the 1 No. Hex • bolt. Fig. 8.1.5 SERVICE MANUAL ROYAL ENFIELD...

  • Page 418: Electrical System

    ELECTRICAL SYSTEM...
  • Page 419 Remove the 2 Nos. Philip screw (a) from RH wind • shield. Fig. 8.1.12 5 mm Allen socket with Ratchet Fig. 8.1.9 Gently remove instrument cluster (a). • Philip screw driver • Gently remove the wind shield (a). Fig. 8.1.13 Fig. 8.1.10 SERVICE MANUAL ROYAL ENFIELD...
  • Page 420 3.2 Cluster Assembly • Disconnect the navigation unit connector (a). • Install the navigation unit using 2 Nos. Hex nut (a) on the bracket. Fig. 8.1.14 • Remove 2 Nos. Hex socket head bolts (M6) (a) Fig. 11.12.1 located below cluster bracket on RH. Connect the connector (a) to the navigation unit.
  • Page 421 • Install instrument cluster using 3 Nos. Hex nut (a). Fig. 11.12.4 5 mm Hex socket with Ratchet Torque 10 N-m/1.01 kgf-m • Connect the instrument cluster connector (a). Fig. 11.12.5 SERVICE MANUAL ROYAL ENFIELD...

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