Royal Enfield Himalayan User manual

Carburettor Version Model

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 1

PREFACE

“FIRST TIME RIGHT” is a very important element for enhancing Customer Satisfaction.

Royal Enfield is committed to upgrade the skills and knowledge of technicians so that they follow scientific repair

techniques to ensure “FIRST TIME RIGHT” practices and carry out repairs accurately so that customers will enjoy

trouble free performance at all times.

This manual will help in complete understanding of systematic procedures for dismantling, inspection, diagnosis and

reassembly for the new Royal Enfield Himalayan motorcycle, in a simple and scientific manner.

While this manual is updated with latest Information and Specifications at the time of going to print, due to continuous

improvements being done to improve performance, some of the data, illustrations etc., in this manual may be different

from some of the parts fitted in the motorcycle.

Please do feel free to write to us at support@royalenfield.com , if you have any queries, clarification, suggestions or

feedback.

With warm regards

SERVICE HEAD QUARTERS

Royal Enfield, A Unit of Eicher Motors Limited,

Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019.

E-mail: Support@royalenfield.com

Website: www.royalenfield.com

Part No: 888435 / Jan. ’17

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

HIMALAYAN – VEHICLE VIEWS

VEHICLE VIEW LH

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 3

VEHICLE VIEW RH

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

VEHICLE VIEW FRONT

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 5

VEHICLE VIEW BACK

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

VEHICLE VIEW TOP

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 7

TABLE OF CONTENTS

SL.NO. DESCRIPTION PG.NO. SL.NO. DESCRIPTION PG.NO.

1. Technical Specifications ........................................ 8

2. Periodical Maintenance ......................................... 10

3. Special Tools Usage List ......................................... 11

4. Engine Dismantling from Frame & Reassembly . 12

5. Rider & Pillion Seat ................................................. 47

6. Control Cables ........................................................ 50

7. Air Filter.................................................................... 57

8. Pulse Air Valve ......................................................... 63

9. Fuel Tank .................................................................. 67

10. Exhaust Pipe & Silencer ......................................... 71

11. Front Suspension

11.1 Front Mudguard ............................................ 84

11.2 Front Wheel ................................................... 85

11.3 Front Fork ....................................................... 86

11.4 Handle Bar ...................................................... 89

11.5 Steering Stem ................................................. 90

12. Rear Suspension

12.1 Rear Wheel ..................................................... 110

12.2 Rear Sprocket / Drive Chain Adjustment .... 111

12.3 Rear Mudguard .............................................. 113

12.4 Mono Shockabsorber ................................... 114

12.5 Drag & Drop Links .......................................... 115

12.6 Swing Arm ...................................................... 116

13. Hydraulic Disc Brakes -Front & Rear ..................... 127

14. Carburetor ............................................................... 161

15. Electrical Components ........................................... 175

16. Electricals ................................................................. 184

17. Wiring Harness ........................................................ 206

18. Trouble Shooting .................................................... 210

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

SECTION 01 - TECHNICAL SPECIFICATION

A. ENGINE: LS 410

B. CHASSIS:

1. Frame Half duplex split cradle

2. Suspension

Front Telescopic, Hydraulic Damping,Front wheel travel:

200 mm

Front fork oil grade 2W 35

Capacity / leg 455ml/leg

Rear Swing arm with Linkage type Hydraulic damping Mono

shock, Rear wheel travel: 180 mm

3. Brakes

Front Disc 300mm Dia disc.

Rear Disc 240mm Dia disc.

Hydraulic oil Grade DOT3 / DOT4

Hydraulic oil reservoir capacity - Front & Rear 50ml.

4. Tyre size

Front 90 / 90 – 21

Rear 120 / 90 – 17

5. Tyre Pressures

6. Steering lock In Built

7. Fuel Tank * Values below are approximate & actual capacity may

vary with each fuel tank .

Tank capacity 15+0.5 litres approx.*

Reserve 3.0 + 0.5 Litres approx.*

Low fuel warning - Fuel Gauge (Red zone) 5.5+0.50 litres approx.*

Dead stock (unusable fuel) 0.5 litre approx.*

VEHICLE & VEHICLE SYSTEMS

Solo With Pillion

Front 25 PSI / 1.75Kg/cm2 27 PSI / 1.89Kg/cm2

Rear 32 PSI / 2.25 Kg/cm2 34 PSI / 2.39 Kg/cm2

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 9

C. ELECTRICALS:

Generation Alternator

System 12V - DC

Battery 12V - 8 AH MF

Head lamp Bulb H4 12V 60/55W

Tail lamp / Brake lamp 2V- 4/1W LED

License Plate illuminator 12V- LED

Front position lamp 12V- LED

Speedometer lamp 12V- LED

Hi beam indicator 12V- LED

Neutral lamp telltale 12V- LED

Turn signal telltale 12V- LED

Turn signal 12V – 10W

Horn 12V, 2.5 Amp

Starter Motor 12V. 0.7 KW

Instrument Cluster Digital cluster with LCD panel

Side Stand indicator LCD Indication

D. DIMENSIONS:

Length 2190mm

Width 840mm

Height 1360mm

Wheel base 1465mm

Ground clearance 220mm

Saddle Height 800mm

E. WEIGHTS:

Kerb weight with (90% fuel & oil) 182 Kg.

Max. permissible load. 183 Kg.

VEHICLE & VEHICLE SYSTEMS

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