Royal Enfield HIMALAYAN EURO IV 2017 User manual

EURO IV - HIMALAYAN VEHICLE SERVICE MANUAL
HIMALAYAN
HI

ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL
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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 isupdated withlatestInformation and Specifications at the time of goingtoprint, due to continuous
improvementsbeing done to improve performance,some of the data,illustrationsetc., inthismanual maybe different
from some of the parts fitted in the motorcycle.
Please do feel free to write to us at
[e-mail]
, 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: [e-mail]
Website: www.royalenfield.com
Part No: 1017122/A / Oct. ’17
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ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL
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HIMALAYAN – VEHICLE VIEWS
VEHICLE VIEW LH
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ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL
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VEHICLE VIEW RH
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ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL
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VEHICLE VIEW TOP
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ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL
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TABLE OF CONTENTS
SL.NO. DESCRIPTION PG.NO. SL.NO. DESCRIPTION PG.NO.
1. Technical Specifications ........................................ 6
2. Periodical Maintenance ......................................... 9
3. Special Tools Usage List ......................................... 11
4. Engine Dismantling from Frame & Reassembly . 12
5. Rider & Pillion Seat ................................................. 45
6. Control Cables ........................................................ 48
7. Air Filter.................................................................... 53
8. Pulse Air Valve ......................................................... 59
9. Fuel Tank .................................................................. 63
10. Exhaust Pipe & Silencer ......................................... 67
11. Front Suspension
11.1 Front Mudguard ............................................ 81
11.2 Front Wheel ................................................... 82
11.3 Front Fork ....................................................... 83
11.4 Handle Bar ...................................................... 86
11.5 Steering Stem ................................................. 87
12. Rear Suspension
12.1 Rear Wheel ..................................................... 109
12.2 Rear Sprocket / Drive Chain Adjustment .... 114
12.3 Rear Mudguard .............................................. 116
12.4 Mono Shockabsorber ................................... 117
12.5 Drag & Drop Links .......................................... 118
12.6 Swing Arm ...................................................... 119
12. ABS ......................................................................... 128
13. Hydraulic Disc Brakes - Front & Rear .................... 139
14. EVAP ......................................................................... 175
15. Engine Management System (EMS) ..................... 180
16. Electrical Components ........................................... 220
17. Electricals ................................................................. 229
18. NACS II Diagnosis .................................................... 251
19. Wiring Harness ........................................................ 270
20. Trouble Shooting
20.1 Vehicle Trouble Shooting ............................. 277
20.2 EMS Trouble Shooting .................................. 289
21. Notes ........................................................................ 291
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ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL
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SECTION 01 - TECHNICAL SPECIFICATION
A
A. ENGINE
Engine Type SingleCylinder,4Stroke,SOHC,Aircooled,FuelInjection
Bore 78mm
Stroke 86mm
Displacement 411 cc
Compression ratio 9.5:1
Max Power 24.5 bhp (18.02 KW) @ 6500 rpm
Max Torque 32 Nm @ 4250+250 rpm
Idle rpm 1250+50 rpm
Starting System Electric Start
Air filter element Paper element
Lubrication Forced Lubrication, Wet sump
Engine oil capacity 2.3 L (Initial fill only), 2.0 L (Subsequent Refills)
Engine oil grade SAE 15W 50 API SL Grade JASO MA 2
Cooling Air cooled with Oil cooler
B. IGNITION SYSTEM
Ignition system Electronic ECU / Variable
Spark plug Bosch - UR5CC
Spark plug gap 0.7 to 0.8 mm
C. TRANSMISSION
Clutch Wet Multi Plate
Primary drive Gear
Primary ratio 2.312:1
Gear box 5 Speed, Constant Mesh
Gear Ratios
1st Gear 1
st
2.916:1
2nd Gear 2
nd
1.833:1
3rd Gear 3
rd
1.428:1
4th Gear 4
th
1.173:1
5th Gear 5
th
1:000:1
VEHICLE & VEHICLE SYSTEMS
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ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL
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VEHICLE & VEHICLE SYSTEMS
Secondary Drive 5/8” Chain & Sprocket
Secondary Ratio 2.533:1
Drive Chain links 110 links
D
D. CHASSIS
Frame Half duplex split cradle
Suspension Front Telescopic, Hydraulic Damping,
Front wheel travel: 200 mm
Rear Swing arm with Linkage type Hydraulic damping
Mono shock, Rear wheel travel: 180 mm
Brakes Brake system Dual channel ABS
Front Disc 300mm Dia disc.
Rear Disc 240mm Dia disc.
Tyre size Front 90 / 90 - 21
Rear 120 / 90 - 17
Tyre Pressures
Solo Front 25 PSI / 1.75 Kg/cm
2
Rear 32 PSI / 2.25 Kg/cm
2
With Pillion Front 27 PSI / 1.89 Kg/cm
2
Rear 34PSI / 2.39 Kg/cm
2
Steering lock In built
Fuel tank capacity* 15 + 0.5 litres approx *
Low fuel warning Fuel Gauge (Red zone) 5.5+0.5 lts.
Dead stock (unusable fuel) 0.5 litre approx.
E. ELECTRICALS
Flywheel magneto 221W @ 1500 rpm
Generation Alternator, III Phase
System 12V - DC
Battery 12V - 8 AH MF
Head lamp 12V, H4-60/55W - BULB
Tail lamp / Brake lamp 12V- 4/1W LED
Licence Plate illuminator 12V- LED
* The above values
are approximate
and the actual
capacity may
vary with each
fuel tank .
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ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL
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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 * 4 Nos.
Horn 12V, 2.5 Amp.
Starter Motor 12V, 0.7 KW
Instrument Cluster Digital cluster with main
and compass LCD
Side Stand indicator LCD Indication
F
F. DIMENSIONS
Length 2190mm
Width 840 mm
Height 1360 mm
Wheel base 1465 mm
Ground clearance. 220mm
Saddle Height 800 mm
G. WEIGHTS
Kerb weight (90% fuel&oil) 191 kgs.
Max. Pay load 174 Kgs.
WARNING
Usingbulbs/electricalgadgets
other than specified rating
may lead to overloading/
eratic behaviour / premature
failure of electrical system.
Modifications or fitments
which are not approved by
Royal Enfield, will seriously
affect the performance of the
vehicle and will render the
warranty void.
Values / Dimensions
mentioned above are
for reference only.
In view of continuous
improvements being
done on our
motorcycles, the
specifications are
subject to change
without prior notice.
08
VEHICLE & VEHICLE SYSTEMS

ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL
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SECTION 02 - PERIODICAL MAINTENANCE
The Periodical maintenance schedule detailed below is based upon average riding conditions and indicates the
Intervalsatwhichregularinspections,adjustments,replacementsandlubricationsmustbecarriedoutto helpmaintain
your Himalayan motorcycle meticulously
If in case the motorcycle is used frequently in very dusty environment / severe climatic conditions / Poor Roads /
stagnant water etc., the maintenance will need to be done earlier as may be required.
Contact a nearest Royal Enfield Authorised Dealer / Service Center to carry out the periodical maintenance and for
any expert advice.
S
S.
No. DESCRIPTION
whicheveris earlier
PAID SERVICEFREE SERVICE
whicheveris earlier
NOTE:
For maintenance after 50,000 Kms. , please repeat same frequency specified above, in consultation with a Royal
Enfield Authorised Dealer / Service Center.
A : Ad j us t C : C l ea n I : I n s pe c t L : L u br i c at e R : R e p la c e
* Refer Service Manual. # Check every time after vehicle is used for off road riding
Kms (x 1000) 0.5 5 10 15 20 25 30 35 40 45 50
Months 1.5 6 12 18 24 30 36 42 48 54 60
1 EngineOil(Levelcheck/ Replace) RIRI R I RIRI R
Check level at every 1000 Kms or earlier as required
2 Oil Filter Element R R R R R R
3 Engine oil strainer on crankcase LH C C C C C C
4 Inlet/ ExhaustTappet setting I & A I & A I & A I & A I & A I & A I & A I & A I & A I & A I & A
5 Rubber hose, Inlet manifold * I I R I R I R I R I R
6 Oil cooler inlet & outlet pipes * I I I R I I R I I R I
7 Sparkplug C & A C & AC & A R C & A C & A R C & A C & A R C & A
8HTleadsforcrack IIIIIIRIII I
9 FuelHose I I I R I I R I I R I
10 Fuel Hose &Clip/ Injector ‘O’ring/ Seal Ring I I I R I I R I I R I
11 Fuel Pump Checkfor screwtightness in all services
CCRC R C RCRC R
12 Airfilterelement Clean/ Replace more frequently if motorcycle always used
industy / off Road conditions.
13 AcceleratorCable I I R I R I R I R I R
14 Rubber Hose, Air fitler to Throttle body I I R I R I R I R I R
15PAVpipes&Hoseclip IIII IRIIII R
16 Throttle body- Cleaning spray* Carbocleaner/ carb click/orFuellinecleanersprayevery
6000 Km or 6 monthswhicheveris earlier
17 Clutch Cable I I R I R I R I R I R
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