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 [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: 888435 / Jan. ’17

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL
2
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
4
VEHICLE VIEW FRONT

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 5
VEHICLE VIEW BACK

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL
6
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
8
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

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL
10
SECTION 02 - PERIODICAL MAINTENANCE
The Periodical maintenance schedule detailed below is based upon average riding conditions and indicates the
Intervals at which regular inspections, adjustments, replacements and lubrications must be carried out to help maintain
your Himalayan motorcycle meticulously
If in case the motorcycle is used frequently in very dusty environment / severe climatic conditions / Poor Roads /
stagnant water etc., the maintenance will need to be done earlier as may be required.
Contact a nearest Royal Enfield Authorised Dealer / Service Center to carry out the periodical maintenance and for
any expert advice.
S.
No. DESCRIPTION whichever is earlier PAID SERVICEFREE SERVICE whichever is earlier
Kms (X 1000) 0.5 5 10 15 20 25 30 35 40 45 50
Months 1 6 12 18 24 30 36 42 48 54 60
1 HT leads for crack I I I I I RI I I I I
2 Air Filter Element C C RCRCRC R C R
Clean/ Replace more Frequently if motorcycle always used
in dusty / off Road conditions.
3 Accelerator Cable I I RIRIRIRIR
4 Clutch Cable I I RIRIRIRIR
5 Clutch Free Play Adjust every 1000 Kms or earlier as required
6 Steering ball races # I & A I & A I & A I & A I & A I & R I & A I & A I & A I & A I & R
7 Front Fork oil I I I RI I RI I RI
8 Fuel Filter in Fuel Tap C  C  C  C  C  C
9 Fuel Hose I I RIRIRIRIR
10 Battery terminals (apply petroleum jelly) C C C C C C C C C C C
11 Earth wire eyelet Tightness   I  I  I  I  I
12 Hydraulic Brake Fluid - Front & Rear # I I RIRIRIRIR
13 Hydraulic brake hose & Washers - Front & Rear # I I I I RI I I RI I
14 Brake Pads - Front & Rear # I I RIRIRIRIR
15 Tyre wear pattern (Front & Rear)# I I I I I RI I I I R
16 Spokes tightness / Wheel rim run out front & rear # I I I I I I I I I I I
17 Front & Rear wheel bearings for play # I I I I I I & R I I I I I & R
18 Swing arm Pivot bearings # I I I & L I I & L I & R I I & L I I & L I & R
19 Rear Suspension Linkages # I I & L I & L I & R I & L I & L I & R I & L I & L I & R I & L
20 Rear Drive Chain # Clean, Lubricate & Adjust every 1000 Kms or earlier as required
21 Drive chain & Sprockets set # I I RIRIRIRIR
22 Rear wheel cushdrive rubbers# I I RIRIRIRIR
23 All Mounting Fasteners in vehicle for tightness # I I I I I I I I I I I
24 Hand levers, side stand, Rider & Pillion foot rest Pivots Lubricate every 1000 Kms or earlier as required
NOTE:
For maintenance after 50,000 Kms, please repeat the same frequency levels specified above.
A : Adjust C : Clean I : Inspect L : Lubricate R : Replace
* Refer Service Manual. # Check every time after vehicle is used for off road riding

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 11
SECTION 03 - SPECIAL TOOLS USAGE LIST
ST-26461-2 Front Fork Assembling & To hold pipe seat inside fork main
Dismantling Tool tube for loosening / tightening of
Allen bolt on bottom tube.
ST-26485-3 Front Fork Oil Seal Driver To drive slide bush and fork oil seals into
bottom tube
ST-25244-4 Special spanner adjuster To adjust rear shock absorber spring
pre tension
PART NO. DESCRIPTION PHOTOS APPLICATION

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL
12
SECTION 04 - ENGINE DISMANTLING FROM FRAME &
REASSEMBLY
EXPLODED VIEWS
FRAME LH
S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.
A1 Gear Shift Lever Kit 1
1 Main Frame- Black 1
2 Utility Box 1
3 Seat Latch 1
4 Counter Sunk Screw M6 X 1 X 20 2
5 Flanged Hex Bolt M6 X 1 X 10 2
6 Hex Socket Head Screw M8 X 1.25 X 25 4
7 Flanged Hex Bolt M8 X 1.25 X 20 2
8 Grab Rail Black 1
9 Mushroom Head Screw M6 X 8 X 1 2
10 Plate Seat Lock 1
11 Saddle Bag Mtg - LH 1
12 Piece Mudguard 1
13 Flanged Hex Bolt M6 X 1 X 20 5
14 Plain Washer 8
15 Hex Nut with nylon insert 4
16 Flanged Hex Bolt, M6 X 1 X 14 6
17 Grommet 1
18 Stud 2
19 Crossbar Assy 1
20 Dust Cap-Frame Top 1
21 Dust Cap-Frame 1
14
15
13
14
15
8
6
7
5
4
3
2
1
13 41 42
40 20
43
31
22
21
22
13 29 28 27 26
25
2324
30
32
33
12
6
11
10
9
919 18
16
17
1415
38 38
14 14
37
37
39
16
36
36
35
34
A1
Key Nos.
13, 23, 24, 25, 25, 27, 28, 29
22 Flanged Hex. Bolt M10 X 1.25 X 66 2
23 Toe Lever Comp 1
24 Pivot Pin- Gear Shifter 1
25 Sleeve, Gear Lever 1
26 Hex Nut 1
27 Link Rod 1
28 Hex Nut (LH Thread) 1
29 Gear Shift Lever Comp-Short 1
30 Hex Socket Head Cap Screw – M5 X 20 2
31 Switch-Side Stand 1
32 Hex Socket Head Screw M8 X 1.25 X 35 1
33 Side Stand Assy 1
34 Hex Nyloc Nut M8 X 9.5 1
35 Spring 1
36 Support Bush Skid Plate 4
37 Damper - Oil Cooler 4
38 Flanged Hex Bolt M6 X1 X 35 4
39 Skid Plate 1
40 Cradle Frame 1
41 Bracket Assy-Oil Cooler 1
42 Flanged Hex Bolt, M10 X 1.25 X 75 1
43 Flanged Hex Bolt M6 X1 X 27 2

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 13
EXPLODED VIEWS
FRAME RH
S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.
1 Connector Complete Black 1
2 Flanged Hex. Bolt M10 X 1.25 X 66 1
3 Plain Washer 1
4 Flanged Hex Bolt, M10 X 1.25 X 75 1
5 Flange Hex Bolt M10 X 1.25 X 165 1
6 Flange U Nut M10 X 1.25 6
7 Flange Hex Bolt M10 X 1.25 X 183 3
8 Clutch Clamp 1
9 Flanged Hex nut M10X1.25 1
10 Flanged Hex Bolt M8 X 1.25 X 16 2
11 Flanged Hex. Bolt M8 X 1.25 X 45 1
12 Steady Bracket Black 1
13 Flanged Hex. Nut M8 X 1.25 1
14 Flanged Hex Bolt M8 X 1.25 X 20 2
15 Flanged Hex Bolt M6 X 1 X 14 2
16 Brake Pedal Comp - RH 1
17 Pivot Pin-Brake Pedal 1
18 Spring-Pedal Return 1
19 Dust Cap-Frame 1
20 Hex Socket Button head Screw M6 X 1 2
21 Dust Cap-Frame Top 1
22 Hex.Socket Button Head Screw M6 X 1 X 16 1
23 plain washer M6 1
24 Flanged Hex Bolt M6 X 1 X 20 1
25 Bracket Assy. - Air Filter 1
26 Saddle Bag Mtg- RH 1
27 Hex Socket Head Screw M8 X 1.25 X 25 2
7
27
26
17
16
24
25
10
22
23
7
18 6
19
20
21
6
6
5
6
4
3
2
1
986
10
11
6
12
13
14 15

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL
14
COMPONENTS DISMANTLING SEQUENCE TO REMOVE ENGINE FROM FRAME
Skid Plate on Frame bottom
Engine oil (Drain when warm. Remove drain plug /
oil strainer cover on crankcase LH & Oil filter on Cover
RH)
Oil Cooler along with inlet & outlet pipes.
Fuel hose & Pulse Air valve connections
Battery connections
Magneto / Gear position / Side stand switch:
couplers dismantle
Starter motor connections
Spark plug suppressor cap
Engine steady bracket
Control Cables (Clutch / Accelerator)
Carburettor
Exhaust pipe & Silencer
Gear shift linkage
Starter motor
Cover LH
Gear position indicator sensor
Magneto rotor assembly including Starter clutch
Starter idler gears with bush & spindles
Rear Chain (Remove from FD sprocket)
FD sprocket nut (loosen )
Cover RH
Oil pump gears / Oil pump
Crank shaft Nut (LEFT HAND THREADED)
Balancer shaft Bolt
Clutch center nut & Clutch assembly
Gear shift shaft assembly (Remove circlip & washer
on shift shaft from LH crankcase side first)
Cam shaft covers / Cylinder head cover
Automatic chain tensioner
Cam shaft gear & cam shaft Assembly
Cylinder Head Sub Assembly
Chain Tensioner Pads
Cylinder Barrel Sub Assembly
Cradle frame top mountings (with connector)
mounting to frame
Cradle frame bottom mounting LH& RH on frame
Rear top engine mounting on frame (support engine
from bottom suitably)
Four mounting studs of Engine to cradle frame
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ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 15
S.
No. Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle/
Instructions
4.1 Skid plate
Loosen & remove 6
Flanged Hex screws (2 in
front & 4 in bottom.
Flanged Hex Screw: M6
Socket Spanner: 10mm
NOTE:
Ensure the engine oil is
drained from the engine.
Remove the spacers and
washers between the
skid plate and frame.
4.2 Oil Cooler
Remove Inlet & Outlet
Banjo union bolts from
LH & RH Crankcase
respectively & allow oil
to drain.
Ensure the 4 washers
are removed from the oil
pipes / banjo Union
Remove 2 Hex flange
bolts securing oil cooler
to the frame
Remove oil cooler along
with inlet & outlet pipes.
(Ensure the Oil pipe No 2
on RH side between
engine & frame is taken
out carefully, while
dismantling the oil
cooler.)
Banjo Union Bolts: M14
Socket spanner: 19mm
Flanged Hex bolts: M6
Socket spanner: 8mm.
ENGINE DISMANTLING FROM FRAME

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL
16
S.
No. Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle/
Instructions
4.3 Wind Shield
Assembly
Remove 4 Hex socket
head cap screws holding
the Wind shield
assembly to the top
frame.
Remove the 4 plastic
washers along with the
screws and remove wind
shield.
Hex Soc Hd. Cap Screw:
M5
Allen Key: 4mm
NOTE:
Hold the rubber mounted
nuts from behind while
loosening screws.
4.4 Trafficator front LH,
RH & cover cockpit
LH, RH.
Disconnect Trafficator
wiring couplers below
headlamp.
Remove hex socket
head screw mounting
the trafficators to the
top frames on LH & RH
sides.
Gently pull out Cover
cockpit LH & RH from the
rubber grommets in the
top frame LH & RH.
NOTE:
Couplers are color coded as:
LH side: Green
RH side: Red
Hex socket hd. Screw: M5
Allen key: M4

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 17
S.
No. Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle/
Instructions
4.5 Headlamp
Assembly
Disconnect head lamp
wiring coupler below
head lamp.
Hex Socket Hd. screw:
M5
Allen Key: 6mm
Remove the dust caps
from the mounting
holes in top frame LH &
RH.
Remove 2 hex socket
head screws holding
headlamp assembly to
top frame LH & RH &
remove head lamp assy.
4.6 Top frame LH & RH
Remove 2 Flanged Hex
bolts holding the top
frame LH & RH to
Instrument cluster
bracket.
Remove the 2 dust caps
from the connector in
the frame.
Loosen 2 hex socket
head screw clamping
top frames LH & RH, to
connector tube.
Gently rotate & pull out
top frames LH & RH from
connector tube.
Flanged hex bolts: M8
Socket Spanner: 12mm
Hex Socket Hd. screws:
M6
Socket Spanner: 10mm
CAUTION
Take care not to damage
fuel tank while rotating &
removing the side support
brackets.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL
18
S.
No. Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle/
Instructions
4. 7 Pillion & Rider Seat
Unlock pillion seat by
turning key clockwise &
lift pillion seat from front
end to release rear tab &
remove.
Lift rider seat from rear
end to release front tab
& remove.
4.8 Fuel tank -
Dismantling
Remove Seat Assembly
Disconnect fuel hose
from carburetor end.
Remove 2 Hex screws
from the rear end of fuel
tank.
CAUTION:
Drain the fuel completely
from the fuel tank.
Hex Flange Bolt M6
Socket Spanner 10 mm
CAUTION :
Do not lift tank too high to
- Prevent accidental
damage to the front
end of the fuel tank.
- Prevent damage to
EVAP hose
Disconnect fuel gauge
coupler wire by lifting the
tank slightly.
Slide fuel tank towards
rear to release front
clamp from frame
Remove tank along with
the overflow tube
carefully.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 19
S.
No. Fastener, Size, Tool Usage, Precautions, Photos
Aggregate to Dismantle/
Instructions
4.9 Steady Engine
Bracket
Hold U nut at the
cylinder head mounting
area with a double end
spanner and loosen Hex
bolt at the front of the
steady engine bracket.
Remove the bolt and
nut.
Support steady engine
bracket, Loosen &
remove the 2 Flanged
hex bolts at the rear end
of the bracket and
remove the bolts and
steady engine bracket.
Flanged hex bolt: M10
Socket Spanner: 12mm
Flanged hex nut: M10
Socket Spanner: 12mm
4.10 Throttle cable
Push rubber grommets
down and loosen hex
nuts completely.
Gently pull throttle cable
from bracket to release
the threaded position
from the bracket.
Remove inner cable
from the Carburetor.
Double End Spanner:
13mm