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
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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
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VEHICLE VIEW FRONT

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VEHICLE VIEW BACK

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL
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VEHICLE VIEW TOP

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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
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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