Royal Enfield HIMALAYAN BS VI 2021 Owner'S Manual Download

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103

Royal Enﬁeld Himalayan

FUSE

Remove the RH side panel.

Replace the required fuse with the spare fuse available
in the fuse carrier.

The blade fuses are located in the carrier.

NOTE

Please ensure to replace a spare fuse in the holder at the
earliest opportunity.

MINOR MAINTENANCE TIPS

RELAY STARTER - FUSE BOX

Spare Fuse - 40A

F0 - Main Fuse - 40A

Summary of Contents for HIMALAYAN BS VI 2021

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Page 3: ...longandtrouble freelifefor your motorcycle give ittheproper careandmaintenancedescribed inthismanual This Owner s Manual should be considered a permanent part of your motorcycle and should remain with it even if your motorcycle is subsequently sold The Himalayan features a Tripper navigationsystem powered by Google Maps and the Royal Enﬁeld App You can use it to connectyour smartphone withthe moto...

Page 4: ...the latest product information available at the time of publication Due to continuous improvements there may be discrepancies between theinformation in this manual and your motorcycle Royal Enﬁeld reserves the right to make production changes at any time without prior notice and without incurring any obligation tomake thesameor similar changesto motorcycles previously built or sold All imagesshown...

Page 5: ...o Accessories 53 Rules of the Road 56 Running in Period 59 Warning Indications Safety Systems 60 Starting 64 Gear Shifting Riding Stopping 66 Environment Care 70 Parking 68 Periodical Maintenance Chart 71 Tools Kit 78 First Aid Kit 79 Minor Maintenance Tips 80 Long Trip Precautions 107 Shock Absorber 108 Oﬀ Roading 109 Washing Procedure 111 Storage Precautions 116 Trouble Shooting 118 Warranty Ter...

Page 6: ...MOTORCYCLEINFORMATION Name Door No Street Locality Town City Country Contact Res Oﬀ Mobile Email Licence No Valid Till Model Color Engine No Vin No Tyre make Front Rear Tyre Nos Front Rear Battery make Battery No Sold by Date of Sale 04 ...

Page 7: ... Torque 32 Nm 4250 250 rpm Idle rpm 1300 100 rpm StartingSystem Electric Start 05 Air ﬁlter element Paper element Lubrication Forced Lubrication Wet sump Engine oil capacity 2 3 l Initial ﬁll only 1 6 1 8 l Subsequent Reﬁlls Engine oil grade SAE 15 W 50 API SL Grade JASO MA 2 Semi Synthetic Cooling Air cooled with Oil cooler IGNITION SYSTEM Ignition system Electronic ECU Variable Spark plug Bosch ...

Page 8: ...mary ratio 2 312 1 Gear box 5Speed Constant Mesh Gear Ratios st 1st Gear 1 2 916 1 TECHNICALSPECIFICATIONS nd 2nd Gear 2 1 833 1 rd 3rd Gear 3 1 428 1 th 4thGear 4 1 173 1 th 5th Gear 5 1 000 1 Secondary Drive 5 8 Chain Sprocket Secondary Ratio 2 533 1 Drive Chain links 110 links 06 ...

Page 9: ...ic 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 Switchable to Single channel ABS Rear Wheel ABS control deactivation 07 Front Disc 300 mm Dia disc Rear Disc 240 mm Dia disc Tyre size Front 90 90 21 Rear 120 90 17 ...

Page 10: ... the speciﬁed ethanol may cause the fuel tank corrosion paint damage and mayalso damage the rubber tubes in the fuel line as well n It is recommended to use only unleaded petrol as leaded petrol may cause damage to the catalytic converter 08 TyrePressures Solo 2 Front 25 psi 1 75 kg cm 2 Rear 32 psi 2 25 kg cm With Pillion 2 Front 27 psi 1 89 kg cm 2 Rear 34 psi 2 39 kg cm ...

Page 11: ...l tank capacity 15 0 5 l approx Low fuel warning Fuel Gauge Red zone 5 5 0 5 l approx Dead stock 0 5 l approx unusable fuel ELECTRICALS Flywheel magneto 221 W 1500 rpm Generation Alternator IIIPhase System 12 V DC Battery 12 V 8 AH Maintenance Free Head lamp 12 V H4 60 55 W BULB Tail lamp Brake lamp 12 V 4 1 WLED Licence Plate illuminator 12 V LED Front position lamp 12 V LED Speedometer lamp 12 V...

Page 12: ...nts which are not approved by Royal Enﬁeld will seriously aﬀect the performance of the vehicle and will render the warranty void Hi beam indicator 12 V LED Neutral lamp telltale 12 V LED Turn signal telltale 12 V LED Turn signal 12 V 10 W 4 Nos Horn 12 V 2 5 A StarterMotor 12 V 0 7 kW Instrument Cluster Digital cluster with LCD SideStand Indicator LCD Indication Malfunction Indicator 12 V LED ABS ...

Page 13: ...learance 220 mm TECHNICALSPECIFICATIONS Saddle Height 800 mm n Values Dimensions mentioned above are for reference only n Inview of continuous improvementsbeingdoneonour motorcycles thespeciﬁcations are subject to change without prior notice WEIGHTS Kerb weight 90 fuel oil 199 kg Gross Vehicle Weight 365 kg ...

Page 14: ...TION Using Non Recommended In Correct oils can cause serious damage to the moving parts aﬀect performance of the motorcycle AND void the warranty NOTE Recommendation subject to change without notice FRONT FORK OIL Capacity Grade 455 ml leg 10 W Fork Oil Viscosity range 35 BRAKE FLUID Capacity Grade Front Rear 100 ml DOT 4 2 3 l First Fill only 1 6 1 8 l Approx during oil ﬁlter element replacement ...

Page 15: ...others anddamages SAFETYDEFINITIONS tothe motorcycle NOTE Indicates important and useful messagesfor clearer understanding All Images shownin subsequent pages are forreferenceto explain and neednot to be exactlythe same on the model you WARNING Indicates a potentially hazardous situation Disregarding this message may result ininjury to rider or other persons CAUTION This message if disregarded may...

Page 16: ...NUMBER Punched onsteeringhead tube right side ENGINE NUMBER Punched on crankcase top side CAUTION It isillegal to tamper with OR alter the VIN Engine numbersof the motorcycle as it will not only against the lawBUT will render the vehicle registrationand warrantyVOID ...

Page 17: ...on Royal Enﬁeld Himalayan 2 Turn Signal Switch 3 Head Lamp Dip Switch 4 Rear View Mirror Left Side 5 Instrument Cluster 6 Wind Shield 7 Tripper 8 Rear View Mirror Right Side 9 Engine Stop Switch 10 Electric Start Switch 11 Fuel Tank Cap ...

Page 18: ...Enﬁeld Himalayan LOCATIONOF KEYPARTS 1 Front Traﬃcator Right Side 2 Horn 3 Oil Level Window 4 Rear Brake Pedal 5 Rider Foot rest Right Side 6 ABS Module 7 Pillion Foot rest Right Side 8 Rear Traﬃcator Right Side ...

Page 19: ... Left Side Royal Enﬁeld Himalayan 2 Head Lamp 3 Tail Lamp 4 RearTraﬃcator LeftSide 5 Licence plate illuminator 6 Pillion Foot rest Left Side 7 SideStand 8 Center Stand 9 Rider Foot rest Left Side 10 Gear ChangeLever 11 ABS Module 12 Canister ...

Page 20: ...d also cause the key tobend orbreak WARNING STEERING LOCK LOCKING n Turn handle bar to extreme left or right position n Switch OFF ignition gentlydepress key and turn anticlockwise further till steering is locked and remove key AfterunlockingsteeringANDbefore startingengine check the handle bar free movement by turning to bothleft and right sides severaltimes Failure to do so may cause unstable ri...

Page 21: ...se fuel expands when it heats up heat from engine or the sun can cause fuel spill out of fuel tank Petrolis highly explosive Please ensurethere are no open ﬂames or sparks nearby while refueling and ﬁll fuel tank WARNING only in a well ventilated area OPENING n Lift ﬂap and insert key n Turn key clockwise to enable cap to unlock and spring up NOTE Key CANNOT be removed when fuel tank cap is open O...

Page 22: ...rfaces Wipe immediatelyincase fuelspillsover as otherwiseitwillleave a permanent stain on the painted surfaces IGNITION SWITCH OFF ON NOTE n Key can be removed only if ignition is in OFF or steering is locked Anti splash plate 1 Fuel Filler Collar 2 Anti Splash Plate 3 Maximum Fuel Level ...

Page 23: ...Hazard Light ON OFF WARNING DO NOT switch OFF ignition while riding the motorcycle Doing so can cause a potential accident resultinginseriousinjurytobothriderandother road users besides causing severe damage to the motorcycle OPERATIONOFCONTROLS ENGINE STOP SWITCH Engine ON E START SWITCH ...

Page 24: ...ayan OPERATIONOFCONTROLS n Turnsignalsdo not work when the hazard light switch is on n WARNING All the traﬃcator lampswill ﬂash simultaneously HORN Press DIMMER SWITCH High beam Low beam DAY FLASH Press for Head Light Flash ...

Page 25: ...pillion seat and remove n Lift front seat from rear remove DOCUMENT HOLDER n Useful for storingmotor cycle documents and owners manual n Remove the pillion Seat n Gently press on top to release the tabs fromthe frame and open slightly n To completely remove release the bottom tabs from the frame by pulling out gently n Whenwashing the motorcycle becareful not toﬂood this area with water ...

Page 26: ...ld Himalayan INSTRUMENT CLUSTER OPERATIONOFCONTROLS 1 Main LCD 2 Speedometer km major 3 Tell tales 4 Tachometer 5 Mode button 6 Selectbutton 7 Gear position indication 8 Fuel gauge 9 ABS Switch 10 ABS Indicator Lamp ...

Page 27: ...25 OPERATIONOFCONTROLS Royal Enﬁeld Himalayan A MAIN LCD 1 Clock 2 Ambient Temperature 3 Service reminder 4 Odometer 5 Trip Value A B F AVG speed A B 6 Side Stand indication ...

Page 28: ...26 Royal Enﬁeld Himalayan CLOCK n Display in 12 hour format with AM PM indication n Willresetto12 00AMwhenbatteryisdisconnected OPERATIONOFCONTROLS ...

Page 29: ...e s Action CLOCK SETTING MODE 3 s In ignition key ON position when vehicle not running Enters into clock setting mode and hour digits starts to blink SELECT 1 s Hours value shall increment by 1 accordingly for no of press SELECT 3 s Hour value saved and minute digits starts to blink SELECT 1 s Minutes value will increase by 1 by each press of the Select button SELECT 3 s Minute value save and PM A...

Page 30: ...vehicle riding engine ON condition due to increase of engine temperature n Ambient temperature indicationtolerance is 2 C NOTE Theambienttemperaturevalveshouldbereferredtoonlywhentheengineisswitched OFF andtheengineisincoldcondition The temperature displayed will be higher if the engine in running or immediately after it is switched OFF since the sensor will only pickup the higher temperature surr...

Page 31: ...rature sensor push buttonmanagement Required button n Mode Function MODE Button Action 10s TEMPERATURE UNIT CHANGE OVER In ignition key ON position long press and hold MODE button for period 10 s to resettemperatureunitsfromdegreeCelsiusto Fahrenheit and vice versa Pressure time s ...

Page 32: ... will not work Front wheel ABS will only work Procedure to Reset to Dual channel Ignition switch reset vehicle will return to default dual channel ABS mode CAUTION If Single channel ABS mode enabled ABS only controls the front wheel The rear wheel is not controlled by ABS and may lock during braking maneuvers Dual Channel ABS mode Default ABS will work on both wheels Ignition key Reset Turning ign...

Page 33: ...ngle channel mode indication SinglechannelActivationwithignitionkeyreset ABS tell tale will blink thrice to indicate activation followed by ABS tell tale continuous ON once the vehicle is ride more than 5 kmph ABS tell tale will blink continuously Single channel Activation without ignition key reset ABS tell tale will blink continuously Ignition key Reset Turning ignition switch from OFF to ON ABS...

Page 34: ...ter jet directly oninstrument cluster for cleaning Useonlywater spraycleaningandwipe WARNING it with soft dry cloth n Service reminder can be reset ONLY by authorised personnel atservicecentreafter service is completed n Service reminder symbol will ﬂash on as per below distance input from odometer i 1st service 450 km ii 2nd service 4900 km iii from there on for every 5000 km from previous value ...

Page 35: ...RATIONOFCONTROLS 4 ODOMETER n Displays the cumulative kilometers the vehicle has covered TRIP A B AVG SPEED A B n Trip A B indicates distancetravelled in particular trip n AvgA Bindicatesaveragespeedofvehicleinparticular trip mode ...

Page 36: ...n TRIP A AVG A TRIP B AVG B SELECT 1 s In ignition key ON position Move to AVA A SELECT 2 5 s TRIP A AVG A RESET SELECT 1 s Move to TRIP B SELECT 2 5 s TRIP A AVG A RESET SELECT 1 s Move to AVG B SELECT 2 5 s TRIP B AVG B RESET SELECT 1 s Move to TRIP A SELECT 2 5 s TRIP B AVG B RESET ...

Page 37: ...F will get activated when needle on fuel gauge enters the red zone OPERATIONOFCONTROLS n TRIP F MODE Trip F mode would come into function automatically n Trip F mode would de activate automatically if fuel is ﬁlled above 5 5 0 5 l n DuringTrip F mode rider can toggle betweenTripA B but mode will return automatically to Trip F after 25 5 s NOTE n Trip F will stop displaying at approximately 90 5 s ...

Page 38: ...e the select or reset buttons while riding the motorcycle Doing so may cause loss of concentration and unstable riding leading to a potential accident resulting in serious injury to both rider and other road users besides causing severe damage to the motorcycle n Indicates when side stand is extended ...

Page 39: ...S ABS MIL n Displays the gear position in which the vehicle is traveling G represents the Gear and 1 represents the gear position n When in neutral the indication will be N n Whenin gear the appropriate number between 1 to 5 will be displayed 1 Turn Left Left turn signal ON 2 Turn right Right turn signal ON 3 Neutral Transmission is in Neutral TURN LEFT ...

Page 40: ...ated as soon as ignition stop switchare ON and willgo OFF after the engine isstarted n Will remain continuously ON incase of any CAUTION malfunction of the EMS 7 ABS MIL Will be continuously ON during initial check up untilor after vehicle runningfor aparticular distance speed and will turn OFF if system is ok then will light up again in case of any ABS system malfunction DO NOT run motorcycle inc...

Page 41: ...efulforrightselectionof gear withrespecttoengine WARNING rpm n Do not run engine with gears in neutral as rpm will go beyond red zone n Do not ride motorcycle in lower gears with high acceleration as it will cause rpm to start to red zone OPERATIONOFCONTROLS aﬀect the main parts inside engine ...

Page 42: ... DO NOT run motorcycle incase the ABS Indicator lamp continuously ON n The ABS indicator blink continuously to indicate Single channel ABS mode is enabled WARNING Do not use the motorcycle for long duration with the fuel indication inred zone Refuel at the earliest Failure to do so may cause the motorcycle to run out of fuel and get stranded in addition to causing serious damage to the fuel pump ...

Page 43: ...connectivity with navigation search based onRE Mobile app with the support of Google Maps Device is capable of showing turn by turn navigationon a custom designed round color TFT withuniquely designed arrowfont designed intuitively for ease of riding Background display can be switched between day mode and night mode which can be selected by riders from RE Mobile app Scan the QR Code to download In...

Page 44: ...n is reached n User can select day and night mode through RE mobile app only n Mobile Phone low battery indication OPERATIONOFCONTROLS TRIPPER DISCLAIMER Tripper unit display may look dull during sun overhead conditions this is normal and due to impact of direct sunlight on the unit customersto refer duringother riding conditions Primary direction or next turn Secondary direction or next tonexttur...

Page 45: ...ll be shown only when primary turn is less than 100 m ifthereisnoturnthedisplay willbeblankinthisregion n Distance to destination or ETA Shows the total distance to destination or estimated time of arrival OPERATIONOFCONTROLS TRIPPER based on user selection fromRE Mobile app Smartphones compatible version to use RE Mobile app n Compatible with Android and iOS n Android support Current version 2 n ...

Page 46: ...rsion If pairing is initiated one time PIN no display Green helmet Tripper In case of connection lost no input in paired mode tripper will show clock Clock a If no connection is established b If connection is established but no navigation input is observed c Once destination is reached OPERATIONOFCONTROLS TRIPPER ...

Page 47: ...t apply or use gasoline petrol related ﬂuidsfor cleaningor wipingon instrumentcluster or Tripper as it may result inpermanent damage to the same n After every Ignition ON cycle tripper will be in discoverable mode for 120 s n Incasethere isno connection established within 120s display will enter into clock mode to re initiate connection Ignition OFF ON cycle to be repeated n During Navigation mode...

Page 48: ...ion n Bluetooth connection can be established only through RE Mobile app n Ensure bluetooth and location settings are turned always ON before usage n Disablebatteryoptimisationsettings lowbatterycut oﬀ setting of smartphone for Navigation to work in lowbattery mode n RE Mobile app works only with Android Current version 2 and iOS Current Version 1 versions for other lowerversionsperformancelagcanb...

Page 49: ...ower versions performance lag can beexpected n Checkfor networksignalstrength incaseofnavigation lag n Check for data speed in case of navigation lag Navigation system performance is better in 4G band compared to other lower versions n Calibrate mobile phones frequently for more GPS accuracy location accuracy is dependent on ...

Page 50: ...e Oil level 6 Control cables inner notdamaged frayed or broken Clutch and accelerator controls working smoothly 7 Front and rear brake eﬃciency and free play in Front and Rear Brake levers 8 Hydraulicoillevelcorrectinbothfrontandrear master cylinders 9 Free movement of handle bar to left and right sides 10 All electrical controls horn working correctly 11 Head lamp tail lamps brake lamps and indic...

Page 51: ...forother road users n Please ride your motorcycle defensively Remember a motorcycle does not aﬀord the same protection as an automobile n Ride only at moderate speeds and out of traﬃc until you have be come familiar with the handling characteristics of your motorcycle under all conditions n DO NOT exceed the legal speed limit Always reduce speed when poor driving conditions exist Use extra caution...

Page 52: ...gain experience under various conditions while driving at moderate speeds Paystrictattentionto road surfacesand wind conditions n DO NOT allow other individuals under any SAFE HAPPYRIDING know they are experienced licensed riders and are circumstances tooperateyour motorcycleunless you thoroughly familiar with the operating conditions of your motorcycle RIDING GEAR n Motorcycleridingpantsand jacke...

Page 53: ...herear viewmirror SAFE HAPPYRIDING without turning your head n Never wear loose ﬁttingclothes otherwise they could catch on the control levers footrests or wheels and cause injury or an accident n Always wear protectiveclothingthat covers yourlegs anklesandfeet The engineorexhaustsystembecome veryhot duringor afteroperationandcancauseburns CAUTION Avoid any contact with the exhaust system The exha...

Page 54: ...simultaneously for maximum braking eﬃciency n Please use utmost caution while applying brakes especially while riding under wet or bad road WARNING Brake pad wear will be increased if the motorcycle is used conditions frequently oﬀ road Always inspect the brake pads more frequently if the motorcycle is used oﬀ road replace the brake pads before they become worn to or beyond the minimum service thi...

Page 55: ...ecurelystrappedtotherearand sides of the motorcycle and do not become loose or shift while riding n Ensure the weight is distributed evenly on both sides of the motorcycle n Do not carry excessively heavy or huge cargo on the motorcycle n The maximum permissible weight of the pannier box is 5 kg each side n Do not hang any items on the handle bar and luggage carrier while riding which will lead to...

Page 56: ...adhere to the above precautions can cause loss of control on the motorcycle leading to a potential accident resulting in serious injury tobothrider and other roadusers besides causingsevere damage to the motorcycle Totalweight oftherider andanypassenger accessoriesand WARNING luggage must not exceed the maximum load limit WARNING DO NOT tow a disabled motorcycle The steering and handlingof themoto...

Page 57: ...trailertothemotorcycleAttachingatrailer can cause loss of control on the motorcycle leading to a potential accident resultinginseriousinjury to bothrider and other road users besides causing severe damage to WARNING the motorcycle Maxload ongrabrailnot toexceed 7kg ...

Page 58: ...hicle n DONOT exceed the legal speed limit or drive too fast for existing conditions Always reduce speed when poor drivingconditionsexist Highspeedincreasesthe inﬂuenceofany other condition aﬀecting stability and increases the possibility of loss of control n Keep to the correct side of the road center line when meeting oncoming vehicle n All traﬃ c signs including manual controls at intersections...

Page 59: ... through a yellow or red traﬃc light n DONOT leave the curb or parking area without signaling Be sure your way is clear to enter moving traﬃc A moving line of traﬃc always has the right of way RULESOFTHEROAD n Whenparking the motorcycle park on a ﬁrm and ﬂat surface toprevent it from falling over n Protect your motorcycle against theft After parking your motorcycle ensure that the steering head is...

Page 60: ...pe of mirror will look smaller and farther away than when seen in a ﬂat mirror SIDE VIEW MIRRORS NOTE To establish the relative distance of vehicles objects behind your motorcycle through the mirrors adjust each mirror in such a way that a small portion of your shoulder isvisibleand a largeportionbehind yourmotorcycle isseen clearly with reference to your ridingposture Use care when judging the si...

Page 61: ...s shown inthe table below 2 Do not exceed maximum speciﬁed pay load 3 Warmup the enginefor a few minutes at idlingspeed to allow engine oil to lubricate all the moving parts in the engine before riding the motorcycle 4 Avoidfullthrottleoperationand donotrideatconstant throttle continuously Vary the speed by 10 while riding 5 Avoid sudden accelerations and racing starts 6 Avoid prolonged full throt...

Page 62: ...will glow for few seconds and switch OFF this indicates that all the functions of Electronic fuel injection EFI system is functioning normally 1 ENGINE MALFUNCTION INDICATOR LAMP In the event of any malfunction inthe EFI System the MIL will glow continuously It is recommended to take the motorcycle to a nearest Royal Enﬁeld Authorized service station for a detailed inspection and correction of the...

Page 63: ...TI LOCK BRAKING SYSTEM ABS brakes from locking the wheels while reducingthe speed of the vehicle This will help the rider to control the motorcycle AnABSindicatorlamp isprovidedin theconsole asshown in adjacent image to warn the rider in the event of any malfunction of the ABS When the ignition and kill switch are switched ON the ABS sign light up and remain ON till the motorcycle attains a speed ...

Page 64: ...ner and therefore prevent skidding due to loss of traction Please anticipate the stopping distance required for the speed of travel and apply brakes well in advance so as to bring the motorcycle to a safe stop Please applyboth brakestostop front brake momentarily earlier followed by rear brake to have better tractionand control of the motorcycle Always ensure that you ride well within the legal sp...

Page 65: ...the brake ﬂuid at MAX level in the front and rear brake master cylindersand there is no leak in the brakes systems n Apply both the brakes simultaneously for better eﬃciency while braking n Intheevent of theABSindicator remaining continuously ON please take the motorcycle to a nearest authorised Royal Enﬁeld service station to inspect the brakes system control of the vehicle n ABS switchneed to ac...

Page 66: ...r isinNeutralpositionandtheNeutral lamp is glowing in the Instrument Cluster To shift into neutral move the motorcycle back and forth gently while simultaneously shifting the gear CAUTION Do not attempt to shift gears when engine is OFF and rear wheel is stationary as itwillcause damage togear shift mechanism Please move motorcycle backand forthwhile simultaneously shifting gears ...

Page 67: ...t The engine should be allowed to run slowly for 15 to 30 s This will allow the engine to warm up and let oil reach all surfaces needing lubrication Failure to adhere in damage tothe engine NOTE n It isrecommended toswitch oﬀ the engine when the engine is in idling condition for long time n It is recommended not to accelerate by giving excessive throttle for more than 5 min when the engine is in i...

Page 68: ... grip n Press gear pedal withtoe toengage 1st gear n Gently open throttle and release clutch simultaneously If clutch is released suddenly the engine may stall and cause a jerky start CAUTION The clutch must be fully disengaged before attempting a gear shift Failure to fully disengage the clutch may cause ajerkystartORstallingthe enginebesidescausing damage totransmissionparts ...

Page 69: ... may begin to slowdown and show lack of power while climbing steep hills Inthat case you should shift to a lower gear so that engine will be operating in normal power range which will prevent the motorcycle from losing momentum The engine may be used for braking by shifting to a lower gear while riding down to steep hill n Lift gear lever withtoeto engage 2nd and subsequent gears ...

Page 70: ... ﬁrmly toavoid the motorcycle from falling n Selecta ﬁrm ﬂat surface n Extendside stand Tilt the motorcycle tothe left till it is supported ﬁrmly CAUTION When Side stand is in ON position a Engine will start if vehicle is in neutral but will cut oﬀ ignition and fuel when gear is engaged b Engine will not start if gear is engaged already PARKING MOTORCYCLE ON SIDE STAND ...

Page 71: ...d the motorcycle may fall over over andcausinginjurytoyouortoothersand damage tothe motorcycle parts n Do not ride motorcycle with the side stand extended Doing so can cause theside stand totouchthe ground while cornering and result in instability loss of control on the motorcycle leading to a potential accident resultinseriousinjurytobothsidesandother road users besides causing severe damage to t...

Page 72: ...lers do take care of that aspect If you are getting it attended elsewherepleaseensurethatitemsaresegregatedandkept in a suitable container or bag without allowing them to get into soil water or sewerage line drains water bodies like lake canal river seaetc Westrongly recommend that they are disposed oﬀ inaccordance to the applicable law throughPollution Control Board approved agenciesin the locali...

Page 73: ...ncewill need to be done earlier as may berequired Contactanearest Royal Enﬁeld Authorised Dealer ServiceCentreto carry out theperiodical maintenanceandfor any expertadvice Sl DESCRIPTION No PAID SERVICE km 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 FREE SERVICE whicheveris earlier 1 Engine Oil Level check Replace R I R I R I R I R I R Check level at every 1000 ...

Page 74: ... I I I I I I I I I 7 Spark plug C A C A C A R C A C A R C A C A R C A 8 HT leads for crack I I I I I I I I I I I 9 Fuel Hose Clip I I I I I I I I R I I 10 Fuel Pump under tank Mounting Check for screw tightness in all services C C R C R C R C R C R 11 Air ﬁlter element Clean Replace more frequently if motorcycle always used in dusty oﬀ Road conditions 12 Accelerator Cable I A I A I A I A I A R I A...

Page 75: ...pes Hose clip I I I I I I I I R I I 15 Evaporative Emission Equipment rubber hoses I I I I I I I I R I I 16 Throttle body Throttle body should be removed from the vehicle and cleaned with a dry Microﬁbre cloth Usage of throttle body cleaners or any similar solvent or alcohol based liquids for cleaning is strictly prohibited Throttle body cleaning every 10000 km 12 Months or earlier as required 17 ...

Page 76: ...ed 19 Clutch no slippage I I I I I I I I I I I 20 Steering head bearings I A Inspect adjust lubricate for every 5000 km or earlier as required Replace if necessary 21 Front Fork oil I I I I R I I I R I I 22 Rear Wheel Drive Chain I A Clean Lubricate Adjust every 1000 km or earlier as required 23 Battery terminals apply petroleum jelly C C C C C C C C C C C 24 Earth wire eyelet Tightness I I I I I ...

Page 77: ...brake hose Washers Front Rear I I I I I I I I I I I 27 Brake Pads Front Rear I I I I I I I I I I I 28 Tyre wear pattern Front Rear 1 I I I I I I I I I I I 29 Spokes tightness Wheel rim run out front rear I I I I I I I I I I I 30 Front Rear wheel bearings for play I I I I I I R I I I I I R 31 Swingarm Pivot Bearings I Inspect If required lubricate for every 5000 km or earlier as required Replace if...

Page 78: ...ake Pedal free play Adjust every 1000 km or earlier as required 35 Rear wheel cush rubbers I I I I I I I I I I I 36 All Mounting Fasteners in vehicle for tightness I T I T I T I T I T I T I T I T I T I T I T 37 Hand levers Center stand Side stand Rider Pillion foot rest pivots Gear shift levers Lubricate every 1000 km or earlier as required 38 Cam Chain Chain Pads Auto chain Tensioner I I I I I I ...

Page 79: ... ridden in unusually wet or dusty areas Service more frequently when riding in rain or at full throttle PERIODICALMAINTENANCE 1 Tyreto bereplacedif thetyrewear identiﬁcationmark reached 2 To be doneat authorisedRoyalEnﬁeldDealer ServiceCenter Sl DESCRIPTION No PAID SERVICE km 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 FREE SERVICE whicheveris earlier 39 Starter...

Page 80: ... bolt 1 on fork end 3 Tool Spark Plug To Loosen tighten Spark plug 1 4 Screw Driver To Loosen tighten screws 1 of housing 5 Extension Tube Additional leverage for loosening tightening wheel axle nuts 1 6 Combination Spanner To Loosen tighten hex nuts 1 Open end 17 13 mm 7 Combination Ring To Loosen tighten wheel 1 Spanner 24 14 mm axle nuts 8 D E Spanner 10 12 mm To Loosen tighten hex nuts 1 9 Too...

Page 81: ...terilized Gauze Swab 5 cm x 5 cm 2 5 Sterilized elastic plaster 7 cm x 6 cm 1 6 Elastic Gauze bandage 8 cm x 1 mtr 1 7 First aid kit pouch 1 S No Description Qty FIRSTAID KIT Aﬁrst aid kit isprovided withthe motorcyle for any emergency requirements Please inspect the kit regularly and replace materials upon expiry 4 5 2 3 6 7 ...

Page 82: ...le However if you are in experiencedor feelitisbestdonebyanexperiencedperson we recommend you to get in touch with a Royal Enﬁeld AuthorisedDealer ServiceCentre SIDE STAND PIVOTS HAND LEVER PIVOTS Wipe the areafreeofdirt grease Applya fewdropsof oilon the pivots Apply a few drops of oil on thepivotsafter cleaningthe area of dirt ...

Page 83: ... CHAIN n Lubricate the center stand pivot periodically for smoother operation of center stand PERIODICAL MAINTENANCE Cleanthe drive chain carefully Apply chain lubricant while simultaneously rotating the rear wheel Wipe oﬀ the excess lubricant Lubricate ...

Page 84: ...nutes switch oﬀ before checking oil level n The levelis correct if the oillevel isinthemiddleof the oil level window n Top up only with recommended Engine oil OIL LEVEL INSPECTION MAX CAUTION Using Non Recommended In correct oils can cause serious damage to the moving parts aﬀect performance of the motorcycle AND void the warranty ...

Page 85: ...k plug n Remove spark plug using the plug spanner and tommy bar n Clean the insulator tip and electrodes of the plug carefully n Clean adjust electrode gap every 500 km if required and replace every 15 000 km n Reﬁt the spark plug on the cylinder head n Reﬁt the spark plug cap onthe spark plug n Make sure the spark plug spark plugcap and HT cable areproperﬁtment CLEANING AND ADJUSTING PLUG GAP SPA...

Page 86: ...cause damage to painted parts Please ensure brake ﬂuid does not spill on any part of the motorcycle In the event of a spill please cleanthe area immediately with a soft cloth preferably a wet cloth to avoid damage n Replacetyres if Side wall cracks cuts or damages uneven lugs wear etc Tyre lugs work out upto the wear indicator symbol on the side wall Front Rear 2 2 Solo 1 75 kg cm 25 psi 2 25 kg c...

Page 87: ...de and remove spindle nut andwasher fromleftside MINORMAINTENANCETIPS WARNING Dismantling and reassembly of the wheel should be done ONLY by an experienced technician Failure to do so may cause loss of control on the motorcycle leading to a potential accident resulting in serious injury to both rider and other road users besides causing severe damage to the motorcycle FRONT WHEEL REMOVAL ...

Page 88: ...a suitable spacer of 4 mm thickness between the brake pads toavoid accidental compression ofthe brakelever MINORMAINTENANCETIPS n Support wheel and pull out spindle from right side n Remove the wheel along with RH side spacer Disc side spacer OR Remove wheel along with wheel speed sensor and spacer Follow below procedure if vehicle have a wheel speed sensor assembly ...

Page 89: ...side between the front fork legs ensuring the brake disc is located between the brake pads OR Follow below procedure if vehicle have a wheel speed sensor assembly Position wheel along with wheel speed sensor and spacer on left side between the front fork legs ensuring the brake disc is located between the brake pads n Insert wheel spindle from right fork end n Ensure the position of RH side Spacer...

Page 90: ...swing arm side spacer aligned properly OR Follow below procedure if vehicle have a wheel speed sensor assembly Positionwheel speed sensor such that it is parallel to ground n Holds spindle on right side locate washer and nut on spindle on left side and tighten ﬁrmly n Tighten pinch bolt on right fork end n Rotate wheel and check for smoothrotation n MINORMAINTENANCETIPS Pressbrake lever and check ...

Page 91: ...S wheel speed sensor and support it suitably to avoid damage to the brake hose and ABS wheel speed sensor n Slide out the rear wheel from the swing arm taking care not to drop the spacers on the wheel hub CAUTION Do not press the brake pedal when wheel is removed as this will result in the brake pads coming out too far from the brakecaliper Place a suitable spacer of 4 mm thickness between the bra...

Page 92: ...gs correctly n Removethespacer betweenthe brakepadsand locatethecaliper such that the brake disc is between the brakepads n Locate the caliper bracket slot on the lug in the swing arm n Position the respective spacers on the left and right side of the wheel hub n Ensure theaxlemountinghole intheswingarm wheel hub and caliper bracket are aligned n Insert the wheel axle from the left side of the swi...

Page 93: ...r damage as it will seriously aﬀect the performance of the rear brake n Check rear brake for eﬀectiveness and correct functioning before using the motorcycle n Assemble washer and wheel axle nut onright side and tighten to correct torque n Fix the brake hose pipe in swing armclips properly n Ensure correct chain tension and rear wheel alignment withfront wheel by adjusting the adjusters onbothleft...

Page 94: ...ut n Loosen lock nuts of the chain adjuster onbothends of the swing arm n Tighten loosentheadjusternut onleftswingarmend to reduce increase chaintension n Ensure the ground is level ﬁrm and place the motorcycle in its center stand n Rotate wheel slowly and check chain free play at the top run to be between 20 30 mm WARNING Please follow instructions as per periodical maintenance DRIVE CHAIN TENSIO...

Page 95: ...eadjuster nuts takingcare notto disturb the adjuster nut settings n Tighten rear wheel spindle nut to a speciﬁed torque WARNING Chain slackness beyond 30 mm will lead to chain slippage Maintain drive chain slackness within the speciﬁed limits at every 1000 km interval Please Check the front and rear wheels are correctly aligned after the chainadjustment IftheEngine Rear sprocket are worn replaceth...

Page 96: ... MINORMAINTENANCETIPS adjustment is done Rear brake pedal free play7 to 11 mm n Loosen the lock nut in master cylinder push rod assembly n Rotate the master cylinder pushrod anti clockwise to reduce the rear brake pedal free play n Rotate the master cylinder push rod clockwise to increasethe rear brake pedal free play n After adjustment tighten the lock nut in master Cylinder pushrod assembly ADJU...

Page 97: ...ENANCETIPS BRAKE PAD WEAR Check thewearindicator mark oneachpad If either pad is worn tothewear indicator mark Replace both padsas set Visit royalenﬁeld dealer for this service Check thewearindicator mark oneachpad If either pad is worn tothewear indicator mark Replace both padsas set Visit royalenﬁeld dealer for this service ...

Page 98: ...inals n Remove the side panel on the right sight by unscrewing the hex socket button head screws n Ensure motorcycle is parked on its center stand in a well ventilated area n Ensure the ignition switchand engine stop switch are in OFF position n Disconnect the Harness connectors around the batterylocated area REMOVAL OF BATTERY FROM THE MOTORCYCLE BATTERY MAINTENANCE ...

Page 99: ...ble while removing the battery connections n Unlock turnthe key clockwise and remove the pillion seat n Remove front seat n Remove the Battery carrier bracket by looseningthehex bolt n Disconnect boththe Battery terminals wires negative ﬁrst and positive next MINORMAINTENANCETIPS respectively n Take out the battery ...

Page 100: ...tterycarriersuch that the terminals are facing inside n Ensure ignition switch is in OFF condition n Connecttheredwireto thepositive terminal of the battery ﬁrst n Next connect the black wire to the negative terminal ofthebattery n Smear the terminalswithpetroleum jelly Do not use grease in the battery terminals n Place the terminal boot cap properly n Reﬁtthebatterybracket n Reconnect the harness...

Page 101: ...ain lead and lead components known to cause cancer and birth defects or other reproductive harm Always wear approved protective face shield rubberized gloves and protective clothing when working withbatteries KEEPBATTERIES AND ACID OUT OF REACH OF CHILDREN WARNING CAUTION Keep the ve and ve cables ﬁrmly conneted to the respective battery terminals Failure todo so mayresult in damage to the motorcy...

Page 102: ... the protective rubber cap over the bulb MINORMAINTENANCETIPS n Gentlypressthebulbholding clip and release it from the slot in thereﬂector n Remove the bulb from the reﬂector NOTE Never touch the bulb with your ﬁngers Finger prints willetchthe glass and decrease bulb life Always hold the bulb with clean dry cloth during handling Don t disturb the vent cap providedintheinner bodymould CHANGING ELEC...

Page 103: ...it in the slot inthereﬂector n Put the protectiverubber cap over the bulb correctly such that the vent pipe is facing downwards n Connect head lamp coupler on the bulb terminals correctly n Locate theheadlamp rim in the housing correctly such that it locks in place and the 2 mounting holes of the rim are aligned with the holes in the housing n Assemble the 2 screws and tighten ﬁrmly ...

Page 104: ...ckwise direction to lock the bulb in the holder n Reﬁt the traﬃcator cover with reﬂector and tighten the screw MINORMAINTENANCETIPS The tail lamp license plate illuminator has a LED lighting system Inthe event of failure the entire tail lamp license plate illuminator assembly should be replaced Contact an Authorised Royal Enﬁeld Dealer Service Centre toreplace thesame TAIL LAMP LICENSE PLATE ILLUM...

Page 105: ...acetherequiredfusewiththesparefuseavailable inthe fusecarrier n The blade fuses are located in the carrier NOTE Please ensure to replace a spare fuse in the holder at the earliest opportunity MINORMAINTENANCETIPS RELAY STARTER FUSE BOX Spare Fuse 40A F0 Main Fuse 40A ...

Page 106: ...se carrier NOTE F2 Device Bt Fuse 10 A EMS ECU Instrument Cluster Tripper F3 Ignition Fuse EFI 15 A Relay Coil EMS ECU Ignition Coil Fuel pump Injector O2 Sensor E purge and Diagnostic tool F4 Signalling Fuse 15 A Instrument Cluster Tripper Gear Position Sensor Flasher Brake Switch and Horn F6 Lighting Fuse 15 A Headlamp Low High Beam Front Position Lamp Rear Position Lamp License Plate Illuminato...

Page 107: ...in torepeated fuse failures Usage of fuses other than speciﬁed rating will damage the complete electrical system ID No Function Rating F1 CHARGING FUSE 25 A F2 DEVICE Bt FUSE 10A F3 IGNITION FUSE EFI 15 A F4 SIGNALLING FUSE 15 A F5 SPARE FUSE 5 A F6 LIGHTING FUSE 15 A F7 ABS MAIN 1 15 A F8 ABS MAIN 2 10 A F9 ABS IGNITION 5 A SF1 SPARE FUSE 10 A SF2 SPARE FUSE 15 A SF3 SPARE FUSE 25 A ID No Functio...

Page 108: ...tances such as stain removers water repellent compounds petroleum WARNING Never attempt to clean the windshield while riding Failure to do so may cause loss of control on the motorcycle leading to a potential accident resulting in serious injury to both rider and other road users besides causing severe damage to the motorcycle products solvents and alcohol based material will seriously aﬀect the w...

Page 109: ...S PRIOR TO THE COMMENCEMENT Spark plug Spark plug cap OF LONG JOURNEY n Service the motorcycle at a Royal Enﬁeld Authorised Dealer ServiceCentre n Ensuresuﬃcient quantityofpetrol inthe fuel tankfor the journeyplanned n Check andcorrect tyrepressure ifnecessary CHECKS AFTER EVERY 1500 km OF RUN n Any loosefasteners n Conditionof the tyres n Correct oil level in engine n Working of all lights and ho...

Page 110: ...E PRELOAD n Toincreasespringpreload turnpreloadadjuster inthe clockwise direction REDUCING THE PRELOAD n To decrease the springpreload turnpreloadadjuster in the anti clockwise direction CAUTION It is recommended to visit Authorised Dealer for adjusting springpreload and shock absorber settings ...

Page 111: ...or eﬀectiveriding on surfaced roads n Always checkthe tyrepressuresare correct BRAKES n Riding on dirty muddy roads brakes may not be eﬀective immediately because of dirts moisture on OFFROADING n the disc pads Apply the brakes in good time until the brakes have been cleaned RIMS n It is recommended to check the rims wheels for damage after oﬀ roading ...

Page 112: ...motorcycle s handling characteristics on surfaced roads n Remember to correct the spring shock absorber settings before returningto surfaced roads AIR FILTER ELEMENT n Cleaning of air ﬁlter element is recommended for eﬀective utilisationofair ﬁlter element in returningto surfaced roads n Check for any damagesor clog inair ﬁlter and replace ifrequired ...

Page 113: ...he bearings and course the handle WASHINGPROCEDURE bar movement to become sticky n Never spray water with great force on head lamp speedometer ﬂasher lights frontandrear wheelhubs electrical connections and wires control cables cables sparkplug battery ABS ECU EMS ECU side mirrors steeringstem etc n Donotapplyanycorrosivesolventonpaintedsurfaces or rubber parts n Use luke warm water and mild deter...

Page 114: ... No direct jet at the edges of decal electrical parts coupler joints silencer tail pipe radiator lubrication points like steering cone kit brake pedal wheel bearings chain brake cam swing arm bushes to be washed in spray mode only not in jet mode n Once the motorcycle has been ridden in salty conditionsor near coastal areas it is recommended to wash your motorcycle with cold water Please do not us...

Page 115: ... Wipe Steeringarea with Cotton Cloth WARNING Do not spray high pressure water on top bottom dust seal area as shown Wet a small piece of cloth and gently rub on required areas to clean the steering tube area NOTE High pressure water Jet should not directly Shown on the above mentioned Locations ...

Page 116: ...e Instrument Cluster Use protector tocover the ﬁns Location Don t use High pressure water jet on Oil Cooler Wipe Head lamp glass with Cotton Cloth Don t use Highpressure Water on Head lamp Front back NOTE High pressure water Jet should not directly Shown on the above mentioned Locations ...

Page 117: ...115 Royal Enﬁeld Himalayan WASHINGPROCEDURE Location Stickers on Front Mudguard Rear Mudguard Side Panel High pressure water Jet should not directly Shown on these Locations Note ...

Page 118: ... throughspark plug hole Close the hole and crank engine several times and reﬁt spark plug n Cleanrear chain thoroughly and apply a chain lube n Remove battery from the motorcycle Clean the terminalsfree of corrosion and apply petroleum jelly to terminals n Storethebatteryinacool dryandwellventilatedplace n Coverthesilencerwithplastic bagstopreventmoisture entry Set the motorcycle on its center sta...

Page 119: ...ensure the motorcycle is restored to its peak operating conditions n Ifthemotorcycleisnotused fora month orlonger Itis advised to disconnect battery terminals and remove the battery Before reﬁtting the battery in the motorcycle check the battery voltage is within speciﬁcation if not recharge it from authorised STORAGEPRECAUTIONS service workshop battery dealer ...

Page 120: ...roblem and to ensure trouble free performance Symptom Observations Check for Remedy 1 Ignition Engine stop switch is in OFF position Engine Does not start Switch ON Ignition Engine stop switch 1 Battery completely dead Replace battery 2 Fuse Blown Replace appropriate fuse Note If fuse blows again contact Authorised ServiceCentre 4 Electricals not working 3 Lights horn very dim HornPoor Low Sound W...

Page 121: ...s ON SIDE STAND SWITCH MALFUNCTION Check if gear is engaged and the side stand is down If the ambient Temperature is low use Manual Bi starter Engine shuts oﬀ as soon as throttle is closed Engine Starts BUT shuts oﬀ immediately Idling rpm set too low setting disturbed Contact Authorised Service Centre for resetting the Idling rpm Check if the MIL Lamp is glowing If yes Contact AuthorisedServiceCen...

Page 122: ...g station 1 Typically happens after a Reﬁll Adulterated Water in Fuel Engine Misﬁres Runs Erratically Stops 2 Motorcycle driven in Low gear High rpm Crowded places for long time Excessive Engine temperature Switch OFF Engine and allow to cool down Check if the MIL Lamp is glowing If yes Contact TROUBLESHOOTING AuthorisedServiceCentre ...

Page 123: ... Clutch is Slipping Check for sticky clutch clutch not having any free play Rear Chain excessively loose causing chain to slip on Sprocket Adjust Rear chain to correct tension Check if the MIL Lamp is glowing If yes Contact AuthorisedServiceCentre Take the vehicle to service centre for diagnosis ABS lamp continuously ON ABS Anti lock Braking system ...

Page 124: ...rlier 2 Inorder toavail warranty beneﬁtsbysecondor subsequentowner the second subsequent owner should inform the nearest Royal Enﬁeld Service Centreabout the purchase ofthe bike andshallﬁll inthe requisite details inthe formas requested by Royal Enﬁeld 3 Thewarrantyshall beapplicableonlyifalltheservicesareavailedinthe respectiveperiod kilometer rangesasperthe schedule inthe owner s manual from RE ...

Page 125: ...customer RE shall not be liable in anymanner to replace them through their dealers RE will however provide assistance in referring such claimson the respective manufacturer 7 Warranty shall not apply to a Normal ageing deterioration or rustingof plated parts paints coat rubber parts soft items glass items plastic partsetc b Components like fuel ﬁlter oil ﬁlter air ﬁlter paper element control cable...

Page 126: ...nce of the motorcycle f Parts damaged due toaccidents collision abuse etc g Irregularities not recognised as aﬀecting the quality or function of the motorcycle such as slight vibration Oil leakage discolorationof exhaust pipe bend and cat region silencer soft or hard shockabsorber etc h Warrantyis not applicable for discolorationof Exhaust Pipe Silencer as it is a natural process that will happen ...

Page 127: ...s cleaning fuel system engine tune upand other such adjustments n Oxidizationof buﬀed painted powder coated items etc 8 Use only Royal Enﬁeld approved parts and accessories Use of certain other manufacturer sperformance parts will void your new motorcycle warranty 9 RE reserves the right to ﬁnally decide on all warranty claims 10 RE reservesthe right tomake changes indesign of the motorcycle witho...

Page 128: ...s then the Authorised Service Centre shall take necessary corrective measures and shall at its sole discretion repair or replace free of charge components of the emission control system to meet the required emissionstandards The method s of examination to determine the warranty conditions of the emission warranty related componentswill be at the sole discretion of Royal Enﬁeld and or our Authorise...

Page 129: ...for replacement under warranty will become the property of Royal Enﬁeld Royal Enﬁeld will not be responsible for the cost of transportation of the motorcycle to the nearest Authorised Service Centre or for any loss due to non availability of the motorcycle during the period of examination and repairs by Royal Enﬁeldand or their Authorised Service Centre Royal Enﬁeld will not be responsible for any...

Page 130: ...e upon discoveryof failure tocomplywith the emission standard inspite of having maintained and used the motorcycle in accordance with the instructions in the owner s manual andhaving carried out such repairsand adjustments as maybe required with a view to establish such compliance n Production of a valid Pollution Under Control Certiﬁcate is necessary to claim Emission Warranty n Produces the owne...

Page 131: ...diﬁedorreplacedinanunauthorised manner n The odometer is not functioning or the odometer and or its reading has been changed tampered with so that the actual distance covered cannot be readily determined n The motorcycle has been used for competitions races and rallies or for the purpose of establishing records n On examination by Royal Enﬁeld or its Authorised Dealer Service Centre if the motorcy...

Page 132: ...through a Royal Enﬁeld AuthorisedServiceCentre n Use only Unleaded petrol 91 RON or higher from reputed fuel pumps n Ensure the fuel used isnot adulterated n Use correct spark plug asrecommended in the owner s manual n Use lubricants as per recommendations given on grade brand in the owner s manual n The emission related components are tampered with n All service and partsrelated bills and voucher...

Page 133: ...rvice 20000 km 24 Months 6 6th Paid Service 25000 km 30 Months 7 7th Paid Service 30000 km 36 Months NOTE Costofparts lubricants ﬁltersand other consumablesarechargeabletothecustomer ontheirrespectiveserviceactivities Refer the Periodic maintenanceChart for therespectiveservice activities S No Date Dealer Code Type of Service Job Card No Brief details of service km Schedule Labour is free for this...

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