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Royal Enfield HIMALAYAN EURO IV 2017, Service Manual

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Royal Enfield HIMALAYAN EURO IV 2017 Service Manual Download Page 289

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ROYAL ENFIELD    HIMALAYAN EURO IV VEHICLE SERVICE MANUAL

A. Clutch cable related

Routing improper

Check & correct

Strapped too tight to frame

Check & correct

Inner cable sticky

Check & replace

Inner / outer cable damaged

Check & replace

Free play excess

Correct free play to 2-3mm

B

B. Oil related

Oil less / more viscous. Wrong specification

Check & correct

Oil level too high / too low

Check & correct

Gear lever position incorrect

Check & correct

Shift lever sticky / jammed on pivot pin

Check, clean & lubricate pivot pin

C. Shift lever / linkage /

Gear shift linkage ball joint stuck/worn out Check & correct

shifting M

echanism

Return spring weak / broken

Check & replace

related

Indexing pawl pins worn out

Check & replace

Shift forks sticky in pin / selector drum

Check & correct

Shift forks / pins worn out

Check & replace

Selector drum grooves worn out

Check & replace

Clutch pad sticky / worn out

Check & replace

Clutch plates movement sticky

Check & correct

D. Clutch assembly related

Springs weak / broken

Check & replace

Friction plates worn out / burnt

Check & replace

Steel plates warped

Check & replace

No end float of clutch assembly in shaft

Check & correct

E. Gears does not engage

Shift forks sticky in pin / selector drum

Check & correct

Selector drum rotation sticky

Check & correct

Sliding gear movement sticky in shaft

Check & correct

Gears / bushes partially seized in shaft

Check & correct

F. Gears overshifts

Shift forks / pins worn out

Check & replace

Selector drum grooves worn out

Check & replace

Sliding Gear dogs worn out

Check & replace

Drive shaft/counter shaft splines worn out Check & replace

Drive / counter shaft bearings wornout

Check & replace

Attribute

 Probable Cause

                   Remedy

9.   GEAR SHIFTING HARD / SLIPS

Summary of Contents for HIMALAYAN EURO IV 2017

Page 1: ...EURO IV HIMALAYAN VEHICLE SERVICE MANUAL HIMALAYAN HI ...

Page 2: ... diagnosis and reassembly for the new Royal Enfield Himalayan motorcycle in a simple and scientific manner WhilethismanualisupdatedwithlatestInformationandSpecificationsatthetimeofgoingtoprint duetocontinuous improvementsbeingdonetoimproveperformance someofthedata illustrationsetc inthismanualmaybedifferent from some of the parts fitted in the motorcycle Please do feel free to write to us at suppo...

Page 3: ...ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL 2 HIMALAYAN VEHICLE VIEWS VEHICLE VIEW LH 02 ...

Page 4: ...ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL 3 VEHICLE VIEW RH 03 ...

Page 5: ...ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL 4 VEHICLEVIEW TOP 04 ...

Page 6: ... 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 Ele...

Page 7: ... 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 G...

Page 8: ...Disc 240mm Dia disc Tyre size Front 90 90 21 Rear 120 90 17 Tyre Pressures Solo Front 25 PSI 1 75 Kg cm2 Rear 32PSI 2 25 Kg cm2 With Pillion Front 27 PSI 1 89 Kg cm2 Rear 34PSI 2 39 Kg cm2 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 A...

Page 9: ... base 1465mm Ground clearance 220mm Saddle Height 800mm 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 affecttheperformanceofthe vehicle and will render the w...

Page 10: ...vice Manual Check every time after vehicle is usedfor 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 R I R I R I R I R I R Checklevelatevery1000Kmsorearlierasrequired 2 OilFilterElement R R R R R R 3 EngineoilstraineroncrankcaseLH C C C C C C 4 Inlet ExhaustTappetsetting I A I A I A I A I A I A I A I A I A I A I A ...

Page 11: ...ads Front Rear I I R I R I R I R I R 31 Tyrewearpattern Front Rear 1 I I I I I R I I I I R 32 Spokestightness Wheelrimrunoutfront rear I I I I I I I I I I I 33 Front Rearwheelbearingsforplay I I I I I I R I I I I I R 34 SwingarmPivotbearings I L I L I L I L I L I L I L I L I L I L I R 35 RearSuspensionLinkages I I L I L I R I L I L I R I L I L I R I L 36 RearDriveChain Clean Lubricate Adjustevery1...

Page 12: ...ing 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 Todriveslidebushandforkoilsealsinto bottom tube ST 25244 4 Special spanner adjuster To adjust rear shock absorber spring pre tension PART NO DESCRIPTION PHOTOS APPLICATION ...

Page 13: ... SaddleBagMtg LH 1 14 FlangedHexBoltM6X1X20 5 15 Plain Washer 4 16 Hexnutwithnyloninsert 4 17 PieceMudguard 1 18 Grommet 1 19 STUD 2 20 CrossbarAssy 1 21 Dust Cap Frame Top 1 22 Cap Swing pivot 1 23 Toe Lever Comp 1 24 PivotPin GearShifter 1 25 Sleeve GearLever 1 26 HexNut 1 27 Link Rod 1 28 HexNut LHThread 1 29 GearShiftLeverComp Short 1 30 HexSocHeadCapScrew M5X20 2 31 Switch SideStand 1 32 HexS...

Page 14: ... FlangedHex NutM8X1 25 1 14 SteadyBracketBlack 1 15 FlangedHex NutM8X1 25 2 16 BrakePedalComp RH 1 17 PivotPin BrakePedal 1 18 Spring PedalReturn 1 19 Cap Swingpivot 1 20 HexSocHeadCapScrew M6X16 2 21 Dust Cap Frame Top 1 22 Hex SocketButtonHeadScrewM6X1X16 1 23 Plain Washer 1 24 FlangedHexBoltM6X1X20 1 25 BracketAssy Airfilter 1 26 SaddleBagMtg RH 1 27 HexSocketHeadScrewM8X1 25X25 2 28 Philipspan...

Page 15: ...Silencer Gearshiftlinkage Startermotor CoverLH Gearpositionindicatorsensor MagnetorotorassemblyincludingStarterclutch Starteridlergearswithbush spindles RearChain RemovefromFDsprocket FDsprocketnut loosen CoverRH Oilpumpgears Oilpump CrankshaftNut LEFTHANDTHREADED BalancershaftBolt Clutchcenternut Clutchassembly Gearshiftshaftassembly Removecirclip washer onshiftshaftfromLHcrankcasesidefirst Camsh...

Page 16: ...ashers 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 areremovedfrom theoil 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 pipeNo 2 on RH side between engine frame is taken out carefully while d...

Page 17: ...e screwsandremovewind 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 cockpitLH RHfromthe rubber grommets in the top frame...

Page 18: ...d 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 topframesLH RHfrom connector tube Flanged hex bolts M8 Socket Span...

Page 19: ...elease front tab remove 4 8 Fuel Tank Remove 2 Hex screws from the rear end of fuel tank Gently lift fuel tank at the rear and low fuel sensor Disconnect fuel pump wiring coupler on right sight of fuel tank Disconenct fuel hose from fuel pump by disconnecting the quick fix adopter at fuel pump end Disconnect rubber hose from fuel tank to cannister Slide fuel tank towards rear to release front clam...

Page 20: ...ket 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 Gentlypullthrottlecable from bracket to release the threaded positio...

Page 21: ...he rubber grommet away from the adjuster while removing nut 4 12 Bi starter Cable Remove the Bi starter cable from the clutch lever at handle bar end At throttle body end Remove the tank assy asdetailedinsection10 Loosen the hex faced plastic nut on holder cable valve at the throttle body end slowly pull out the valve bi starter from throttle body Compress spring disconnect cable from the vale bi ...

Page 22: ...anel LH Remove 3 Hex socket Button head screws except left bottom one Gentlypullouttorelease locater from frame rubber Grommet Hex Socket Button Hd Screw M6X12 Allen Key M5 4 14 Side Panel RH Remove 3 Hex socket Button head screws except right bottom one Gentlypullouttorelease locater from frame rubber Grommet Hex Socket Button Hd Screw M6X12 Allen Key M5 ...

Page 23: ...anged hex bolt securing the earth wireeyelettocrankcase C Throttle Position Sensor TPS Disconnect black coupler from the throttlebody on LH side D MAP Disconnect black coupler from throttle body top as RH side E Fuel Injector sensor Disconnect black coupler from fuel injector at LH side F EOT Disconnect EOT Sensor coupler white on RH side G Oxygen Sensor Disconnect black coupler from Oxygen sensor...

Page 24: ...o Dismantle Instructions 4 14 E Electrical connections H Magneto coupler Disconnect white coupler from LH side Disconnect small Black coupler Pulsar wire connections from LH Side I Gear position switch coupler DisconnectBIG SMALL Black coupler from LH side J Side stand switch coupler Disconnect Red coupler from LH side ...

Page 25: ...s atthecylinderheadend Release the clamp from the studs Remove 2 Hex bolts nuts at the silencer mounting bracket end Support the silencer and remove the bolt Gently pull out the exhaust pipe from the cylinder head and remove exhaust pipe with silencer from the vehicle Hex Nuts M8X1 25 Tubularspanner 12mm NOTE Remove copper washer in cylinder head exhaust pipe seating area after removing exhaust pi...

Page 26: ...ng the braided hose to cylinder head Gently pull out the braided hose from the bottom tube and remove along with gasket from cylinder head Hd Capscrews M6X20 Allen Key M5 4 17 Fuel Injector Throttle body A Fuel Injector Ensure wiring coupler is disconnected Loosen Hex nut and remove completely Gently pull out fuel injector along with fuel hose and spacer tube B Throttle body Ensure TPS MAP Sensor ...

Page 27: ...orm clip on the front rear of throttle body sufficients Disconnect here from throttle body to pulse valve Hodl the hex nuts on inlet manifold loosen the 2 hex socket screws Slide out throttle body from Air filter housing 4 18 Gear shifter linkage LoosenHexboltonsmall gear lever mounted on gear shaft on LH side of engine Slideoutsmallleverfrom shaft Hex flange bolt M6 Socketspanner 10mm ...

Page 28: ...s Aggregate to Dismantle Instructions 4 19 R Rear Chain Link Lock Loosen rear wheel axle nut sufficiently Loosenthechainadjuster nuts on LH RH sides of the swing arm and push the rear wheel inside to create sufficient slack in the rear chain Remove chain link lock and remove chain from the engine sprocket ...

Page 29: ...Flanged Hex bolt from the rear top location of the engine DO NOT REMOVE THE BOLT FROMTHE FRAME Loosen remove 2 flanged Hex bolts from the cradle frame rear bottom on both LH RH sides RemovetheFlangedHex bolt loosened earlier from the rear top location of the engine Loosen remove Flanged Hex bolt along with oil cooler bracket holding oil cooler bracket cradle frame to main frame Gentlyremovethesupp...

Page 30: ...ame top LH side HoldflangedHexbolton Cradle frame bottom RH side and remove Flanged U nut on the cradle frame bottom LH side HoldflangedHexbolton Cradle frame rear RH side and remove Flanged U nut on the cradle frame rear LH side Hex flange bolt M10X165 HexU Nut M10X1 25 Socket Spanner 14mm Ring Spanner 14mm Hex flange bolts M10X183 HexUNuts M10X1 25 Socket Spanner 14mm Ring Spanner 14mm Removethe...

Page 31: ...have been used and removed Inspect all control cables for internal cables fraying damage Carefully inspect studs and nuts that are welded in the frame for any thread damage If found damaged use suitablethreadcleaningdiestorepairthedamages Ifthethreadsarebeyondrepair removethedamagedstuds nuts and reweld new studs nuts correctly Clean the threads in the frame carefully using suitable cleaning and s...

Page 32: ... M8X1 25X20 25 2 5 21 3 2 1 28 8 2 9 9 Skid Plate Mtg to Cradle frame Hex Flanged Bolt M6X1X10 10 1 0 8 5 0 9 11 5 1 2 10 Side Panels mounting to frame Hex Button Head M6X1X12 5 0 5 4 3 0 4 5 8 0 6 11 Gear Shift Linkage Mtg to Frame M10X1 25 30 3 0 25 5 2 6 34 5 3 5 12 Gear Shift Linkage to Shift shaft M6X1 10 1 0 8 5 0 9 11 5 1 2 13 Fuel tank Mtg to frame Hex Flange M6X1X27 5 0 5 4 3 0 4 5 8 0 6 ...

Page 33: ... mountings diagonally to torque Hex flange bolts M10X165 M10X183 HexUNuts M10X1 25 Ring Spanner 14mm Socket Spanner 14mm Torque 50 Nm 5 0 Kg M Hex flange bolts M10X183 M10X165 HexUNuts M10X1 25 Ring Spanner 14mm Socket Spanner 14mm 4 23 Cradle frame with engine on Main Frame Locate cradle frame engine from underneath main frame and lift up with suitable support under engine such that the stud moun...

Page 34: ...rame Locate Flanged Hex bolt M10X75 over oil cooler bracket and assemble U nut DO NOT TIGHTEN FULLY Tighten all the mountings diagonally to torque Hex flange bolt M10X75 HexU Nut M10X1 25 Ring Spanner 14mm Socket Spanner 14mm Torque 50 Nm 5 0 Kg M 4 24 Rear chain assembly and chain adjustment Place vehicle on center stand with the rear wheel off the ground Ensurerearaxlenut lock nuts adjusternutso...

Page 35: ...hain has a slack of 20 to 25 mm on its top run Ensure the reference linesontheLH RHchain adjusters are matching at the same reference lines in the swing arm on LH RH sides Tighten rear wheel axle nut to torque Tightenlocknutsagainst the adjuster nuts on LH RH sides Hex U Nut M17 Socket Spanner 24mm Torque 70 80Nm 7 0 8 0Kg M 4 25 Gear Shifter Linkage Locate small lever on gearshiftshaft ensuring s...

Page 36: ...haust pipe in cylinder head 4 27 Exhaust pipe Silencer Locate a new exhaust pipe gasket on the exhaust pipe Locate exhaust pipe into the cylinder head position the clamp over the studson the cylinder head assemble 2 hex nuts M8 DO NOT TIGHTEN FULLY Position silencer mounting bracket against the frame at the rear and insert flanged hex bolt Assemble hex nut over bolt Tighten the 2 hex nuts at the c...

Page 37: ...O ring on Inlet manifold Position inlet manifold adaptor with throttle body againstinletmani fold Ensure the 2 mounting holes are aligned Assemble new copper washersonthe2hexsoc head cap screws and insert from the inlet manifod adaptor end Assemble 2 hex nuts on the screws and tighten adaptor to manifold inlet Tighten worm clip screw on air filter bellow and inlet manifold adaptor Insert valve Bi ...

Page 38: ...urge valve to throttle body B Fuel Injector Ensure new seal ring is located on fuel injector Locate fuel injector on manifold inlet Ensure stud injector is firmly tightened on manifold inlet Assemblespaceronstud injector Assemble O ring on injector top Positon Cap injector assembly with fuel hose on injector and stud injector correctly Tighten cap injector assembly to stud using hex nut M6 Connect...

Page 39: ...cable in the throttle body rotor eyelet and route inner cable on the rotor Gently pull outer cable upwards till the inner cable canbe located into the braket slot and release slowly till the threaded portion of the outercableisfullyresting on the bracket Tighten outer cable to bracket using the hex nut M6 Slide the rubber grommets over the threaded sleeve on outer cable Adjust the throttle cable f...

Page 40: ... Flanged Hex Bolt at the front end of the steady bracket through the cylinder head assemble flange U Nut Tighten all the bolts to torque Flanged hex bolts M10X20 Socket Spanner 12mm Torque 20Nm 2 0Kg M Flanged hex bolt M10X47 Socket Spanner 12mm Flanged hex nut M10X1 25 Ring Spanner 12mm Torque 50Nm 5Kg M 4 31 Electrical connections A Starter Motor Connections Position earth wire eyelet on outer m...

Page 41: ...ections B Throttle Position Sensor TPS Connect black coupler to throttle body on LH side C MAP Sensor Connect black coupler to throttle body RH side F Oxygen Sensor Connect Black coupler to sensor wires on the exhaust pipe top D Fuel Injector Sensor Connect black coupler to fuel injector E Engine Oil Temperature EOT Sensor Connect white coupler to EOT sensor wires ...

Page 42: ...s Connect small Black coupler Pulsar wire connections on LH Side to wiring harness H Gear position switch Connect BIG SMALL Black coupler to wiring harness on LH side CAUTION Ensure Ignition switch enginestopswitchisinOFF position before connecting any wiring couplers NOTE Ensure Protection couplers are correctly slid over the coupler after connecting Ensure wiring harness is correctly strapped to...

Page 43: ...d to the positive terminal of the battery Connect negative terminal Black to negative terminal of the battery 4 32 Fuel Tank Align the two clamps in the fuel tank inside channel with the rubber supports on the frame and gently push forward to lock in place Lift rear endofthetankslightlyand Route the drain hose between the frame without any kinks Connect blue coupler of Lowfuelsensortowiring harnes...

Page 44: ...nnister to fuel tank bottom Ensure rubber grommets are in place in the rear mounting holes and align mounting holes to the frame Locate 2 washers on the hex flange bolts assemble the bolts and tighten to torque Hex flange bolts M6X27 Socket Spanner 10mm Torque 5Nm 0 5Kg M 4 33 Side Panel LH RH Locate the tab of the side panel in the rubber grommet in frame and press in gently Assemble 3 Hex socket...

Page 45: ...len Key M5 Torque 5Nm 0 5Kg M 4 35 Rider Pillion Seat Locate the rider seat tab under the fuel tank and positionthelockingplate centrally on the frame Locate rear seat tab in the frame align lock pin with the seat latch and gently press on seat to lock Remove key after locking pillion seat 4 36 Connector tube Top frames Position connector tube from inside the frame such that the horn mounting brac...

Page 46: ...he screws Hex Socket Hd Cap screws M6 Allen Key M5 Flanged hex bolts M8 Socket Spanner 12mm Torque 25Nm 2 5 Kg M Align the mounting holes of top frames LH RH with the holes in the cockpit mounting bracket assembly and tighten using Hex bolts Tighten the 2 hex socket head cap screws on the top frame LH RH to clamp them against the connector tube Ensure the dust caps are fitted on the connector Flan...

Page 47: ...s are color coded as LH side Green RH side Red Tightentrafficator tothe top frame with hex socket button head screw hex nut Connect the wiring coupler to the wiring harness 4 39 Trafficator front RH Locate the front lug of the cockpit cover into the rubber grommet in top frame RH Insert trafficator with RED wire coupler into covercockpitonRHside Tightentrafficator tothe top frame with hex socket b...

Page 48: ...op frame and tighten Connect head lamp wiring coupler Ensure the dust caps are fittedintheslotsonLH RH sides Hex Socket Hd Cap screws M8X25 Allen Key M6 Torque 10Nm 1 0Kg M NOTE Ensure the head lamp beam is properly aligned before final torqueing 4 41 Windshield Assembly Locate 4 rubber nuts in the top frame LH RH Locate wind shield on the top frame ensure the mounting holes are aligned on both si...

Page 49: ...tion 4 43 Clutch Cable Assembly Ensure proper location of inner cable in clutch lever outer cable in LH bracket at handle bar end Ensure proper routing of cable along the frame and insert into the bracket in cover RH Assemble outer lock nut larger end of rubber grommet on the adjuster Lock inner cable in the clevisonCoverRH gently pull cable outwards till resistanceisfelt thread outinnerlocknutsot...

Page 50: ...cooler mounting holes with the bracket on LH side tighten with 2 flanged Hex bolts Position 1 each aluminum washer on either sides of the hose banjo union of H Hose no 2 and tighten to cover RH with Banjo union bolt Flanged Hex bolts M6X20 Socket spanner 8mm Torque 10Nm 1 0Kg M Position 1 each aluminum washer on either sides of the hose banjounionofHose no 1 and tighten to crankcase LH with Banjo ...

Page 51: ...id plate and locate 4 damper bushes on the rubber bushes Position the Skid plate under the cradle frame and align the mounting holes Ensure the damper bushes do not fall off Assemble 4 4 Flanged Hex Bolts M6 X1 X 35 at the bottom of the Skid plate Assemble 2 Flanged Hex Bolts M6 X 1 X 14 at the front of the skid plate Tighten all the 6 bolts evenly and diagonally Flanged Hex Screw M6 Socket Spanne...

Page 52: ...RVICE MANUAL 51 SECTION 05 RIDER PILLION SEAT EXPLODEDVIEWS RIDER PILLION SEAT 4 3 4 3 5 2 1 S NO DESCRIPTION QTY S NO DESCRIPTION QTY 1 Pillion Seat Assy 1 2 Rider Seat Assy 1 3 Rubber Support Front 4 4 Rubber Support Rear 4 5 Tool Kit Strap 1 ...

Page 53: ...ener Size Tool Usage Precautions Photos Aggregate to Dismantle Instructions 5 1 Rider Pillion Seat Dismantling Unlock pillion seat by turning key clockwise liftpillionseatfromfront end to release rear tab remove Lift rider seat from rear end to release front tab remove ...

Page 54: ... Aggregate to Assemble Instructions 5 2 Rider Pillion Seat Assembly Locate the rider seat tab under the fuel tank and position the locking plate centrally on the frame Locate rear seat tab in the frame align lock pin with the seat latch and gently press on seat to lock Remove key after locking pillion seat ...

Page 55: ...FIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL 54 SECTION 06 C CONTROL CABLES EXPLODEDVIEWS CONTROL CABLES 1 3 2 S NO DESCRIPTION QTY 1 Clutch Cable Assy 1 2 Throttle Cable Assembly 1 3 Seat Latch Cable Assy 1 ...

Page 56: ...le Loosen cable lock nut at thecablebracketend on engine cover RH push adjuster in fully Disconnect inner cable from clutch lever on engine cover RH Remove protective rubber cover nut completely from cable remove cable from bracket Disconnect cable inner from clutch lever on handle bar LH remove clutch cable CAUTION Inspect Cables for any fraying or damage ...

Page 57: ... inner cable from rotor Remove bottom nut from cable adjuster remove cable with adjuster from bracket At handle bar end Loosen the 2 screws on the throttle housing on handle bar Loosen the screw holding the cable strap plate slideoutthestrap plate from the cable Separate the rotor housing from the handle bar and remove the inner cable from the rotor Remove outer cable from rotor housing Hex nut M6...

Page 58: ...m the clutch lever at handle bar end At throttle body end Remove the tank assy asdetailedinsection10 Loosen the hex faced plastic nut on holder cable valve at the throttle body end slowly pull out the valve bi starter from throttle body Compress spring disconnect cable from the vale bi starter Removespring valvebi starter slide out cable from the guide At handle bar end Loosen switch LH holding sc...

Page 59: ...d insert into the bracket in cover RH Assemble outer lock nut larger end of rubber grommet on the adjuster Lock inner cable in the clevis on Cover RH gently pull cable outwards till resistance is felt thread out inner lock nut so that it rests against the bracket Ensure 2 3 mm clutch lever free play at handle bar end by suitably turning inner lock nut on cable cable Tighten outer lock nut against ...

Page 60: ... Install the 2 screws on the throttle housing on handle bar At Throttle body end Locate the Throttle cable assembly Slacken the adjusters at thethrottlebodyendfor both cables Hex nut Double End Spanner 10mm CAUTION Inspect Cables for any fraying or damage 6 6 Bi Starter Cable Locate the Bi starter cable in the lever at handle bar end Route thecable correcly on the frame tube under fuel tank Assemb...

Page 61: ...Kit 1 A2 Air Filter Box Assembly 1 1 ScrewsM5 3 2 Inlet Cover 1 3 Seal 1 4 Element Air Filter 1 5 Clamp 1 6 Pipe Outlet 1 7 Drain Tube 1 8 Clip 1 9 TA SENSOR 1 10 HEX SOCKET HEAD CAP SCREW M5 X 16 2 11 Hex Flange Bolt M6 X 1 X 14 2 12 Rear Damper Tank 1 13 Lid Battery Carrier 1 SECTION 07 AIR FILTER EXPLODEDVIEWS AIRFILTER A1 Key Nos 3 4 A2 Key Nos 1 to 8 ...

Page 62: ...7 1 Air filter Element from housing Remove 2 hex socket button head screws from the LH side panel Pull out the side panel gently to release from the grommet in the frame Loosen Remove the 3 Pan head screws from the air filter cover Remove Cover Removeairfilterelement from housing Pan head Screw M5 Allen Key 4mm Pan head Screw M5 Allen Key 4mm ...

Page 63: ...anged hex bolts holding air filter housing to frame Gently pull out Fuse box along with its rubber holder from air filter housing Remove RR unit with its rubber holder from air filter housing Loosen and remove 3 flange hex bolts holding the cross bar assembly below air filter housing to frame Remove cross bar assembly Loosen flanged Hex bolt holding bracket air filter to frame and remove the bolt ...

Page 64: ...dust particles Clean the element on the inside and outside using a soft cloth Clean the insides of the air filter housing and cover using a soft cloth Replace seals O Rings and rubber parts whenever the induction system is serviced Replace Air filter element every 15 000 Kms or earlier if motorcycle is used in dusty off road conditions TORQUE VALUES S No Aggregate Fastener Torque NM Kg M 1 Bracket...

Page 65: ...y under air filter housing and tighten to frame using2flangedhexbolts Positionbracketassembly airfilteronframeRHside and tighten using flanged hex bolt M8 on top and 2 M6 flanged hex bolts at bottom Assemblepiecemudguard and tighten to frame with flanged bolts washers and nylock nuts Assemble battery connectterminals locate lid battery carrier in housing and tighten with hexbolts Referelectricals ...

Page 66: ...ter element in housing such that the open end of the element is facing outside Locate cover on the air filter housing such that thelocatingpegsandthe three mounting holes are aligned Tighten cover with 3 screwsevenlyandfirmly Locatesidepanelwithits bottomleglocatedinthe rubber grommet Tighten side panel with 2 hex socket button head screws Philips head screw driver PanheadscrewM5 Allen Key 4mm ...

Page 67: ...Y 1 PAV Air Filter Hose 1 2 Clip 1 3 Flange Nyloc Type Nut M6 X 1 2 4 Pulse Air Valve 1 5 Damper Oil Cooler 2 6 Spacer Oil Cooler 2 7 Hex flange bolt M6 X 30 2 8 Clip PAV Adaptor 2 9 PAV Adaptor Hose 1 10 Gasket Mounting Plate 1 11 Braided Hose assy 1 12 SS Hose Clip 1 13 Hex Socket Head Cap Screw M6 X 20 2 14 Clip PAV air filter hose 1 EXPLODEDVIEWS PULSE AIR VALVE ...

Page 68: ...r valve braided hose Loosen screw on the SS hose clip Loosen remove 2 hex socket head cap screws holding braided hose flange to cylinder head on the exhaust end Gently pull out braided hosefrompulseairvalve bottom tube and remove along with gasket Pulse air valve from frame Holding the nuts on the inside loosen and remove the 2 flanged hex bolts from frame Remove pulse air valve from frame taking ...

Page 69: ...as recommended Inspect braided hose for any leaks cracks and proper sealing at cylinder head TORQUE VALUES S No Aggregate Fastener Torque NM Kg M 1 Braided hose mtg to cyl head HexSocketHeadCapScrewM6X20 1 10 1 0 2 PAV mtg to frame Hex flange bolt M6 X 30 10 1 0 Min Torque Nm Kg M Max Torque Nm Kg M 8 0 8 8 0 8 12 1 2 12 1 2 ...

Page 70: ... and tighten with 2 hex flange bolts M6X30 Apply grease on the gasket and locate it on the cylinder head Locate worm clip on the braided hose and assemble braided hose on the outlet tube of the pulse air valve Position braided hose flangeoverthegasketon cylinder head align the holes and tighten with two hex socket head cap screws Tighten worm clip over the braided hose Connect the rubber hoses fro...

Page 71: ...now 1 2 Front Damper Tank 2 3 O Ring Fuel Gauge 1 4 Fuel Level Sensor Unit 1 5 Hex Flange Nut M5 X 0 8 4 6 O Ring Fuel pump 1 7 Fuel Pump Assy 1 8 Clamp Plate FPM 1 9 Flanged Hex Bolt M6 X 1 X 10 4 10 P A Tube Assy 1 11 Drain Hose 1 12 Rear Damper Tank 2 13 Bush Fuel Tank 2 14 Flanged Hex Bolt M6 X 1 X 27 2 15 Cap Fuel Tank 1 16 Hex socket head cap screw m5x15 3 1 2 3 4 5 6 7 8 9 10 2 11 12 13 14 ...

Page 72: ...rews 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 EVAP hose connection from tuel tank Disconnect fuel gauge couplerwirebyliftingthe tank slightly Slide fuel tank towards rear to release...

Page 73: ...eral deterioration Replace if necessary WARNING Gasoline is extremely flammable and highly explosive which could result in serious injury Do not smoke or allow open flame or sparks in the vicinity Store the fuel carefully to avoid spillage TORQUE VALUES Fuel Tank Fuel tank Mounting FlangedHex BoltM6 1 27 5 0 5 Torque Range NM Kg M A Aggregate Fastener Component ...

Page 74: ... fuel tank forward to lock in place Lift rear end of the tank slightly and Connect EVAP hose remove proper routing in frame wihtout any kinks Connect blue coupler of Lowfuelsensortowiring harness Ensure rubber grommets are in place in the rear mounting holes and align mounting holes to the frame Locate 2 washers on the hex flange bolts assemble the bolts and tighten to torque Connectfuelhosetofuel...

Page 75: ... M8 X 1 25 4 2 Exhaust Gasket 1 3 Exhaust Pipe Assy 1 4 Guard Cat Pipe 1 5 FlangedHex Bolt M6 x 1 x 7 6 6 Guard Exhaust Pipe 1 7 Clamp Silencer 1 8 Hex Flange Bolt M8X 1 25 X 38 1 9 Pin Damper 2 10 Damper Bush 1 11 Silencer Assy 1 12 Hex Flange Bolt M8 X 1 25 X 55 1 13 Guard Silencer 1 14 Gasket Exhaust Pipe Silencer 1 15 Oxygen sensor 1 1 9 10 11 1 7 9 12 5 5 8 5 4 6 13 3 1 1 2 15 14 ...

Page 76: ...aust pipe seating area after removing exhaust pipe Remove 2 Hex bolts nuts at the silencer mounting bracket end Support the silencer and remove the bolt Gently pull out the exhaust pipe from the cylinder head and remove exhaust pipe with silencer from the vehicle Release the clamp from the studs The Hego sensor is assembled on the inner side of the exhaust down pipe near the cylinder head Ensure I...

Page 77: ...t gas leakage CAUTION Do not clean the silencer and exhaust internals with any solvents gasoline etc as it will damage the catalytic converters REPLACE Copper gasket between exhaust pipe and cylinder head whenever exhaust pipe is dismantled from cylinder head 1 Exhaust Pipe Mounting to Cyl head Flanged Hex Bolt M8 X 1 25 X 16 1 10 1 2 Silencer Mounting to Frame Hex Socket M8X1 25X25 25 2 5 Torque ...

Page 78: ...et spanner 12mm Torque 10Nm 1 0Kg M Hex bolts M8 X 1 25X45 Hex Nuts M8 X1 25 Socket spanner 12mm Double End Spanner 12mm Torque 25Nm 2 5Kg M Position silencer mounting bracket against the frame at the rear and insert flanged hex bolt Assemble hex nut over bolt Tighten the 2 hex nuts at the cylinder head first and then the silencer bracket nut S No Deep Groove Socket 21mm Locate Hego sensor along w...

Page 79: ...78 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL SECTION 11 T TOP BRACKET HANDLE BAR FRONT MUDGUARD FRONT WHEEL FRONT SUSPENSION STEERING STEM ...

Page 80: ...LH 1 4 Cover Cockpit LH 1 5 Flanged Hex Bolt M8 2 6 Dust Cap Frame Top 2 7 Grommet 2 8 Rubber Nut M5 4 9 Cover Cockpit Top 1 10 Hex Socket Button Head Screw M6X1 2 11 Washer Plastic 4 12 Hex socket head cap screw M5X16 4 13 Wind Shield 1 14 Grommet Cluster 3 15 Plain Washer 3 16 Hex Nut M6 with nylon insert 3 17 Cockpit Mtg bracket Black 1 18 Hex Socket Head Cap Screw M8 X 45 2 19 Top frame RH wit...

Page 81: ...rt Front Fender 4 2 Front Mudguard with sticker assy Granite 1 3 Clamp Wheel Speed Sensor 1 4 Lock washer Internal teeth 4 5 Hex Socket Head Cap Screw M6 X 20 4 6 Fork Brace 1 7 Front Mudguard Bottom 1 8 Hex Socket Button Head Screw M6 X 1 4 9 Flanged Hex Bolt M6 X 1 X 27 4 10 Sticker Front mudguard 1 1 2 3 4 5 6 9 8 7 10 ...

Page 82: ...re Front 1 2 Tube Front 1 3 Rim Tape Front 1 4 Rim Front 1 5 Disc Front 1 6 Hex Flanged Bolt M8 X 1 25 X 25 6 7 Spokes Front 36 8 Nipple 36 9 Hex U Nut M16 X1 5 1 10 Washer 1 11 Spacer 1 12 Grease Seal 25x40x7 1 13 Deep Groove Sealed Ball Bearing 6203 17 X 40 X 12 2 14 Spacer Front Hub 1 15 Front Hub Assy 1 16 Wheel Speed Sensor Assy 1 17 Spindle Front Wheel 1 ...

Page 83: ...t 2 9 Bolt M10X1 2 10 Hex Socket Head Screw M8 X 1 25 X 25 1 11 Spindle Taper 2 12 Piston Front Fork 2 13 Spring 2 Short 2 14 Piston Ring 2 15 Spring 1 Long 2 16 Washer Spring Top 2 17 Spacer 2 18 Washer 2 2 19 O Ring 2 20 Bolt Cap 2 21 Outer Tube LH 1 22 Cable Guide Brake Hose 1 23 Cable Guide Speedo Cable 1 24 Lock Washer M6 2 25 Plain Washer 2 26 Hex Bolt M6 X 12 2 27 Bellow Fork 2 28 Fork Gait...

Page 84: ... 48 2 2 Counter Weight Assy 2 3 Hand Grip LH 1 4 Switch Module LH 1 5 Handle Bar Complete 1 6 Rear View Mirror LH 1 7 Lever Holder Assy LH 1 8 Clutch Switch 1 9 Front Brake Switch 1 10 Rear View Mirror RH 1 11 Master Cylinder Front 1 12 Switch Module RH 1 13 Grip Comp Throttle RH 1 14 Mountable Strap Handle bar 2 15 Bracket Lever Clutch LH 1 16 Clutch Lever 1 17 Screw Clutch Switch 2 18 Screw Brak...

Page 85: ...p Yoke 1 6 Hex Socket Head Cap Screw M6 X 20 2 7 Ring Nut 1 8 Clip Holder Assy Wiring Harness 1 9 Flanged Hexogonal Bolt M6 X 1 X 10 4 10 Dust Seal Steering Assy top 1 11 Tapered Roller Bearing 30205 25 X 52 2 12 Dust Seal Steering Assy 1 13 Steering Stem Assy 1 14 Bracket Comp Number Plate 1 15 Number Plate Front 1 16 Cross Recessed Pan Head Screw M5 X 0 8 X 12 2 17 Clamp Wheel Speed Sensor 1 1 2...

Page 86: ...dremovewind shield Hex Soc Hd Cap Screw M5 Allen Key 4mm 11 2 Trafficator front LH RH cover cockpit LH RH Disconnect Trafficator wiring couplers below headlamp NOTE Hold the rubber mounted nuts from behind while loosening screws NOTE Couplers are color coded as LH side Green RH side Red Hex Soc Hd Cap crews M5 Allen Key 4mm Hex Nut M6 Doubleendspanner 10mm Remove hex socket head screw mounting the...

Page 87: ...ad screws holding headlamp assembly to top frame LH RH remove head lamp assy 11 4 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 Flanged hex bolts M8 Socket Spanner 12mm Hex Socket Hd screws M6 Socket Spanner 10mm CAUTION Take care not to damage fuel tankwhilerotating removing the side supp...

Page 88: ...d vertically and away from magnetic objects to prevent damage tothecompassanddisplays Loosen and remove the 3Hexcapnutsalongwith the washers Remove the Instrument cluster from the cockpit bracket Disconnect ignition switch wiring coupler Loosen and remove 2 hex socket head cap screws beneath switch and remove switch Remove 2 Allen screws mounting the Instrument cluster bracket to frame head tube H...

Page 89: ...bolts from inside of mudguard Remove front mudguard top Hex bolt M6 D E Spanner 10mm NOTE Ensure the 4 inserts are removed from the top of the mudguard 11 7 Front Mudguard Bottom Remove 4 Allen screws securing fork brace to fork legs Remove 4 Allen screws inside front mudguard bottom to separate mudguard from fork brace Hex soc Hd cap Screw M5 Allen key 4mm Hex soc Hd cap Screw M5 Allen key 4mm ...

Page 90: ...rk end with 6 mm Allen key Hold spindle on right side and remove spindle nut and washer from left side Support wheel and pull out spindle from right side Remove wheel along withwheelspeedsensor and spacer Remove speedo sensor Placeasuitablespacerof 4 mm thickness between the brake pads to avoid accidental compression of the brake lever CAUTION Donotpress thebrakelever when wheel is removed as this...

Page 91: ... cap bolts on the LH RH side fork crown plate Loosen 2 each hex socket head cap bolts on the LH RH side on steering stem assy Rotate main tube simultaneously pull out from fork crown plate and steering stem assembly Repeat same process with other fork assembly Hex bolt M8 TSpanner 12mm NOTE Support the wheel caliper suitablytopreventdamage to it Ensure front wheel wheel speed sensor connecting wir...

Page 92: ...from the top and loosen cap nut Remove fork assembly from the bench vise hold upright and remove cap nut with washer slowly to allow the main spring to expand completely Remove washer spacer and washer spring top andmainspringfromthe inner tube Invert the fork assembly to drain out the oil from the fork Gently pump main tube into the bottom tube to drain out the oil completely Hex capnut M16 Ring ...

Page 93: ... from the main tube end Locateontheguidetube to prevent it from rotating Remove Allen screw at the bottom Remove special tool from inner tube Remove the dust seal retainer clip and fork sealfromtheoutertube Separate fork tubes by sharply pulling inner tube out of the outer tube along with the guide bush seat pipe assembly rebound spring and cap oil lock Hexsochd capscrew M8 Allen key 6mm ...

Page 94: ...of LH and RH switch assemblies from the wiring harness Disconnect Front Brake Switch wire connections Disconnect clutch switch wiring coupler Remove2Hexboltsfrom master cylinder top mounting bracket on handle bar RH and remove master cylinder complete with brake lever from handle bar Remove 4 Hex socket screws mounting top raiser to steering stem top bracket remove handle bar with top raiser Hex n...

Page 95: ... cluster Ignition switch Electrical connections to wheelspeedsensor clutch switch frontbrakeswitch Top frames LH RH cockpit bracket Clutch and throttle cables from handle bar Front disc brake system from handle bar fork end LH Top raiser and handle bar assembly Front wheel Top front mudguards ForkassembliesLH RH Loosen top nut on steeringstemandremove Support steering stem from bottom and remove a...

Page 96: ...gregate to Dismantle Instructions 11 13 Steering stem assembly Remove dust washer from the top Remove steering stem from the frame Remove tapper roller bearing from the frame head tube NOTE The bottom taper roller bearing will be tight in the steeringstemandwillhave tobepulledoutofthestem using suitable puller ...

Page 97: ... 13 28 75 2 88 5 Top Raiser Mtg Hex socket Head screw M8X1 25X45 25 2 5 21 25 2 13 28 75 2 88 6 Top Yoke Mtg Hex socket head screw M8X1 25X25 25 2 5 21 25 2 13 28 75 2 88 7 Front Number Plate Cross Recessed M5X0 8X12 5 0 5 4 25 0 43 5 75 0 58 8 Bottom Yoke Mtg Hex socket head screw M8X1 25X25 25 2 5 21 25 2 13 28 75 2 88 9 Steering Stem Lock Nut M24X1 7H 60 70 6 0 7 0 60 00 6 00 70 00 7 00 10 Fron...

Page 98: ...D HIMALAYAN EURO IV VEHICLE SERVICE MANUAL Main tube straightness Long Pitch Short Pitch SpringLength mm Fork spring short ServiceLimit 0 15mm Guide Bush Length NewSpring mm ServiceLimit mm WEAR LIMIT Fork spring long ...

Page 99: ... bottom Support steering stem and assemble taper roller bearing on top of the frame head tube with the taper facing downwards Assemble dust seal washer over the frame head tube Assemble adjuster nut on steering stem and tighten till there is no sideways play of the steering stem Rotate steering stem and check for free smooth rotation on both LH RH Locatetopyokeoverthe steering stem Assemble top nu...

Page 100: ...vehicle Clutchand throttlecables Cockpit bracket Top frames LH RH Electrical connections to clutch switch front brake switch Ignition switch Instrument cluster Headlamp trafficators Mirrors LH RH Windshield FrontforkassemblyLH RH Wheel Caliper on fork end LH Front Wheel Hold both forks at wheel axle end and check for any axial play Turn handle bar to both LH RH Check for Free movement without any ...

Page 101: ...ter cylinder on handle bar RH side Locate top clamp over bracket andtighten with 2 Hex bolts Route the brake hose wheel caliper towards the left side of vehicle Connect Front Brake Switch wire connections Connect clutch and throttle cables refer section 5 Connect clutch switch wiring coupler Connect wiring couplers of LH and RH switch assemblies from the wiring harness Assemble rear view mirrors L...

Page 102: ...ls Locate dust cap oil seal with its spring facing downwards and spacer from the bottom of inner tube assembly Assemblespring2 short on piston frontfork and insert tapered end into main tube from the top Locate spindle taper with a little bit of grease to hold it in position on the piston front fork Insert special tool into inner tube assembly from top to hold piston front fork S No ...

Page 103: ... hex socket screw and tighten outer tube to piston front fork Remove special tool Gentlytap plasticspacer andoilseal intoforkend till the oil seal is below the lock ring groove in the fork end Assemble lock ring over oil seal on the main tube Press dust cap into fork endtillitisseatedflushin fork end Insert closed coil end of the spring 1 long into inner tube Fill455mlofforkoilperleg Locate thrust...

Page 104: ... assy RH from RH side ofsteeringstem bottom till it is seated into the top yoke and flush with the top of the top yoke Tighten 4 Hex socket head screws on the LH and RH sides of the steering stem assembly sufficiently Tighten 4 Hex socket head screws on LH and RH sides of the top yoke sufficiently Assemble front mudguard and brace Locate front wheel caliper on fork Lh and tightenwith2Hexflange bol...

Page 105: ... 4 hex screws Locate front mudguard bottom with brace between fork legs and tightenwith 4hexsocket head screws S No Front Mudguard Top Locate insertfender into the mounting holes in front mudguard Locate front mudguard top below the steering stem and ensure mounting holes are aligned Tighten front mudguard top to steering stem using 4 hex bolts from inside of mudguard Hex Bolt M6 D E Spanner 10 MM...

Page 106: ... along withwheelspeedsensor and spacer on left side between the front fork legs ensuring the brake disc is located between the brake pads Insert wheel spindle from right fork end Position wheel speed sensor such that it is parallel to ground Hold spindle on right side locate washer and nut on spindle on left side and tighten firmly Tighten pinch bolt on right fork end Rotate wheel and check for sm...

Page 107: ...r to ignition switch Position cockpit mounting bracket on frame head tube and tighten with 2 Allen screws Locate instrument cluster on cockpit moutnig bracket Assemble 3 washers on the studs and tighten with 3 cap nuts Connect instrument cluster wiring coupler S No Hex Soc Hd Cap Screw M5 Allen Key 4mm Torque Hex soc Hd capScrew M8 Allen key 6mm Torque C CAUTION Instrument cluster must always be s...

Page 108: ...H RHandtightentocockpit mounting bracket S No Flanged hex bolts M8 Socket Spanner 12mm Torque C CAUTION Take care not to damage fuel tank while assembling top frames Hex Socket Hd screws M6 Socket Spanner 10mm Torque Tighten the 2 hex socket head screw clamping top frames LH RH to connector tube Assemble 2 dust caps on the connector tube HeadlampAssembly Position Headlamp housing between top frame...

Page 109: ...nd tighten with hex socket head screw Repeat aboveprocess to assemble the other trafficator Connect Trafficator wiring couplers below headlamp S No HexSoc Hd Capscrews M5 Allen Key 4mm Hex Nut M6 Double end spanner 10mm Torque NOTE Couplers are color coded as LH side Green RH side Red NOTE Hold the rubber mounted nuts from behind while Tightening screws Wind Shield Assembly Locate windshield assem...

Page 110: ...YAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL SECTION 12 REAR WHEEL CHAIN SPROCKET SAREE GUARD CHAIN GUARD REAR GUARDS SHOCK ABSORBER DRAG DROP LINKS SWING ARM REAR CHAIN ADJUSTMENT AND WHEEL ALIGNMENT ...

Page 111: ...lip Nut M5 4 5 Plain Washer 6 6 Hex socket head cap screw M5X16 4 7 Rear Number Plate Assy 1 8 Hex Socket Button HeadScrew M6 X 1 X 16 2 9 Reflector 1 10 Hex Nut M6x1 U Nut 2 11 Flanged Hex Bolt M6 X 1 X 20 2 12 Grommet Rear Mudguard 2 13 Mudflap Rear 1 14 Bracket addon Rear mudguard 1 15 Spacer Oil Cooler 2 16 Grommet 2 17 Spacer Rear mudguard 2 18 Sticker Rear mudguard 1 1 2 3 4 5 6 5 5 7 8 9 5 ...

Page 112: ... Wheel Spindle Spacer Kit 1 A7 Chain Sprocket Kit 1 1 Hex Socket Button Head Screw M6X1X14 6 2 Rear Disc Plate 1 3 Tyre Rear 1 4 Tube Rear 1 5 RimRear 1 6 Rim Tape Rear 1 7 Spindle Long 1 8 Washer 2 9 Spacer Sprocket Side Rear 1 10 Rear Hub Grease Seal 1 11 Ball Bearing 6005 25 X 47 X12 Double Side Rubber Sealed 1 12 Socket Head Bolt M10 X 1 25 X 30 6 13 Sprocket Rear Drive 1 14 Chain Rear 1 15 Ad...

Page 113: ...ing Arm 1 8 Hex Nut With Nylock M12 X 1 5 1 9 Rear Chain Pad 1 10 Washer Chain Pad 2 11 Hex Socket Button Head Screw M6 X 1 X 16 2 12 Philips pan head screw M6X6 2 13 Clip Rear Disc Hose 2 14 Chain Guard 1 15 Chain Tensioner comp LH 2 16 Plate Chain Adjuster 2 17 Flanged Hex Nut M8 X 1 25 4 18 Hex Nut M6x1 U Nut 2 19 Flanged Hex Bolt M6 X 1 X 27 2 20 Chain Guide 1 21 Saree Guard 1 22 SS Hex socket...

Page 114: ...2 2 4 Inner Race Drag Link Back 1 5 Inner Race Drag Link Front 1 6 Flanged Hex Bolt M10 X 1 25 X 66 1 7 Drag link Assy with bearing 1 8 Dust Seal Linkage 8 9 Flanged Hex Bolt M10X1 25 X 132 1 10 Drop link Assy with bearing 2 11 Flanged Hex Bolt M10X1 25 X 47 2 12 Inner Race Drop Link 2 13 Swing Arm with bearing Assy 1 13 11 8 12 8 2 8 12 8 11 9 2 10 8 6 7 3 3 2 1 2 4 5 A1 Key Nos 7 8 8 Nos 10 2 No...

Page 115: ... remove along with washer Pull out the wheel axle from the left side taking care not to drop the wheel spacers Remove the brake caliper assembly from the slot in the swing arm and support it suitably to avoid damage to the brake hose Slide out the rear wheel from the swing arm taking care not to drop thespacersonthewheel hub CAUTION Do not press the brake pedal when wheel is removedasthiswillresul...

Page 116: ...tructions 12 2 Saree Chain guards Remove 2 hex socket head cap screws at the top and 1 hex socket head cap screw at the bottom of saree guard Removesareeguardand chain guard from swing arm Hexsochd capscrews M6 Allen Key 5mm Hex Bolt M6 Socket spanner 10mm 12 3 Piece mudguard Remove4Hexbolts 2at thetop 2atthebottom Removepiecemudguard ...

Page 117: ...or coded LH side Green RH side Red NOTE Support saddle mounting plate LH to prevent damage to seat latch cable Hex Soc Hd cap screws M5 Allen key 4mm Hex Soc Hd capscrews M5 Allen key 4mm 12 3 Mud flap rear Remove 2 hex socket head cap screws with washers holding mud flap to rear mudguard bottom Remove 2 hex bolts holding mud flap to rear mudguard top remove mud flap Ensure 2 rubber grommets 2 fac...

Page 118: ...ructions 12 5 Mono shock absorber Ensure Air filter housing and piece mudguard are removed Hold hex bolt and loosen hex U nut at shock absorber bottom mounting to drag link Hold hex bolt and loosen hex U nut at shock absorber Top mounting to frame Remove shock absorber Hex nut M10 Hex bolt M10 Double end spanner 17mm Ring spanner 14mm ...

Page 119: ... Support drag link and remove hex bolt to remove drag link from frame along with dust seals Hold hex bolts and loosen hex U nuts holding the 2 drop links to swing arm bottom Remove the 2 hex bolts one after the other to release drop links along withdustsealsandinner race from swing arm Hex nut M10 Hex bolt M10 Doubleendspanner 17mm Ring spanner 14mm NOTE It will be required to dismantle centre sta...

Page 120: ...les in the frame Support the swing arm suitably Hold swing arm spindle from LH side and remove hex nut from RH side Remove swing arm assembly along with the spacers dust seals and innerracefromtheframe assembly Hex nut M12 Spindle M12 Socketspanner 17mm NOTE The needle bearings pressed into the swing arm cannot be replaced individually In case of bearing worn out or damaged the entire swing arm as...

Page 121: ...x Flanged Bolt M10X1 25X47 50 0 5 0 42 50 4 25 57 50 5 75 5 Swing Arm Pivot M12X1 5 70 0 7 0 59 50 5 95 80 50 8 05 6 Chain Guide Mtg Hex Flange Bolt M6X1X27 10 0 1 0 8 50 0 85 11 50 1 15 7 Rear Wheel Spindle Hex U Nut M16X1 5 70 0 7 0 59 50 5 95 80 50 8 05 8 Chain Adjuster Hex Nut M8X1 25 25 0 2 5 21 25 2 13 28 75 2 88 9 Rear Disc Mtg Button Head Collar Bolt M6X1X14 10 12 1 0 01 2 10 00 1 00 12 00...

Page 122: ...m correctly between the frame and locate new end cups on either side of the swing arm outer and frame inner Locate inner spacer between the swing arm eyelets in the centre Ensure all mounting holes of the swing arm spacers swing arm inner spacer are aligned and insert spindle fully into frame from the LH side Assemblespacerwasher and hex nylock nut on the spindle RH side and tighten to torque Ensu...

Page 123: ...of the drag link ensure theholesarealignedand insert inner race drag link back through the drop link till it is flush on either sides of the drop links Assemble long hex bolt and hex nut D DO NOT TIGHTEN Support swing arm and position drag link with inner race drag link front and dust seals in the mounting bracket in frame ensure holes are aligned and insert hex bolt to lock drag link to frame Ass...

Page 124: ...ert hex bolt assemble hex nut Tighten top and mounting fasteners to torque Assemble Air filter housing S No Hex nut M10 Hex bolt M10 Double end spanner 17mm Ring spanner 14mm Torque 50Nm 5KgM 12 11 Rear Mudguards Rear Mudguard Locate rear mudguard in frame assemble 2 hex socket head cap screws on LH RH side frame and tighten to torque Position saddle bag mounting LH RH on frame and tighten with 2 ...

Page 125: ...th 2 hex bolts to rear mudguard top remove mud flap Locate 2 hex socket head cap screws with washers on the rear front end of mud flap and tighten to rear mudguard bottom S No NOTE Support mud flap and connect number plate illuminator coupler trafficators LH RH NOTE Couplers are color coded LH side Green RH side Red Hex bolt M6 Socket spanner 10mm Hex Soc Hd cap screws M5 Allen key 4mm 12 13 Piece...

Page 126: ...ue S No Hexsochd capscrews M6 Allen Key 5mm Torque 12 15 Rear Wheel Chain Sprocket Assembly Ensure proper seating of bearing and dust seal in adaptor Locate rear wheel sprocket on the adaptor Ensure the 6 mounting holes are aligned Locate six hex socket head cap screws from the sprocket end Assemble 6 Nylock nuts on the screws at the adaptor end Tighten the 6 bolts diagonally and evenly to torque ...

Page 127: ...l hub Ensure the axle mounting hole in the swing arm wheel hub and caliper bracket are aligned Insert the wheel axle from the left side of the swingarmandgentlytap it in S No CAUTION Do not force the spindlethroughasitwill cause damage to the threaded end Ensure correct chain tension and rear wheel alignment with front wheel by adjusting the adjusters on both left and right side of swing arm Assem...

Page 128: ...g position of the reference lines on the chain adjuster LH and swing arm LH Loosen locknut on chain adjuster RH Loosen tighten inner nut on chain adjuster RH such that the reference lines on chain adjuster RH and swing arm RH aligns at the same reference as in the LH side Hold the inner nuts firmly and tighten the lock nuts on chain adjusters LH RH against the inner nuts while ensuring they are he...

Page 129: ...Brake hose Caliper Front 1 8 Front Caliper 1 9 Reservoir Kit Rear M C Threaded 1 EXPLODEDVIEWS HIMALAYAN ANTILOCK BRAKE SYSTEM 10 Bracket Assy ABS Modulator 1 11 Grommet ABS Modulator 2 12 Hex Soc Head CapScrew M6 X 16 4 13 Flanged Hex Bolt M6 X 1 X 20 2 14 Sleeve ABS Modulator 2 15 Master Cylinder Rear 1 16 Rubber Hose Reservoir 1 17 ABS Modulator 1 18 Brake hose Master Cylinder Rear 1 1 2 3 4 5 ...

Page 130: ...t lock the brake disc and cause the motorcycle to skid during emergency brake applications CAUTION While ABS assists in improved vehicle control during braking decreased stopping distances on dry and graveled surfaces it maynot bevery effectiveinwet snowcovered offroad conditions loosegravel surfaces hilly roadsetc since the traction of the wheel itself will be very minimal in these conditions Asf...

Page 131: ...SERVICE MANUAL 3 ABS ECU Located adjacent to Modulator 4 FRONT BRAKE MASTER CYLINDER Located on Handle bar RH side 8 1 LOCATION OF THE ABS SYSTEM PARTS Located inside the Instrument Cluster Located inside panel RH 1 ABS INDICATOR 2 MODULATOR ABS ...

Page 132: ...OF THE ABS SYSTEM PARTS 5 FRONT WHEEL CALIPER Located on the fork end LH side 6 WHEEL SPEED SENSOR FRONT Located on the fork end LH side 7 TONER RING FRONT WHEEL Located on front Hub centre below brake disc 8 REAR BRAKE MASTER CYLINDER Located on the frame bottom on RH side ...

Page 133: ...L CALIPER Located on swing arm RH side 11 WHEEL SPEED SENSOR REAR Located on the rear caliper assembly mounting bracket 12 TONER RING REAR WHEEL Located on Rear wheel right side 9 REAR HYDRAULIC FLUID RESERVOIR Located on Frame RH Side 8 1 LOCATION OF THE ABS SYSTEM PARTS ...

Page 134: ...CT THE BRAKING EFFICIENCY SEVERELY BUT WILL ALSO DEACTIVATE THE MODULATOR AND THE ECU DO NOT ATTEMPT TO REMOVE THE ECU OR THE ELECTRICAL CONNECTIONS FROM THE MODULATOR AS IT WILL ERASE THE MEMORY AND THE PROGRAMME IF FOR ANY REASON THE BRAKE HOSES OR THE MODULATOR HAS TO BE SERVICED THEN THE ENTIRE HYDRAULIC FLUID SYSTEM BLEEDING HAS TO BE CARRIED OUT AND THE ECU HAS TO BE REPROGRAMMED ...

Page 135: ...sure Ignition switch andenginestopswitchis in OFF position Drain out hydraulic brake fluid from the front and rear reservoirs and brake calipers by loosening the bleeding screws in the front and rear calipers and gently pumping the brakes Remove the side panel RHbyloosening2Socket head cap screws on the sides CAUTION Brake fluid is extremely corrosiveandhenceplease takecarenottospillonany part of ...

Page 136: ...s Photos Aggregate to Dismantle Instructions 13 2 ABS Modulator ECU Remove wiring coupler to the ABS ECU and gently pull out ECU Remove 2 hex bolts on the sides and 1 hex bolt at the bottom holding modulator to the mount ing bracket Removemodulater from the bracket Hex Bolt M6 Double end spanner 10mm ...

Page 137: ...e ABS assembly to the bracket Ensure Ignition switch andenginestopswitchis in OFF position Install 2 hex bolts on the sides and 1 hex bolt at the bottom holding modulator to the mount ing bracket Connect wiring coupler to the ABS ECU and gently locate out ECU Hex Bolt M6 Double end spanner 10mm Locate and install the 4 banjo bolts holding 4 brake hoses to the modulator ...

Page 138: ... SERVICE MANUAL S No Fastener Size Tool Usage Precautions Photos Aggregateto Assemble Instructions 13 3 ABS Modulator ECU Locate theside panel RH on the RH side by installing 2 socket head cap screws on the sides Headcap Screw M6 Allen Key 5 mm ...

Page 139: ...tion between Wheel speeds WSS_GENERIC 6 5017 H Front Inlet Valve malfunction EV 7 5018 H Front Outlet Valve malfunction AV 8 5013 H Rear Inlet Valve malfunction EV 9 5014 H Rear Outlet Valve malfunction AV 10 5035 H Pump Motor Malfunction 11 5019 H Valve Relay malfunction Failsafe relay 12 5055 H ECU malfunction 13 5052 H Power Supply Malfunction Low Voltage 14 5053 H Power Supply Malfunction High...

Page 140: ...139 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL SECTION 14 H HYDRAULIC DISC BRAKES ...

Page 141: ... Front Caliper 1 1 Diaphragm Kit Front M C 1 2 Reservoir Cover Kit Front M C 1 3 Lever Kit Front M C 1 4 Front Brake Switch 1 16 16 e a g 15 c b d c b d 14 35 34 13 11 12 A5 9 10 10 910 10 A4 A2 9 2 1 8 7 5 6 4 3 f A1 A3 Key Nos 9 2 Nos 10 4 Nos A6 Key Nos a to g A7 Key Nos a to c e to g 5 Major Kit Front M C 1 6 Minor Kit Front M C 1 7 Clamp Kit Front M C 1 8 Oil Window Assembly Kit 1 9 Banjo Bol...

Page 142: ...iper 1 A7 Minor Kit Rear Caliper 1 A8 Banjo Bolt Kit 1 1 Reservoir Kit Rear M C Threaded 1 2 Reservoir Tube Kit Rear M C 1 1 2 3 4 A2 A3 a b cd e f g h 5 A1 g h m i j k l 8 6 9 10 7 11 12 12 11 12 12 A5 A3 Key Nos a to h A6 Key Nos a to d f g h A6 Key Nos g to m A7 Key Nos g to k m A8 Key Nos 11 12 3 Connector Kit Rear M C 1 4 Boot Rear M C 1 5 Push Rod kit Rear M C 1 6 Pad Spring Rear 1 7 Primary...

Page 143: ...rake 13 1 1 Master cylinder from handle bar Removerearviewmirror RH Disconnect front brake Switch coupler Gently depress the lock tab of front brake switch with a blunt object to release from the bracket and remove switch Double end spanner 14mm Remove protective rubber cap on bleeder nipple on the caliper Loosen bleeder nipple by about 2 turns Ring Spanner 10mm ...

Page 144: ...e tube of length about 12 30cms firmly to the bleeder nipple Insert the other end of the tube into a clean glass or plastic container tocollectthebrakefluid Gently depress brake lever slowly and release to drain the brake fluid through the bleeder screw Repeat this process several times till the fluid is completely drained from the brake system CAUTION Brake fluid is extremely corrosive hence ensu...

Page 145: ...ake system Loosen and remove the banjo bolt along with sealingwashersfromthe brake hose at wheel caliper end Ring Spanner 14mm Loosen and remove the banjo bolt along with sealingwashersfromthe brake hose at master cylinder end Remove the brake hose from vehicle Remove2slottedscrews from the top cover Remove top cover diaphragm plate and rubber diaphragm from master cylinder NOTE Ensure brake fluid...

Page 146: ...pivot lock nut brake leverpivotfrombracket Remove brake lever and protective rubber boot from master cylinder Remove Circlip from the Master cylinder body slowly and carefully Remove conical spring and piston with seals from master cylinder housing Screw driver Double end spanner 8mm CAUTION Spring loaded Remove with care Remove 2 hex bolts on the clamp Remove clamp and mastercylinderfromthe handl...

Page 147: ...l caliper from fork end LH Loosen the 2 hex bolts holding brake caliper to fork end Remove caliper assembly from fork end Hex nut M10 Ring spanner 12mm 13 1 3 Brake pads from caliper Remove the 2 grub screws on the caliper body Screw Driver Loosen and remove 2 socket headed pin screws from the caliper body Remove the brake pad from Caliper Assembly Allen screws 4mm Allen key M5 ...

Page 148: ...ssembly Remove the Pad tensioner spring plate from caliper 13 1 Front Disc Brake 13 1 4 Pistons seals from caliper Remove the bellow boot from the caliper assembly Hold the caliper body with the pistons facing downwards Blow low pressure compressed air with a nozzle into the oil passage hole on the caliper to drive out the pistons from the caliper bores Gently remove the seals from caliper using a...

Page 149: ...lexible tube of length about 12 30cms firmly to the bleeder nipple Insert the other end of the tube into a clean glass or plastic container tocollectthebrakefluid Loosen bleeder nipple by about 2 turns Bleeder Nipple Ring spanner 10mm Gently depress brake pedal slowly and release to drain the brake fluid through the bleeder screw Repeat this process several times till the fluid is completely drain...

Page 150: ...ar brake light switch coupler black from wiring harness near battery Using a double end spanner loosen the hex nut cum brake light switch and remove Remove the brake hose from vehicle Banjo bolt Ring spanner 12mm NOTE Place a clean tray below brake hose to collect residual brake fluid Brake light switch Double end spanner 14mm NOTE Removethesealingwashers fromeithersideofthebrake hose banjo 13 2 2...

Page 151: ...nd disconnect hose from reservoir to master cylinder Hex soc Hd screw M4 Allen key 5mm Loosen and remove hex socket screw holding reservoir to frame and remove reservoir along with hose Split pin Nose pliers Remove split pin from the pin on brake pedal Remove pin and disconnect brake pedal from the link rod in master cylinder Hex soc Hd screw M4 Allen key 5mm Loosen 2 socket head screws holding ma...

Page 152: ...linder Remove Circlip from the Master cylinder body slowly and carefully Circlip Circlip pliers Gently pull out piston with bush seals spring guide and conical spring from master cylinder housing CAUTION Do not use any sharp tool to pull out the piston from the master cylinder Pull out gently with minimum force 13 2 Front Disc Brake 13 2 4 Brake pads from wheel caliper Remove 2 locking clips from ...

Page 153: ...r Disc Brake 13 2 4 Brake pads from wheel caliper Pull out the pivot pin from the inside of the caliper Remove the brake pads from the caliper 13 2 5 Wheel caliper from swing arm Loosen and remove rear wheel axle nut Pull out the pivot pin from the inside of the caliper Separate the Mounting Bracket from the Caliper Assembly by gently pulling them apart ...

Page 154: ...y with the piston facing downwards Blow low pressure compressed air with a nozzle into the oil passage hole on the caliper to drive out the piston from the caliper bore Gently remove the piston with seal from caliper using a blunt and soft tool 13 2 Rear Disc Brake 13 2 5 Piston seal from caliper CAUTION Donotusehighpressureair Support piston while removing from caliper Ensure the bore in the cali...

Page 155: ... brake disc thoroughly Inspect brake hose joints reservoir and wheel caliper ends for any traces of fluid seepage or leaks Check and correct the leaks immediately if any noticed Inspect Brake hoses for any damage cracks or cuts ageing etc and replace damaged parts immediately Inspect brake pads for embedded foreign objects abnormal wear age hardening of friction material etc Inspect and ensure the...

Page 156: ...OT attempt to repair damaged pistons pins master cylinder caliper etc as it may render the disc brake system to become ineffective and seriously affect braking efficiency Ensure the brake disc is clean and dry at all times for the brakes to work at peak efficiency WEAR LIMITS Component What to Measure Service Limit Where to Measure Front Disc Rear Disc Thickness of the disc plate Minimumdiscthickn...

Page 157: ...ar out of pistons 25 31 mm Wheel caliper Pistons OD TORQUE VALUES S No Aggregate Fastener Suggested Torque NM Kg M 1 Master cylinder assembly clamp HexBoltM6 9 0 0 9 2 Brake lever pivot Pivot bolt 6 0 0 6 3 Brake lever pivot lock nut Pivot bolt lock nut 6 0 0 6 4 Brake hose banjo bolts Banjo bolts 35 0 3 5 5 Master cylinder cover screws Slotted screws 1 5 0 15 6 Brake pad pin bolts Socket pin bolt...

Page 158: ...OVE Together Do not clean the rubber parts with petrol or any other gasoline product or water Use clean brake fluid only In case of water contamination of Brake fluid drain the fluid completely refill the system and bleed Do not top up brake fluid above Max level to avoid front wheel binding problem CheckperiodicallywhethertheDischasbeencontaminatedwithoil brakefluidorgreaseandcleancontaminated Di...

Page 159: ...bly Coat the caliper cylinders and pistons with fresh brake fluid Insert the closed end of the pistons into the caliper bores and gently press it into caliper fully till the open ends of the piston are flush with the caliper bore outer edge Smear fresh brake fluid on the caliper boot and bellow and assemble them on the caliper body S No 13 3 1 Pistons seals in caliper NOTE Do not apply force while...

Page 160: ...otos Aggregate to Assemble Instructions 13 3 F Front Disc Brake Install the pad tension springplateintheCaliper body S No 13 3 1 Pistons seals in caliper Assemble Bleed screw with the dust cap on the caliper body Assemble the Mounting Bracket on the caliper Body Ring Spanner 8 mm Torque 10Nm 0 1Kgm ...

Page 161: ...ake pad with the friction material facing the opposite brake pad S No 13 3 2 Brake pads in caliper Apply Silicon grease on thepinODandassemble the Pin bolt by pressing gently through the brake pads into caliper body NOTE Ensure pads are positioned and locked correctly in the mounting bracket lug Tighten the pins to the caliper body Assemble Grub screws on the pins and tighten Brake pad pins Allen ...

Page 162: ...n fork end LH Hex bolt M10 Socketspanner 12mm Torque 30Nm 3 0Kgm 13 3 Front Disc Brake Locate master cylinder assembly on the handle bar Locate clamp on handle bar and tighten the master cylinder assy To handle bar with 2 hex bolts Smear the piston seals and cylinder bore with fresh brake fluid and assemble piston sub assembly into the mastercylinderbygently pushing it into the bore 13 3 4 Master ...

Page 163: ...n the Lever pivot hole and on the Piston surface Position brake lever insidethebracket locate pivot screw from the top and tighten to bracket Assemblelocknutbelow and tighten CAUTION Do not use tools with sharp ends Locatetheconicalspring on the piston compress andassembleCirclipinto thegrooveof themaster cylinder Hex Screw Hex nut M5 Screw driver Spanner 8mm Torque 6Nm 0 6 KgM Assemble the Brake ...

Page 164: ...ith banjo bolt Route the brake hose correctly from the right side towards the wheel caliper in fork end LH Position brake hose against the mounting hole on wheel caliper correctly Locate 2 new copper washers on either sides of the brake hose banjo and tighten with banjo bolt Fill fresh brake fluid in the Master cylinder till MAX mark Assemblethediaphragm plate and cover Tighten screws gently S No ...

Page 165: ...Piston seals in caliper Coat fresh brake fluid on new dust seals and piston seals Install piston seals in the inner groove and dust seals in the outer groove in the bore in caliper assembly Coat the caliper cylinder and piston with fresh brake fluid Insert the closed end of the piston into the caliper bore and gently press it into caliper fully till the open ends of the piston are flush with the c...

Page 166: ...3 4 R Rear Disc Brake Install the pad tension springplateintheCaliper body S No 13 4 1 Piston seals in caliper Ring Spanner 8 mm Torque 10Nm 0 1Kgm Assemble Bleed screw with the dust cap on the caliper body Position the guides on the Caliper and mounting bracket correctly on the rubber boot and assemble caliper body in the mounting bracket ...

Page 167: ...correctly positioned inside the caliper Assemble wheel axle through the caliper bracket on the swing arm Assemble axle nut and tighten to torque S No 13 4 1 Wheel caliper on swing arm Locate the brake pads inside the caliper on either sides of the disc withthefrictionmaterial facing the disc 13 4 2 Brake pads on wheel caliper Locate the pivot pin from the inside of the caliper correctly Assemble t...

Page 168: ... spring guide Locate large bush over the piston Insert the large end of thespringalongwiththe piston and guide bush into the master cylinder bore and hold it in compressed position inside the master cylinder Assemble Circlip in the master cylinder body and ensure it is locked properly in the groove Assemble the protective rubber boot on the master cylinder S No 13 4 3 Master cylinder CAUTION Do no...

Page 169: ...sure the mounting holes are aligned Assemble 2 socket head screws on the mounting holesandtightenmaster cylinder to frame x Insert link rod in master cylinder and align mounting eyelet with brake pedal eyelet correctly Insert lock pin from outside and assemble split pin on lock pin on the inside S No 13 4 3 Master cylinder Hex soc Hd screw M4 Allen socket 5mm Torque 10Nm 0 1Kg M Split pin Nose pli...

Page 170: ...e to reservoir and master cylinder and lock metal clip in place firmly at both ends Position brake hose against the mounting hole on master cylinder such that it is pointing inwards correctly Locate 2 new copper washers on either sides of the brake hose banjo Assemble Banjo bolt with brake switch on the brake hose banjo and tighten banjo to master cylinder Connect brake light switch coupler to mai...

Page 171: ...ommets on the brake hose in the clips in swing arm Position brake hose against the mounting hole on wheel caliper correctly S No 13 4 5 Brake hose Locate 2 new copper washers on either sides of the brake hose banjo and tighten with banjo bolt Banjo bolt Ring spanner 12mm Fill fresh brake fluid in the Master cylinder till MAX mark Bleed the air out of the hydraulic brake system ...

Page 172: ...cylinderreservoirisfilled with fresh brake fluid from a sealed container up to MAX level Fix the diaphragm plate andtopcoverandtighten cover just sufficiently Depress brake lever brake pedal completely andreleasefully toallow thebrakefluidtofillupin the brake system and caliper Repeatabovestepseveral times while periodically inspecting the fluid level in the reservoir Top as required to maintain l...

Page 173: ...ough the bleedernipple thebrake lever pedalwill depress further DO NOT RELEASE THE LEVER BUT HOLD IT FIRMLY AT THIS POSITION After all the air bubbles escape thro the bleeder nipple tighten bleeder screw firmly and then only release brake lever pedal Check and top up brake fluid in the master reservoir up to MAX level Repeat the steps above tillthebrakelever pedal movement is minimal and locks fir...

Page 174: ...ad Screw driver Torque 1 5Nm 0 015KgM NOTE Checkandensurethereisno sponginess of the brake lever pedal when brakes are applied Carry out a road test to checkthebrakingefficiency Check for any leaks at the banjo or the bleeding screw areas and ensure all tightness of all fasteners For front brake master cylinder Assemble diaphragm plate and top cover and tighten with 2 slotted screws on the front b...

Page 175: ...et Assy Canister mounting 2 5 Rubber Strap Canister 1 6 Canister Assy 1 7 Clip 1 8 Hose Air vent 1 9 Hose Purge Valve to Throttle body 1 10 Hose Clip 4 10 10 9 11 12 13 14 3 10 19 10 12 18 1 2 2 16 17 12 15 12 5 2 4 6 7 8 3 2 11 Hose Canister to Purge valve 1 12 Hose Clip 6 13 Purge Valve 1 14 Grommet Purge Valve 1 15 Hose Canister to T Connector 1 16 Bracket Assy Purge Valve 1 17 T Connector 1 18...

Page 176: ...D HIMALAYAN EURO IV VEHICLE SERVICE MANUAL LOCATION OF EVAP IN MOTORCYCLE The canister is connected to the fuel tank to trap all the fuel vapours that build up in the fuel tank HIMALAYAN Location Located on Skid Plate ...

Page 177: ...ents gasoline vapors from escaping into the atmosphere from the fuel tank As soon as the motorcycle is parked after riding or parked under the sun the hot radiation from the engine sunlight causes the fuel in the tank to warm up and releases fuel vapors The EVAP system prevents these fuel vapors recycled to engine to avoid vapor into the atmosphere and stored in a charcoal canister As soon as the ...

Page 178: ... Canister Hex Bolt M6 Socket Spanner 8mm Hex Soc Head Screw M6 Allen Key 5 mm Loosen 6 hex bolts mounted on skid plate on LH RH Top Portion of the skid plate Loosen 5 hex screws mounted on canister assy Purge valve Gently remove the 2 canister bracket assy along with rubber strap Gently remove the canister from the skid plate assy with the hoses ...

Page 179: ...y for any cuts cracks or fractures Replace if damaged Inspect Canister periodically for any damage to its body cuts or cracks Replace all rubber hoses and connectors every 12 000 Kms Aggregate Component Fastener Torque Range NM Kg M Canister Canister Assembly Bracket Hex Flange bolt M6 X 1 X 20 10 1 0 TORQUE CHART ...

Page 180: ...tructions 1 Canister Hex Bolt M6 Socket Spanner 8mm Torque 10 Nm Hex Soc Head Screw M6 Allen Key 5 mm Locate canister assy on the skid plate along with the hoses Locatge the canister bracket assy on the skid plate along with rubber strap Install 5 hex screws okn canister assy purge valve Install6hexboltsonskid plate LH RH Top portion ...

Page 181: ...180 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL S SECTION 15 ENGINE MANAGEMENT SYSTEM EMS ...

Page 182: ...iance with BS IV regulation related to exhaust emissions Optimum fuel efficiency and power output Excellent cold start ability and sustained high speed drive ability F FUNCTIONAL DIAGRAM OF THE EMS In addition to optimizing engine performance the ECU also has an inbuilt memory by which any EMS related malfunctions will get stored and help diagnose the fault accurately Thereisalsoaninbuiltsafetysys...

Page 183: ...mory records informationrelatedtoperformanceofthevarioussensorsintheEMS onarealtimebasisANDalsorecordsanysensor failures if it occurs during operation of the motorcycle The main advantage of E2PROM is it records data even when the motorcycle s electrical system is switched OFF This will help in diagnosing the motorcycle performance and also to view the history and defect codes whenever the Royal E...

Page 184: ...G1 Power Ground1 10 PG2 Power Ground2 11 IG Ignition Coil 12 CRK P Crank Pulse Sensor 13 14 TA Air Temperature 15 TEST Test Switch 16 INJ Injector 17 VSP Vehicle Speed Sensor 18 19 20 21 22 MIL Multi Indicator Lamp 23 CRK M Crank Pulse Sensor GND 24 TW Engine Temp Sensor 25 SSTAND Side Stand Switch 26 ROLL Roll Sensor 27 PM Manifold Pressure Sensor 28 EXAJ Exhaust Air Injection 29 NLSW Neutral Swi...

Page 185: ...le is held wide open with gears in neutral leading to crankshaft speed above 5500 RPM the high frequency electrical pulses from the crank position sensor will prompt the ECU to restrict fuel supply so that the crank speed reduces below 5000 RPM This is a safety aspect to prevent damage to moving engine parts 3 ENGINE TEMPERATURE SENSOR LOCATION The engine temperature sensor EOT is located on the c...

Page 186: ... time basis to the ECU based on which the fuel injection is metered continuously to control exhaust emissions and for optimum performance of the motorcycle 5 EXHAUST AIR INJECTION UNIT SOLENOID LOCATION The exhaust air injection unit EXAI is located underneath the fuel tank In addition to the Hego sensor the EXAI gets inputs from the ECU to supply filtered air into the exhaust end of the cylinder ...

Page 187: ...idling RPM in extreme cold conditions The throttle body also has a throttle position sensor TPS and manifold absolute pressure sensor MAP 7 THROTTLE POSITION SENSOR TPS LOCATION Throttle Position Sensor TPS is located on the throttle body at the end of the butterfly valve spindle to monitor the position of the butterfly valve The sensor consists of a potentiometer and provides a variable resistanc...

Page 188: ... provide the required amount of vaporized fuel into the combustion chamber for optimum performance of the motorcycle 9 AMBIENT AIR TA SENSOR LOCATION The TA sensor is located on the rear side of the filter box assembly in Bullet EFI Classic EFI Thunderbird EFI models and on the outlet pipe of the air filter housing in Continental GT models The ambient temperature input is provided to the ECU on a ...

Page 189: ...ureinthefuelsystemtopreventdamagetothefuelinjector fuelhose Anyexcesspressureisbypassed back into the fuel tank 11 FUEL INJECTOR LOCATION Thefuelinjectorislocatedatanangleontheintakesideofthecylinderheadsoastomaximizefuelsprayandminimize wall wetting for optimum performance of the motorcycle The Fuel Injector is a solenoid operated electromagnetic valve which enables the pressurized fuel delivered...

Page 190: ...R LOCATION The rollover sensor is located on the frame under the seat The rollover sensor also known as a banking sensor is a safety feature If the banking angle of the motorcycle goes below 60o OR in the event of an accident causing the motorcycle to fall over on either of its sides with the engine running the rollover sensor will command the ECU to cut off both the fuel supply and ignition thus ...

Page 191: ...heIgnition Enginekillswitchis ON andaftervehicle isstarted MILwillglowforfewsecondsandswitchOFF thisindicates that all the functions of EMS are functioning correctly In the event of any malfunction the MIL will glow continuously The EMS should be checked using either the test pin method OR the Royal Enfield NACS II diagnostic tool connected to the socket in the wiring harness of the motorcycle ...

Page 192: ...trol Unit ECU Himalayan TheECUislocatedunder the fuel tank Ensure Ignition switch and stop switch are in OFF position UnlocksidepanelLHand remove the panel LH Gently pull seat latch cable to release seat and remove seat Gently pull out the ECU from the rubber housing located in the frame Gently release lock and disconnect the wiring coupler from the ECU Remove ECU ...

Page 193: ...tre and bottom Loosen and remove 1 Hex Flange Bolt M6 X 1 X 45 from cover RH rear It may be necessary to gently tap and remove coverRHasthemagnetic forcesintherotorcanbe acting on the stator and making it difficult to remove Remove gasket Remove 2 Hex Flange Bolt M5 X 0 8 X 16 holding Pulsar coil to cover RH inside Remove 3 Hex Socket HeadCapScrewM5X30 holding stator coil to cover RH inside Fasten...

Page 194: ...ctions 4 4 3 Engine Temperature Sensor The Engine temperature sensor is located on the cylinder head right side belowtheinletmanifold Deep Groove Socket bit 17mm Gently Loosen engine temperature sensor and remove along with O ring Ensure Ignition switch and stop switch are in OFF position Disconnect wiring harness coupler from the sensor ...

Page 195: ...tructions 4 4 4 O2 Sensor The Hego sensor is assembled on the inner side of the exhaust down pipe near the cylinder head Ensure Ignition switch and stop switch are in OFF position Disconnect wiring harness coupler from the sensor Loosen Hego sensor and remove along with copper washer from the exhaust down pipe Deep Groove Socket 21mm ...

Page 196: ...he EXAI solenoid Releasethe2clipsonthe Inlet and outlet pipes connected to the EXAI solenoid and dis connect the pipes Gland Nut Double end spanner 16mm SocHdCapScrew M5X20 Allen Key 4mm Hex Screw M6 X 16 Socket spanner 8mm NOTE Ensure spacer between the EXAI solenoid bracket is removed Loosen Gland nut at cylinder head end and disconnect braided hose connecting reed valve to cylinder head Remove ...

Page 197: ...nd hence should not be removed from the throttle body Slacken the locknuts on the adjusters and remove throttle cables from the throttle body Disconnect rubber hose connecting throttle body to the EVAP canister Disconnect manual Bi Starter cable from throttle body by loosening and removing the plastic nut on LH side Loosen hose clip on air inlet rubber hose Loosen hose clip on Adaptor between thro...

Page 198: ...oc Hd Cap Screws M5X20 Allen Key 4mm Himalayan TheTAsensorisassembled on the pipe outlet bet ween air filter housing and Throttle body Ensure Ignition switch and stop switch are in OFF position Remove seat assembly Disconnect the wiring coupler from the TA sensor UsingalongreachPhilips head screw driver loosen and remove the 2 screws holding TA sensor to pipe outlet Remove TA sensor along with gas...

Page 199: ...and fuel tank Loosen remove 5 Hex Socket Button Head Cap Screws along with the copper fibre washers Remove clamp plate Pull out fuel pump from the fuel tank Take care to remove the Oringfromthefueltank CAUTION Store fuel in a tight sealed container in a well ventilated cool and dry place Do not smoke or allow open flame or sparks in the vicinity NOTE Ensure Ignition switch and engine kill switch a...

Page 200: ...tank Ensure Ignition switch and stop switch are in OFF position Remove Seat assembly and fuel tank Disconnect the wiring coupler from the fuel injector Loosen worm clip on the inlet fuel hose and remove fuel hose from cap injector assembly Remove hex nut from top of injector cap assembly and remove injector cap along with O ring Remove the spacer from the stud Gently pull out the Injector from the...

Page 201: ...antle Instructions 4 4 10 EFI ECU Power Side Stand Relays Himalayan Two identical relays are located near the battery Located in a rubber holder on the side of the battery carrier Ensure Ignition switch and stop switch are in OFF position Remove side panel LH Gently pull out relay from the rubber holder and electrical socket ...

Page 202: ...o Dismantle Instructions 4 4 11 Roll Over Sensor Located below the seat on the frame Ensure Ignition switch and engine stop switch are in OFF position Disconnect the wiring coupler from the sensor Loosen and remove the hexsocketscrewholding the sensor to the frame and remove the sensor Hex Soc Hd Screw M6 Allen Key 5mm ...

Page 203: ...ge Precautions Photos Aggregate to Dismantle Instructions 4 4 12 Malfunction IndicatorLamp Himalayan Located in the RPM meter in the instrument cluster Ensure Ignition switch and engine stop switch are in OFF position The instrument cluster does not have any individual serviceable parts ...

Page 204: ...structions 4 4 13 Electronic Control Unit ECU Himalayan Locate ECU under the Fuel tank Connect the wiring coupler on the ECU and gently lock Gently push the ECU on its rubber housing located in the frame TheECUislocatedunder the seat Locateseatontheframe and push it for proper seating Locate the side panel LH and lock side panel LH ...

Page 205: ... tighten 1 Hex Flange Bolt M6 X 1 X 45 on cover RH rear Install and tighten 7 Hex Flange Bolt M6 X 1 X 70 on cover RH top centre and bottom Install and tighten 2 Hex Flange Bolt M6 X 1 X 85 on cover RH front ConnectMagnetowiring coupler in the electrical harness Fill engine oil CAUTION Ensure stator coupler is disconnected before removing cover RH Gently tap on the tabs provided in the front andre...

Page 206: ...otos Aggregateto Assemble Instructions 4 4 15 Engine Temperature Sensor Locate engine temperature sensor alongwith O ringonthe cylinder head right side belowtheinletmanifold Ensure Ignition switch and stop switch are in OFF position Connect wiring harness coupler on the sensor Deep Groove Socket bit 17mm ...

Page 207: ... Precautions Photos Aggregateto Assemble Instructions 4 4 16 O2 Sensor Deep Groove Socket 21mm Locate Hego sensor along with copper washer on the exhaust down pipe near the cylinder head Ensure Ignition switch and stop switch are in OFF position Connect wiring harness coupler on the sensor ...

Page 208: ... solenoid to the reed valve bracket Install the 2 Hex Screws on the reed valve mounting bracket to frame Locate EXAI Solenoid on the frame under the fuel tank along with the reed valve Install Gland nut at cylinder head end and connect braided hose connectingreedvalveto cylinder head Connect 2 clips on the Inlet and outlet pipes connected to the EXAI solenoid Ensure Ignition switch and stop switch...

Page 209: ...r Locate throttle body between the cylinder head inlet and air filter outlet house Gently slide throttle body on the inlet bellow and adaptor Locate hose clip on Adaptor between throttlebodyandcylinder head Locate hose clip on air inlet rubber hose Connect manual Bi Starter cable on throttle body by tightening and locating the plastic nut on LH side Connect rubber hose from throttle body to the EV...

Page 210: ...rews Philips Screw driver Hex Soc Hd Cap Screws M5X20 Allen Key 4mm Himalayan Locate TA sensor along with gasket on pipe outlet between air filter housing and throttle body UsingalongreachPhilips headscrewdriver Install 2 screws holding TA sensor to pipe outlet Ensure Ignition switch and stop switch are in OFF position Connect the wiring coupler in the TA sensor Assemble seat assembly ...

Page 211: ... are in OFF position Hex Soc Button Hd Cap Screws M6X12 Socket spanner 8mm Locate the O ring in the fuel tank Locate fuel pump assembly inside the fuel tank at left side Install clamp plate Install 5 Hex Socket Button Head Cap Screws along with the copper fibre washers AssembleSeat assembly and fuel tank NOTE In three times operation of kill switch in ignition on condition 210 ml to 240ml of fuel ...

Page 212: ...ector on the inlet side of the cylinder head below the fuel tank Locate the spacer in the stud Locate hex nut from top of injector cap assembly and place injector cap along with O ring Locate worm clip on the inletfuelhoseandlocate fuel hose on cap injector assembly Ensure Ignition switch and stop switch are in OFF position Connect the wiring coupler from the fuel injector AssembleSeat assembly an...

Page 213: ...Photos Aggregateto Assemble Instructions 4 4 22 EFI ECU Power Side Stand Relays Himalayan Ensure Ignition switch and stop switch are in OFF position Gently push the two identical relays in the rubber holder and electrical socket Locateinarubberholder onthe sideofthe battery carrier Locate side panel LH ...

Page 214: ...teto Assemble Instructions 4 4 23 Roll Over Sensor Hex Soc Hd Screw M6 Allen Key 5mm Locate the hex socket screw on the sensor to the frame and install the sensor which is located below the seat on the frame Connect the wiring coupler from the sensor Ensure Ignition switch and engine stop switch are in OFF position ...

Page 215: ... Usage Precautions Photos Aggregateto Assemble Instructions 4 4 24 Malfunction IndicatorLamp Himalayan Ensure Ignition switch and engine stop switch are in OFF position Locate theRPM meter in the instrument cluster The instrument cluster does not have any individual serviceable parts ...

Page 216: ...N and does not switch OFF the test pin method will help narrow down to the sensor electrical connection that caused the malfunction LEVEL 3 GENERIC SCAN TOOL NACS II DIAGNOSTIC TOOL A generic scan tool supplied by Royal Enfield will help identify the exact cause of the malfunction in the EMS when connected between the motorcycle and a computer The tool will take inputs from the ECU and provide to ...

Page 217: ...d the MIL glows continuously proceed to l level 2 test pin method to resolve the defect LEVEL 2 TEST PIN METHOD An open single pole connector is provided close to the UCE Connect a piece of wire to this connector and suitably ground it to the motorcycle body Switch ON ignition and engine stop switch and observe the MIL keenly for a series of short and long blinks at different intervals to identify...

Page 218: ...on Long 1 Short 5 Roll over sensor Malfunction Long 3 Short 3 Fuel Injector Circuit Malfunction Long 3 Short 7 Ignition Coil Circuit Malfunction Long 4 Short 1 Fuel pump relay circuit Malfunction Long 7 short 0 Vehicle Wheel speed sensor Malfunction only for Continental GT Model LEVEL 3 GENERIC SCAN TOOL METHOD When the fault is detected the GST raises a flag to conform readiness Permanent Confirm...

Page 219: ...gh input voltage O2 Sensor HG Short circuit to ground or open circuit low or open P0130 Fuel Injector IJ1 Short circuit to ground or open circuit P0201 Short circuit to Battery Ignition Coil IG1 Short circuit to ground or open circuit P0351 Short circuit to Battery Fuel Pump Relay FLR Short circuit to ground or open circuit P0230 Short circuit to Battery O2 sensor Heater HR Short circuit to ground...

Page 220: ...T rev the engine fully immediately after starting OR just before shutting off the engine 5 DONOTremovethefuelhose highpressure fromthefuelpumptofuelinjector whenengineisrunningORwith the ignition switch ON Fuel flows at a very high pressure during these times 6 DO NOT use a booster or high voltage charging unit instead of a battery Use only a good correctly charged battery to start OR check the mo...

Page 221: ...220 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL SECTION 16 ELECTRICAL COMPONENTS ...

Page 222: ...TER WIRING LAYOUT TECHNICAL SPECIFICATIONS System Battery 12V DC 12V 14 Ah Starter Motor 0 9KW Solenoid Switch Magnetic Relay type S STARTER MOTOR INSPECTION Ensure earth terminal is located on the outside hex flange bolt of the starter motor before tightening both bolts ...

Page 223: ...NG 1 Give a supply voltage of 12V across the relay coil 2 pole female terminal Battery positive on coil positive and Battery negative on coil negative 2 After energizing the coil check the continuity between Battery ve terminal and Starter ve terminal Ring terminal usingMultimeter IftheMultimeterindicates0Ùwithabeepsound thecontactshavegotclosed Ifthe Multimeter indicates as open OL contacts have ...

Page 224: ... black and red wires to discharge the capacitor STEP 2 To check the condition of 3 positive diodes of RR unit keep the positive probe Red of the multimeter in any one of the 3phase terminals yellow wire inserted in black red connector and the negative probe Black of multimeter on the positive terminal of DC output red wire inserted in two pole connector and check for the condition of diode as show...

Page 225: ...gative terminal of DC output black wire with eyelet single pole connector and negative probe Black colour of the multimeter shall be kept on anyone of the 3 phase terminals yellow wire If the diode is good then the multimeter will show a voltage drop of 0 4 0 7V If diode has failed multimeter will show either open or short with beep sound then Replace the RR unit STEP5 All the three diodes to be c...

Page 226: ... STEP 1 1 Set the Multimeter in Resistance check mode 2 Keep the positive Red and negative Black probes of the multimeter on two ends of the suppressor cap 3 Resistance shall be 3 75 to 6 25 Kilo Ohms 4 If resistance deviates from the specification or open Suppressor cap to be replaced ...

Page 227: ... magneto If multimeter shows open during resistance check the coil has got cut or short with the core and magneto has to be replaced B INSULATION TEST 1 For checking the insulation strength keepthe multimeter in continuity mode and check continuity between any 3 phase terminalsand engine body If there isa body short insulation failure multimeter willindicate 0ohms or resistance value 50 ohms with ...

Page 228: ...parallel to the load element is connected in series to the load 2 The excess power from the magneto is returned The excess power will not be returned back to the back to the source through the control element source When magneto output voltage goes beyond The control device gets t turned OFF when the 3 the setting voltage Eg 14 5 0 2V the control magneto o p volatge goes beyond the setting element...

Page 229: ...ain the cause of a fuse blowout and rectify to prevent fuses blowing frequently BLADEFUSEUSAGELIST F1 CHARGING FUSE 25A F2 MAIN FUSE 25A F3 IGNITION EFI FUSE 15A F4 SIGNALLING FUSE 10A F5 HORNFUSE 10A F6 LIGHTING FUSE 15A F7 ABS MAIN 1 FUSE 25A F8 ABS MAIN 2 FUSE 10A F9 ABS ECU 5A SPARE 1 SPARE FUSE 1 25A SPARE 2 SPARE FUSE 2 15A SPARE 3 SPARE FUSE 3 10A SPARE 4 SPARE FUSE 4 5A Rating Function ID ...

Page 230: ...s positive terminal first negative terminal next Remove flasher unit along with its rubber holder from battery strap Disconnect starter relay couplers Whitecolourfromwiring harness Red colour from Battery Remove starter relay along with its rubber holder from battery strap Remove Hex screw from battery strap front Release battery strap from the slot in the rear and remove strap Remove battery from...

Page 231: ...Disconnect head lamp wiring coupler below head lamp Remove 2 Allen screws holding headlamp assy to LH RH Top bracket remove head lamp assy Hex Cap nut M6 Tspanner 10mm 17 3 Instrument Cluster Assy Disconnect Instrument cluster wiring coupler Remove 3 Hex cap nuts along with washers Remove instrument cluster from its mounting bracket Hex Socket cap screw M8 Allen Key M6 ...

Page 232: ...rative cover from the rubber grommet in the side support bracket NOTE The couplers are color coded as LH side Green RH side Red Hex Socket Cap screw M6 Allen key 4 mm 17 5 Trafficator Rear LH RH Disconnect Trafficator couplers red green Remove the screw from the trafficator housing back side Remove outer lens Remove the fused bulb by pushing and turning anticlockwise 17 6 Tail Lamp Number plate il...

Page 233: ...nnect black wire to the negative terminal of the battery Locate starter relay along with its rubber holder from battery strap Install Hex screw on battery strap front Locate battery strap from the slot in the rear and remove strap Locate side panel on the right side by installing 2 hex socket button head screws Lock turn the key Anti clockwise and locate the pillion seat Locate the front seat S No...

Page 234: ...nstall 2 Hex cap screws holding headlamp assy to LH RH Top bracket locate head lamp assy Connect head lamp wiring coupler below head lamp S No Allen screw M8 Allen Key M6 17 9 Instrument Cluster Assy Locate instrument cluster on its mounting bracket Install 3 Hex cap nuts along with washers Connect Instrument cluster wiring coupler Hex Cap nut M6 Allen Key 5 mm ...

Page 235: ...side support bracket Install Allen screw mounting the trafficator to the side support bracket Connect Trafficator wiring couplers below headlamp S No Hex Cap Screw M6 Allen key 5 mm NOTE Thecouplersare colorcoded as LH side Green RH side Red 17 11 Trafficator Rear LH RH Locate the bulb by pushing and turning clockwise Locate outer lens Install the screw on the trafficator housing back side Connect...

Page 236: ...ar are reusable hence do not remove them from the handle bar if not required to be removed 17 13 Handle Bar Switch RH Open cable straps to release the wiring harness Disconnect wire coupler from main cable harness near Steering stem on RH side Remove 2 Philips head screw from bottom of switch RH Screw driver NOTE The straps fixed in the handle bar are reusable hence do not remove them from the han...

Page 237: ...ns to thefront brake switch onhandlebarRH bottom Release lock and gently pull switch out of the front brake bracket 17 16 Ignition Switch Disconnect ignition switch wiring coupler Remove 2 Hex screws from bottom of switch housing and remove switch Hex Cap Screw M6 Allen key 5 mm 17 17 Side stand switch coupler Remove strap to frame Pull the bellow down Disconnect Red coupler from LH side ...

Page 238: ...bar are reusable hence do not remove them from the handle bar if not required to be removed 17 19 Handle Bar Switch RH Install 2 Philips head screw on bottom of switch RH Connect wire coupler on main cable harness near Steering stem on RH side Closecablestrapstolock the wiring harness Screw driver NOTE The straps fixed in the handle bar are reusable hence do not remove them from the handle bar if ...

Page 239: ...tly push switch inside the front brake bracket Locate wire connections to thefront brake switch on handle bar RH bottom Hex Cap Screw M6 Allen key 5 mm 17 22 Ignition Switch Install2Hexscrewsfrom bottom of switch housing and locate switch Connect ignition switch wiring coupler 17 23 Side stand switch coupler Connect Red coupler from LH side Push the bellow upwards Locate strap to frame ...

Page 240: ...amp rim along with reflector assembly Disconnect head lamp coupler Remove the protective rubber cap over the bulb Gently press the bulb holding clip and release it from the slot in the reflector Remove the bulb from the reflector X X NOTE Never touch the bulb with your fingers Finger prints will etch the glass and decrease bulb life Always hold the bulb with clean dry cloth during handling Don t d...

Page 241: ... screw from the trafficator housing back side Remove outer lens Remove the fused bulb by pushing and turning in anticlockwise direction Position the new bulb inside the holder ensuring that the pins in the bulb match with slots in the holder Push the bulb and turn clockwise direction to lock the bulb in the holder Refit the trafficator cover with reflector and tighten the screw ...

Page 242: ...tinthereflector Locate protective rubber capoverthebulbcorrectly suchthattheventpipeis facing downwards Position wiring coupler over the bulb terminals correctly and press it in gently to lock the coupler Locate head lamp rim in the housing correctly such that it locks in place and the 2 mounting holes at the bottom of the rim are aligned Tighten with 2 Philips head screws firmly NOTE Do Not over ...

Page 243: ...to Assemble Instructions 17 28 Trafficator Bulb Position bulb in the reflector ensuring that the pinsin the bulb match with slots in the holder Locate bulb correctly in the reflector gently press bulb and turn clockwise to lock bulb inholder Refit trafficator cover with reflector into the housing and tighten the screw ...

Page 244: ...ellow down on middle RH side and disconnect 2 pole T type connector to main harness Loosen 2 hex bolts holdingRRunittoframe Remove RR unit mounting from frame 17 30 HT Coil Assy Disconnect the white coupler from the main wiring harness HT coil Loosen the 2 Hex flange bolts mounted on the welded nut in frame Remove HT Coil assy from frame Hex Flange Bolt M6 Socket Spanner 10 mm Hex Flange Bolt M6 S...

Page 245: ...ole T type connector to main harness Locate single pole black connector chassis ground Hex Flange Bolt M6 Socket Spanner 10 mm 17 32 HT Coil Assy Position the HT coil on the frame such that the couplerisontheleftside andtheHTcoilistowards the rear of the frame Assemble 2 Hex flange bolts M6X14 into the welded nut in frame Tighten thebolts using 8 mm socket spanner to a torque of 10 12 Nm 1 0 1 2 K...

Page 246: ...required fuse with the spare fuse available in the fuse carrier 17 34 BLADE FUSE USAGE LIST F1 CHARGING FUSE 25A F2 MAIN FUSE 25A F3 IGNITION EFI FUSE 15A F4 SIGNALLING FUSE 10A F5 HORNFUSE 10A F6 LIGHTING FUSE 15A F7 ABS MAIN 1 FUSE 25A F8 ABS MAIN 2 FUSE 10A F9 ABS ECU 5A SPARE 1 SPARE FUSE 1 25A SPARE 2 SPARE FUSE 2 15A SPARE 3 SPARE FUSE 3 10A SPARE 4 SPARE FUSE 4 5A Rating Function ID No Spar...

Page 247: ...ock setting mode and hour digits starts to blink SELECT 1 sec Hours value shall increment by 1 accordingly for no of press SELECT 3 sec Hour value saved and minute igits starts to blink SELECT 1 sec Minutes value will increase by 1 by each press of the Select button SELECT 3 sec Minute value save and PM AM digits starts to blink SELECT 1 sec PM AM is interchangeable by each press of the Select but...

Page 248: ...EMPERA TURE UNIT CHANGE OVER MODE 10 secs In ignition key ON position long press and hold MODE button for period 10 secs to reset temperature units from degree Celsius to Fahrenheit and vice versa SERVICE REMINDER Service reminder is provided to remind about service due Spannersymbolwillflashtillvehicleisservicedat service center ServiceremindercanberesetONLYbyauthorized personnel at service cente...

Page 249: ...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 6 SIDE STAND INDICATOR Indicates when side stand is extended SIDE STAND INDICATOR The word Trip F will flash when the Trip F mode is active Trip F is provided to measure distance travelled by the vehicle when fuel level in the vehicle is 5 5...

Page 250: ...ine is started Will remain continuously ON incase of any malfunction of the EMS TURN LEFT NEUTRAL TURN RIGHT EMS MALFUNCTION INDICATION LOW BATTERY INDICATION HI BEAM INDICATION CAUTION DO NOT run motorcycle incase the malfunction remains ON continuously as it can cause severe damage to the ECU Sensors Please visit the nearest autorise Royal Enfield dealer to diagnose rectify the defect in the EMS...

Page 251: ...fluctuation during riding is normal operation due to impact of road irregularities 4 Compass indication tolerance is 45 WARNING DO NOT focus on the compass while riding Doing so many cause loss of concentration and unstable riding leading to a potential accident resulting in serious injurytobothrides otherroadusersbesidescausing severe damage to the motorcycle H FUEL GAUGE Indicates fuel level in ...

Page 252: ... 3 Diagnostic cable 6 PIN NACS II ROYAL Interface USB Hi speed cable connector Reset Button SD memory card Diagnostic connector 4 USB Hi speed cable 5 Cigarette lighter cable 6 SD memory Card 7 SD card reader 8 Carrying Box 9 Installation CD 10 User Manual Included on CD 2 NACS II ROYAL DIAGNOSTIC TOOL KIT SECTION 18 NACS II DIAGNOSIS ...

Page 253: ...erating Current 300mA Operating Temperature 00 C 700 C Dust and water resistance IP55 Standard 5 WARNING When NACS II is already connected to the motorcycle do NOT plug in AC Adaptor Do not remove SD card when you are using NACS II The failure caused by the use of unapproved cables accessories is out of warranty The warranty will become void if NACS II is disassembled or altered We recommend you t...

Page 254: ...e setting below to run out software successfully First you need to disable User Account Control UAC before installing our software The way to disable UAC is as follows Click Start button andselect Control Panel Why there is a pop up window displaying cannot find COM port A Check whether the driver of USB Hi speed cable is installed If USB port is not recognized please install USB driver 8 1 6 TROU...

Page 255: ... User Account Control Settings Click User Accounts 8 4 Click Finish to complete the installation ROYAL ENFIELD NACS II DIAGNOSIS 9 SOFTWARE INSTALLATION 9 1 Start the computer 9 2 Insert installation CD to CD ROM drive and install following software a Main software NACSII_ROYAL_V0 03_install exe b Recording data analyzing software NACSII RECORD_ROYAL V0_01_setup ...

Page 256: ... 9 5 9 6 Click Finish to exit installation After installing Firmware program USB high speed driver will start installation Click Extract to install Click Next to continue Click Finish to complete the installation 10 SOFTWARE REMOVAL Click Star Menu All Programs Control Panel Click Uninstall a program 10 2 ...

Page 257: ...ol kit with your motorcycle NACSII ROYAL interface maincable Diagnostic cable Motorcycle Orange light indicates whether the system is communicating 11 A1 When the IG of the motorcycle is ON the system starts to run entering welcome page ROYAL ENFIELD Press Diagnosis 11 A2 F1 Find NACSII_ROYAL and click Change Remove When Unistalling NACSII_ROYAL window pops up please click Next Click Finish to exi...

Page 258: ...e main menu 11 A6 C 11 A7 Using and to move the cursor Move the cursor to select Diagnostic Trouble Code Press tosee the content OK 11 A8 Diagnostic trouble code page includes F1 Current F2 History and F4 Erase Current is for the DTC occurred at the time and History is for DTC occurred in the past Erase is for erasing current DTC and History DTC Press to view Current DTC OK OK Select Royal Enfield...

Page 259: ...orsavingtheenginedynamicdatafor further analysis 11 A10 When displays on the screen press toview freeze data Press andto view next page and last page After viewing all content press to exit The screen will return to the previous page Erace DTC It s the function to erace Diagnostic Trouble Code in both Current and History 11 A11 Press toerace To confirm erasing DTC Press Yes When showing on the scr...

Page 260: ... move the cursor to Special Function and Press 11 A16 Special function is customized functions provided to specific vehicles 11 A17 OK C F1 Select CO Adjustment press and toadjust the CO value is for increasing fuel injection value is for decreasing fuel injection value After finish adjustment press tosave Press to exi t If you want to OK go back to the main page press unti l the page return to th...

Page 261: ...o move the cursor Press to select the item Change figure using or and press to confirm the item At this time the pink block will return to white Press to apply the setting 11 B4 ABS Functions 11 C Select BOSCH ABS System Press to continue 11 C1 Select Special Function Then select Repair Air Bleed 11 C2 Read the warning first before start operating air bleeding 11 C3 OK OK OK ...

Page 262: ...t operating air bleeding 1 11 C3 Follow each step on thescreen to finish the procedure 11 C4 SILA Lamp Blinking Test Follow the screen guide to finish the test 11 C5 Front Channel Activation 11 C6 Follow the instructions on screen to finish the activation 11 C7 Follow the instructions on screen to finish the activation 11 C8 ...

Page 263: ...face Main Cable Diagnostic Cable Motorcycle IG ON 12 1 Double click NACSII_ROYAL onthe desktop to open diagnostic software 12 2 When the first time you use software the software will enter register process automatically Please make sure your PC is connected to the internet When the window displays Product key click NEXT Software will get the password by itself 12 3 Registration is completed Click ...

Page 264: ...lick to continue 12 7 Connecting to engine system Please wait 12 8 There are various green buttons on the right button is for displaying all the vehicle info 12 9 ROYAL ENFIELD NACS II DIAGNOSIS Click to read the Diagnostic Trouble code Click Current toread current DTC Click History to read history DTC 12 10 If you want to print trouble code click to print DTC data It will take a moment 12 11 ...

Page 265: ...and one time only record one Diagnostic Trouble Code freeze data it s for saving the engine dynamic data for further analysis Click to return to Diagnostic Trouble Code page 12 14 To erase the Diagnostic Trouble Code click Note if you click the erase button all Diagnostic Trouble Code in Current and History will be erased 12 15 Click tosee specification of live data 12 16 Click toseethe live data ...

Page 266: ...ime 12 17 Click to erase ALL selected live data If you want to erase only one item please press and hold Shift key and select the item that you want to delete Then click button The selected item will be erased 12 17 D This button is for special function Functions depend on ECU type Take CO adjustment as an example Select the item and click 12 18 The page will display What to do for next step Click...

Page 267: ... II handheld tool and insert SD card to PC 13 RECORD ANALYZINGSOFTWARE Open the software of NACSII_Record_Royal Select Analyze Record Data 13 1 Select Record Date and File name then click 13 2 Select the items which used often Selecteditemswillbe listed in the block of Live Data Item Click toview wave chart of selected items 13 3 13 4 Wave chart starts running until press Stop button Drag Yellow l...

Page 268: ...wave chart please click toselect page number Click the2nd to go back to last page Select items to set breakdown point for analysis After selecting items click For example setting Engine speed grater than 3150 enter 3150 in the right block Click to confirm the setting value 13 9 When window pops up Setting OK the setting is completed 13 10 The setting value will display in the blockunder Break Clic...

Page 269: ...set the second value please select Live data item Take throttle position as an example Enter throttle position grater than 9 8 in the right block and click to finish setting 13 12 After Setting 2 values of the 2 items the 2 items will be listed in the block of All value match Click to go back to Live data selection page Backto Livedata selectionpage click toview wave chart of the 2 setting values ...

Page 270: ...ted in Any of value match block Continue to set match conditions AND OR AND All conditions of setting items must be satisfied OR One of or any of selected items must be satisfied Setting items listed in All value match and Any of value match must be satisfied If there isno matched condition the window will pop up showing condition can t match 1 13 17 Click towave chart 13 18 Click to quick find ma...

Page 271: ...270 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL SECTION 19 WIRING HARNESS ...

Page 272: ...271 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL WIRING DIAGRAM COMPLETE LS 410 ...

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Page 275: ...274 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL ...

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Page 277: ...276 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL ...

Page 278: ... slipping Adjust clutch cable free play 8 Main or EFI Fuse failed Replace with new fuse II ENGINE MISFIRING 1 Loose spark plug cap Fix cap lead firmly 2 Spark plug fouled Clean spark plug or non specified heat range plug 3 Any sensor loose connections Check MAP or EOT or TPS sensor wiring coupler loose connections 4 Water in petrol tank Clean petrol tank Fill tank with fresh petrol III POOR PICKUP...

Page 279: ...r pipe fuel line pump VII BRAKES POOR 1 Brake pad worn Uneven wear Replace Brake pads 2 Oil grease on disc Clean and refit 3 spongy brake fill brake fluid remove air from the system VIII MOTORCYCLE WOBBLES 1 Under inflated tyres Inflate to correct pressure 2 Loose Broken spokes Tighten Replace spokes 3 Wheels misaligned Ensure proper alignment 4 Wheel rim runout Rectify 5 Tyres not fitted correctl...

Page 280: ...roper connections Check and correct 2 Bulb fused Replace Brake light remains on 1 Switch not adjusted properly Adjust connecting links properly 2 Switch sticky Replace switch X ELECTRONIC FUEL INJECTION EFI Malfunctioning Indicator Lamp MIL glowing continuously 1 Sensor Coupler Loose Connection Check for any EFI sensor coupler loose connection and correct them 2 Any EFI Sensor Failure Check replac...

Page 281: ...ce Ignition coil Pulsar coil defective Check Replace No Fuel in fuel tank Fill fuel tank Stale adulterated fuel Clean fuel tank Fill with fresh fuel C Fuelrelated Air vent blocked in fuel cap Clean air vent s Fuel filter clogged Clean fuel filter Fuel line pinched Check correct fuel line Ambient temperature too low for Use Bi starter for starting in engine to start cold conditions D Compressionrel...

Page 282: ...heck correct battery B Startermotorrotates battery worn out starter motor starter motor BUTenginedoes brush notcrank Magneto rotor woodruff key broken Check replace woodruff key Starter clutch assembly slipping Check replace starter clutch assy Inlet Exhaust rocker arm seized in Investigate cause of seizure rocker shaft check correct as required Cam shaft seized in cylinder Investigate cause of se...

Page 283: ...ductionrelated partially blocked Fuel flow partially blocked Check clean Fuel filter Air filter dirty clogged Check clean replace Pulse air valve pipe connections Check correct loose cracked C C Compressionrelated Spark plug loose Check tighten to torque Inlet Exhaust tappets adjusted Check correct wrongly Cylinder head gasket blown Check correct Cylinder head studs loose Check tighten to torque C...

Page 284: ...tappets adjusted wrongly Check correct Cylinder head gasket blown Check correct Cylinder head studs loose Check tighten to torque Cylinder head seating area warped Check replace Cam shaft sticky rotation seized Check correct in cylinder head Valve spring broken or weak Check replace Valve not seating properly stem Check replace bent Heavy carbon deposit on seating surface Piston rings worn out bro...

Page 285: ...Check clean Fuel filter B Fuel Inductionrelated Inlet manifold loose cracked Check tighten replace inlet manifold C CompressionRelated Spark plug loose Tighten spark plug to torque Tappets adjusted too tight Check adjust tappets correctly Cylinder head bolts loose Check tighten to torque Cylinder head gasket damaged Check Replace Cylinder head warped Check Replace Valve spring broken or weak Check...

Page 286: ... Check correct loose cracked Ignition coil defective Check replace B Brownsmoke Adulterated Bad fuel Clean fuel tank Fill with fresh fuel Air filter box poorly sealed Check correct element partially clogged C Bluish Whitesmoke Engine oil level too high Check Maintain Oil level as Recommended Valve stem seal damaged Check correct Excess clearance between valve Check correct stem guide Oil scrapper ...

Page 287: ...rect spark plug Spark plug insulator cracked Check replace Suppressor cap H T lead loose Check correct as required Suppressor cap H T lead defective Check correct as required Ignition coil defective Check Replace Pulsar coil Magneto defective Check replace C Fuel Inductionrelated Adulterated Bad fuel Clean fuel tank Fill with fresh fuel Air filter dirty clogged Check clean replace D CompressionRel...

Page 288: ... replace Valve stem squeaky noise Replace stem seals Valve stem to guide clearance high Check replace D D Cylinderbarrel central Piston rings broken Check replace portionnoise Cylinder Piston scored Check replace Check air filter housing also for damages Excess clearance between piston barrel Check replace Piston slap Cam chain pads worn out Check replace Auto chain tensioner jammed Check replace ...

Page 289: ...or drum Check correct Shift forks pins worn out Check replace Selector drum grooves worn out Check replace Clutch pad sticky worn out Check replace Clutch plates movement sticky Check correct D Clutchassemblyrelated Springs weak broken Check replace Friction plates worn out burnt Check replace Steel plates warped Check replace No end float of clutch assembly in shaft Check correct E Gearsdoesnoten...

Page 290: ...eck for crank shaft position sensor resistance FlywheelMagnetoAssy Check for stator short circuit Check for connector loose fitment DTC History not ECU Clear DTC using only scan tool do not re set ECU by test pin able to clear method Fuel pump ECU ECU internal short replace ECU Continuous ON Fuel Pump Fuel Pump Check for Connector loose fitment terminal back out or wire Not working cut etc Check f...

Page 291: ...erminal back out or wire cut etc Sensor Circuit Failure HEGO Sensor Check for Connector loose fitment terminal back out or wire cut etc Engine Oil Check Connectors for loose pin Temperature TE If the issue still persists Replace Sensor Sensor TA Sensor Check for Connector loose fitment terminal back out or wire cut etc Sensor Circuit MAP Sensor Check for Connector loose fitment terminal back out o...

Page 292: ...291 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL NOTES ...

Page 293: ...292 ROYAL ENFIELD HIMALAYAN EURO IV VEHICLE SERVICE MANUAL NOTES ...

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