Royal Enfield Himalayan, Service Manual, Page: 143 / 214

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL
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GENERAL PRECAUTIONS

Check the system for any fluid leaks at banjo union joints, damaged brake hose etc. at periodic intervals as detailed
in the maintenance schedule.

Whenever checking brake fluid level, ensure vehicle is on its centre stand and the fluid reservoir is parallel to the
ground, whenever checking fluid level.

Cover motorcycle painted surfaces, plastic and rubber parts while overhauling or bleeding a brake system. Do
not allow brake fluid to come in contact with any parts of the motorcycle as brake fluid has highly corrosive
properties.
CLEANING

Clean master cylinder filler cap before removing.

Use only fresh brake fluid to clean rubber and other parts of the hydraulic brake system. DO NOT use any
petroleum based cleaning solvents, water or detergents etc.
INSPECTION:

Inspect brake fluid level is always between the MAX and MIN level markings in the reservoir.

Prior to riding the motorcycle every time, check brake disc inside and outside surfaces carefully for any
contamination with oil, grease, slippery substances, brake fluid etc. as these will render the braking system
ineffective. In case of any contamination, wash the brake disk with water and mild detergent to remove the
contaminations, clean well with a good degreasing agent, blow compressed air to dry the 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 pads are not worn out beyond the wear indication limit marks on the pads. Replace pads
as soon as they have reached the wear limit marks

Check rubber seals on the plunger for wear, cracked edges or any other damage. Replace seals whenever the
plunger is removed

Check master cylinder housing and piston for any scoring, pitting due to corrosion or any other damages.

Check the master cylinder bore for any damages, scoring marks etc.

Check piston outside surfaces for any damages, scoring marks, corrosion etc. Replace pistons if any of the above
is observed.
CAUTION:

Use only DOT 3 or DOT 4 grade brake fluid from a sealed container . Do not mix different types of brake fluid
as they may not be compatible.

Whenever the disc brake system is overhauled, ensure that the old fluid is drained out completely and then filled
with fresh brake fluid ONLY from a sealed container.

In case of any brake fluid contamination in the brake system, the contaminated brake fluid must be flushed out
completely from the entire system, the internal parts cleaned well, filled with fresh brake fluid and the brake
system bleeding must be carried out.