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Royal Enfield Himalayan, Service Manual, Page: 79 / 214

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Royal Enfield Himalayan Service Manual Download Page 79

ROYAL ENFIELD    HIMALAYAN BS III VEHICLE SERVICE MANUAL

78

FRONT FORK

S. NO.

DESCRIPTION

QTY.

S. NO.

DESCRIPTION

QTY.

A1 Front Fork Assy. LH

1

A2 Front Fork Assy. RH

1

1

Inner Tube Assy.

2

2

Dust Seal

2

3

Circlip (Snap - Ring

2

4

Oil Seal

2

5

Bush Washer

2

6

Bush (Outer Tube)

2

7

Outer Tube RH

1

8

Gasket

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 Gaiter Clip

2

9

8

7

10

11

12

13

14

15

16

17

18

19

20

21

6

5

4

3

2

1

A1

A2

24

25

23

26

22

27

28

Summary of Contents for Himalayan

Page 1: ...Carburettor Version Model ...

Page 2: ...tion 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 dofeel free to write tous at sup...

Page 3: ...ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 2 HIMALAYAN VEHICLE VIEWS VEHICLE VIEW LH ...

Page 4: ...ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 3 VEHICLE VIEW RH ...

Page 5: ...ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 4 VEHICLE VIEW FRONT ...

Page 6: ...ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 5 VEHICLE VIEW BACK ...

Page 7: ...ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 6 VEHICLEVIEW TOP ...

Page 8: ... Pulse Air Valve 63 9 Fuel Tank 67 10 Exhaust Pipe Silencer 71 11 Front Suspension 11 1 Front Mudguard 84 11 2 Front Wheel 85 11 3 Front Fork 86 11 4 Handle Bar 89 11 5 Steering Stem 90 12 Rear Suspension 12 1 Rear Wheel 110 12 2 Rear Sprocket Drive Chain Adjustment 111 12 3 Rear Mudguard 113 12 4 Mono Shockabsorber 114 12 5 Drag Drop Links 115 12 6 Swing Arm 116 13 Hydraulic Disc Brakes Front Rea...

Page 9: ...c 300mm Dia disc Rear Disc 240mm Dia disc Hydraulic oil Grade DOT3 DOT4 Hydraulic oil reservoir capacity Front Rear 50ml 4 Tyre size Front 90 90 21 Rear 120 90 17 5 Tyre Pressures 6 Steering lock In Built 7 Fuel Tank Values below are approximate actual capacity may vary with each fuel tank Tank capacity 15 0 5 litres approx Reserve 3 0 0 5 Litres approx Low fuel warning Fuel Gauge Red zone 5 5 0 5...

Page 10: ...er lamp 12V LED Hi beam indicator 12V LED Neutral lamp telltale 12V LED Turn signal telltale 12V LED Turn signal 12V 10W Horn 12V 2 5 Amp Starter Motor 12V 0 7 KW Instrument Cluster Digital cluster with LCD panel Side Stand indicator LCD Indication D DIMENSIONS Length 2190mm Width 840mm Height 1360mm Wheel base 1465mm Ground clearance 220mm Saddle Height 800mm E WEIGHTS Kerb weight with 90 fuel oi...

Page 11: ...ierasrequired 6 Steeringballraces I A I A I A I A I A I R I A I A I A I A I R 7 FrontForkoil I I I R I I R I I R I 8 FuelFilterinFuelTap C C C C C C 9 FuelHose I I R I R I R I R I R 10 Batteryterminals applypetroleumjelly C C C C C C C C C C C 11 EarthwireeyeletTightness I I I I I 12 HydraulicBrakeFluid Front Rear I I R I R I R I R I R 13 Hydraulicbrakehose Washers Front Rear I I I I R I I I R I I...

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: ...8 Stud 2 19 CrossbarAssy 1 20 Dust Cap Frame Top 1 21 DustCap Frame 1 14 15 13 14 15 8 6 7 5 4 3 2 1 13 41 42 40 20 43 31 22 21 22 13 29 28 27 26 25 23 24 30 32 33 12 6 11 10 9 9 19 18 16 17 14 15 38 38 14 14 37 37 39 16 36 36 35 34 A1 Key Nos 13 23 24 25 25 27 28 29 22 FlangedHex BoltM10X1 25X66 2 23 Toe Lever Comp 1 24 PivotPin GearShifter 1 25 Sleeve GearLever 1 26 Hex Nut 1 27 Link Rod 1 28 He...

Page 14: ... 25 X 16 2 11 Flanged Hex Bolt M8 X 1 25 X 45 1 12 Steady Bracket Black 1 13 Flanged Hex Nut M8 X 1 25 1 14 Flanged Hex Bolt M8 X 1 25 X 20 2 15 Flanged Hex Bolt M6 X 1 X 14 2 16 Brake Pedal Comp RH 1 17 Pivot Pin Brake Pedal 1 18 Spring Pedal Return 1 19 Dust Cap Frame 1 20 Hex Socket Button head Screw M6 X 1 2 21 Dust Cap Frame Top 1 22 Hex Socket Button Head Screw M6 X 1 X 16 1 23 plain washer ...

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

Page 16: ...shers 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 di...

Page 17: ... 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: ... 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 Spann...

Page 19: ...8 Fuel tank Dismantling Remove Seat Assembly Disconnect fuel hose from carburetor end Remove 2 Hex screws from the rear end of fuel tank CAUTION Drain the fuel completely from the fuel tank Hex Flange Bolt M6 Socket Spanner 10 mm CAUTION Do not lift tank too high to Prevent accidental damage to the front end of the fuel tank Prevent damage to EVAP hose Disconnect fuel gauge couplerwirebyliftingthe...

Page 20: ...gine bracket Remove the bolt and nut Support steady engine bracket Loosen remove the 2 Flanged hex bolts at the rear end of the bracket and remove the bolts and steady engine bracket Flanged hex bolt M10 Socket Spanner 12mm Flanged hex nut M10 Socket Spanner 12mm 4 10 Throttle cable Push rubber grommets down and loosen hex nuts completely Gentlypullthrottlecable from bracket to release the threade...

Page 21: ...le Loosen remove outer locknut from the rear of the cable adjuster Loosen inner locknut fully push adjuster fully into bracket Releaseinner cablefrom the clevis in the clutch shaft Removerubber grommet outer lock nut remove clutch cable from the bracket Hex Nut M8 D E Spanner 12mm NOTE Gently push the rubber grommet away from the adjuster while removing nut ...

Page 22: ...nel 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 13 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: ...nect negative battery cable Removepositiveterminal screw and disconnect positive battery cable B Starter Motor Remove the Hex nut securing the wire eyelet tostartermotorterminal and remove the wire Remove flanged hex bolt securing the earth wireeyelettocrankcase Socket Spanner 10mm CAUTION Ensure Ignition switch engine stop switch are in OFF position before disconnection battery wiring couplers Ph...

Page 24: ...o Dismantle Instructions 4 14 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: ...flanged Hex nuts along with washers 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 seat...

Page 26: ...l gear lever mounted on gear shaft on LH side of engine Slideoutsmallleverfrom shaft Hex flange bolt M6 Socketspanner 10mm 4 17 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 27: ...anged 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 Gentlyremovethesuppor...

Page 28: ...e 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 Removethe3s...

Page 29: ...ave 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 so...

Page 30: ...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 1...

Page 31: ...ountings 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 21 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 mounti...

Page 32: ...me 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 22 Rear chain assembly and chain adjustment Place vehicle on center stand with the rear wheel off the ground Ensurerearaxlenut lock nuts adjusternutsont...

Page 33: ...in 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 23 Gear Shifter Linkage Locate small lever on gearshiftshaft ensuring sma...

Page 34: ...Hd Capscrews M6X20 Allen Key M5 Torque NOTE Assemble new exhaust pipegasket beforelocating exhaust pipe in cylinder head 4 25 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 th...

Page 35: ...e properly Locate inner cable in the Carburetor Gently pull outer cable upwards till the inner cable canbe locatedinto 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 free play correctly Hex nut M...

Page 36: ...langed 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 28 Electrical connections A Starter Motor Connections Position earth wire eyelet on outer mou...

Page 37: ...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 f...

Page 38: ...otos Aggregate toAssemble Instructions 4 29 Electrical connections I Side stand switch coupler Connect Red coupler to wiring harness on LH side J Battery Connections Connect Positive terminal Red to the positive terminal of the battery Connect negative terminal Black to negative terminal of the battery ...

Page 39: ...l tank such that the front mounting clamps are correctly located on the rubber supports on the frame Gently push fuel tank forward to lock in place Lift rear end of the tank slightly and Route the drain hose between the frame without 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 L...

Page 40: ...n Key M5 Torque 5Nm 0 5Kg M 4 33 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 34 Connector tube Top frames Position connector tube from inside the frame such that the horn mounting bracke...

Page 41: ... 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 Flange...

Page 42: ...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 37 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 but...

Page 43: ... 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 39 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 side...

Page 44: ...e 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 outinnerlocknutsothat itrestsagainstthebracket 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 cabl...

Page 45: ...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 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 un...

Page 46: ...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 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 Spanner ...

Page 47: ...VICE MANUAL 46 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 48: ...ner 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 49: ... Aggregate toAssemble 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 50: ...ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 49 SECTION 06 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 51: ...er cable from clutch lever Release the inner cable from the clevis in the clutch lever on cover RH Remove the rubber grommet from the clutch cable Remove the outer lock nutfromtheclutchcable Pull out the clutch cable from the front end of the bracket Removal from Handle bar end Remove the outer cable from the clutch lever holder assembly at the handle bar end Remove clutch cable inner from the clu...

Page 52: ... up till cablebecomesfreefrom the rotor gently rotate the cable and remove from the rotor eyelet Removethebottomlock nut from the cable Remove cable adjuster and inner cable from the bracket Removal from Handle bar end Loosen remove throttle cable stop plate screw at the bottom of the throttle rotor grip housing on handle bar RH Loosen remove 2 screws at the bottom of the throttle rotor grip housi...

Page 53: ...y inspect inner cable topand bottom ends for frayedstrands loose noipples on the cable and or uneven wear of the nipple surfaces Free movement of the inner cable inside outer cable Carefully inspect the outer cables for cuts damages Brittleness of the cables and no flexibility ...

Page 54: ...nner lock nut on threaded adjuster is resting on the bracket Ensure inner locknut is fully threaded into adjuster Insert the outer lock nut through the inner cable and thread it on the adjuster by 3 or 4 turns Insert larger end of the rubber grommet on the inner cable and position it on the adjuster Locatetheinnercableon the clutch lever clevis Gently pull the cable adjuster out of the bracket asf...

Page 55: ...ousing Position top housing over bottom housing ensuring the mounting holes are matching and the throttle rotor is located in the slot in the housingandrotatesfreely Locate long head screw in front mounting hole and the short screw in rear mounting hole of bottom housing and tighten evenly till the housing are firmly tightened against handle bar Locate throttle cable stopplateonoutercable and tigh...

Page 56: ... threaded into adjuster and insert cable into the bracket on carburetor end Assemble bottom lock nut on cable adjuster Locate inner cable in the throttle rotor eyelet Gently pull the adjuster upwards and tighten top lock nut against the bracket Ensure free play of 2 3mmatthethrottlerotor at the handle bar end and adjust top lock nut accordingly Tighten bottom lock nut against the bracket at carbur...

Page 57: ...ilter Box Assembly 1 1 Pan Head Screw M5 X12 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 Hex Flange Bolt M6 X 1 X 14 2 10 Rear Damper Tank 1 11 Lid Battery Carrier 1 SECTION 07 AIR FILTER 1 3 2 4 5 6 7 8 10 9 11 A2 A1 Key Nos 3 4 A2 Key Nos 1 to 8 EXPLODEDVIEWS AIRFILTER ...

Page 58: ...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 59: ...ed 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 and...

Page 60: ... 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 Bracke...

Page 61: ...er 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 andtighten with hexbolts Referelectricals sectio...

Page 62: ...r 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 63: ...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 64: ...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 ca...

Page 65: ... 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 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 66: ...d 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 twohex socket headcap screws Tighten worm clip over the braided hose Connect the rubber hoses from air...

Page 67: ...CRIPTION QTY 1 Fuel Tank With Sticker 1 2 Flanged Hex Bolt M6 X 1 X 27 2 3 Bush Fuel Tank 2 4 Rear Damper Tank 2 5 Fuel Hose 1 6 Drain Hose 1 7 Fuel Tap Assy 1 8 Plain Washer 2 9 Fiber Washer 2 10 Hex socket head cap screw M6X16 2 11 Front Damper Tank 2 12 O Ring Fuel Gauge 1 13 Fuel Level Sensor Unit 1 14 Hex Flange Nut M5 X 0 8 4 15 Hex socket head cap screw M5X16 3 ...

Page 68: ...e 2 Hex screws from the rear end of fuel tank CAUTION Drain the fuel completely from the fuel tank Hex Flange Bolt M6 Socket Spanner 10 mm CAUTION Do not lift tank too high to Prevent accidental damage to the front end of the fuel tank Prevent damage to EVAP hose Disconnect fuel gauge couplerwirebyliftingthe tank slightly Slide fuel tank towards rear to release front clamp from frame Remove tank a...

Page 69: ...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 Aggregate Fastener Component ...

Page 70: ... tank forward to lock in place Lift rear end of the tank slightly and Route the drain hose between the frame without 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 tap and carbur...

Page 71: ...13 3 1 1 2 S NO DESCRIPTION QTY S NO DESCRIPTION QTY 1 Flanged Hex Nut M8 X 1 25 4 2 Exhaust Gasket 1 3 Exhaust Pipe Assy 1 4 Guard Cat Pipe 1 5 Philips Pan HeadScrew M6 X 6 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 ...

Page 72: ...25 Socket spanner 12mm Hex bolts M8 X 1 25X45 Hex Nuts M8 X1 25 Socket spanner 12mm Double End Spanner 12mm NOTE Remove copper washer in cylinder head exhaust 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...

Page 73: ...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 10 1 2 Silencer Mounting to Frame Hex Socket M8X1 25X25 25 2 5 Torque Ra...

Page 74: ...e clamp over the studson the cylinder head assemble 2 hex nuts M8 DO NOT TIGHTEN FULLY Hex Nuts M8X1 25 Socket 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 c...

Page 75: ...ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 74 SECTION 11 TOP BRACKET HANDLE BAR FRONT MUDGUARD FRONT WHEEL FRONT SUSPENSION STEERING STEM ...

Page 76: ...st Cap Connector Comp 2 3 DecalLH 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 Scre...

Page 77: ...SCRIPTION QTY S NO DESCRIPTION QTY 1 Insert Front Fender 4 2 Front Mudguard with sticker assy Black 1 3 Flanged Hex Bolt M6 X 1 X 27 4 4 Hex Socket Head Cap Screw M6 X 20 4 5 Fork Brace Yenmar Bronze 1 6 Front Mudguard Bottom 1 7 Hex Socket Button Head Screw M6 X 1 4 7 3 1 2 6 4 5 ...

Page 78: ...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 79: ... 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 Gaite...

Page 80: ...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 Brake...

Page 81: ...t Head Cap Screw M6 X 20 2 7 Ring Nut 1 8 Clip Holder Assy Wiring Harness 1 9 Flanged Hexagonal Bolt M6 X 1 X 10 2 10 Dust Seal Steering Assy 2 11 Tapered Roller Bearing 30205 25 X 52 2 12 SteeringStemAssy withBearings DustSeals 1 13 Hex Bolt M6X 1X 12 2 14 Plain Washer 2 15 Bracket Comp Number Plate 1 16 Number Plate Front 1 17 CrossRecessedPanHeadScrewM5X0 8X12 2 18 Clamp Wheel Speed Sensor 1 4 ...

Page 82: ...emovewind 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 t...

Page 83: ... 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 suppor...

Page 84: ...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 Hex...

Page 85: ...olts 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 86: ...from bottom of fork end RH Support wheel and pull outspindlefromRHside taking care not to drop the spacers Remove wheel from between the fork ends along with wheel speed sensor and spacer Remove wheel speed sensor from the hub Hex nut M16 Ring Spanner 24mm Hex soc Hd cap Screw M8 Allen key 6mm CAUTION Take care not to damage the wheel speed sensor whileremovingfrontwheel CAUTION Place a suitable s...

Page 87: ... capbolts on the LH RH side fork crown plate Loosen 2 each hex socket head capbolts 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 wire ...

Page 88: ...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 89: ... 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 90: ...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 91: ... 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 92: ...regate 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 93: ...3 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 Front ...

Page 94: ...IMALAYAN BS III VEHICLE SERVICE MANUAL 93 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 95: ... 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 96: ...vehicle Clutchandthrottlecables 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 s...

Page 97: ...er 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 LH...

Page 98: ...s 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 99: ...ex 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 w...

Page 100: ...ssy 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 bolts...

Page 101: ...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 102: ...tween the brake pads Wheel speed sensor is positioned in the fork end LH Locate spacer between wheel speed sensor and fork end RH and insert spindle through the fork end LH completely Assemble washer and Hex nut on the spindle Hold spindle and tighten axle nut to torque Tightenthepinchbolton fork end LH Remove the support provided under the vehicle S No NOTE Ensure inner lugs are properly seatedin...

Page 103: ...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 CAUTION Instrument cluster must always be sto...

Page 104: ...H RHandtightentocockpit mounting bracket S No Flanged hex bolts M8 Socket Spanner 12mm Torque 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 L...

Page 105: ...d 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 assemb...

Page 106: ...ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 105 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 107: ...1 2 Clip Nut M5 4 3 Plain Washer 4 4 Rear Number Plate Assy 1 5 Hex SocketButtonHeadScrewM6X1X16 2 6 Reflector 1 7 Hexagonal Nut M6 X 1 2 8 Flanged Hex Bolt M6 X 1 X 20 2 9 Plain Washer M6 2 10 Grommet Rear Mudguard 2 11 Mudflap Rear 1 12 Hex socket head cap screw M5X16 4 13 Spacer Oil Cooler 4 14 Grommet 2 8 3 7 9 10 6 12 13 14 11 2 2 12 3 1 13 5 2 14 13 4 ...

Page 108: ...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 Ada...

Page 109: ...ing Arm with bearing Assy 1 2 Spindle Swing Arm 1 3 End Cup Swing Arm 2 4 OilSeal SwingArm 4 5 Inner Race Needle Bearing 2 6 Inner Spacer Swing Arm 1 7 Spacer Swing 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 HeadScrew 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 Pl...

Page 110: ... 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 Nos...

Page 111: ...he ground Gently release brake hose along with its rubber grommets from the locating clips on swing arm Loosen rear axle nut on RH side and remove along with washer Loosen chain adjuster inner outer lock nuts on both LH and RH side completely to increase chain slack Hex nut M16 Ring Spanner 24mm Remove Chain Link Lock RemoveChainlinkplate O rings and link to disconnect rear chain from sprocket Hex...

Page 112: ...move Rear wheel along with sprocket assembly from swing arm Gently pull out sprocket with adaptor from the wheel hub Holding Hex Nylock nut at the sprocket adaptor end loosen and remove six Hex socket head cap screws Separate sprocket from the adaptor CAUTION Place a suitable spacer of 4 mmthickness betweenthe brakepadstopreventthem from coming out too far incase brake pedal is depressed accidenta...

Page 113: ...ructions 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 114: ... 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 faced...

Page 115: ...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 116: ...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 stan...

Page 117: ...s 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 asse...

Page 118: ...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 1...

Page 119: ...he 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 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 Assemble ...

Page 120: ...t 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 10 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 andtighten with 2 eac...

Page 121: ... 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 Ensur...

Page 122: ...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 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 Assem...

Page 123: ...t 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 andtighten with 2 eac...

Page 124: ... 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 m...

Page 125: ... 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 fo...

Page 126: ...on RH side and tighten Locate the brake hose pipe in swing arm clips properly Check rear brake for effectiveness and correct functioning before using the motorcycle S No NOTE Remove the spacer betweenthebrakepads Ensure rear wheel sprocket lugs are located correctly in the cush rubbers CAUTION Ensuretheaxlemounting hole in the swing arm chain adjusters wheel hubandcaliperbracket are all aligned Do...

Page 127: ...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 held...

Page 128: ...ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 127 SECTION 13 HYDRAULIC DISC BRAKES ...

Page 129: ... 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 130: ...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 131: ...ake 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 132: ... 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 ensur...

Page 133: ...ke 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 134: ...vot 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 handleb...

Page 135: ... 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 136: ...sembly 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 137: ...exible 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 draine...

Page 138: ...r 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 139: ... 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 mast...

Page 140: ...nder 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 th...

Page 141: ... 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 142: ... 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 calip...

Page 143: ... 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 144: ... 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 Minimumdiscthicknes...

Page 145: ... 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 bolts ...

Page 146: ...y 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 a...

Page 147: ...hotos Aggregate toAssemble Instructions 13 3 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 148: ...ke 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 padpins Allen ke...

Page 149: ...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 cy...

Page 150: ... 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 Donot 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 Sw...

Page 151: ...h 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 13...

Page 152: ...ston 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 cal...

Page 153: ...3 4 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 154: ...rrectly 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 the...

Page 155: ...pring 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 not ...

Page 156: ...re 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 plier...

Page 157: ...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 main ...

Page 158: ...mets 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 159: ...linderreservoirisfilled 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 lev...

Page 160: ...gh 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 firml...

Page 161: ... 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 bra...

Page 162: ...N 1 12 Needle Jet NJ P 0M 1 13 Needle Assy Float 1 14 O Ring FCB Float Chamber 1 15 Pin Float 1 16 Float Assembly 1 17 Main Jet MJ 125 1 18 Jet Holder JH 1 19 Screw Assy FCB Bowl Mtg 4 20 Screw Float 1 21 Screw DH Cover 4 22 Bracket TH Cable 1 23 O Ring TPS 1 24 Throttle Position Sensor 1 25 Screw Bracket TH Cable 2 26 Screw TPS Mtg 1 27 Clip Air Vent Hose 1 28 Hose Air Vent 1 29 Clip Drain 1 30 H...

Page 163: ...n cable lock nuts push adjuster fully into bracket Disconnect inner cable from carburetor rotor Remove bottom nut from adjuster and pull up till it is free of the bracket slide inner cable out of bracket Loosen screw on the worm clip on inlet manifold Loosen screw on worm clip on the air filter connection tube Gently slide carburetor towards the rear such that it comes out of the inlet manifold Ti...

Page 164: ...ve float assembly along with pin and needle assembly from carburetor body Remove float pin from float assembly Release float needle clip from the tab in float assembly and remove float needle from float assembly Holding the jet holder with a spanner loosen and remove main jet Loosen and remove jet holder from carburetor body CAUTION Fuel is extremely explosive and highly inflammable Ensure there a...

Page 165: ... top Remove spring from piston valve assembly Gently pullout piston valve assembly along with diaphragm from the carburetor top Slotted Screw Driver CAUTION Gently depress and hold diaphragm cover while removing the screws slowly and evenly to prevent the spring from recoiling and pushing cover up NOTE It is not recommended to removethediaphragmfrom the throttle valve or disturb the setting of the...

Page 166: ...SERVICE MANUAL 165 14 2 Carburetor internals S No Fastener Size Tool Usage Precautions Photos Aggregate toDismantle Instructions Loosen Hex nut and remove Starter plunger assembly along with O ring from the carburetor body D E spanner 14 mm ...

Page 167: ...the reverse direction of normal flow to fuel to remove blockages dirt deposits etc Clean all the jets and other parts of the carburetor only with carburetor spray CAUTION Do not use any other cleaning solvents to clean the carburetor body and other parts as it can cause damage rust etc to the parts and carburetor Do not use metal object or cable strands to clean the jets or the carburetor passages...

Page 168: ...r any abnormal wear and for proper spring action of the pin in the float needle Check float height and ensure it is as per specifications Ensure that the seating areaof the choke plunger assembly is not worn or damaged If worn or damaged replace the plunger assembly Pilot Jet 8 2kgf cm Holder Main Jet 18 5kgf cm Main Jet 18 5kgf cm Float Pin Fixing Screw 20 kgf cm BowlFixingScrew 35 10 kgf cm Drai...

Page 169: ...to carburetor body and tighten D E Spanner 14 mm Torque 18 5 Kgf Assemble Pilot jet in carburetor body and tighten gently Screw driver Torque 8 2Kgf Insert the small dia face of the needle jet intothe main jet holder hole in carburetor body CAUTION Ensure the Needle jet is assembled correctly Locate main jet holder in carburetor body and tighten Assemble Main jet on holder D E Spanner 8 mm Torque ...

Page 170: ...ghten to carburetor body Ensure free up down movement of the float Float height setting procedure Hold carburetor in inverted position Using a vernier caliper depth gauge measure the height of the individual floats from the carburetor body bowl seating area Gently bend the tab of the needle pin seating area in the float to adjust the height Recheck and ensure the correct float height is maintained...

Page 171: ...l the cover rests on carburetor body and the mounting holes are aligned Tighten cover to body with the three screws Assemblespring washer inside and outside O rings on pilot air screw Locate pilot air screw in carburetor body and gently tighten till resistance is felt and screw cannot be tightened further Loosen pilotair screw by 1 TO 2 FULL TURNS NOTE Ensure proper seating of rubber ring in the g...

Page 172: ...y in the slotintheinletmanifold Tighten screws on the worm clip on inlet manifold Tighten screw on worm clip on the air filter connection tube Route the overflow breather pipes suitably without any kinks Ensure top adjuster nut is fully threaded into the throttle cable adjuster and locate adjuster in the cable bracket Push cable adjuster fully intocablebracket till the top lock nut on the cable ad...

Page 173: ...t is resting on the cable adjuster bracket Checkthrottle cablefree play at handle bar end and adjust top nut on cable adjuster till a free play of 3 4 mm is available at the throttle grip end Hold top lock nut and tighten bottom lock nut firmly against bracket Connect TPS black coupler to carburetor on LH side Connect fuel hose to carburetor and fuel tank NOTE Ensure proper seating of rubber ring ...

Page 174: ...ing speed check for its stability flat spot missing if any by accelerating3to4times Repeat above said the steps until engine speed increases smoothly Check engine idling stability and drive vehicle to check for smooth operation no misfiring or flat spot Optimum Air Screw setting CAUTION During idle speed turn the handle bar to extreme right or left hand side if any changeinidlespeednoticed the thr...

Page 175: ... and ensure no damage in piston valve and diaphragm High fuel level Adjust float height to spec FLOODING Improper seating of needle Clean needle valve replace if necessary valve in valve seat Float puncture Replace float Main pilot jet clogged Clean replace POORPICKUP High Low fuel level Adjust float height to spec Incorrect E ring position in Assemble E ring in correct position Jet needle Cloggin...

Page 176: ...ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 175 SECTION 15 ELECTRICAL COMPONENTS ...

Page 177: ...y RELAY STARTER WIRING LAYOUT TECHNICAL SPECIFICATIONS System Battery 12V DC 12V 14 Ah Starter Motor 0 9KW Solenoid Switch Magnetic Relay type STARTER MOTOR INSPECTION Ensure earth terminal is located on the outside hex flange bolt of the starter motor before tightening both bolts ...

Page 178: ... 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 no...

Page 179: ...lack 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 shown ...

Page 180: ...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 181: ...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 182: ...he 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 andcheck continuity between any 3phase terminalsandengine body If there isa body short insulation failure multimeter willindicate 0ohms or resistance value 50 ohms with a...

Page 183: ...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 turned OFF when the 3 the setting voltage Eg 14 5 0 2V the control magneto o p volatge goes beyond the setting element g...

Page 184: ...d at the earliest opportunity Always get the circuit checked to ascertain the cause of a fuse blowout and rectify to prevent fuses blowing frequently BLADEFUSEUSAGELIST Spare 1 Spare 2 Spare 3 F1 F2 F3 F4 F5 F6 F1 CHARGING FUSE 25A F2 MAIN FUSE 25A F3 IGNITION EFI FUSE 15A F4 INSTRUMENT CLUSTER 10A SIGNALLING FUSE F5 HORNFUSE 10A F6 LIGHTING FUSE 15A SPARE 1 SPARE FUSE 1 25A SPARE 2 SPARE FUSE 2 1...

Page 185: ...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 t...

Page 186: ...sconnect 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 16 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 187: ...ative 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 16 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 16 6 Tail Lamp Number plate ill...

Page 188: ...nect 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 189: ...stall 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 16 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 190: ...ide 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 16 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 191: ...ar are reusable hence do not remove them from the handle bar if not required to be removed 16 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 192: ...ns tothefront brake switch onhandlebarRH bottom Release lock and gently pull switch out of the front brake bracket 16 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 16 17 Side stand switch coupler Remove strap to frame Pull the bellow down Disconnect Red coupler from LH side ...

Page 193: ...ar are reusable hence do not remove them from the handle bar if not required to be removed 16 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 n...

Page 194: ...tly push switch inside the front brake bracket Locate wire connections tothefront brake switch on handle bar RH bottom Hex Cap Screw M6 Allen key 5 mm 16 22 Ignition Switch Install2Hexscrewsfrom bottom of switch housing and locate switch Connect ignition switch wiring coupler 16 23 Side stand switch coupler Connect Red coupler from LH side Push the bellow upwards Locate strap to frame ...

Page 195: ...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 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 dis...

Page 196: ...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 197: ...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 198: ...toAssemble Instructions 16 27 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 199: ...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 16 29 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 200: ...le T type connector to main harness Locate single pole black connector chassis ground Hex Flange Bolt M6 Socket Spanner 10 mm 16 31 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 Kg...

Page 201: ...fuse carrier lid replace fuse as indicated inside the lid Replace the required fuse with the spare fuse available in the fuse carrier 16 33 BLADE FUSE USAGE LIST F1 CHARGING FUSE 25A F2 MAIN FUSE 25A F3 IGNITION EFI FUSE 15A F4 INSTRUMENT CLUSTER 10A SIGNALLING FUSE F5 HORNFUSE 10A F6 LIGHTING FUSE 15A SPARE 1 SPARE FUSE 1 25A SPARE 2 SPARE FUSE 2 15A SPARE 3 SPARE FUSE 3 10A Spare 1 Spare 2 Spare...

Page 202: ...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 digits 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 button SELECT ...

Page 203: ...MPERA 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 center...

Page 204: ... 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 tomeasure distance travelled by the vehicle when fuel level in the vehicle is 5 5...

Page 205: ...ill glow continuously indicating a low battery 5 High Beam Indication Head lamp high beam ON TURN LEFT NEUTRAL TURN RIGHT EMS MALFUNCTION INDICATION LOW BATTERY INDICATION HI BEAM INDICATION D TACHO METER 1 Indicates the RPM at which engine is working 2 Useful for right selection of gear with respect to engine RPM WARNING Do not run engine with gears in neutral as RPM will go beyound red zone Do n...

Page 206: ... 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 207: ...ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 206 SECTION 17 WIRING HARNESS ...

Page 208: ...ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 207 COMPLETE DIAGRAM LS 410 HIMALAYAN WIRING DIAGRAM COMPLETE LS 410 ...

Page 209: ...STER KILL SWITCH MAIN LIGHTING SWITCH E START SWITCH TCI UNIT CPS TPS IGNITION COIL THROTTLE POSITION SENSOR STARTER MOTOR BATTERY 12V 8 Ah FUSE BOX ENGINE GROUND CHASSIS GROUND CHASSIS GROUND STARTER SOLENOID BATTERY POSITIVE TACHOMETER NEUTRAL LED OFF IGNITION SWITCH R BR BR G BR L R M Br Br G Gr BR P B P R L BR P R L B P Gr B Br W R Gr Gr B BR B B RR UNIT CLUTCH SWITCH MAGNETO GEAR POSITION SEN...

Page 210: ... 8 Ah ENGINE GROUND CHASSIS GROUND TAIL LAMP LICENSE PLATE ILLUMINATOR F6 F5 F4 F3 F2 F1 1 3 5 7 9 11 10 2 4 6 8 12 FUSE BOX BATTERY 12V 8 Ah ENGINE GROUND CHASSIS GROUND R Y R V R W R BR R R W SWITCH MODULE LH TRAFFICATOR SWITCH FLASHER UNIT 1 2 MAIN FUSE 30A ALL SUB SYSTEM FUSES AND LOADS 3 4 SIGNALLING FUE 10A CLUSTER TRAFFICATOR VSS STOP LAMP 5 6 FUSE DETAILS FRONT BRAKE SWITCH WHEEL SPEED SEN...

Page 211: ...pping Adjust clutch cable free play 8 Fuse failed Replace with new fuse II ENGINE MISFIRING 1 Loose spark plug gap Fix cap lead firmly 2 Spark plug fouled Clean spark plug or non specified heat range plug 3 Water in petrol tank Clean petrol tank Fill tank with fresh petrol III POOR PICKUP 1 Brake pedal adjusted too tight Re adjust properly 2 Choked air filter Clean Replace air filter 3 Rear chain ...

Page 212: ...glow 1 Bulb fused Replace bulb 2 Fuse blown Check and Replace fuse 3 Loose improper connection Check and correct Horn not working 1 Fuse blown Check and correct 2 Loose connections Check and correct Trafficators not working 1 Loose improper connections Check and correct 2 Bulb fused Replace Brake light remains on 1 Switch not adjusted properly Adjust connecting links properly 2 Switch sticky Repla...

Page 213: ...ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 212 NOTES ...

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