Royal Enfield Himalayan Service Manual

Carburettor Version Model

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

PREFACE

“FIRST TIME RIGHT” is a very important element for enhancing Customer Satisfaction.

Royal Enfield is committed to upgrade the skills and knowledge of technicians so that they follow scientific repair techniques to ensure “FIRST TIME RIGHT” practices and carry out repairs accurately so that customers will enjoy trouble free performance at all times.

This manual will help in complete understanding of systematic procedures for dismantling, inspection, diagnosis and reassembly for the new Royal Enfield Himalayan motorcycle, in a simple and scientific manner.

While this manual is updated with latest Information and Specifications at the time of going to print, due to continuous improvements being done to improve performance, some of the data, illustrations etc., in this manual may be different from some of the parts fitted in the motorcycle.

Please do feel free to write to us at support@royalenfield.com , if you have any queries, clarification, suggestions or feedback.

With warm regards SERVICE HEAD QUARTERS Royal Enfield, A Unit of Eicher Motors Limited, Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019. E-mail: Support@royalenfield.com Website: www.royalenfield.com

Part No: 888435 / Jan. ’17

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

HIMALAYAN – VEHICLE VIEWS

VEHICLE VIEW LH

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

VEHICLE VIEW RH

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

VEHICLE VIEW FRONT

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

VEHICLE VIEW BACK

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

VEHICLE VIEW TOP

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

TABLE OF CONTENTS

SL.NO. DESCRIPTION PG.NO.

1. Technical Specifications ........................................ 8

2. Periodical Maintenance ......................................... 10

3. Special Tools Usage List ......................................... 11

4. Engine Dismantling from Frame & Reassembly . 12

5. Rider & Pillion Seat ................................................. 47

6. Control Cables ........................................................ 50

7. Air Filter.................................................................... 57

SL.NO. DESCRIPTION PG.NO.

12. Rear Suspension

12.1 Rear Wheel ..................................................... 110

12.2 Rear Sprocket / Drive Chain Adjustment .... 111

12.3 Rear Mudguard .............................................. 113

12.4 Mono Shockabs orber ................................... 114

12.5 Drag & Drop Links .......................................... 115

12.6 Swing Arm ...................................................... 116

13. Hydraulic Disc Brakes -Front & Rear ..................... 127

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 ................................................. 9 0

14. Carburetor ............................................................... 161

15. Electrical Components ........................................... 175

16. Electricals ................................................................. 184

17. Wiring Harness ........................................................ 206

18. Trouble Shooting .................................................... 210

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

SECTION 01 - TECHNICAL SPECIFICATION

VEHICLE & VEHICLE SYSTEMS

A. ENGINE: LS 410 B. CHASSIS:

1. Frame Half duplex split cradle

2. Suspension

Front Telescopic, Hydraulic Damping,Fron t wheel travel:

200 mm Front fork oil grade 2W 35 Capacity / leg 455ml/leg Rear Swing arm with Linkage type Hydraulic damping Mono

shock, Rear wheel travel: 180 mm

3. Brakes

Front Disc 300mm Dia disc. Rear Disc 240mm Dia disc. Hydraulic oil Grade DOT3 / DOT4 Hydraulic oil reservoir capacity - Front & Rear 50ml.

4. Tyre size

Front 90 / 90 – 21 Rear 120 / 90 – 17

Solo With Pillion

5. Tyre Pressures

6. Steering lock In Built

7. Fuel Tank * Values below are approximate & actual capacity may

Front 25 PSI / 1.75Kg/cm2 27 PSI / 1.89Kg/cm2 Rear 32 PSI / 2.25 Kg/cm2 34 PSI / 2.39 Kg/cm2

vary with each fuel tank .

Low fuel warning - Fuel Gauge (Red zone) 5.5+0.50 litres approx.*

Dead stock (unusable fuel) 0.5 litre approx.*

Tank capacity 15+0.5 litres approx.*

Reserve 3.0 + 0.5 Litres approx.*

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

VEHICLE & VEHICLE SYSTEMS

C. ELECTRICALS:

Generation Alternator System 12V - DC Battery 12V - 8 AH MF Head lamp Bulb H4 12V 60/55W Tail lamp / Brake lamp 2V- 4/1W LED License Plate illuminator 12V- LED Front position lamp 12V- LED Speedometer lamp 12V- LED Hi beam indicator 12V- LED Neutral lamp telltale 12V- LED Turn signal telltale 12V- LED Turn signal 12V – 10W Horn 12V, 2.5 Amp Starter Motor 12V. 0.7 KW Instrument Cluster Digital cluster with LCD panel Side Stand indicator LCD Indication

D. DIMENSIONS:

Length 2190mm Width 840mm Height 1360mm Wheel base 1465mm Ground clearance 220mm Saddle Height 800mm

E. WEIGHTS:

Kerb weight with (90% fuel & oil) 182 Kg. Max. permissible load. 183 Kg.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

SECTION 02 - PERIODICAL MAINTENANCE

The Periodical maintenance schedule detailed below is based upon average riding conditions and indicates the Intervals at which regular inspections, adjustments, replacements and lubrications must be carried out to help maintain your Himalayan motorcycle meticulously

If in case the motorcycle is used frequently in very dusty environment / severe climatic conditions / Poor Roads / stagnant water etc., the maintenance will need to be done earlier as may be required.

Contact a nearest Royal Enfield Authorised Dealer / Service Center to carry out the periodical maintenance and for any expert advice.

S. No .

Months 1 6 12 18 24 30 36 42 48 54 60

1 HT leads for crack I I I I I R I I I I I

2 Air Filter Element C C R C R C R C R C R

3 Accelerator Cable I I R I R I R I R I R 4 Clutch Cable I I R I R I R I R I R 5 Clutch Free Play Adjust every 1000 Kms or earlier as required 6 Steering ball races # I & A I & A I & A I & A I & A I & R I & A I & A I & A I & A I & R 7 Front Fork oil I I I R I I R I I R I 8 Fuel Filter in Fuel Tap C  C  C  C  C  C 9 Fuel Hose I I R I R I R I R I R

10 Battery terminals (apply petroleum jelly) C C C C C C C C C C C

11 Earth wire eyelet Tightness   I  I  I  I  I 12 Hydraulic Brake Fluid - Front & Rear # I I R I R I R I R I R 13 Hydraulic brake hose & Washers - Front & Rear # I I I I R I I I R I I

14 Brake Pads - Front & Rear # I I R I R I R I R I R

15 Tyre wear pattern (Front & Rear)# I I I I I R I I I I R

16 Spokes tightness / Wheel rim run out front & rear # I I I I I I I I I I I

17 Front & Rear wheel bearings for play # I I I I I I & R I I I I I & R

18 Swing arm Pivot bearings # I I I & L I I & L I & R I I & L I I & L I & R 19 Rear Suspension Linkages # I I & L I & L I & R I & L I & L I & R I & L I & L I & R I & L

20 Rear Drive Chain # Clean, Lubricate & Adjust every 1000 Kms or earlier as required

21 Drive chain & Sprockets set # I I R I R I R I R I R

22 Rear wheel cushdrive rubbers# I I R I R I R I R I R 23 All Mounting Fasteners in vehicle for tightness # I I I I I I I I I I I

24 Hand levers, side stand, Rider & Pillion foot rest Pivots Lubricate every 1000 Kms or earlier as required

DESCRIPTION

whichever is earlier

Kms (X 1000) 0.5 5 10 15 20 25 30 35 40 45 50

Clean/ Replace more Frequently if motorcycle always used

in dusty / off Road conditions.

A : A dj u st C : C le a n I : I ns p ec t L : L ub ri c at e R : R ep la c e

* Refer Service Manual. # Check every time after vehicle is used for off road riding

NOTE:

For maintenance after 50,000 Kms, please repeat the same frequency levels specified above.

PAID SERVICEFREE SERVICE

whichever is earlier

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

SECTION 03 - SPECIAL TOOLS USAGE LIST

PART NO. DESCRIPTION PHOTOS APPLICATION

ST-26461-2 Front Fork Assembling & 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 To drive slide bush and fork oil seals into

bottom tube

ST-25244-4 Special spanner adjuster To adjust rear shock absorber spring

pre tension

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

SECTION 04 - ENGINE DISMANTLING FROM FRAME & REASSEMBLY

EXPLODED VIEWS

FRAME LH

Key Nos.

13, 23, 24, 25, 25, 27, 28, 29

S. NO.

DESCRIPTION

A1 Gear Shift Lever Kit 1 1 Main Frame- Black 1 2 Utility Box 1 3 Seat Latch 1 4 Counter Sunk Screw M6 X 1 X 20 2 5 Flanged Hex Bolt M6 X 1 X 10 2 6 Hex Socket Head Screw M8 X 1.25 X 25 4 7 Flanged Hex Bolt M8 X 1.25 X 20 2 8 Grab Rail Black 1 9 Mushroom Head Screw M6 X 8 X 1 2 10 Plate Seat Lock 1 11 Saddle Bag Mtg - LH 1 12 Piece Mudguard 1 13 Flanged Hex Bolt M6 X 1 X 20 5 14 Plain Washer 8 15 Hex Nut with nylon insert 4 16 Flanged Hex Bolt, M6 X 1 X 14 6 17 Grommet 1 18 Stud 2 19 Crossbar Assy 1 20 Dust Cap-Frame Top 1 21 Dust Cap-Frame 1

QTY. S. NO.

22 Flanged Hex. Bolt M10 X 1.25 X 66 2 23 Toe Lever Comp 1 24 Pivot Pin- Gear Shifter 1 25 Sleeve, Gear Lever 1 26 Hex Nut 1 27 Link Rod 1 28 Hex Nut (LH Thread) 1 29 Gear Shift Lever Comp-Short 1 30 Hex Socket Head Cap Screw – M5 X 20 2 31 Switch-Side Stand 1 32 Hex Socket Head Screw M8 X 1.25 X 35 1 33 Side Stand Assy 1 34 Hex Nyloc Nut M8 X 9.5 1 35 Spring 1 36 Support Bush Skid Plate 4 37 Damper - Oil Cooler 4 38 Flanged Hex Bolt M6 X1 X 35 4 39 Skid Plate 1 40 Cradle Frame 1 41 Bracket Assy-Oil Cooler 1 42 Flanged Hex Bolt, M10 X 1.25 X 75 1 43 Flanged Hex Bolt M6 X1 X 27 2

DESCRIPTION

QTY.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

EXPLODED VIEWS

FRAME RH

S. NO.

DESCRIPTION

1 Connector Complete Black 1 2 Flanged Hex. Bolt M10 X 1.25 X 66 1 3 Plain Washer 1 4 Flanged Hex Bolt, M10 X 1.25 X 75 1 5 Flange Hex Bolt M10 X 1.25 X 165 1 6 Flange U Nut M10 X 1.25 6 7 Flange Hex Bolt M10 X 1.25 X 183 3 8 Clutch Clamp 1 9 Flanged Hex nut M10X1.25 1 10 Flanged Hex Bolt M8 X 1.25 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

QTY. S. NO.

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 M6 1 24 Flanged Hex Bolt M6 X 1 X 20 1 25 Bracket Assy. - Air Filter 1 26 Saddle Bag Mtg- RH 1 27 Hex Socket Head Screw M8 X 1.25 X 25 2

DESCRIPTION

QTY.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

COMPONENTS DISMANTLING SEQUENCE TO REMOVE ENGINE FROM FRAME

Skid Plate on Frame bottom



Engine oil (Drain when warm. Remove drain plug / oil strainer cover on crankcase LH & Oil filter on Cover RH)



Oil Cooler along with inlet & outlet pipes.

 

Fuel hose & Pulse Air valve connections

 

Battery connections

 

Magn eto / Gear posit ion / Side stand swit ch: couplers dismantle

 

Starter motor connections

 

Spark plug suppressor cap

 

Engine steady bracket

 

Control Cables (Clutch / Accelerator)

 

Carburettor

 

Exhaust pipe & Silencer

 

Gear shift linkage

 

Starter motor

 

Cover LH

 

Gear position indicator sensor

Rear Chain (Remove from FD sprocket)



FD sprocket nut (loosen )



Cover RH

Oil pump gears / Oil pump

Crank shaft Nut (LEFT HAND THREADED)

Balancer shaft Bolt

Clutch center nut & Clutch assembly

Gear shift shaft assembly (Remove circlip & washer on shift shaft from LH crankcase side first)

Cam shaft covers / Cylinder head cover

Automatic chain tensioner

Cam shaft gear & cam shaft Assembly

Cylinder Head Sub Assembly

Chain Tensioner Pads

Cylinder Barrel Sub Assembly

Cradl e frame top mountings (with connector) mounting to frame

Cradle frame bottom mounting LH& RH on frame

 

Magneto rotor assembly including Starter clutch

 

Starter idler gears with bush & spindles



Rear top engine mounting on frame (support engine from bottom suitably)

Four mounting studs of Engine to cradle frame

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

ENGINE DISMANTLING FROM FRAME

Aggregate to Dismantle/

No.

Instructions

4.1 Skid plate

Fastener, Size, Tool Usage, Precautions, Photos

 Loosen & remove 6

Flanged Hex screws (2 in front & 4 in bottom.

 Remove the spacers and

washers 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.

Flanged Hex Screw: M6 Socket Spanner: 10mm

NOTE:

Ensure the engine oil is drained from the engine.

Banjo Union Bolts: M14 Socket spanner: 19mm

 Ensure the 4 washers

are removed from the oil 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 pipe No 2 on RH s id e be tw een engine & frame is taken out caref ull y, whil e dism antl ing the oil cooler.)

Flanged Hex bolts: M6 Socket spanner: 8mm.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

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No.

Instructions

4.3 Wind Shield

Assembly

 Remove 4 Hex socket

head cap screws holding the Wind shield assembly to the top frame.

 Remove the 4 plastic

washers along with the screws and remove wind shield.

4.4 Trafficator front LH, RH & cover cockpit LH, RH.

Fastener, Size, Tool Usage, Precautions, Photos

Hex Soc Hd. Cap Screw: M5

Allen Key: 4mm

NOTE:

Hold the rubber mounted nuts from behind while loosening screws.

 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

cockpit LH & RH from the rubber grommets in the top frame LH & RH.

NOTE:

Couplers are color coded as: LH side: Green RH side: Red

Hex socket hd. Screw: M5 Allen key: M4

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

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No.

Instructions

4.5 Headlamp

Assembly

 Disconnect head lamp

wiring coupler below head lamp.

 Remove the dust caps

from the mounting holes in top frame LH & RH.

Fastener, Size, Tool Usage, Precautions, Photos

 Remove 2 hex socket

head 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

top frames LH & RH from connector tube.

Hex Socket Hd. screw: M5

Allen Key: 6mm

Flanged hex bolts: M8 Socket Spanner: 12mm

Hex Socket Hd. screws: M6

Socket Spanner: 10mm

CAUTION

Take care not to damage fuel tank while rotating & removing the side support brackets.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

4. 7

Instructions

Pillion & Rider Seat

 Unlock pillion seat by

turning key clockwise & lift pillion seat from front end to release rear tab & remove.

 Lift rider seat from rear

end to release front tab & remove.

4.8 Fuel tank Dismantling

Fastener, Size, Tool Usage, Precautions, Photos

 Remove Seat Assembly  Disconnect fuel hose

from carburetor end.

 Remove 2 Hex screws

from the rear end of fuel tank.

 Disconnect fuel gauge

coupler wire by lifting the tank slightly.

 Slide fuel tank towards

rear to release front clamp from frame

 Remove tank along with

the overflow tube carefully.

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

- Preve nt accidental damage to the front end of the fuel tank.

- Preve nt damage to EVAP hose

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

4.9 Steady Engine

Bracket

 Hold U nut at the

cylinder head mounting area with a double end spanner and loosen Hex bolt at the front of the steady engine bracket.

Fastener, Size, Tool Usage, Precautions, Photos

Flanged hex bolt: M10 Socket Spanner: 12mm

Flanged hex nut: M10

 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.

4.10

Throttle cable

 Push rubber grommets

down and loosen hex nuts completely.

 Gently pull throttle cable

from bracket to release the threaded position from the bracket.

Socket Spanner: 12mm

Double End Spanner: 13mm

 Remove inner cable

from the Carburetor.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

4.11

Instructions

Clutch Cable

Fastener, Size, Tool Usage, Precautions, Photos

 Loosen & remove outer

locknut from the rear of the cable adjuster.

 Loosen inner locknut

fully & push adjuster fully into bracket.

 Release inner cable from

the clevis in the clutch shaft

 Remove rubber 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.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

4.12

Instructions

Side Panel LH

Fastener, Size, Tool Usage, Precautions, Photos

 Remove 3 He x socket

Button head screws (except left bottom one).

 Gently pull out to release

locater from frame rubber Grommet.

4.13

Side Panel RH

 Remove 3 He x socket

Button head screws (except right bottom one).

Hex. Socket Button Hd Screw M6X12

Allen Key: M5

Hex. Socket Button Hd Screw M6X12

Allen Key: M5

 Gently pull out to release

locater from frame rubber Grommet.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

4.14

Instructions

Electrical connections

Fastener, Size, Tool Usage, Precautions, Photos

A. Battery

 Remove negative terminal

scre w and disconnect negative battery cable.

 Remove positive terminal

screw and disconnect positive battery cable.

B. Starter Motor

 Remove the Hex nut

securing the wire eyelet to starter motor terminal and remove the wire.

 Remove flanged hex

bolt securing the earth wire eyelet to crankcase.

Philips Hd screw driver

Socket Spanner: 10mm

CAUTION

Ensure Ignition switch & engine stop switch are in OFF position before disconnection battery & wiring couplers.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

4.14

Instructions

Electrical connections

H. Magneto coupler

 Disconnect white

coupler from LH side.

 Disconnect small Black

coupler (Pulsar wire connections from LH Side.

Fastener, Size, Tool Usage, Precautions, Photos

I. Gear p osi tion s witch

coupler

 Disconnect BIG & SMALL

Black coupler from LH side.

J. Si de st an d sw it ch

coupler

 Disconnect Red coupler

from LH side.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

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No.

4.14

Instructions

Electrical connections

K. Horn Terminals

 Disconnect horn

terminals.

L. Spark plug suppressor

cap

 Disconnect suppressor

cap from sparkplug.

Fastener, Size, Tool Usage, Precautions, Photos

4.15

Exhaust pipe & Silencer

 Remove 2 flanged Hex

nuts along with washers at the cylinder head end.

 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 silen cer from the vehicle.

Hex Nuts: M8X1.25 Tubular spanner - 12mm

NOTE

Remove copper washer in cylinder head, exhaust pipe seating area after removing exhaust pipe.

Hex bolts: M8 X 1.25X45 Hex Nuts: M8 X1.25 Socket spanner -12mm Double End Spanner: 12mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

4.16

Instructions

Gear shifter/ linkage

Fastener, Size, Tool Usage, Precautions, Photos

 Loosen Hex bolt on small

gear lever mounted on gear shaft on LH side of engine.

 Slide out small lever from

shaft.

4.17

Rear Chain Link Lock

 Loosen rear wheel axle

nut sufficiently.

 Loosen the chain adjuster

nuts on LH & RH sides of the swing arm and push the rear wheel inside, to create sufficient slack in the rear chain

Hex flange bolt: M6 Socket spanner: 10mm

 Remove chain link lock

and remove chain from the engine sprocket.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

4.18

Instructions

Cradle frame with Engine, separation from Main frame

 Support cradle frame /

engine suita bly at the bottom such that it will not drop of when mounting bolts are removed.

Fastener, Size, Tool Usage, Precautions, Photos

 Loosen Flanged Hex.,

holding cradle frame top, to main frame.

 Remove bolt & connector

complete. (Ensure the top frame LH&RH and horn connections are removed from the connector tube.)

 Loosen Flanged Hex

bolt from the rear top location of the engine.

DO NOT REMOVE THE BOLT FROM THE FRAME.

 Loosen & remove 2

flanged Hex bolts from the cradle frame rear bottom on both LH & RH sides.

 Remove the Flanged Hex

bolt (loosened earlier) from the rear top location of the engine.

Hex flange bolt: M10X66 Socket Spanner: 14mm

Hex flange bolt: M10X183 Socket Spanner: 14mm

Hex flange bolts: M10X65 Socket Spanner: 14mm

 Loosen & remove

Flanged Hex bolt along with oil cooler bracket, holding oil cooler bracket & cradle frame to main frame.

 Gently remove the support

from the bottom of the cradle frame / engine and simul taneously remo ve cradle frame with crankcase from main frame.

Hex flange bolts: M10X75 Socket Spanner: 14mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

4.19

Instructions

Engine separation from cradle frame

Fastener, Size, Tool Usage, Precautions, Photos

 Hold flanged Hex bolt on

Cradle frame top RH side, and remove Flanged U nut on the cradle frame top LH side.

 Hold flanged Hex bolt on

Cradle frame bottom RH side, and remove Flan ged U nut on the cradle frame bottom LH side,

 Hold flanged Hex bolt on

Cradle frame rear RH side, and remove Flan ged U nut on the cradle frame rear LH side.

 Remove the 3 studs from

the cradle frame & gently lift up the engine away from the frame.

Hex flange bolt: M10X165 Hex U Nut: M10X1.25 Socket Spanner: 14mm Ring Spanner: 14mm

Hex flange bolts: M10X183 Hex U Nuts: M10X1.25 Socket Spanner: 14mm Ring Spanner: 14mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

INSPECTION & PRECAUTIONS

 Inspect all the studs & bolts for bends, distortion, thread wear , threads stripped off etc

 Inspect all nuts for thread wear , threads stripped off etc

 DO NOT REUSE Nylock Nuts and Hex U nuts, and Pre coated fasteners once they have been tightened and

removed. Replace them every time they have been removed.

 DO NOT REUSE Washers, O Rings, Oil seals, Dust seals, rubber and plastic material rubber parts, plastic parts,

gaskets etc once they 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

suitable thread cleaning dies to repair the damages. If the threads are beyond repair, remove the damaged studs/ nuts and reweld new studs / nuts correctly.

 Clean the threads in the frame carefully using suitable cleaning and solving agents to clean off dirt and scales

 Apply suitable thread locking liquid as appropriate on non precoated fasteners before assembling and tightening

to torque.

 Always tighten fasteners diagonally and evenly to the correct specified torque values

 Clean, and repaint rusted areas in frame and other parts before assembly

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

TORQUE VALUES

No.

Engine Mtg to Cradle Frame - Flanged Hex Bolt

front top M10X1.25X165

Engine Mtg to Cradle Frame - Flanged Hex Bolt

front Bottom M10 X1.25X183

Engine Mtg to Cradle Frame - Flanged Hex Bolt

Rear Bottom M10X1.25X183

4 Cradle frame Mtg to Frame top Flanged Hex Bolt M10X1.25X60 5 0 5. 0 42.5 4.3 57.5 5.8

Cradle frame Mtg to Frame Hex Flange Bolt

rear bottom M10X1.25X65

6 Oil Cooler Mtg to frame Hex Flange M6X1X20 10 1.0 8.5 0.9 11.5 1.2

Steady Bracket Mtg to Hex Flange Bolt

Cylinder head M10X1.25X47

8 Steady Bracket Mtg to Frame Hex Flange Bolt 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

Aggregate Fastener

Torque

NM Kg.M

50 5.0 42.5 4.3 57.5 5 .8

50 5.0 42.5 4.3 57.5 5 .8

50 5.0 42.5 4.3 57.5 5.8

50 5.0 42.5 4.3 57.5 5 .8

Min. Torque

(Nm) (Kg.M)

Max. Torque

(Nm) (Kg.M)

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

14 Exhaust Pipe Mtg to Cyl Head Flanged Hex Nut M8X1.25 1 0 1. 0 8.5 0.9 11.5 1.2

15 Silencer Mtg to Frame Hex Socket M8X1.25X25 25 2.5 21.3 2.1 28. 8 2.9

17 Rear Wheel Spindle Nut Hex U Nut M16X1.5 7 0 7.0 59. 5 6.0 80.5 8.1

18 Chain Adjuster Lock nut Hex Nut M8X1.25 25 2.5 21. 3 2.1 28. 8 2.9

Head Lamp Mtg to Support Hex Soc. Hd. screw

Brackets M8X1.25X25

Trafficators Mtg to Support

Brackets

Windshield Mtg to Support

Brackets

Button Head M6X1X20 5 0 .5 4.3 0.4 5.8 0.6

Hex Socket Head Screws M5X16 5 0.5 4.3 0.4 5.8 0.6

10 1.0 8.5 0.9 11.5 1.2

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

ENGINE ASSEMBLY TO FRAME

Aggregate to Assemble/

No.

4.20

Instructions

Engine on Cradle Frame

 Locate Engine on cradle

frame & ensure the 3 mounting holes of the cradle frame and th e engine are aligned.

 Insert Hex bolt M10X165

from RH side and assemble U nut M10X1.25. DO N OT

TIGHTEN FULLY.

 Insert2 flanged Hex bolts

M10X183 from the front & rear bottom RH side and assemble U nut M10X1.25. DO N OT

TIGHTEN FULLY.

 Tighte n al l the

mo untings diagonally to torque.

Hex flange bolts: M10X165 & M10X183

Hex U Nuts: M10X1.25 Ring Spanner: 14mm. Socket Spanner: 14mm.

Torque: 50 Nm (5.0 Kg.M)

Fastener, Size, Tool Usage, Precautions, Photos

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 mounting holes align as follows:

- Crankcase rear top hole with frame mounting.

- 2 mounting holes of cradle frame with 2 holes in frame down tube.

- 2 mounting holes at the rear bottom of cradle frame with 2 holes in main frame.

 Insert flanged Hex Bolt

M10X 183 at rear top of engine and assemble U nut.

DO NO T TIG HTE N FULLY.

Hex flange bolts: M10X183 & M10X165 Hex U Nuts: M10X1.25 Ring Spanner: 14mm. Socket Spanner: 14mm.

Torque: 50 Nm (5.0 Kg.M)

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.21

Instructions

Cradle frame with engine, on Main

Frame

 Locate 2 flanged Hex

bolts M10X65, at rear bottom, LH & RH sides and assemble U nuts DO

NOT TIGHTEN FULLY.

 Position Oil cooler

mounting bracket in frame with its small tab resting on the frame inside.

 Align the mounting hole

with the low er mounting hole in frame.

 Locate Flanged Hex bolt

M10X75, over oil cooler bracket and assemble U nut. DO NOT TIGHTEN

FULLY. Ti ghten all the

mo untings diagonally to torque.

Fastener, Size, Tool Usage, Precautions, Photos

Hex flange bolt: M10X75 Hex U 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.

 Ensure rear axle nut, lock

nuts & adjuster nuts on the LH & RH chain adjusters are loosened fully.

 Push wheel fully inside.  Route rear chain through

final drive sprocket and locate it on rear wheel sprocket

 Ensure ‘O’ rings are

located on the chain link and Insert link from the inside of the chain.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.22

Instructions

Rear chain assembly and chain adjustment

 Assemble ‘O’ Rings on

the chain link and assemble the link plate.

 Assemble chain link lock

on the chain link, ensuring the closed end of the lock is towards the normal direction of rotation of the chain.

Fastener, Size, Tool Usage, Precautions, Photos

 Tighten adjuster nuts on

LH & RH side evenly till the chain has a slack of 20 to 25 mm on its top run.

 Ensure the reference

lines on the LH & RH chain adjusters are matching at the same reference lines in the swing arm on LH & RH sides.

 Tighten rear wheel axle

nut to torque.

 Tighten lock nuts against

the adjuster nuts on LH & RH sides.

4.23

Gear Shifter / Linkage

 Locate small lever on

gear shift shaft, ensuring, small lever is vertical to ground and the gear shift pedal is parallel to rider footrest LH.

Hex U Nut: M17 Socket Spanner: 24mm. Torque: 70-80Nm

(7.0-8.0Kg.M)

Hex Flange Bolt : M6X20 Socket Spanner : 10mm. Torque: 10Nm(1.0Kg.M)

 Assemble Hex bolt on

gear shift lever short from the front side and tighten to torque.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.24

Instructions

Pulse air valve Connections

Fastener, Size, Tool Usage, Precautions, Photos

Braided hose (PAV to Cylinder head)

 Locate gasket on cylinder

head with a little grease to hold it in position.

 Locate PAV pipe flange

on the gasket. ENSURE

THE OPEN END OF THE PIPE IS FACING UPWARDS.

 Tighten PAV pipe to

cylinder head with 2 hex socket head cap screws.

 Locate braided hose with

worm clip on the PAV outlet pipe and tighten screw.

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 studs on the cylinder head & assemble 2 hex nuts M8 DO NO T

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 cyli nder head, first an d t he n t he silencer bracket nut.

Hd. Cap screws: M6X20 Allen Key: M5 Torque :

NOTE

Asse mble new exhaust pipe gasket before locating exhaust pipe in cylinde r head.

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)

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.26

Instructions

Throttle Cable

 Ensure hex nut and

rubber grommet are located on the inner cable properly.

 Locate inner cable in the

Carburetor.

 Gently pull outer cable

upwards till the inner cable can be located into the brake t slot and release slowly till the threaded portion of the outer cable isfully resting on the bracket.

 Tighten outer cable to

bracket using the hex nut M6.

 Slide the rubber

grommets over the threaded sleeve on outer cable.

Fastener, Size, Tool Usage, Precautions, Photos

Hex nut : M6 Double end spanner :

10mm

 Adjust the throttle cable

free play correctly.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.27

Instructions

Steady engine plate

 Position steady engine

plate such that the single mounting hole aligns with the cylinder head mounting location & the 2 mounting holes align with the welded nuts in the frame.

Fastener, Size, Tool Usage, Precautions, Photos

 Locate 2 Flanged Hex

Bolts over the steady engine plate.

DO NO T TIG HTE N FULLY.

 Locate 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.

4.28

Electrical connections

A. St arte r Motor

Connections:

 Position earth wire

eyelet on outer mounting hole of starter motor & tighten with flanged hex bolt.

 Locate Relay starter

cable on the starter motor terminal & tighten with Hex nut.

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.)

Socket Spanner: 10mm

Hex flange bolt: M6 X 30 Socketspanner: 8mm Torque: 8-12Nm

(.8-1.2Kg.M)

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.29

Instructions

Electrical connections

Fastener, Size, Tool Usage, Precautions, Photos

G. Magneto

 Connect white coupler

on LH side to wiring harness

 Connect small Black

coupler (Pulsar wire connections on LH Side to wiring harness.

H. Gear position switch

CAUTION

Ensure Ignition switch & engine stop switch is in OFF position before connecting any wiring couplers.

NOTE

 Connect BIG & SMALL

Black coupler to wiring harness on LH side.

Ensure Protection couplers are correctly slid over the coupler after connecting. Ensure wiring harness is correctly strapped to frame after connecting couplers.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.29

Instructions

Electrical connections

I. Si de st and switc h

coupler

 Connect Red coupler to

wiring harness on LH side.

J. Battery Connections

 Connect Positive

terminal (Red) to the positive terminal of the battery.

Fastener, Size, Tool Usage, Precautions, Photos

 Connect negative

terminal (Black) to negative terminal of the battery.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.30

Instructions

Fuel tank Assembly

 Position fuel 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 Low fuel sensor to wiring harness

 Ensure rubber grommets

are in place in the rear mounting hole s and align mounting holes to the frame,

 Locate 2 washers on the

hex flange bolts, assemble the bolts and tighten to torque.

 Connect fuel hose to fuel

tap and carburetor and lock the clips in place.

Fastener, Size, Tool Usage, Precautions, Photos

Hex Flange Bolt M6 Socket Spanner 10 mm Torque 5 NM (0.5 Kg.M)

4.31

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

Button head screws over the panel and tighten.

Hex. Soc Button Hd Screw: M6X12

Allen Key: M5 Torque: 5Nm(0.5Kg.M)

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.32

Instructions

Side Panel RH

Fastener, Size, Tool Usage, Precautions, Photos

 Locate the tab of the

side panel in the rubber grommet in frame and press in gently.

 Assemble 3 Hex socket

Button head screws over the panel and tighten.

4.33

Rider & Pillion Seat

 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.

Hex. Soc Button Hd Screw M6X12

Allen Key: M5 Torque: 5Nm (0.5Kg.M)

 Remove key after

locking pillion seat.

4.34

Connector tube & Top frames

 Position connector tube

from inside the frame such that the horn mounting bracket is on the RH side.

 Align mounting holes

with the upper mounting hole in Frame.

Hex flange bolt: M10X75 Socket Spanner: 14mm. Torque: 50 Nm (5.0 Kg.M)

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.34

Instructions

Connector tube & Top frames

 Locate Flanged Hex bolt

from LH side & thread into the welded nut

 Ensure the 2 Hex socket

screws in top frames LH & RH are loose & locate on the connector tube till they are flush with the outer surface of the connector tube.

Do not ti ghte n the screws.

Fastener, Size, Tool Usage, Precautions, Photos

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.

4.35

Horn

 Locate horn in the

bracket and tighten.

 Connect horn terminals

Flanged Hex Bolts: M8 Socket Spanner: 12mm Torque: 25Nm(2.5Kg.M)

NOTE

Take care not to damage fuel tank or fork legs while assembling the top frames.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.36

Instructions

Trafficator front LH

Fastener, Size, Tool Usage, Precautions, Photos

 Locate the front lug of

the cockpit cover into the rubber grommet in top frame LH.

 Insert trafficator with

GREEN wire coupler into cover cockpit on LH side.

 Tighten trafficator to the

top frame with hex socket button head screw & hex nut.

 Connect the wiring

coupler to the wiring harness

4.37

Trafficator front RH

Hex Socket Hd. Cap screws: M6X20

Allen Key: M5 Hex Nut: M6 Double end spanner:10mm Torque: 10Nm.(1.0Kg.M.)

NOTE:

Couplers are color coded as: LH side: Green RH side: Red

 Locate the front lug of

the cockpit cover into the rubber grommet in top frame RH.

 Insert trafficator with

RED wire coupler into cover cockpit on RH side.

 Tighten trafficator to the

top frame with hex socket button head screw & hex nut.

 Connect the wiring

coupler to the wiring harness

Hex Socket Hd. Cap screws: M6X20

Allen Key: M5 Hex Nut: M6 Double end spanner:10mm Torque: 10Nm.(1.0Kg.M.)

NOTE:

Couplers are color coded as: LH side: Green RH side: Red

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.38

Instructions

Headlamp Assembly

Fastener, Size, Tool Usage, Precautions, Photos

 Position head lamp

assembly between top frames LH & RH an d ensure the mounting holes are aligned.

 Locate 2 Hex socket

head screws on either sides of the top frame and tighten.

 Connect head lamp

wiring coupler.

 Ensure the dust caps are

fitted in the slots on LH & RH sides.

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 sides and tighten using 4 Pan head screws with plastic washers..

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

Pan Head screws: M8X25 Philips screw driver Torque: 5Nm.(0.5Kg.M.)

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.40

Instructions

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 in sert 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 cable bracket.

Fastener, Size, Tool Usage, Precautions, Photos

NOTE:

Ensure the rubber grommet is correctly positioned between adjuster & clutch lever on RH cover

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.41

Instructions

Oil Cooler

 Insert Oil cooler pipe No

2 from the left side to the Right side, between the engine and the cradle frame.

Fastener, Size, Tool Usage, Precautions, Photos

 Position Oil 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 os e no.2 and tighten to cover RH with Banjo union bolt.

 Position 1 each

aluminum washer on either sides of the hose banjo union ofHose no.1 and tighten to crankcase LH with Banjo union bolt.

Flanged Hex bolts: M6X20 Socket spanner: 8mm. Torque: 10Nm.(1.0Kg.M.)

Banjo Union Bolts: M14 Socket spanner: 19mm. Torque: 38Nm.(3.8Kg.M.)

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

4.42

Instructions

Skid Plate

 Assemble the 4 rubber

bushes in the bottom mounting holes of the Skid 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 Fl an ged

Hex Bolts M6 X1 X 35 at

the bottom of the Skid plate.

Fastener, Size, Tool Usage, Precautions, Photos

Flanged Hex Screw: M6 Socket Spanner: 10mm Torque: 10Nm (0.1 Kg.M)

 Assemble 2 Flan ged

Hex Bolts, M6 X 1 X 14

at the front of the skid plate.

 Tig hte n all the 6 bolts

evenly and diagonally.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

SECTION 05 - RIDER & PILLION SEAT

EXPLODED VIEWS

RIDER & PILLION SEAT

S. NO.

DESCRIPTION

1 Pillion Seat Assy 1

2 Rider Seat Assy 1

QTY. S. NO.

4 Rubber Support - Rear 4

5 Tool Kit Strap 1

DESCRIPTION

QTY.

3 Rubber Support - Front 4

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

5.1 Rider & Pillion Seat Dismantling

 Unlock pillion seat by

turning key clockwise & lift pillion seat from front end to release rear tab & remove.

Fastener, Size, Tool Usage, Precautions, Photos

 Lift rider seat from rear

end to release front tab & remove.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

Instructions

5.2 Rider & Pillion Seat Assembly

 Locate the rider seat tab

under the fuel tank and position the locking plate ce ntrally on the frame.

 Locate rear seat tab in

the frame, align lock pin with the seat latch and gently press on seat to lock.

Fastener, Size, Tool Usage, Precautions, Photos

 Remove key after

locking pillion seat.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

SECTION 06 - CONTROL CABLES

EXPLODED VIEWS

CONTROL CABLES

S. NO.

1 Clutch Cable Assy. 1

2 Throttle Cable Assembly 1

3 Seat Latch Cable Assy 1

DESCRIPTION

QTY.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

6.1 Clutch Cable Removal from

Cover RH end

Fastener, Size, Tool Usage, Precautions, Photos

 Loosen outer lock nut of

the cable adjuster on Cover RH, completely.

 Loosen inner locknut

sufficiently such that the adjuster can be pushed in to release inner 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

nut from the clutch cable

Hex Nut: M8 D E Spanner: 12mm

NOTE:

Gently pus h the rubbe r grommet away from the adjuster while removing nut.

 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

inne r from the clutch lever

 Remove the clutch cable

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

6.2 Throttle Cable Removal from

Carburetor end

 Loosen bottom hex nut

and unscrew till it is free from the throttle cable adjuster.

 Loosen top lock nut till it

is resting against the top of the adjuster.

 Lift throttle rotor up till

cable becomes free from the rotor, gently rotate the cable and remove from the rotor eyelet.

 Remove the bottom lock

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 housing on handle bar RH.

 Lower the housing and

release the inner cable from the eyelet on the throttle rotor

 Remove the inner cable

on the throttle rotor housing bottom

Fastener, Size, Tool Usage, Precautions, Photos

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

INSPECTION

 Carefully inspect inner cable top and bottom ends for frayed strands, 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.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

Instructions

6.3 Clutch Cable Assembly at Handle

bar end

 Locate inner cable nipple

in the slot in clutch lever

 Locate outer cable in the

clutch lever bracket.

 Route cable suitably

along the frame from the LH side such that the other end is towards the clutch cover.

Assembly at Clutch cover end:

 Insert inner cable into

the clutch bracke t on Cover RH till the inner 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.

 Locate the inner cable on

the clutch lever clevis.

 Gently pull the cable

adjuster out of the bracket - as far as possible and tighten outer lock nut against the bracket.

 Check clutch lever free

play is between 2-3 mm and tighte n /loosen inner lock nut.

 Tighten outer locknut

against clutch bracket.

Fastener, Size, Tool Usage, Precautions, Photos

NOTE:

Ensure proper seating of rubber grommet on the cable adjuster.

Hex Nut: M8 D E Spanner: 12mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

Instructions

6.4 Throttle cable Assembly at Handle

bar end

 Route throttle cable

inne r through the bottom half of the throttle rotor housing.

Fastener, Size, Tool Usage, Precautions, Photos

 Insert throttle rotor on

handle bar RH and locate inner cable in the rotor eyelet

 Support bottom half of

the throttle rotor housing against handle bar and ensure proper resting of throttle rotor on top of the housing.

 Position top housing

over bottom housing, ensuring the mounting holes are matching and the throttle rotor is located in the slot in the housing and rotates freely.

 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.

NOTE:

Ensure free rotation of the throttle rotor in handle bar.

NOTE:

Ensure free movement of throttle rotor and cable before tightening the screws fully.

Philips head screw driver

 Locate throttle cable

stop plate on outer cable and tighten to bottom housing with screw.

 Route the throttle cable

below fuel tank and strap properly to frame.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

Instructions

6.4 Throttle cable Assembly on

carburetor end

 Ensure top lock nut in

the cable adjuster is fully 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

Fastener, Size, Tool Usage, Precautions, Photos

 Ensure free play of 2 –

3mm at the throttle rotor at the handle ba r end and adjust top lock nut accordingly.

 Tighten bottom lock nut

against the bracket at carburetor end

Hex Nut: M6 D E Spanner: 10mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

SECTION 07 - AIR FILTER

EXPLODED VIEWS

AIRFILTER

Key Nos.

3 & 4

Key Nos.

1 to 8

S. NO.

DESCRIPTION

A1 A/F Element Kit 1

A2 Air Filter Box Assembly 1

1 Pan Head Screw M5 X12 3

QTY. S. NO.

7 Drain Tube 1

8 Clip 1

9 Hex Flange Bolt, M6 X 1 X 14 2

DESCRIPTION

QTY.

2 Inlet Cover 1

3 Seal 1

4 Element Air Filter 1

5 Clamp 1

6 Pipe Outlet 1

10 Rear Damper - Tank 1

11 Lid – Battery Carrier 1

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

7.1 Air filter Element from housing

Fastener, Size, Tool Usage, Precautions, Photos

 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.

Pan head Screw M5 Allen Key 4mm

 Remove air filter element

from housing.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

7.2 Air filter Housing

from frame

Fastener, Size, Tool Usage, Precautions, Photos

 Disconnect battery

terminals and remove from air filter housing. (refer electricals section for dismantling battery)

 Remove 4 flanged hex

bolts and remove piece mudguard.

 Disconnect breather

hose from air filter housing

 Loosen carburetor

worm clip sufficiently.

 Loosen & remove 2

flanged 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 bracket air filter.

 Remove air filter housing

from rear side of the frame.

Hex Bolts: M6

Socket spanner: 8mm

Screw driver

Hex Bolts: M8

Socket spanner: 12mm

NOTE:

Ensure the wiring connections are removed

Hex Bolts: M6 Socket spanner: 10mm

Hex Bolts: M8 Socket spanner: 12mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

INSPECTION & CLEANING

 Inspect air filter element carefully for any deformation, damages, heavily clogged with dirt, soggy condition, and

/ or foreign particles embedded in the element. Replace if any of these conditions are observed.

 Inspect rubber seals, hoses, for cuts, cracks, damages.  Clean Air filter element every 5,000 Kms OR more frequently if motorcycle is used in dusty / Off road conditions.  Gently Tap filter element with minimum force to dislodge heavy / embedded dust particles.  Use compressed air from the outside of the filter element to remove 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

No.

1 Bracket Assy-Airfilter top Flanged Hex Bolt M8 X 1.25 X 16 22.5 2.25

2 Bracket Assy-Airfilter bottom Flanged Hex Bolt M6 X 1 X 20 10 1.0

3 Crossbar Assy Flanged Hex Bolt, M6 X 1 X 14 10 1.0

4 Piece mudguard Flanged Hex Bolt, M6 X 1 X 20 1 0 1. 0

5 Lid battery carrier Flanged Hex Bolt, M6 X 1 X 14 10 1.0

Aggregate Fastener

Torque

NM Kg.M

Min. Torque

(Nm) (Kg.M)

20 2.0

8 0. 8

Max. Torque

(Nm) (Kg.M)

25 2.5

12 1.2

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

Instructions

7.3 Air filter Housing

on frame

 Position air filter

housing inside frame from rear side with its outlet hole facing carburetor.

 Ensure connecting is

correctly & fully seated on both air filter and carburetor & tighten hose clip to prevent slipping of the connection tube

Fastener, Size, Tool Usage, Precautions, Photos

Screw driver

 Locate cross bar assembly

under air filter housing and tighten to frame using 2 flanged hex bolts.

 Position bracket assembly,

air filter on frame RH side and tighten using flanged hex bolt M8 on top and 2 M6 flanged hex bolts at bottom.

 Assemble piece mudguard

and tighten to frame with flanged bolts, washers and nylock nuts.

 Assemble batter y,

connect terminals, locate lid battery carrier in housing and tighten with hex bolts. (Refer electricals section for battery assembly)

Flanged Hex Bolts: M6 Socket spanner: 8mm Torque:8-12Nm(0.8-1.2

KgM.)

Flanged Hex Bolt: M8 Socket spanner: 12mm Torque:20-25Nm(2.0-2.5

KgM.)

Flanged Hex Bolt: M6 Socket spanner: 8mm Torque: 8-12Nm(0.8-1.2

KgM.)

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

Instructions

7.4 Air filter Element

into housing

 Locate air filter element

in housing such that the open end of the element is facing outside.

 Locate cover on the air

filter housing such that the locating pegs and the three mounting hole s are aligned.

Fastener, Size, Tool Usage, Precautions, Photos

 Tighten cover with 3

screws evenly and firmly

 Locate side panel with its

bottom leg located in the rubber grommet

 Tighten side panel with

2 hex socket button head screws

Philips head screw driver

Pan head screw M5 Allen Key 4mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

SECTION 08 - PULSE AIR VALVE

EXPLODED VIEWS

PULSE AIR VALVE



S. NO.

DESCRIPTION

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

QTY. S. NO.

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

DESCRIPTION

QTY.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

8.1 Pulse air valve pipe

connections

 Remove fuel tank from

frame.

 Gently expand the clip

and disconnect rubber hose from inlet manifold.

 Disconnect air inlet hose

from pulse air valve.

Puls e a ir va lv e b ra id ed hose:

Fastener, Size, Tool Usage, Precautions, Photos

 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

hose from pulse air valve 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 care not to drop the spacers and dampers

Screw driver

Hex. Soc head cap screw: M6X20

Allen Key 5mm

Hex bolts & nuts: M6 Double end spanner:

8mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

INSPECTION

 Inspect the hoses for ageing, cuts and / or cracks. Replace as recommended.  Inspect braided hose for any leaks, cracks and proper sealing at cylinder head

TORQUE VALUES

No.

1 Braided hose mtg to cyl head Hex Socket Head Cap Screw M6 X 20 10 1.0

2 PAV mtg to frame Hex flange bolt M6 X 30 10 1.0

Aggregate Fastener

Torque

NM Kg.M

Min. Torque

(Nm) (Kg.M)

8 0. 8

Max. Torque

(Nm) (Kg.M)

12 1.2

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

Instructions

8.2 Pulse air valve on

frame

 Locate pulse air valve in

the frame such that the outlet is facing down, the inlet from carburetor is on the RH side and the inlet from air filter is on the Left side of the frame

Fastener, Size, Tool Usage, Precautions, Photos

 Ensure the dampers and

spacers are in place in the mounting locations 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

flange over the gasket on cylinder head , align the holes and tighten with two hex socket head cap screws

Flanged Hex Bolts: M6 Socket spanner: 8mm Torque:10-12Nm

(1.0-1.2 Kg.M)

Screw driver

Hex soc hd cap screws: M6X20

Allen key: M5 Torque:10-12Nm

(1.0-1.2 Kg.M)

 Tighten worm clip over

the braided hose.

 Connect the rubber

hoses from airfilter and inlet manifold respectively and slide the clips in place.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

SECTION 09 - FUEL TANK

EXPLODED VIEW

FUEL TANK

S. NO.

DESCRIPTION

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

QTY. S. NO.

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

DESCRIPTION

QTY.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

9.1 Fuel tank -

Dismantling

Fastener, Size, Tool Usage, Precautions, Photos

 Remove Seat Assembly  Disconnect fuel hose

from carburetor end.

 Remove 2 Hex screws

from the rear end of fuel tank.

 Disconnect fuel gauge

coupler wire by lifting the tank slightly.

 Slide fuel tank towards

rear to release front clamp from frame.

 Remove tank along with

the overflow tube carefully.

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

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

INSPECTION

 Carefully inspect fuel hose and vent hose for damage, cuts, cracks, holes, wear or general 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

Aggregate FastenerComponent

Torque Range

NM Kg-M

Fuel Tank Fuel tank Mounting Flanged Hex Bolt M6 * 1*27 5 0.5

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

Instructions

9.2 Fuel tank Assembly

 Position fuel 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

Low fuel sensor to wiring harness

Fastener, Size, Tool Usage, Precautions, Photos

 Ensure rubber grommets

are in place in the rear mounting hole s and align mounting holes to the frame,

 Locate 2 washers on the

hex flange bolts, assemble the bolts and tighten to torque.

 Connect fuel hose to fuel

tap and carburetor and lock the clips in place.

Hex Flange Bolt M6 Socket Spanner 10 mm Torque 5 NM (0.5 Kg.M)

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

SECTION 10 – EXHAUST PIPE & SILENCER

EXPLODED VIEWS

EXHAUST PIPE & SILENCER

S. NO.

DESCRIPTION

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 Head Screw M6 X 6 6 6 Guard Exhaust Pipe 1 7 Clamp Silencer 1

QTY. S. NO.

8 Hex Flange Bolt M8 X 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

DESCRIPTION

QTY.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

10.1 Exhaust pipe & Silencer

Fastener, Size, Tool Usage, Precautions, Photos

 Remove 2 flanged Hex

nuts along with washers at the cylinder head end.

 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 silen cer from the vehicle.

Hex Nuts: M8X1.25 Socket spanner -12mm

NOTE:

Remove copper washer in cylinder head, exhaust pipe seating a rea after removing exhaust pipe.

Hex bolts: M8 X 1.25X45 Hex Nuts: M8 X1.25 Socket spanner - 12mm Double End Spanner: 12mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

INSPECTION

 Inspect Silencer and Exhaust assembles for any damages / dents as it might cause damage to the internals.  Inspect silencer and exhaust pipe joint for any signs of exhaust 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.

S No. Aggregate Fastener

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 Range

NM Kg-M

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

S.No.-

Aggregate to Assemble/

Instructions

10.2

Exhaust pipe & Silencer

 Locate a new gasket on

the exhaust pipe.

 Locate exhaust pipe

into the cylinder head, position the clamp over the studs on the cylinder head & assemble 2 hex nuts M8 DO NO T

TIGHTEN FULLY.

 Position silencer

mounting bracket against the frame at the rear and insert flanged hex bolt. Assemble hex nut over bolt.

Fastener, Size, Tool Usage, Precautions, Photos

Hex Nuts: M8X1.25 Socket spanner -12mm Torque: 10Nm (1.0Kg.M.)

 Tighten the 2 hex nuts at

the cylinder head, first and then the silence r bracket nut.

Hex bolts: M8 X 1.25X45 Hex Nuts: M8 X1.25 Socket spanner -12mm Double End Spanner: 12mm Torque: 25Nm (2.5Kg.M)

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

SECTION 11 - TOP BRACKET, HANDLE BAR,

FRONT MUDGUARD, FRONT WHEEL FRONT

SUSPENSION & STEERING STEM

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

EXPLODED VIEWS

TOP FRAME, WINDSCREEN & COCKPIT BRACKET

Key Nos.

11 (4 Nos.),

12 (4 Nos.),

& 13

7 5

S. NO.

DESCRIPTION

1 Top frame LH with Decal 1 2 Dust Cap - Connector Comp 2 3 Decal 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

QTY. S. NO.

DESCRIPTION

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 with Decal 1 20 Cover Cockpit RH 1 21 Decal RH 1 22 Hex Socket Head Cap Screw-M6 2

QTY.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

FRONT MUDGUARD

S. NO.

DESCRIPTION

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

QTY. S. NO.

5 Fork Brace- Yenmar Bronze 1

6 Front Mudguard - Bottom 1

7 Hex. Socket Button Head Screw M6 X 1 4

DESCRIPTION

QTY.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

FRONT WHEEL

S. NO.

DESCRIPTION

1 Tyre - 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

QTY. S. NO.

DESCRIPTION

11 Spacer 1 12 Grease Seal, ,25x40x7 1

Deep Groove Sealed Ball Bearing 6203

(17 X 40 X 12) 14 Spacer - Front Hub 1 15 Front Hub Assy 1 16 Wheel Speed Sensor Assy 1 17 Spindle - Front Wheel 1

QTY.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

FRONT FORK

S. NO.

DESCRIPTION

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

QTY. S. NO.

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

DESCRIPTION

QTY.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

HANDLE BAR

3 4

Key Nos.

1 to 18

Key Nos.

17 (2 Nos)

S. NO.

& 18

DESCRIPTION

QTY. S. NO.

DESCRIPTION

QTY.

A1 Handle Bar Assy Comp with Switch etc 1 A2 Clamp Kit Front M/C 1 1 Hex Socket Head Screw M8 X 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 lever fixing 1

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

STEERING STEM

S. NO.

DESCRIPTION

1 Hex Socket Head Screw M8 X 45 4 2 Top Raiser-Handle Bar 1 3 Lock Nut 1 4 Hex Socket Head Screw M8 X 1.25 X 25 8 5 Top 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 Hexagonal Bolt M6 X 1 X 10 2

QTY. S. NO.

10 Dust Seal-Steering Assy 2 11 Tapered Roller Bearing - 30205 (25 X 52) 2 12 13 Hex Bolt - M6 X 1 X 12 2 14 Plain Washer 2 15 Bracket Comp Number Plate 1 16 Number Plate – Front 1 17 18 Clamp-Wheel Speed Sensor 1

DESCRIPTION

Steering Stem Assy. with Bearings & Dust Seals

Cross Recessed Pan Head Screw M5 X 0.8 X 12

QTY.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

11.1 Top Frame LH & RH Wind Shield

Assembly

Fastener, Size, Tool Usage, Precautions, Photos

 Remove 4 Hex socket

head cap screws holding the Wind shield assembly to the top frame.

 Remove the 4 plastic

washers along with the screws and remove wind shield.

11.2 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.

Hex Soc Hd. Cap Screw: M5

Allen Key: 4mm

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 Double end spanner:10mm

 Gently pull out Cover

cockpit LH & RH from the rubber grommets in the top frame LH & RH.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

11.3 Headlamp

Assembly

 Disconnect head lamp

wiring coupler below head lamp.

 Remove the dust caps

from the mounting holes in top frame LH & RH.

 Remove 2 hex socket

head screws holding headlamp assembly to top frame LH & RH & remove head lamp assy.

Fastener, Size, Tool Usage, Precautions, Photos

Hex soc hd. cap screws: M8

Allen Key: 6mm

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.

 Loosen 2 hex socket

head screw clamping top frames LH & RH, to connector tube.

 Gently rotate & pull out

top frames LH & RH from connector tube.

Flanged hex bolts: M8 Socket Spanner: 12mm

Hex Socket Hd. screws: M6

Socket Spanner: 10mm

CAUTION:

Take care not to damage fuel tank while rotating & removing the side support brackets.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

11.5 Instrument cluster Ignition switch & Cockpit mounting bracket

 Disconnect the

instrument cluster wiring coupler

Fastener, Size, Tool Usage, Precautions, Photos

CAUTION:

Instrument cluster must always be stored vertically and away from magnetic objects to prevent damage to the compass and displays.

 Loosen and remove the

3 Hex cap nuts along with 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 cap nuts: M6 Socket Spanner: 10mm

Hex soc. Hd. cap Screw: M5 Allen key: 4mm

Hex soc. Hd. cap Screw: M8

Allen key: 6mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

Instructions

11.6 Front Mudguard Front Mudguard Top

Fastener, Size, Tool Usage, Precautions, Photos

 Remove 4 Hex bolts

from ins ide of mudguard.

 Remove front

mudguard top.

11.7 Front Mudguard Bottom

Hex bolt: M6 D E Spanner: 10mm

NOTE:

Ensure the 4 inserts are removed from the top of the mudguard.

 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

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

11.8

Instructions

Front Wheel

Fastener, Size, Tool Usage, Precautions, Photos

 Support vehicle suitably

such that the front wheel is off the ground.

 Hold front wheel axle on

fork end RH & loosen hex nut.

 Remove hex nut and

washer.

 Loosen pinch bolt from

bottom of fork end RH.

 Support wheel and pull

out spindle from RH side, taking care not to drop the spacers.

 Remove whee l 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 while removing front wheel

CAUTION:

Place a suitable spacer of 4 mm thickness, between the brake pads to prevent them from coming out too far, incase brake lever is depressed accidentally.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

11.9

Instructions

Front Fork Assy LH & RH Fork assy from vehicle

 Remove 2 Hex bolts

holding brake caliper to fork LH.

 Loosen 2 ea ch hex

socket head cap bolts on the LH & RH side fork crown plate.

Fastener, Size, Tool Usage, Precautions, Photos

Hex bolt: M8 T Spanner: 12mm

NOTE:

Support the wheel caliper suitably to prevent damage to it.

Ensure front wheel, wheel speed sensor connecting wire & front mudguards are already removed

 Loosen 2 ea ch 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 soc. Hd. cap Screw: M8

Allen key: 6mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

11.10

Instructions

Front Fork Internals

Fastener, Size, Tool Usage, Precautions, Photos

 Hold fork assembly in a

bench vice with soft jaws, approximately 6 inches 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 sprin g to expand completely.

 Remove washer, spacer

and washer spring top and main spring from the inner tube.

Hex cap nut : M16 Ring spanner: 24mm

 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.

Fork oil capacity: 455ml/leg

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

11.11

Instructions

Front Fork Internals

 Insert special tool from

the main tube end & Locate on the guide tube to prevent it from rotating.

 Remove Allen screw at

the bottom.

 Remove special tool

from inner tube.

Fastener, Size, Tool Usage, Precautions, Photos

Hex soc hd. cap screw: M8

Allen key: 6mm

 Remove the dust seal,

retainer clip, and fork seal from the outer tube.

 Separate fork tubes by

sharply pulling inner tube out of the outer tube along with the guide bush, seat pipe assembl y, rebound spring and cap oil lock.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

11.12

Instructions

Handle Bar Assembly

 Remove rear view

mirrors LH & RH from handle bar

 Disconnect clutch and

throttle cable s. (refer section 5)

 Disconnect wiring

couplers of LH and RH switch assemblies from the wiring harness

 Disconnect Front Brake

Switch wire connections.

 Disconnect clutch switch

wiring coupler.

Fastener, Size, Tool Usage, Precautions, Photos

Hex nut: M10 Double end spanner:14mm

 Remove 2 Hex bolts from

master cylinder top mounting bracket on handle bar RH and remove master cylinder comple te 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 bolt: M6 Socket spanner: 8mm

Hex soc hd. cap screw: M8 Allen key: 6mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

11.13

Instructions

Steering stem assembly

 Ensure following are

removed:

- Mirrors LH & RH, Windshield

- Headlamp & trafficators.

- Instrument cluster.

- Ignition switch.

- Electrical connections to

wheel speed sensor, clutch switch & front brake switch.

- Top frames LH, RH &

cockpit bracket

- Clutch and throttle

cables from handle bar.

Fastener, Size, Tool Usage, Precautions, Photos

- Front disc brake system

from handle bar & fork end LH

- Top raiser and handle

bar assembly

- Front wheel.

- Top & front mudguards

- Fork assemblies LH & RH  Loosen top nut on

steering stem and remove

 Support steering stem

from bottom and remove adjuster nut at the top

Hex nut : M24 Double end Spanner :

30mm

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Dismantle/

No.

11.13

Instructions

Steering stem assembly

 Remove dust washer

from the top

 Remove steering stem

from the frame

Fastener, Size, Tool Usage, Precautions, Photos

 Remove tapper roller

bearing from the frame head tube.

NOTE:

The bottom taper roller bearing will be tight in the steering stem and will have to be pulled out of the stem using suitable puller.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

INSPECTION

 Inspect steering stem ball races for uneven wear, damage and rusting  Steering stem for bend  Inspect front forks for oil leaks  Spokes for looseness / breakages  Wheel out of trueness  Tyre for uneven thread wear, cuts, crackes  Wheel bearings for sticky rotation, wear out, loose in hub  Brake pads for uneven / completely worn out

TORQUE VALUES

No.

1 Wind shield Mtg Hex Socket Head Screws M5X16 5 0. 5 4.25 0.43 5.75 0.58 2 Head Lamp Mtg 3 Trafficator Mtg Button Head M6X1X20 5 0.5 4.25 0.43 5.75 0.58 4 Handle Bar End Mass Mtg Hex socket cap screw M8x1.25X50 25 2.5 21. 25 2.13 28.75 2.88 5 Top Raiser Mtg 6 Top Yoke Mtg Hex socket head screw M8X1.25X25 2 5 2.5 2 1.25 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 2 1.25 2.13 28.75 2 .88 9 Steering Stem Lock Nut M24X1-7H 6 0-70 6.0 -7.0 60.00 6.00 70.00 7.00 10 Front Fender Top M6X1X27 5 0.5 4.25 0.43 5.75 0.58 11 Front Fender Bottom M6X1X13 5 0. 5 4.25 0.43 5.75 0.58 12 Fork Brace Mtg Hex socket head screw M6X1X20 10 1.0 8 .50 0.85 11.50 1.15 13 Front Wheel Spindle Nut Hex U Nut M16 X1.5 7 0 7.0 5 9.50 5.95 80.50 8.05 14 Fork Pinch Bolt Hex Socket head screw M8X1.25X30 10 1.0 8.50 0.85 11.50 1.15 15 Front Caliper Mtg Hex Flange Bolt M8X1.25X55 25 0. 3 21. 25 0.21 28.75 0.29

Aggregate Fastener

Hex socket head screw M8X1.25X25

Hex socket Head s crew M8X1.25X45

Torque

NM Kg.M

10 1.0 8.50 0.85 11.50 1.15

25 2.5 2 1.25 2.13 28.75 2.88

Min. Torque

(Nm) (Kg.M)

Max. Torque

(Nm) (Kg.M)

16 Front Disc Plate Mtg Hex Flange bolt M8X1.25X25 2 5 0. 3 21.25 0.21 28.75 0.29

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

WEAR LIMIT

 Fork spring long

Spring Length ------ mm

Long Pitch

 Fork spring short

Main tube straightness

Service Limit: 0.15 mm

Short Pitch

Length New Spring: --------mm Service Limit: -------mm

Guide Bush

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

11.14

Instructions

Steering stem assembly

Fastener, Size, Tool Usage, Precautions, Photos

 Assemble taper roller

bearing on the steering stem such that the taper is facing upwards

 Insert the steering stem

into the frame head tube from the bottom.

 Support steering stem

and assemble taper roller bearing on top of the frame head tube with the taper facin g downwards

 Assemble dust seal

washer over the frame head tube.

NOTE:

Ensure taper roller bearings are greased well before assembly.

 Assemble adjuster nut

on steering stem and tighten till there is n o sideways play of the steering stem.

 Rotate steering stem

and check for free & smooth rotation on both LH & RH.

 Locate top yoke over the

steering stem

 Assemble top nut over

the top yoke. Do not tighten fully.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

11.1 4

Instructions

Steering stem assembly

 The adjustment should

be carried outonly after assembly of the following.

- Cable bracket on top

yoke bottom.

- Handle bar on Top yoke.

- Top mudguard on steering

stem.

- Front disc brake master

cylinder on handle bar RH. (Route the brake hose & wheel caliper towards the left side of vehicle).

- Clutch and throttle cables.

- Cockpit bracket & Top

frames LH & RH.

- Electrical connections to

clutch switch & front brake switch.

- Ignition switch.

- Instrument cluster.

- Headlamp & trafficators.

- Mirrors LH & RH

- Windshield

- Front fork assembly LH &

- 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 stickyness.

 Loosen / tighten adjuster

nut on steering stem to correct axial play and / or sticky movement of steering assembly.

 Tighten top nut stem to

torque on steering.

Fastener, Size, Tool Usage, Precautions, Photos

Ste ering Stem locknut : M24

Socket Spanner - 30m Torque - 70 Nm (7.0 Kg.m)

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

11.1 5

Instructions

Handle Bar Assembly

Fastener, Size, Tool Usage, Precautions, Photos

 Locate handle bar on

top yoke.

 Assemble top raiser over

handle bar and tighten with 4 hex socket head screws.

 Locate Master cylinder

on handle bar RH side.

 Locate top clamp over

bracket and tighten with 2 Hex bolts. (Route the brake hose & wheel caliper towards the left side of vehicle)

 Connect Front Brake

Switch wire connections.

Hex soc hd. cap screw: M8 Allen key: 6mm Torque: 25Nm (2.5Kg.M)

 Connect clutch and

throttle cable s. (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 & RH from handle bar.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

11.16

Instructions

Front Fork Assy LH & RH Front Fork Internals

 Locate dust cap, oil seal

with its spring facing downwards and spacer from the bottom of inner tube assembly.

 Assemble spring 2 (short)

on piston – front fork 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

Fastener, Size, Tool Usage, Precautions, Photos

 Insert special tool into

inne r tube assembly, from top to hold piston – front fork.

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

11.16

Instructions

Front Fork Assy LH & RH Front Fork Internals

 Assembly Outer tube

over inner tube assembly bottom such that it is seated fully against the spindle taper.

 Locate copper was her

on hex socket screw and tighten outer tube to piston – front fork.

 Remove special tool  Gently tap plastic spacer

and oil seal, into fork end 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

end till it is seated flush in fork end.

Fastener, Size, Tool Usage, Precautions, Photos

 Insert closed coil end of

the spring 1 (long) into inner tube.

 Fill 455ml of fork oil per leg  Locate thrust washer

and tube spacer inside inner tube.

 Assemble plain washer

over spacer and tighten with the special hex cap nut.

 Repeat process to

assemble other fork.

Fork oil capacity: 455ml/leg

ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

Aggregate to Assemble/

No.

11.17

Instructions

Front Fork Assy LH & RH

Fork assy on steering stem

 Insert fork assy LH from

LH side of steering stem

bottom till it is seated into the top yoke and flush with the top of the top yoke.

 Insert fork assy RH from

RH side of steering stem

bottom till it is seated into the top yoke and flush with the top of the top yoke.

Fastener, Size, Tool Usage, Precautions, Photos

 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 tighten with 2 Hex flange bolts.

Hex. Socket screw : M8 Allen head socket : 6mm Torque : 22.5 Nm (2.25

Kg.m)

Hex. Socket screw : M8 Allen head socket : 6mm Torque : 22.5 Nm (2.25

Kg.m)

Royal Enfield Himalayan Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual