Himalayan Vehicle Service Manual - BS IV Spec

EFI Model
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 [email protected] , 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: [email protected]
Website: www.royalenfield.com
Part No: 1040333/A / May ’17
ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL 011

HIMALAYAN – VEHICLE VIEWS
VEHICLE VIEW LH
2
02 ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL
VEHICLE VIEW RH

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VEHICLE VIEW TOP
4
TABLE OF CONTENTS
SL.NO. DESCRIPTION PG.NO. SL.NO. DESCRIPTION PG.NO.
1. Technical Specifications ........................................ 6 12. Rear Suspension
12.1 Rear Wheel ..................................................... 107

2. Periodical Maintenance ......................................... 9
12.2 Rear Sprocket / Drive Chain Adjustment .... 108
12.3 Rear Mudguard .............................................. 109

3. Special Tools Usage List ......................................... 11
12.4 Mono Shockabsorber ................................... 110
12.5 Drag & Drop Links .......................................... 111

4. Engine Dismantling from Frame & Reassembly . 12
12.6 Swing Arm ...................................................... 112
5. Rider & Pillion Seat ................................................. 45

13. Hydraulic Dis Brakes - Front & Rear ...................... 122
6. Control Cables ........................................................ 48

14. EVAP ......................................................................... 156
7. Air Filter .................................................................... 53

15. Engine Management System (EMS) ..................... 162
8. Pulse Air Valve ......................................................... 59

16. Electrical Components ........................................... 202
9. Fuel Tank .................................................................. 63

17. Electricals ................................................................. 211
10. Exhaust Pipe & Silencer ......................................... 67

18. NACS II Diagnosis .................................................... 233
11. Front Suspension

19. Wiring Harness ........................................................ 252
11.1 Front Mudguard ............................................ 81
11.2 Front Wheel ................................................... 82

20. Trouble Shooting
11.3 Front Fork ....................................................... 83
20.1 Vehicle Trouble Shooting ............................. 258
11.4 Handle Bar ...................................................... 86
20.2 EMS Trouble Shooting .................................. 270
11.5 Steering Stem ................................................. 87

5
SECTION 01 - TECHNICAL SPECIFICATION
VEHICLE & VEHICLE SYSTEMS

A. ENGINE
Engine Type Single Cylinder, 4 Stroke, SOHC, Air cooled, Fuel Injection
Bore 78 mm
Stroke 86 mm
Displacement 411 cc
Compression ratio 9.5:1
Max Power 24.5 bhp (18.02 KW) @ 6500 rpm
Max Torque 32 Nm @ 4250+250 rpm
Idle rpm 1250+50 rpm
Starting System Electric Start
Air filter element Paper element
Lubrication Forced Lubrication, Wet sump
Engine oil capacity 2.3 L (Initial fill only), 2.0 L (Subsequent Refills)
Engine oil grade SAE 15W 50 API SL Grade JASO MA 2
Cooling Air cooled with Oil cooler
B. IGNITION SYSTEM
Ignition system Electronic ECU / Variable
Spark plug Bosch - UR5CC
Spark plug gap 0.7 to 0.8 mm
C. TRANSMISSION
Clutch Wet Multi Plate
Primary drive Gear
Primary ratio 2.312:1
Gear box 5 Speed, Constant Mesh
Gear Ratios
1st Gear 1st 2.916:1
2nd Gear 2 nd 1.833:1
3rd Gear 3 rd 1.428:1
4th Gear 4 th 1.173:1
5th Gear 5 th 1:000:1
6
Secondary Drive 5/8” Chain & Sprocket
Secondary Ratio 2.533:1
Drive Chain links 110 links
D. CHASSIS
Frame Half duplex split cradle
Suspension Front Telescopic, Hydraulic Damping,
Front wheel travel: 200 mm
Rear Swing arm with Linkage type Hydraulic damping
Mono shock, Rear wheel travel: 180 mm
Brakes Front Disc 300mm Dia disc.
Rear Disc 240mm Dia disc.
Tyre size Front 90 / 90 - 21
Rear 120 / 90 - 17
Tyre Pressures
Solo Front 25 PSI / 1.75 Kg/cm2
Rear 32 PSI / 2.25 Kg/cm2
With Pillion Front 27 PSI / 1.89 Kg/cm2
Rear 34 PSI / 2.39 Kg/cm2
Steering lock In built * The above values
are approximate
Fuel tank capacity* 15 + 0.5 litres approx * and the actual
capacity may
Low fuel warning Fuel Gauge (Red zone) 5.5 +0.5 lts.
vary with each
Dead stock (unusable fuel) 0.5 litre approx. fuel tank .
E. ELECTRICALS
Flywheel magneto 221W @ 1500 rpm
Generation Alternator, III Phase
System 12V - DC
Battery 12V - 8 AH MF
Head lamp 12V, H4-60/55W - BULB
Tail lamp / Brake lamp 12V- 4/1W LED
Licence Plate illuminator 12V- LED
Front position lamp 12V - LED

7
Speedometer lamp 12V - LED
WARNING
Hi beam indicator 12V - LED
Using bulbs/ electrical gadgets
Neutral lamp telltale 12V - LED other than specified rating
may lead to overloading/
Turn signal telltale 12V - LED
eratic behaviour / premature
Turn signal 12V, 10W * 4 Nos. failure of electrical system.
Horn 12V, 2.5 Amp. Modifications or fitments
Starter Motor 12V, 0.7 KW which are not approved by
Royal Enfield, will seriously
Instrument Cluster Digital cluster with main affect the performance of the
and compass LCD vehicle and will render the
Side Stand indicator LCD Indication warranty void.
F. DIMENSIONS
Length 2190 mm
Width 840 mm
Height 1360 mm
Wheel base 1465 mm
Ground clearance. 220 mm
Saddle Height 800 mm
G. WEIGHTS
 Values / Dimensions
Kerb weight (90% fuel&oil) 191 kgs. mentioned above are
for reference only.
Max. Pay load 174 Kgs.
 In view of continuous
improvements being
done on our
motorcycles, the
specifications are
subject to change
without prior notice.
8
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. DESCRIPTION FREE SERVICE PAID SERVICE
whichever is earlier whichever is earlier
Kms (x 1000) 0.5 5 10 15 20 25 30 35 40 45 50
Months 1.5 6 12 18 24 30 36 42 48 54 60
R I R I R I R I R I R
1 Engine Oil (Level check / Replace)
Check level at every 1000 Kms or earlier as required
2 Oil Filter Element R R R R R R
3 Engine oil strainer on crankcase LH C C C C C C
4 Inlet / Exhaust Tappet setting I&A I&A I&A I&A I&A I&A I&A I&A I&A I&A I&A
5 Rubber hose, Inlet manifold * I I R I R I R I R I R
6 Oil cooler inlet & outlet pipes * I I I R I I R I I R I
7 Spark plug C & A C & AC & A R C&A C&A R C&A C&A R C&A
8 HT leads for crack I I I I I I R I I I I
9 Fuel Hose I I I R I I R I I R I
10 Fuel Hose & Clip/ Injector ‘O’ ring/ Seal Ring I I I R I I R I I R I
11 Fuel Pump Check for screw tightness in all services
C C R C R C R C R C R
12 Air filter element Clean/ Replace more frequently if motorcycle always used
industy / off Road conditions.
13 Accelerator Cable I I R I R I R I R I R
14 Rubber Hose, Air fitler to Throttle body I I R I R I R I R I R
15 PAV pipes & Hose clip I I I I I R I I I I R
Carbo cleaner/ carb click/ or Fuel line cleaner spray every
16 Throttle body- Cleaning spray*
6000 Km or 6 months whichever is earlier
17 Clutch Cable I I R I R I R I R I R
A : Adjust C : Clean I : Inspect L : Lubricate R : Replace

* Refer Service Manual. # Check every time after vehicle is used for off road riding
NOTE:
For maintenance after 50,000 Kms. , please repeat same frequency specified above, in consultation with a Royal
Enfield Authorised Dealer / Service Center.

9
S.
No. DESCRIPTION FREE SERVICE PAID SERVICE
whichever is earlier whichever is earlier
Kms (x 1000) 0.5 5 10 15 20 25 30 35 40 45 50
Months 1.5 6 12 18 24 30 36 42 48 54 60
18 Clutch free play Adjust every 1000 Kms or earlier as required
19 Clutch no slippage I I I I I I I I I I I
20 Clutch Plates R R R
21 Cam Chain / Chain Pads / Auto chain Tensioner I I I I I I I I I I I&R
22 Inlet / Exhaust valve seating (compression test) * I I

23 Steering head bearings # I & A I & A L & A I & A L & A I&R I & A L & A I & A L & A I&R
24 Front Fork oil I I I R I I R I I R I
25 Fuel Pipe I I R I R I R I R I R
26 Battery terminals (apply petroleum jelly) C C C C C C C C C C C

27 Earth wire eyelet Tightness I I I I I
28 Hydraulic Brake Fluid - Front & Rear # I I R I R I R I R I R
29 Hydraulic brake hose & Washers - Front & Rear # I I I I R I I I R I I
30 Brake Pads - Front & Rear # I I R I R I R I R I R
31 Tyre wear pattern (Front & Rear)# (1) I I I I I R I I I I R

32 Spokes tightness / Wheel rim run out front & rear # I I I I I I I I I I I
33 Front & Rear wheel bearings for play # I I I I I I&R I I I I I&R

34 Swing arm Pivot bearings # I&L I&L I&L I&L I&L I&L I&L I&L I&L I&L I&R
35 Rear Suspension Linkages # I I&L I&L I&R I&L I&L I&R I&L I&L I&R I&L
36 Rear Drive Chain # Clean, Lubricate & Adjust every 1000 Kms or earlier as required
37 Drive chain & Sprockets set # I I R I R I R I R I R

38 Rear wheel cush drive rubbers # I I R I R I R I R I R
39 All Mounting Fasteners in vehicle for tightness # I I I I I I I I I I I
40 Hand levers, side stand, Rider & Pillion foot rest Pivots Lubricate every 1000 Kms or earlier as required
41 Evaporative Emission Equipment rubber hoses * I I I R I I R I I R I
A : Adjust C : Clean I : Inspect L : Lubricate R : Replace

* Refer Service Manual. # Check every time after vehicle is used for off road riding
NOTE:
For maintenance after 50,000 Kms. , please repeat same frequency specified above, in consultation with a Royal
Enfield Authorised Dealer / Service Center.

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

SECTION 04 - ENGINE DISMANTLING FROM FRAME &
REASSEMBLY
EXPLODED VIEWS
FRAME LH
7
4
5
1 3
2 6
8
9 10 11 13
6 14
9 12
19
43 18
15
17
40 13 16 14
22 20 14 15
41 42
30 21 15
22 23
31 24
32
34 33 25
36 36 13 29
28
16 35 27
39 26 A1
37
37
14 Key Nos.
14
13, 23, 24, 25, 25, 27, 28, 29
38 38
S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

A1 Gear Shift Lever Kit 1 22 Flanged Hex. Bolt M10 X 1.25 X 66 2
1 Main Frame- Black 1 23 Toe Lever Comp 1
2 Utility Box 1 24 Pivot Pin- Gear Shifter 1
3 Seat Latch 1 25 Sleeve, Gear Lever 1
4 Counter Sunk Screw M6 X 1 X 20 2 26 Hex Nut 1
5 Flanged Hex Bolt M6 X 1 X 10 2 27 Link Rod 1
6 Hex Socket Head Screw M8 X 1.25 X 25 4 28 Hex Nut (LH Thread) 1
7 Flanged Hex Bolt M8 X 1.25 X 20 2 29 Gear Shift Lever Comp-Short 1
8 Grab Rail Black 1 30 Hex Socket Head Cap Screw – M5 X 20 2
9 Mushroom Head Screw M6 X 8 X 1 2 31 Switch-Side Stand 1
10 Plate Seat Lock 1 32 Hex Socket Head Screw M8 X 1.25 X 35 1
11 Saddle Bag Mtg - LH 1 33 Side Stand Assy 1
12 Piece Mudguard 1 34 Hex Nyloc Nut M8 X 9.5 1
13 Flanged Hex Bolt M6 X 1 X 20 5 35 Spring 1
14 Plain Washer 8 36 Support Bush Skid Plate 4
15 Hex Nut with nylon insert 4 37 Damper - Oil Cooler 4
16 Flanged Hex Bolt, M6 X 1 X 14 6 38 Flanged Hex Bolt M6 X1 X 35 4
17 Grommet 1 39 Skid Plate 1
18 Stud 2 40 Cradle Frame 1
19 Crossbar Assy 1 41 Bracket Assy-Oil Cooler 1
20 Dust Cap-Frame Top 1 42 Flanged Hex Bolt, M10 X 1.25 X 75 1
21 Dust Cap-Frame 1 43 Flanged Hex Bolt M6 X1 X 27 2

EXPLODED VIEWS
FRAME RH
27
26
25
24 10 14
15 13 1
12
23
22 2
11 3
21 4
6 10
20 6
7
19 5
6
9 8
6
18
6
17
6
16

1 Connector Complete Black 1 15 Flanged Hex Bolt M6 X 1 X 14 2
2 Flanged Hex. Bolt M10 X 1.25 X 66 1 16 Brake Pedal Comp - RH 1
3 Plain Washer 1 17 Pivot Pin-Brake Pedal 1
4 Flanged Hex Bolt, M10 X 1.25 X 75 1 18 Spring-Pedal Return 1
5 Flange Hex Bolt M10 X 1.25 X 165 1 19 Dust Cap-Frame 1
6 Flange U Nut M10 X 1.25 6 20 Hex Socket Button head Screw M6 X 1 2
7 Flange Hex Bolt M10 X 1.25 X 183 3 21 Dust Cap-Frame Top 1
8 Clutch Clamp 1 22 Hex.Socket Button Head Screw M6 X 1 X 16 1
9 Flanged Hex nut M10X1.25 1 23 plain washer M6 1
10 Flanged Hex Bolt M8 X 1.25 X 16 2 24 Flanged Hex Bolt M6 X 1 X 20 1
11 Flanged Hex. Bolt M8 X 1.25 X 45 1 25 Bracket Assy. - Air Filter 1
12 Steady Bracket Black 1 26 Saddle Bag Mtg- RH 1
13 Flanged Hex. Nut M8 X 1.25 1 27 Hex Socket Head Screw M8 X 1.25 X 25 2
14 Flanged Hex Bolt M8 X 1.25 X 20 2

COMPONENTS DISMANTLING SEQUENCE TO REMOVE ENGINE FROM FRAME

Skid Plate on Frame bottom Rear Chain (Remove from FD sprocket)
 
Engine oil (Drain when warm. Remove drain plug /
oil strainer cover on crankcase LH & Oil filter on Cover FD sprocket nut (loosen )
RH)
 
Oil Cooler along with inlet & outlet pipes. Cover RH
 
Fuel hose & Pulse Air valve connections Oil pump gears / Oil pump
 
Battery connections Crank shaft Nut (LEFT HAND THREADED)
 
Fuel pump / Injector / TPS / MAP / O2 Sensor / EOT /
Magneto / Gear position / Side stand switch: couplers Balancer shaft Bolt
dismantle
 
Starter motor connections Clutch center nut & Clutch assembly
 
Gear shift shaft assembly (Remove circlip & washer
Spark plug suppressor cap
on shift shaft from LH crankcase side first)
 
Engine steady bracket Cam shaft covers / Cylinder head cover
 
Control Cables (Clutch / Accelerator) Automatic chain tensioner
 
Throttle body Cam shaft gear & cam shaft Assembly
 
Exhaust pipe & Silencer Cylinder Head Sub Assembly
 
Gear shift linkage Chain Tensioner Pads
 
Starter motor Cylinder Barrel Sub Assembly
 
Cover LH Cradle frame top mountings (with connector)
mounting to frame
 
Gear position indicator sensor Cradle frame bottom mounting LH& RH on frame
 
Magneto rotor assembly including Starter clutch Rear top engine mounting on frame (support engine
from bottom suitably)
 
Starter idler gears with bush & spindles Four mounting studs of Engine to cradle frame


ENGINE DISMANTLING FROM FRAME
S. Aggregate to Dismantle/
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
4.1 Skid plate
 Loosen & remove 6 Flanged Hex Screw: M6

Flanged Hex screws (2 in
front & 4 in bottom. Socket Spanner: 10mm
 Remove the spacers and NOTE:

washers between the
skid plate and frame. Ensure the engine oil is
drained from the engine.
4.2 Oil Cooler Banjo Union Bolts: M14

 Remove Inlet & Outlet Socket spanner: 19mm
Banjo union bolts from
LH & RH Crankcase
respectively & allow oil
to drain.
 Ensure the 4 washers
are removed from the oil
pipes / banjo Union
 Remove 2 Hex flange
bolts securing oil cooler Flanged Hex bolts: M6
to the frame
Socket spanner: 8mm.
 Remove oil cooler along
with inlet & outlet pipes.
(Ensure the Oil pipe No 2
on RH side between
engine & frame is taken
out carefully, while
dismantling the oil
cooler.)

No. Instructions
4.3 Wind Shield

Assembly
 Remove 4 Hex socket Hex Soc Hd. Cap Screw:
head cap screws holding M5
the Wind shield
assembly to the top Allen Key: 4mm
frame.
 Remove the 4 plastic NOTE:
washers along with the Hold the rubber mounted
screws and remove wind nuts from behind while
shield. loosening screws.
4.4 Trafficator front LH,

RH & cover cockpit
LH, RH.
 Disconnect Trafficator
wiring couplers below NOTE:
headlamp. Couplers are color coded as:
LH side: Green
RH side: Red
 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.
Hex socket hd. Screw: M5

Allen key: M4

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.
 Remove 2 hex socket
Hex Socket Hd. screw:
head screws holding
M5
headlamp assembly to
top frame LH & RH & Allen Key: 6mm
remove head lamp assy.
4.6 Top frame LH & RH

 Remove 2 Flanged Hex Flanged hex bolts: M8
bolts holding the top
frame LH & RH to Socket Spanner: 12mm
Instrument cluster
bracket. Hex Socket Hd. screws:
 Remove the 2 dust caps M6
from the connector in Socket Spanner: 10mm
the frame.
 Loosen 2 hex socket CAUTION
head screw clamping
top frames LH & RH, to Take care not to damage
connector tube. fuel tank while rotating &
removing the side support
 Gently rotate & pull out brackets.
top frames LH & RH from
connector tube.

No. Instructions
4.7 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
 Remove 2 Hex screws

from the rear end of fuel Flanged hex bolts: M6
tank. Socket Spanner: 10mm
 Gently lift fuel tank at
the rear and low fuel
sensor.
 Disconnect fuel pump
wiring coupler on right
sight of fuel tank.
 Disconenct fuel hose
from fuel pump by
disconnecting the quick
fix adopter at fuel pump
end.
 Disconnect rubber hose
from fuel tank to
cannister.
 Slide fuel tank towards
rear to release front
clamp from frame
 Remove tank along with
the overflow tube
carefully.

No. Instructions
4.9 Steady Engine

Bracket
 Hold U nut at the cylinder
Flanged hex bolt: M10
head mounting area
with a double end Socket Spanner: 12mm
spanner and loosen Hex
bolt at the front of the
steady engine bracket. Flanged hex nut: M10
 Remove the bolt and Socket Spanner: 12mm
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 Double End Spanner:
nuts completely. 13mm
 Gently pull throttle cable

from bracket to release
the threaded position
from the bracket.
 Remove inner cable
from the throttle body
rotor eyelet.

No. Instructions
4.11 Clutch Cable
 Loosen & remove outer

Hex Nut: M8
locknut from the rear of
the cable adjuster. D E Spanner: 12mm
 Loosen inner locknut
fully & push adjuster NOTE:
fully into bracket.
Gently push the rubber
 Release inner cable from grommet away from the
the clevis in the clutch adjuster while removing
shaft nut.
 Remove rubber grommet
& outer lock nut &
remove clutch cable
from the bracket.
4.12 Bi-starter Cable

 Remove the Bi starter
cable from the clutch
lever at handle bar end.
At throttle body end
 Remove the tank assy.
(as detailed in section 10)
 Loosen the hex faced
plastic nut on holder
cable valve at the
CAUTION
throttle body end slowly Spring loaded cable hence
pull out the valve bi remove slowly.
starter from throttle
body.
 Compress spring &
disconnect cable from
the vale bi starter. Double end spanner :
 Remove spring & valve bi 12 x 13 mm
starter & slide out cable
from the guide.
At handle bar end
 Loosen switch LH
holding screws at the
bottom & seperate the
switch.
 Disconnect cable from
lever & remove.

No. Instructions
4.13 Side Panel LH

 Remove 3 Hex socket
Hex. Socket Button Hd
Button head screws
Screw M6X12
(except left bottom
one). Allen Key: M5
 Gently pull out to release
locater from frame
rubber Grommet.
4.14 Side Panel RH

Hex. Socket Button Hd
Button head screws
Screw M6X12
(except right bottom
one). Allen Key: M5
 Gently pull out to release
locater from frame
rubber Grommet.

No. Instructions
4.14 Electrical connections

A. Battery
Philips Hd screw driver
 Remove negative terminal
screw and disconnect
negative battery cable.
 Remove positive terminal
screw and disconnect
positive battery cable.
B. Starter Motor
 Remove the Hex nut Socket Spanner: 10mm
securing the wire eyelet
CAUTION
to starter motor terminal
and remove the wire. Ensure Ignition switch &
 Remove flanged hex engine stop switch are in
bolt securing the earth OFF position before
wire eyelet to crankcase. disconnection battery &
wiring couplers.
C. Throttle Position
Sensor (TPS)
 Disconnect black Hex flange bolt: M6 X 30
coupler from the
Socketspanner: 8mm
throttlebody on LH side.
D. MAP
 Disconnect black
coupler from throttle
body top as RH side.
E. Fuel Injector sensor TPS
 Disconnect black
coupler from fuel
injector at LH side.
F. EOT
 Disconnect EOT Sensor
coupler (white) on RH
side.
G. Oxygen Sensor
 Disconnect black MAP
coupler from Oxygen
sensor as exhauste pipe
top.

No. 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
 Disconnect BIG & SMALL
Black coupler from LH
side.
J. Side stand switch

coupler
 Disconnect Red coupler
from LH side.

No. Instructions
4.14 Electrical
connections
K. Horn Terminals
 Disconnect horn
terminals.
L. Spark plug suppressor

cap
 Disconnect suppressor
cap from sparkplug.
4.15 Exhaust pipe &

Silencer
 Remove 2 flanged Hex Hex Nuts: M8X1.25
nuts along with washers Tubular spanner - 12mm
at the cylinder head end.
 Release the clamp from NOTE
the studs. Remove copper washer in
 Remove 2 Hex bolts & cylinder head, exhaust
nuts at the silencer pipe seating area after
mounting bracket end. removing exhaust pipe.
 Support the silencer and
remove the bolt. NOTE
Take care not to damage
 Gently pull out the Oxygen sensor while
exhaust pipe from the removing exhause pipe.
cylinder head and
remove exhaust pipe Hex bolts: M8 X 1.25X45
with silencer from the Hex Nuts: M8 X1.25
vehicle. Socket spanner -12mm
Double End Spanner: 12mm

No. Instructions
4.16 EXAI / REED

Connections
A. Braided hose to
Cylinder head
 Loosen screw on the
worm clip at end.
 Loosen & remove 2 hex
socket head cap screws,
holding the braided
hose to cylinder head.
 Gently pull out the
braided hose from the
bottom tube and
remove along with
gasket from cylinder
head.
Hd. Cap screws: M6X20
Allen Key: M5
4.17 Fuel Injector &

Throttle body
A. Fuel Injector
 Ensure wiring coupler is
disconnected.
 Loosen Hex nut and
remove completely.
 Gently pull out fuel
injector along with fuel
hose and spacer tube.
B. Throttle body
 Ensure TPS & MAP
Sensor coupler are
disconnecting.
 Remove Bi starter from
throttle body after
loosening plastic nut.

No. Instructions
4.17 Fuel Injector &

Throttle body
 Loosen worm clip on the
front & rear of throttle
body sufficients.
 Disconnect here from
throttle body to pulse
valve.
 Hodl the hex nuts on
inlet manifold & loosen
the 2 hex socket screws.
 Slide out throttle body
from Air filter housing.
4.18 Gear shifter/

linkage
 Loosen Hex bolt on small
Hex flange bolt: M6
gear lever mounted on
gear shaft on LH side of Socket spanner: 10mm
engine.
 Slide out small lever from
shaft.

No. Instructions
4.19 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
 Remove chain link lock

and remove chain from
the engine sprocket.

No. Instructions
4.20 Cradle frame with
Engine, separation
from Main frame
 Support cradle frame /
engine suitably at the
bottom such that it will not
drop of when mounting
bolts are removed.
 Loosen Flanged Hex.,
holding cradle frame Hex flange bolt: M10X66
top, to main frame. Socket Spanner: 14mm
 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 Hex flange bolt: M10X183
location of the engine. Socket Spanner: 14mm
DO NOT REMOVE THE
BOLT FROM THE FRAME.
 Loosen & remove 2
flanged Hex bolts from Hex flange bolts: M10X65
the cradle frame rear Socket Spanner: 14mm
bottom on both LH & RH
sides.
 Remove the Flanged Hex
bolt (loosened earlier)
from the rear top
location of the engine.
 Loosen & remove
Flanged Hex bolt along Hex flange bolts: M10X75
with oil cooler bracket, Socket Spanner: 14mm
holding oil cooler bracket
& cradle frame to main
frame.
 Gently remove the support
from the bottom of the
cradle frame / engine
and simultaneously
remove cradle frame
with crankcase from
main frame.

No. Instructions
4.21 Engine separation
from cradle frame
 Hold flanged Hex bolt on Hex flange bolt: M10X165
Cradle frame top RH side,
Hex U Nut: M10X1.25
and remove Flanged U
nut on the cradle frame Socket Spanner: 14mm
top LH side. Ring Spanner: 14mm
 Hold flanged Hex bolt on
Cradle frame bottom RH
side, and remove
Flanged U nut on the
cradle frame bottom LH
side,
 Hold flanged Hex bolt on
Cradle frame rear RH Hex flange bolts: M10X183
side, and remove Hex U Nuts: M10X1.25
Flanged U nut on the Socket Spanner: 14mm
cradle frame rear LH Ring Spanner: 14mm
side.
 Remove the 3 studs from

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

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

TORQUE VALUES
S. Torque Min. Torque Max. Torque

No. Aggregate Fastener
NM Kg.M (Nm) (Kg.M) (Nm) (Kg.M)
Engine Mtg to Cradle Frame - Flanged Hex Bolt
1 50 5.0 42.5 4.3 57.5 5.8
front top M10X1.25X165

2 50 5.0 42.5 4.3 57.5 5.8
front Bottom M10X1.25X183

3 50 5.0 42.5 4.3 57.5 5.8
Rear Bottom M10X1.25X183
4 Cradle frame Mtg to Frame top Flanged Hex Bolt M10X1.25X60 50 5.0 42.5 4.3 57.5 5.8
Cradle frame Mtg to Frame Hex Flange Bolt

5 50 5.0 42.5 4.3 57.5 5.8
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

7 50 5.0 42.5 4.3 57.5 5.8
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
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 10 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 70 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

19 10 1.0 8.5 0.9 11.5 1.2
Brackets M8X1.25X25
Trafficators Mtg to Support

20 Button Head M6X1X20 5 0.5 4.3 0.4 5.8 0.6
Brackets
Windshield Mtg to Support

21 Hex Socket Head Screws M5X16 5 0.5 4.3 0.4 5.8 0.6
Brackets

ENGINE ASSEMBLY TO FRAME
S. Aggregate to Assemble/
No. Instructions
4.22 Engine on Cradle
Frame
 Locate Engine on cradle
frame & ensure the 3
mounting holes of the
cradle frame and the
engine are aligned.
 Insert Hex bolt M10X165
from RH side and
assemble U nut
M10X1.25. DO NOT
TIGHTEN FULLY.
 Insert2 flanged Hex bolts Hex flange bolts:
M10X183 from the front M10X165 & M10X183
& rear bottom RH side Hex U Nuts: M10X1.25
and assemble U nut
M10X1.25. DO NOT Ring Spanner: 14mm.
TIGHTEN FULLY. Socket Spanner: 14mm.
 Tighten all the
mountings diagonally Torque: 50 Nm (5.0 Kg.M)
to torque.

engine, on Main
Frame
 Locate cradle frame /
engine from underneath Hex flange bolts:
main frame and lift up M10X183 & M10X165
with suitable support Hex U Nuts: M10X1.25
under engine such that Ring Spanner: 14mm.
the stud mounting holes Socket Spanner: 14mm.
align as follows:
- Crankcase rear top hole
with frame mounting. Torque: 50 Nm (5.0 Kg.M)
- 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 NOT TIGHTEN
FULLY.

No. Instructions
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 Hex flange bolt: M10X75
with the lower
mounting hole in frame. Hex U Nut: M10X1.25
 Locate Flanged Hex bolt Ring Spanner: 14mm.
M10X75, over oil cooler
bracket and assemble U Socket Spanner: 14mm.
nut. DO NOT TIGHTEN
FULLY.
Tighten all the Torque: 50 Nm (5.0 Kg.M)
mountings diagonally
to torque.
4.24 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.

No. Instructions
4.24 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.
 Tighten adjuster nuts on
Hex U Nut: M17
LH & RH side evenly till
the chain has a slack of Socket Spanner: 24mm.
20 to 25 mm on its top Torque: 70-80Nm
run. (7.0-8.0Kg.M)
 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.
4.25 Gear Shifter /

Linkage
 Locate small lever on Hex Flange Bolt : M6X20
gear shift shaft, ensuring,
small lever is vertical to Socket Spanner : 10mm.
ground and the gear Torque: 10Nm(1.0Kg.M)
shift pedal is parallel to
rider footrest LH.
 Assemble Hex bolt on
gear shift lever short
from the front side and
tighten to torque.

No. Instructions
4.26 Pulse air valve
Connections
Braided hose (PAV to Hd. Cap screws: M6X20
Cylinder head)
Allen Key: M5
 Locate gasket on cylinder
head with a little grease Torque :
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.
4.27 Exhaust pipe & NOTE

Silencer Assemble new exhaust
 Locate a new exhaust pipe gasket before locating
pipe gasket on the exhaust pipe in cylinder
exhaust pipe. head.
 Locate exhaust pipe
into the cylinder head, Hex Nuts: M8X1.25
position the clamp over Socket spanner -12mm
the studs on the cylinder Torque: 10Nm (1.0Kg.M.)
head & assemble 2 hex
nuts M8 DO NOT Hex bolts: M8 X 1.25X45
TIGHTEN FULLY. Hex Nuts: M8 X1.25
 Position silencer Socket spanner -12mm
mounting bracket Double End Spanner:
against the frame at the 12mm
rear and insert flanged Torque: 25Nm (2.5Kg.M)
hex bolt. Assemble hex
nut over bolt.
NOTE
 Tighten the 2 hex nuts
Ensure Oxygen sensor is
at the cylinder head,
assembled on the exhaust
first and then the
silencer bracket nut. pipe. Take care not to damage
the oxygen sensor while
 Connect the Oxygen
locating exhaust pipe on
sensor coupler to the
cylinder head.
sensor.

No. Instructions
4.28 Throttle body &

Fuel Injector
A. Throttle Body
 Ensure worm clip is
located on air filter
bellow.
 Locate throttle body
inside air filter bellow.
 Ensure clip hose is
located on inlet manifold
adaptor.
 Assemble inlet manifold
adaptor on throttle body.
 Locate ‘O’ ring on Inlet
manifold.
 Position inlet manifold
adaptor (with throttle
body) against inlet mani-
fold. Ensure the 2
mounting holes are
aligned.
 Assemble new copper
washers on the 2 hex soc
head cap screws and
insert from the inlet
manifod adaptor end.
 Assemble 2 hex nuts on
the screws and tighten Hex Soc. Hd. Cap Screw :
adaptor to manifold - M6 x 25
inlet. Hex nylock nut : M6
 Tighten worm clip screw Allen Key : 5 mm
on air filter bellow and Double end spanner :
inlet manifold adaptor. 10mm
 Insert valve - Bi Starter Torque : 10Nm (1.0 Kg.M)
plunger into throttle
body are tighten the
plastic hex nut to throttle
body sufficiently.

No. Instructions
4.28 Throttle body &

Fuel Injector
 Connect all electrical
couplers as described in
the Electricals connections
chapter.
 Connect hose from
purge valve to throttle
body.
B. Fuel Injector
 Ensure new seal ring is
located on fuel injector.
 Locate fuel injector on
manifold - inlet.
 Ensure stud - injector is
firmly tightened on
manifold - inlet.
 Assemble spacer on stud
- injector.
 Assemble ‘O’ ring on
injector top. Hex nylock nut : M6
Socket spanner : 10mm
 Positon Cap, injector
assembly with fuel hose Torque : 10Nm (1.0 Kg.M)
on injector and stud -
injector correctly.
 Tighten cap, injector
assembly to stud using
hex nut M6.
 Connect fuel injector
coupler.

No. Instructions
4.29 Throttle Cable

 Ensure hex nut and
rubber grommet are
located on the inner
cable properly.
 Locate inner cable in the
throttle body rotor
eyelet and route inner
cable on the rotor.
 Gently pull outer cable
upwards till the inner
cable can be located into
the braket 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 Hex nut : M6
nut M6. Double end spanner :
 Slide the rubber 10mm
grommets over the
threaded sleeve on
outer cable.
 Adjust the throttle cable
free play correctly.

No. Instructions
4.30 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.
 Locate 2 Flanged Hex

Flanged hex bolts:
Bolts over the steady
M10X20
engine plate.
Socket Spanner: 12mm
DO NOT TIGHTEN
FULLY. Torque: 20Nm. (2.0Kg.M)
 Locate Flanged Hex Bolt
at the front end of the Flanged hex bolt: M10X47
steady bracket, through Socket Spanner: 12mm
the cylinder head & Flanged hex nut: M10X1.25
assemble flange U Nut.
Ring Spanner: 12mm
Tighten all the bolts to
Torque: 50Nm(5Kg.M.)
torque.
4.31 Electrical
connections
A. Starter Motor Socket Spanner: 10mm
Connections:
 Position earth wire
eyelet on outer Hex flange bolt: M6 X 30
mounting hole of starter Socketspanner: 8mm
motor & tighten with
Torque: 8-12Nm
flanged hex bolt.
(.8-1.2Kg.M)
 Locate Relay starter
cable on the starter
motor terminal & tighten
with Hex nut.

No. Instructions
4.31 Electrical
connections
B. Throttle Position
Sensor (TPS)
 Connect black coupler
to throttle body on LH
side.
C. MAP Sensor
to throttle body RH side.
D. Fuel Injector Sensor

to fuel injector.
E. Engine Oil Temperature

(EOT) Sensor
 Connect white coupler
to EOT sensor wires.
F. Oxygen Sensor
 Connect Black coupler
to sensor wires on the
exhaust pipe top.

No. Instructions
4.31 Electrical
connections
G. Magneto
CAUTION
 Connect white coupler
Ensure Ignition switch &
on LH side to wiring
engine stop switch is in OFF
harness
position before connecting
any wiring couplers.
 Connect small Black

coupler (Pulsar wire
connections on LH Side
to wiring harness.
H. Gear position switch NOTE

 Connect BIG & SMALL Ensure Protection
Black coupler to wiring couplers are correctly slid
harness on LH side. over the coupler after
connecting. Ensure wiring
harness is correctly
strapped to frame after
connecting couplers.

No. Instructions
4.31 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.
4.32 Fuel Tank

 Align the two clamps in CAUTION
the fuel tank inside
channel, with the rubber When connecting the fuel
supports on the frame & cannister hoses ensure
and gently push forward they are routed correctly
to lock in place. Lift rear without any kinks.
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

No. Instructions
4.32 Fuel Tank
 Connect fuel pump

wiring coupler on RH
side bottom of fuel tank.
 Connect fuel hose to fuel
pump with the quick fix
adaptor.
 Connect rubber hose
from cannister to fuel
tank bottom.
 Ensure rubber grommets
are in place in the rear
mounting holes and
align mounting holes to
the frame,
 Locate 2 washers on the Hex flange bolts: M6X27
hex flange bolts, Socket Spanner: 10mm
assemble the bolts and
tighten to torque. Torque: 5Nm (0.5Kg.M.)
4.33 Side Panel LH & RH

 Locate the tab of the
side panel in the rubber Hex. Soc Button Hd Screw:
grommet in frame and M6X12
press in gently. Allen Key: M5
 Assemble 3 Hex socket Torque: 5Nm(0.5Kg.M)
Button head screws over
the panel and tighten.

No. Instructions
4.34 Side Panel RH

 Locate the tab of the
side panel in the rubber Hex. Soc Button Hd Screw
grommet in frame and M6X12
press in gently. Allen Key: M5
 Assemble 3 Hex socket Torque: 5Nm (0.5Kg.M)
Button head screws over
the panel and tighten.
4.35 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.
 Remove key after
locking pillion seat.
4.36 Connector tube &

Top frames
 Position connector tube

from inside the frame Hex flange bolt: M10X75
such that the horn Socket Spanner: 14mm.
mounting bracket is on
Torque: 50 Nm (5.0 Kg.M)
the RH side.
 Align mounting holes
with the upper
mounting hole in Frame.

No. Instructions
4.36 Connector tube &

Top frames
 Locate Flanged Hex bolt
Hex Socket Hd. Cap
from LH side & thread
screws: M6
into the welded nut
Allen Key: M5
 Ensure the 2 Hex socket
screws in top frames LH
& RH are loose & locate Flanged hex bolts: M8
on the connector tube
till they are flush with
the outer surface of the Torque: 25Nm(2.5 Kg.M)
connector tube.
Do not tighten the
screws.
 Align the mounting
holes of top frames LH & Flanged Hex Bolts: M8
RH with the holes in the Socket Spanner: 12mm
cockpit mounting
bracket assembly and Torque: 25Nm(2.5Kg.M)
tighten using Hex bolts.
NOTE
 Tighten the 2 hex socket
Take care not to damage
head cap screws on the fuel tank or fork legs while
top frame LH & RH to assembling the top frames.
clamp them against the
connector tube.
 Ensure the dust caps are
fitted on the connector.
4.37 Horn
 Locate horn in the
bracket and tighten.
 Connect horn terminals

No. Instructions
4.38 Trafficator front LH
 Locate the front lug of Hex Socket Hd. Cap

the cockpit cover into screws: M6X20
the rubber grommet in
Allen Key: M5
top frame LH.
Hex Nut: M6
 Insert trafficator with
Double end spanner:10mm
GREEN wire coupler into
cover cockpit on LH side. Torque: 10Nm.(1.0Kg.M.)
 Tighten trafficator to the NOTE:

top frame with hex
socket button head Couplers are color coded as:
screw & hex nut. LH side: Green
 Connect the wiring RH side: Red
coupler to the wiring
harness
4.39 Trafficator front RH

 Locate the front lug of Hex Socket Hd. Cap
the cockpit cover into screws: M6X20
the rubber grommet in
top frame RH. Allen Key: M5
Hex Nut: M6
 Insert trafficator with Double end spanner:10mm
RED wire coupler into Torque: 10Nm.(1.0Kg.M.)
cover cockpit on RH side.
 Tighten trafficator to the

NOTE:
top frame with hex
socket button head Couplers are color coded as:
screw & hex nut. LH side: Green
 Connect the wiring RH side: Red
coupler to the wiring
harness

No. Instructions
4.40 Headlamp
Assembly
 Position head lamp Hex Socket Hd. Cap
assembly between top screws: M8X25
frames LH & RH and Allen Key: M6
ensure the mounting
holes are aligned. Torque: 10Nm.(1.0Kg.M.)
 Locate 2 Hex socket

head screws on either
NOTE:
sides of the top frame Ensure the head lamp beam
and tighten. is properly aligned before
final torqueing
 Connect head lamp
wiring coupler.
 Ensure the dust caps are
fitted in the slots on LH &
RH sides.
4.41 Windshield
Assembly
 Locate 4 rubber nuts in Pan Head screws: M8X25
the top frame LH & RH.
Philips screw driver
 Locate wind shield on
the top frame, ensure Torque: 5Nm.(0.5Kg.M.)
the mounting holes are
aligned on both sides
and tighten using 4 Pan
head screws with plastic
washers..

No. Instructions
4.42 Bi Starter Cable

 Locate the Bi starter
cable in the lever at
handle bar end.
 Route the cable correcly,
on the frame tube under
fuel tank.
 Assemble the cable
guide, spring & valve bi
starter on the cable.
 Insert Valve bi starter
into throttle body and
tighten cable guide to
throttle body.
 Assemble fuel tank on
frame as detailed in
section ...
4.43 Clutch Cable
Assembly
 Ensure proper location
of inner cable in clutch NOTE:
lever & outer cable in LH Ensure the rubber grommet
bracket at handle bar is correctly positioned
end. between adjuster & clutch
 Ensure proper routing lever on RH cover
of cable along the frame
and insert into the
bracket in cover RH.
 Assemble outer lock nut
& larger end of rubber
grommet on the adjuster.
 Lock inner cable in the
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.

No. Instructions
4.44 Oil Cooler
 Insert Oil cooler pipe No

2 from the left side to the
Right side, between the
engine and the cradle
frame.
 Position Oil cooler Flanged Hex bolts: M6X20
mounting holes with the
bracket on LH side & Socket spanner: 8mm.
tighten with 2 flanged Torque: 10Nm.(1.0Kg.M.)
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.
 Position 1 each Banjo Union Bolts: M14

aluminum washer on
either sides of the hose Socket spanner: 19mm.
banjo union of Hose no.1 Torque: 38Nm.(3.8Kg.M.)
and tighten to
crankcase LH with Banjo
union bolt.

No. Instructions
4.44 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 Flanged Hex Screw: M6
fall off.
 Assemble 4 Flanged
Hex Bolts M6 X1 X 35 at Torque: 10Nm (0.1 Kg.M)
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.

SECTION 05 - RIDER & PILLION SEAT
EXPLODED VIEWS
RIDER & PILLION SEAT
4 3
4
3
1 Pillion Seat Assy 1 4 Rubber Support - Rear 4
2 Rider Seat Assy 1 5 Tool Kit Strap 1
3 Rubber Support - Front 4

No. Instructions
Dismantling
 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.

No. Instructions
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.

SECTION 06 - CONTROL CABLES
EXPLODED VIEWS
CONTROL CABLES
1 2
S. NO. DESCRIPTION QTY.
1 Clutch Cable Assy. 1
2 Throttle Cable Assembly 1
3 Seat Latch Cable Assy 1

No. Instructions
6.1 Clutch Cable
 Loosen cable lock nut at

the cable bracket end, on
engine cover RH & push
adjuster in fully
 Disconnect inner cable
from clutch lever on
CAUTION:
engine cover RH. Inspect Cables for any
fraying or damage
 Remove protective
rubber cover & nut
completely from cable &
remove cable from
bracket.
 Disconnect cable inner
from clutch lever on
handle bar LH& remove
clutch cable.

No. Instructions
6.2 Throttle cable
At Throttle body end

 Loosen cable lock nuts &
push adjuster fully into Hex nut : M6
bracket at throttle body Double End Spanner :
end. 10mm
 Disconnect inner cable
from rotor.
 Remove bottom nut
from cable adjuster &
remove cable with
adjuster from bracket.
At handle bar end

 Loosen the 2 screws on
the throttle housing on CAUTION:
handle bar. Inspect Cables for any
fraying or damage
 Loosen the screw
holding the cable strap
plate & slide out the strap
plate from the cable
 Separate the rotor
housing from the handle
bar and remove the
inner cable from the
rotor.
 Remove outer cable
from rotor housing.

No. Instructions
6.3 Bi-starter Cable
 Remove the Bi starter

cable from the clutch
lever at handle bar end.
At throttle body end
 Remove the tank assy.
(as detailed in section 10)
 Loosen the hex faced CAUTION
plastic nut on holder Spring loaded cable hence
cable valve at the remove slowly.
throttle body end slowly
pull out the valve bi
starter from throttle
body.
Double end spanner :
 Compress spring & 12 x 13 mm
disconnect cable from
the vale bi starter.
 Remove spring & valve bi
starter & slide out cable
from the guide.
At handle bar end
 Loosen switch LH
holding screws at the
bottom & seperate the
switch.
 Disconnect cable from
lever & remove.

No. Instructions
6.4 Clutch Cable
 Ensure proper location

of inner cable in clutch
NOTE:
lever & outer cable in LH Ensure the rubber
bracket at handle bar grommet is correctly
end. positioned between
adjuster & clutch lever on
 Ensure proper routing RH cover
of cable along the frame
and insert into the
bracket in cover RH.
 Assemble outer lock nut
& larger end of rubber
grommet on the
adjuster.
 Lock inner cable in the
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

No. Instructions
6.5 Throttle cable

At Handle bar end
Hex nut:
 Locate outer cable on
rotor housing. Double End Spanner:
10mm
 Locate the rotor
housing on the handle
bar and locate the inner
cable on the rotor.
 Install the screw holding
the cable strap plate &
CAUTION:
slide out the strap plate
from the cable. Inspect Cables for any
fraying or damage
 Install the 2 screws on
the throttle housing on
handle bar.
At Throttle body end
 Locate the Throttle
cable assembly.
 Slacken the adjusters at
the throttle body end for
both cables.
6.6 Bi Starter Cable

 Locate the Bi starter
cable in the lever at
handle bar end.
 Route the cable correcly,
on the frame tube under
fuel tank.
 Assemble the cable
guide, spring & valve bi
starter on the cable.
 Insert Valve bi starter
into throttle body and
tighten cable guide to
throttle body.
 Assemble fuel tank on
frame as detailed in
section ...

SECTION 07 - AIR FILTER
EXPLODED VIEWS
AIRFILTER
A1
Key Nos.
3&4
9
A2
5
Key Nos.
1 to 8 6
10
A2 11
3
2
A1 A/F Element Kit 1 7 Drain Tube 1
A2 Air Filter Box Assembly 1 8 Clip 1
1 Pan Head Screw M5 X12 3 9 Hex Flange Bolt, M6 X 1 X 14 2
2 Inlet Cover 1 10 Rear Damper - Tank 1
3 Seal 1 11 Lid – Battery Carrier 1
4 Element Air Filter 1
5 Clamp 1
6 Pipe Outlet 1

No. Instructions
7.1 Air filter Element
from housing
 Remove 2 hex socket Pan head Screw M5
button head screws
from the LH side panel. Allen Key 4mm
 Pull out the side panel

gently to release from
the grommet in the
frame.
 Loosen & Remove the 3 Pan head Screw M5

Pan head screws from
the air filter cover. Allen Key 4mm
 Remove Cover.
 Remove air filter element

from housing.

No. Instructions
7.2 Air filter Housing
from frame
 Disconnect battery Hex Bolts: M6
terminals and remove
from air filter housing. Socket spanner: 8mm
(refer electricals section
for dismantling battery)
 Remove 4 flanged hex
bolts and remove piece Screw driver
mudguard.
 Disconnect breather
hose from air filter Hex Bolts: M8
housing Socket spanner: 12mm
 Loosen throttle body
worm clip sufficiently.
 Loosen & remove 2
flanged hex bolts, NOTE:
holding air filter housing
to frame Ensure the wiring connections
are removed
 Gently pull out Fuse box
along with its rubber
holder from air filter Hex Bolts: M6
housing
Socket spanner: 10mm
 Remove RR unit with its
rubber holder from air
filter housing
 Loosen and remove 3
flange hex bolts holding
the cross bar assembly Hex Bolts: M8
below air filter housing
to frame Socket spanner: 12mm
 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.

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

1 Bracket Assy-Airfilter top Flanged Hex Bolt M8 X 1.25 X 16 22.5 2.25 20 2.0 25 2.5
2 Bracket Assy-Airfilter bottom Flanged Hex Bolt M6 X 1 X 20 10 1.0 8 0.8 12 1.2
3 Crossbar Assy Flanged Hex Bolt, M6 X 1 X 14 10 1.0 8 0.8 12 1.2
4 Piece mudguard Flanged Hex Bolt, M6 X 1 X 20 10 1.0 8 0.8 12 1.2
5 Lid battery carrier Flanged Hex Bolt, M6 X 1 X 14 10 1.0 8 0.8 12 1.2

No. Instructions
7.3 Air filter Housing
on frame
 Position air filter
housing inside frame
from rear side with its
outlet hole facing
Throttle body.
 Ensure connecting is
correctly & fully seated
on both air filter and
Throttle body & tighten
Screw driver
hose clip to prevent
slipping of the
connection tube.
 Locate cross bar assembly
under air filter housing
and tighten to frame
using 2 flanged hex bolts.
Flanged Hex Bolts: M6
 Position bracket assembly,
Socket spanner: 8mm
air filter on frame RH side
and tighten using Torque:8-12Nm(0.8-1.2
flanged hex bolt M8 on KgM.)
top and 2 M6 flanged
hex bolts at bottom.
Flanged Hex Bolt: M8
Socket spanner: 12mm
Torque:20-25Nm(2.0-2.5
 Assemble piece mudguard KgM.)
and tighten to frame
with flanged bolts,
washers and nylock nuts.
 Assemble battery,
connect terminals, locate Flanged Hex Bolt: M6
lid battery carrier in
housing and tighten with Socket spanner: 8mm
hex bolts. (Refer electricals Torque: 8-12Nm(0.8-1.2
section for battery KgM.)
assembly)

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 holes
are aligned.
 Tighten cover with 3

Philips head screw driver
screws evenly and firmly
 Locate side panel with its

bottom leg located in the
rubber grommet
 Tighten side panel with
2 hex socket button Pan head screw M5
head screws Allen Key 4mm

SECTION 08 - PULSE AIR VALVE
EXPLODED VIEWS
PULSE AIR VALVE
3 4
5 6
7
2
5 6
12
1 8
13
10 13
14
1 PAV - Air Filter Hose 1 8 Clip – PAV Adaptor 2

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

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.
Pulse air valve braided
hose:
 Loosen screw on the SS
Screw driver
hose clip.
 Loosen & remove 2 hex
Hex. Soc head cap screw:
socket head cap screws
M6X20
holding braided hose
flange to cylinder head Allen Key 5mm
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 Hex bolts & nuts: M6
remove the 2 flanged Double end spanner:
hex bolts from frame 8mm
 Remove pulse air valve

from frame, taking care
not to drop the spacers
and dampers

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

1 Braided hose mtg to cyl head Hex Socket Head Cap Screw M6 X 20 10 1.0 8 0.8 12 1.2
2 PAV mtg to frame Hex flange bolt M6 X 30 10 1.0 8 0.8 12 1.2

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 Throttle body
is on the RH side and the
inlet from air filter is on
the Left side of the frame
 Ensure the dampers and

spacers are in place in Flanged Hex Bolts: M6
the mounting locations Socket spanner: 8mm
and tighten with 2 hex
Torque:10-12Nm
flange bolts M6X30
(1.0-1.2 Kg.M)
 Apply grease on the
gasket and locate it on
the cylinder head
 Locate worm clip on the

braided hose and Screw driver
assemble braided hose
on the outlet tube of the
pulse air valve Hex soc hd cap screws:
M6X20
 Position braided hose
flange over the gasket on Allen key: M5
cylinder head , align the Torque:10-12Nm
holes and tighten with (1.0-1.2 Kg.M)
two hex socket head cap
screws
 Tighten worm clip over
the braided hose.
 Connect the rubber
hoses from airfilter and
inlet manifold
respectively and slide
the clips in place.

SECTION 09 - FUEL TANK
EXPLODED VIEW
FUEL TANK
16
15
14 1
13
2
12
11 3
2
4
10 7
8
5

Fuel Tank With Sticker - Granite 1 9 Flanged Hex Bolt M6 X 1 X 10 4
1
Fuel Tank With Sticker - Snow 1 10 P.A. Tube Assy 1
2 Front Damper-Tank 2 11 Drain Hose 1
3 O Ring-Fuel Gauge 1 12 Rear Damper-Tank 2
4 Fuel Level Sensor Unit 1 13 Bush - Fuel Tank 2
5 Hex Flange Nut M5 X 0.8 4 14 Flanged Hex Bolt M6 X 1 X 27 2
6 O Ring- Fuel pump 1 15 Cap- Fuel Tank 1
7 Fuel Pump Assy 1 16 Hex socket head cap screw m5x15 3
8 Clamp Plate (FPM) 1

No. Instructions
9.1 Fuel tank -
Dismantling
 Remove Seat Assembly CAUTION:
 Disconnect fuel hose
Drain the fuel completely
from fuel pump by from the fuel tank.
removing quick fix
adaptor.
Hex Flange Bolt M6
 Remove 2 Hex screws
from the rear end of fuel Socket Spanner 10 mm
tank.
 Disconnect EVAP hose CAUTION :

connection from tuel
tank. Do not lift tank too high to
 Disconnect fuel gauge - Prevent accidental
coupler wire by lifting the damage to the front
tank slightly. end of the fuel tank.
- Prevent damage to
 Slide fuel tank towards
EVAP hose
rear to release front
clamp from frame
 Remove tank along with
the overflow tube
carefully.

INSPECTION
 Carefully inspect fuel hose, EVAP 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
Torque Range
Aggregate Component Fastener
NM Kg-M
Fuel Tank Fuel tank Mounting Flanged Hex Bolt M6 * 1*27 5 0.5

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 :
- Connect EVAP hose &
remove proper routing
in frame wihtout any
kinks.
- Connect blue coupler of
Low fuel sensor to wiring
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 Bolt M6
hex flange bolts, Socket Spanner 10 mm
assemble the bolts and
tighten to torque. Torque 5 NM (0.5 Kg.M)
 Connect fuel hose to fuel

pump using quick fix
adaptor.

SECTION 10 – EXHAUST PIPE & SILENCER
EXPLODED VIEWS
EXHAUST PIPE & SILENCER
15 1
3 4
1
5
2
5
6
13 5
12
9
14
7
11
1
10
9
1
1 Flanged Hex. Nut M8 X 1.25 4 9 Pin Damper 2

2 Exhaust Gasket 1 10 Damper Bush 1
3 Exhaust Pipe Assy 1 11 Silencer Assy 1
4 Guard, Cat Pipe 1 12 Hex Flange Bolt M8 X 1.25 X 55 1
5 Flanged Hex Bolt M6 x 1 x 7 6 13 Guard Silencer 1
6 Guard Exhaust Pipe 1 14 Gasket(Exhaust Pipe & Silencer) 1
7 Clamp Silencer 1 15 Oxygen sensor 1
8 Hex Flange Bolt M8 X 1.25 X 38 1

No. Instructions
10.1 Exhaust pipe &
Silencer
 The Hego sensor is Deep Groove Socket:
assembled on the inner 21mm
side of the exhaust
down pipe near the
cylinder head.
 Ensure Ignition switch
and stop switch are in
OFF position.
 Disconnect wiring
harness coupler from
the sensor.
 Loosen Hego sensor and
remove along with
copper washer from the
exhaust down pipe.
 Remove 2 flanged Hex

Hex Nuts: M8X1.25
nuts along with washers
at the cylinder head end. Socket spanner -12mm
 Release the clamp from

NOTE:
the studs.
Remove copper washer in
cylinder head, exhaust
pipe seating area after
removing exhaust pipe.
 Remove 2 Hex bolts &

nuts at the silencer Hex bolts: M8 X 1.25X45
mounting bracket end. Hex Nuts: M8 X1.25
 Support the silencer and Socket spanner - 12mm
remove the bolt.
exhaust pipe from the
cylinder head and
remove exhaust pipe
with silencer from the
vehicle.

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.
Torque Range
S No. Aggregate Fastener
NM Kg-M
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

No.-
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 Hex Nuts: M8X1.25
head & assemble 2 hex
Socket spanner -12mm
nuts M8 DO NOT
TIGHTEN FULLY. Torque: 10Nm (1.0Kg.M.)
 Position silencer
mounting bracket
against the frame at the
rear and insert flanged
hex bolt. Assemble hex
nut over bolt.
 Tighten the 2 hex nuts at
the cylinder head, first Hex bolts: M8 X 1.25X45
and then the silencer Hex Nuts: M8 X1.25
bracket nut. Socket spanner -12mm
Torque: 25Nm (2.5Kg.M)
 Locate Hego sensor

Deep Groove Socket:
along with copper
21mm
washer on the exhaust
down pipe near the
cylinder head.
OFF position.
 Connect wiring harness
coupler on the sensor.

SECTION 11 - TOP BRACKET, HANDLE BAR,
FRONT MUDGUARD, FRONT WHEEL FRONT
SUSPENSION & STEERING STEM

EXPLODED VIEWS
TOP FRAME, WINDSCREEN & COCKPIT BRACKET
A1
Key Nos. 13
11 (4 Nos.),
12 (4 Nos.), 12
& 13 11
12
11
10
9 14 15
7 8 16 14
6 15
5 16
4
14
15
16
19 8
17 6
18 7 20
3 5
2
1
22
21
22 2

1 Top frame LH with Decal 1 12 Hex socket head cap screw M5X16 4
2 Dust Cap - Connector Comp 2 13 Wind Shield 1
3 Decal LH 1 14 Grommet-Cluster 3
4 Cover Cockpit LH 1 15 Plain Washer 3
5 Flanged Hex Bolt M8 2 16 Hex Nut M6 with nylon insert 3
6 Dust Cap-Frame Top 2 17 Cockpit Mtg bracket- Black 1
7 Grommet 2 18 Hex Socket Head Cap Screw M8 X 45 2
8 Rubber Nut-M5 4 19 Top frame RH with Decal 1
9 Cover Cockpit Top 1 20 Cover Cockpit RH 1
10 Hex.Socket Button Head Screw M6X1 2 21 Decal RH 1
11 Washer Plastic 4 22 Hex Socket Head Cap Screw-M6 2

FRONT MUDGUARD
2 4
1 Insert- Front Fender 4 5 Fork Brace- Yenmar Bronze 1
2 Front Mudguard with sticker assy - Black 1 6 Front Mudguard - Bottom 1
3 Flanged Hex Bolt M6 X 1 X 27 4 7 Hex. Socket Button Head Screw M6 X 1 4
4 Hex. Socket Head Cap Screw- M6 X 20 4

FRONT WHEEL
1 2
3
4
15
14 13 12 11 10 9
17 16 13

1 Tyre - Front 1 11 Spacer 1
2 Tube - Front 1 12 Grease Seal, ,25x40x7 1
3 Rim Tape- Front 1 Deep Groove Sealed Ball Bearing 6203
13 2
4 Rim Front 1 (17 X 40 X 12)
5 Disc- Front 1 14 Spacer - Front Hub 1
6 Hex Flanged Bolt M8 X 1.25 X 25 6 15 Front Hub Assy 1
7 Spokes Front 36 16 Wheel Speed Sensor Assy 1
8 Nipple 36 17 Spindle - Front Wheel 1

9 Hex U Nut M16 X1.5 1
10 Washer 1

FRONT FORK
20
A2 19
24 18
22 23
27
28 17
26 25
1
16
2 A1
15 3
21 4
5
6
14
13
12
7
11
10 8
9
A1 Front Fork Assy. LH 1 14 Piston Ring 2

A2 Front Fork Assy. RH 1 15 Spring – 1 (Long) 2
1 Inner Tube Assy. 2 16 Washer Spring Top 2
2 Dust Seal 2 17 Spacer 2
3 Circlip (Snap - Ring 2 18 Washer - 2 2
4 Oil Seal 2 19 ‘O’ Ring 2
5 Bush Washer 2 20 Bolt Cap 2
6 Bush (Outer Tube) 2 21 Outer Tube LH 1
7 Outer Tube RH 1 22 Cable Guide - Brake Hose 1
8 Gasket 2 23 Cable Guide - Speedo Cable 1
9 Bolt M10X1 2 24 Lock Washer, M6 2
10 Hex Socket Head Screw M8 X 1.25 X 25 1 25 Plain Washer 2
11 Spindle Taper 2 26 Hex. Bolt M6 X 12 2
12 Piston - Front Fork 2 27 Bellow Fork 2
13 Spring - 2 (Short) 2 28 Fork Gaiter Clip 2

HANDLE BAR
1 2
3 4
16 10
5 7
8
9
11
15
14
17 12
14
13
18 2
A1
1
Key Nos.
1 to 18
A2
Key Nos.
17 (2 Nos)
& 18

A1 Handle Bar Assy Comp with Switch etc 1 9 Front Brake Switch 1
A2 Clamp Kit Front M/C 1 10 Rear View Mirror RH 1
1 Hex Socket Head Screw M8 X 48 2 11 Master Cylinder - Front 1
2 Counter Weight Assy 2 12 Switch Module RH 1
3 Hand Grip LH 1 13 Grip Comp. Throttle RH 1
4 Switch Module LH 1 14 Mountable Strap- Handle bar 2
5 Handle Bar Complete 1 15 Bracket - Lever, Clutch LH 1
6 Rear View Mirror LH 1 16 Clutch Lever 1
7 Lever & Holder Assy- LH 1 17 Screw - Clutch Switch 2
8 Clutch Switch 1 18 Screw Brake lever fixing 1

STEERING STEM
1
2
3
5
8
6
7 9
10
4 11
12
10 16
13
14 15
4
17
18

1 Hex Socket Head Screw M8 X 45 4 10 Dust Seal-Steering Assy 2
2 Top Raiser-Handle Bar 1 11 Tapered Roller Bearing - 30205 (25 X 52) 2
3 Lock Nut 1 12 Steering Stem Assy. with Bearings & Dust Seals 1
4 Hex Socket Head Screw M8 X 1.25 X 25 8 13 Hex Bolt - M6 X 1 X 12 2
5 Top Yoke 1 14 Plain Washer 2
6 Hex. Socket Head Cap Screw- M6 X 20 2 15 Bracket Comp Number Plate 1
7 Ring Nut 1 16 Number Plate – Front 1
8 Clip Holder Assy - Wiring Harness 1 17 Cross Recessed Pan Head Screw M5 X 0.8 X 12 2
9 Flanged Hexagonal Bolt M6 X 1 X 10 2 18 Clamp-Wheel Speed Sensor 1

No. Instructions
11.1 Top Frame LH & RH
Wind Shield
Assembly
head cap screws holding Hex Soc Hd. Cap Screw:
the Wind shield M5
assembly to the top Allen Key: 4mm
frame.
 Remove the 4 plastic
washers along with the NOTE:
screws and remove wind Hold the rubber mounted
shield. nuts from behind while
loosening screws.
RH & cover cockpit
LH, RH.
wiring couplers below NOTE:
Couplers are color coded
headlamp.
as:
LH side: Green
 Remove hex socket RH side: Red
head screw mounting
the trafficators to the Hex Soc Hd. Cap crews:M5
top frames on LH & RH Allen Key: 4mm
sides. Hex Nut: M6
Double end spanner:10mm
 Gently pull out Cover

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

No. Instructions
11.3 Headlamp
Assembly
head lamp.
 Remove the dust caps

from the mounting holes
in top frame LH & RH.
head screws holding Hex soc hd. cap screws:
headlamp assembly to M8
top frame LH & RH &
remove head lamp assy. Allen Key: 6mm
11.4 Top frame LH & RH

 Remove 2 Flanged Hex
bolts holding the top Flanged hex bolts: M8
frame LH & RH to Socket Spanner: 12mm
Instrument cluster
bracket.
 Remove the 2 dust caps
from the connector in
the frame.
 Loosen 2 hex socket
Hex Socket Hd. screws:
head screw clamping
M6
top frames LH & RH, to
connector tube. Socket Spanner: 10mm
 Gently rotate & pull out CAUTION:

top frames LH & RH from
Take care not to damage fuel
connector tube.
tank while rotating & removing
the side support brackets.

No. Instructions
11.5 Instrument cluster
Ignition switch &
Cockpit mounting
bracket
 Disconnect the
instrument cluster
CAUTION:
wiring coupler Instrument cluster must
always be stored vertically
and away from magnetic
objects to prevent damage
to the compass and displays.
 Loosen and remove the Hex cap nuts: M6

3 Hex cap nuts along with
the washers. Socket Spanner: 10mm
 Remove the Instrument
cluster from the cockpit
bracket
 Disconnect ignition
switch wiring coupler.

Hex soc. Hd. cap Screw: M5
hex socket head cap
screws beneath switch Allen key: 4mm
and remove switch.
 Remove 2 Allen screws

Hex soc. Hd. cap Screw:
mounting the
M8
Instrument cluster
bracket to frame head Allen key: 6mm
tube.

No. Instructions
11.6 Front Mudguard
Front Mudguard Top
 Remove 4 Hex bolts
Hex bolt: M6
from inside of
mudguard. D E Spanner: 10mm
 Remove front
mudguard top.
NOTE:
Ensure the 4 inserts are
removed from the top of
the mudguard.
11.7 Front Mudguard

Bottom
 Remove 4 Allen screws Hex soc. Hd. cap Screw:

securing fork brace to M5
fork legs.
Allen key: 4mm
 Remove 4 Allen screws

inside front mudguard Hex soc. Hd. cap Screw:
bottom to separate M5
mudguard from fork Allen key: 4mm
brace.

No. Instructions
11.8 Front Wheel
 Support vehicle suitably

Hex nut: M16
such that the front
wheel is off the ground. Ring Spanner: 24mm
 Hold front wheel axle on

fork end RH & loosen
hex nut.
 Remove hex nut and

Hex soc. Hd. cap Screw:
washer.
M8
 Loosen pinch bolt from
Allen key: 6mm
bottom of fork end RH.
 Support wheel and pull
out spindle from RH side, CAUTION:
taking care not to drop Take care not to damage
the spacers. the wheel speed sensor
while removing front wheel
 Remove wheel from
between the fork ends CAUTION:
along with wheel speed Place a suitable spacer of 4
sensor and spacer. mm thickness, between the
brake pads to prevent them
 Remove wheel speed
from coming out too far,
sensor from the hub.
incase brake lever is
depressed accidentally.

No. Instructions
11.9 Front Fork Assy LH
& RH
Fork assy from vehicle
 Remove 2 Hex bolts
Hex bolt: M8
holding brake caliper to
fork LH. T Spanner: 12mm
NOTE:
Support the wheel caliper
suitably to prevent damage
to it.
Ensure front wheel, wheel
speed sensor connecting
 Loosen 2 each hex wire & front mudguards are
socket head cap bolts on already removed
the LH & RH side fork
crown plate.
 Loosen 2 each hex
socket head cap bolts on Hex soc. Hd. cap Screw:
the LH & RH side on M8
steering stem assy. Allen key: 6mm
 Rotate main tube &

simultaneously pull out
from fork crown plate
and steering stem
assembly.
 Repeat same process
with other fork
assembly.

No. Instructions
11.10 Front Fork Internals
 Hold fork assembly in a

Hex cap nut : M16
bench vice with soft jaws,
approximately 6 inches Ring spanner: 24mm
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
and main spring from the
inner tube.
 Invert the fork assembly

to drain out the oil from
the fork.
 Gently pump main tube

Fork oil capacity:
into the bottom tube to
455ml/leg
drain out the oil
completely.

No. Instructions
11.11 Front Fork Internals
 Insert special tool from

the main tube end &
Locate on the guide tube
to prevent it from
rotating.
Hex soc hd. cap screw:

M8
Allen key: 6mm
 Remove Allen screw at

the bottom.
 Remove special tool

from inner tube.
 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
assembly, rebound
spring and cap oil lock.

No. Instructions
11.12 Handle Bar
Assembly
 Remove rear view
mirrors LH & RH from
handle bar
 Disconnect clutch and
throttle cables. (refer
section 5) Hex nut: M10
 Disconnect wiring Double end spanner:14mm
couplers of LH and RH
switch assemblies from
the wiring harness
 Disconnect Front Brake
Switch wire connections.
 Disconnect clutch switch
wiring coupler.
 Remove 2 Hex bolts from Hex bolt: M6

master cylinder top
mounting bracket on Socket spanner: 8mm
handle bar RH and
remove master cylinder
complete with brake
lever from handle bar.

Hex soc hd. cap screw: M8
screws mounting top
raiser to steering stem Allen key: 6mm
top bracket & remove
handle bar with top
raiser.

No. Instructions
11.13 Steering stem
assembly
 Ensure following are
removed:
- MirrorsLH&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.
- 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

No. 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 NOTE:
head tube. 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.

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

1 Wind shield Mtg Hex Socket Head Screws M5X16 5 0.5 4.25 0.43 5.75 0.58
2 Head Lamp Mtg Hex socket head screw M8X1.25X25 10 1.0 8.50 0.85 11.50 1.15
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 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 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 70 7.0 59.50 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
16 Front Disc Plate Mtg Hex Flange bolt M8X1.25X25 25 0.3 21.25 0.21 28.75 0.29

WEAR LIMIT
 Fork spring long
Spring Length ------ mm
Long Pitch Short Pitch
 Fork spring short
Length
New Spring: --------mm
Service Limit: -------mm
Main tube straightness
Service Limit: 0.15 mm
Guide Bush

No. Instructions
11.14 Steering stem
assembly
 Assemble taper roller
bearing on the steering NOTE:
stem such that the taper Ensure taper roller
is facing upwards bearings are greased well
before assembly.
 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 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.
 Locate top yoke over the
steering stem
 Assemble top nut over
the top yoke. Do not
tighten fully.

No. Instructions
11.14 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 &
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 stickyness.
 Loosen / tighten adjuster
nut on steering stem to Steering Stem locknut :
correct axial play and / or M24
sticky movement of Socket Spanner - 30m
steering assembly.
 Tighten top nut stem to Torque - 70 Nm (7.0 Kg.m)
torque on steering.

No. Instructions
11.15 Handle Bar
Assembly
 Locate handle bar on
Hex soc hd. cap screw: M8
top yoke.
Allen key: 6mm
 Assemble top raiser over
handle bar and tighten Torque: 25Nm (2.5Kg.M)
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.
 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 & RH from
handle bar.

No. Instructions
& 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
 Insert special tool into

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

No. Instructions
& RH
Front Fork Internals
 Assembly Outer tube
over inner tube assembly
bottom such that it is
seated fully against the
spindle taper.
 Locate copper washer
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.
 Insert closed coil end of
the spring 1 (long) into
inner tube.
 Fill 455ml of fork oil per leg
Fork oil capacity:
 Locate thrust washer 455ml/leg
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.

No. Instructions
& 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.
 Tighten 4 Hex socket
head screws on the LH Hex. Socket screw : M8
and RH sides of the Allen head socket : 6mm
steering stem assembly
Torque : 22.5 Nm (2.25
sufficiently.
Kg.m)
 Tighten 4 Hex socket

head screws on LH and Hex. Socket screw : M8
RH sides of the top yoke Allen head socket : 6mm
sufficiently.
Torque : 22.5 Nm (2.25
 Assemble front Kg.m)
mudguard and brace
 Locate front wheel

caliper on fork Lh and
tighten with 2 Hex flange
bolts.

No. Instructions
11.18 Front Mudguard
Front Mudguard
Bottom
 Locate fork brace over
front mudguard bottom
and tighten with 4 hex
screws
 Locate front mudguard

bottom with brace
between fork legs and
tighten with 4 hex socket
head screws.
Front Mudguard
Top
 Locate insert fender into
the mounting holes in Hex Bolt : M6
front mudguard D.E. Spanner : 10 MM
 Locate front mudguard

top below the steering
stem and ensure
mounting holes are
aligned.
 Tighten front mudguard

top to steering stem Hex. Socket Head Cap
using 4 hex bolts from screw : M5
inside of mudguard. Allen key : 4mm

No. Instructions
11.19 Front wheel

 Remove the wedge
placed between the
brake pads in the caliper.
 Ensure pinch bolt on
fork end LH side is loose.
 Apply grease on the
spacer and locate inside
hub on brake disc side.
 Locate wheel speed
sensor on the hub RH NOTE:
side. Ensure inner lugs are
 Position wheel between properly seated in the slots
in wheel hub.
the front forks duly
ensuring.
- Brake disc is correctly
positioned between the
brake pads.
- Wheel speed sensor is NOTE:
positioned in the fork
Ensure outer lug is aligned
end LH. with the slot in fork end RH
 Locate spacer between
wheel speed sensor and NOTE:
fork end RH and insert  Do not force the spindle
spindle through the fork through as it will damage
end LH completely. the bearing and the
threads in the spindle.
 Assemble washer and
Hex. Nut : M16
Hex nut on the spindle.
Ring Spanner : 24 mm
Hold spindle and tighten
Torque : 70Nm / 7Kg.M
axle nut to torque.
 Tighten the pinch bolt on

Hex. Soc. Head Cap
fork end LH.
Screw : M8
 Remove the support
Allen Key : 6mm
provided under the
vehicle.

No. Instructions
Cockpit mounting
bracket, instrument
cluster & Ignition
switch
 Locate Ignition switch in
top yoke and tighten
with 2 Hex socket head
screws.
Hex Soc Hd. Cap Screw: M5
 Connect ignition switch
wiring coupler to Allen Key: 4mm
ignition switch Torque :
 Position cockpit Hex soc. Hd. cap Screw: M8
mounting bracket on
frame head tube and Allen key: 6mm
tighten with 2 Allen Torque :
screws .
CAUTION:
Instrument cluster must
always be stored vertically
and away from magnetic
objects to prevent damage
 Locate instrument to the compass and
cluster on cockpit displays.
moutnig bracket
 Assemble 3 washers on
the studs and tighten Hex cap nuts: M6
with 3 cap nuts Socket Spanner: 10mm
Torque :
 Connect instrument
cluster wiring coupler.

No. Instructions
 Locate top frames LH &

RH on connector tube in Flanged hex bolts: M8
frame and press in till the Socket Spanner: 12mm
mounting holes are flush.
Torque :
 Align top mounting hole
to cockpit bracket
moutning hole CAUTION:
 Assemble 2 Flanged Hex Take care not to damage
bolts on top frame LH & fuel tank while assembling
RH and tighten to cockpit top frames.
mounting bracket.
 Tighten the 2 hex socket Hex Socket Hd. screws:
head screw clamping M6
top frames LH & RH, to
connector tube
Torque :
 Assemble 2 dust caps on

the connector tube.
Headlamp Assembly
 Position Headlamp
housing between top
frame LH & RH and
tighten with 2 hex socket
head screws.
 Assemble 2 dust caps in
the mounting holes in
top frame LH & RH.
head lamp.

No. Instructions
RH & cover cockpit
LH, RH
 Locate Cover cockpit LH
Hex Soc Hd. Cap screws:M5
& RH in the rubber
grommets in the top Allen Key: 4mm
frame LH & RH Hex Nut: M6
 Locate traficator on the Double end spanner:10mm
cover cockpit and Torque :
tighten with hex socket
head screw.
 Repeat above process to
assemble the other NOTE:
trafficator Couplers are color coded
as:
 Connect Trafficator
wiring couplers below LH side: Green
headlamp. RH side: Red
Wind Shield
Assembly
 Locate windshield
assembly on top frame. NOTE:
 Assemble plastic washers Hold the rubber mounted
on the 4 Hex socket head nuts from behind while
Tightening screws.
cap screws and tighten
to top frame LH & RH.

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

EXPLODED VIEWS
REAR MUDGUARDS
13
12
13
14
2 1
2 5
11 14 13
12 3
10
4
9
3
6
1 Rear Mudguard with sticker 1 8 Flanged Hex Bolt M6 X 1 X 20 2
2 Clip Nut M5 4 9 Plain Washer M6 2
3 Plain Washer 4 10 Grommet - Rear Mudguard 2
4 Rear Number Plate Assy 1 11 Mudflap - Rear 1
5 Hex.Socket Button Head Screw M6 X 1 X 16 2 12 Hex socket head cap screw M5X16 4
6 Reflector 1 13 Spacer- Oil Cooler 4
7 Hexagonal Nut M6 X 1 2 14 Grommet 2

REAR WHEEL
A1 A6 A7 6
Key Nos. Key Nos. Key Nos. 5
A2 & A3 4
7, 8, 9, 23 & 24 13, 14 & 27
A2
Key Nos. 3
5, 18, 19, 21,

22, 25 & 26 12
A3
2 16
Key Nos. 7
3, 4 & 6 8
10 9
A4 12 11
Key Nos. 1 15
13
17 16
25 & 26 18
(36 Nos. each) 26
19
20
A5 25 21
19 22
Key Nos. 23 18
10, 11, 18 (2 Nos.) 24 8
14
& 19 (2 Nos.) 27

A1 Rear Wheel Assy 1 12 Socket Head Bolt M10 X 1.25 X 30 6
A2 Rear Wheel Kit without tyre, tube and rim tape 1 13 Sprocket - Rear Drive 1
A3 Tyre & Tube Kit - Rear Wheel 1 14 Chain- Rear 1
A4 Spokes & Nipples Kit 1 15 Adaptor - RD Sprocket 1
A5 Wheel Bearing & Seals Kit 1 16 Flanged Hex nut M10X1.25 6
A6 Rear Wheel Spindle & Spacer Kit 1 17 Spindle Short 1
A7 Chain & Sprocket Kit 1 18 Grease Seal, ,25x40x7 2
1 Hex Socket Button Head Screw M6X1X14 6 Deep Groove Ball Bearing 6203
2 Rear Disc Plate 1 19 2
(17 X 40 X12) [Double Side Sealed]
3 Tyre-Rear 1 20 Cushion Rubber 3
4 Tube-Rear 1 21 Rear Hub Assy 1
5 Rim Rear 1 22 Spacer Assy-Rear Hub 1
6 Rim Tape- Rear 1 23 Spacer-Disc Side Rear 1
7 Spindle - Long 1 24 Hex U Nut M16X1.5 1
8 Washer 2 25 Nipple 36
9 Spacer - Sprocket Side Rear 1
26 Spokes Rear 36
10 Rear Hub Grease Seal 1
27 FD Sprocket comp 1
Ball Bearing 6005 (25 X 47 X12)
11 1
[Double Side Rubber Sealed]

REAR SWING ARM, BEARINGS, CHAIN ADJUSTERS, GUARD, PAD & SAREE GUARD
14
11
10
9
8 12
7 10
13 17
3 12 11 16
4 13
5 15
4
6 18
4 19
1 18
20
5
4
3
A1 A2
Key Nos. Key Nos.
9,10 (2 Nos.), 15,16 (2 Nos.),
21
11 (2 Nos.) 17 (4 Nos.)

A1 Chain Pad Kit 1 11 Hex.Socket Button Head Screw M6 X 1 X 16 2
A2 Chain Tensioner Kit 2 12 Philips pan head screw M6X6 2
1 Swing Arm with bearing-Assy 1 13 Clip - Rear Disc Hose 2
2 Spindle - Swing Arm 1 14 Chain Guard 1
3 End Cup -Swing Arm 2 15 Chain Tensioner comp- LH 2
4 Oil Seal - Swing Arm 4 16 Plate - Chain Adjuster 2
5 Inner Race -Needle Bearing 2 17 Flanged Hex. Nut M8 X 1.25 4
6 Inner Spacer - Swing Arm 1 18 Flanged Hex Bolt M6 X 1 X 27 2
7 Spacer - Swing Arm 1 19 Chain – Guide 1
8 Hex Nut With Nylock M12 X 1.5 1 20 Saree Guard 1
9 Rear Chain-Pad 1 21 Hex socket head screw M6X1X14 3
10 Washer-Chain Pad 2

REAR SUSPENSION
A1
Key Nos. 3
7, 8 (8 Nos.), 2
10 (2 Nos.),
4, 5 &12 (2 nos.)
4 5
11 2
8 6
13 2
12
8
12 8 7
8
11
8
9
2
10
A1 Link Assy Kit 1 7 Drag link Assy with bearing 1

1 Mono Shock 1 8 Dust Seal Linkage 8
2 Flange U Nut M10 X 1.25 6 9 Flanged Hex. Bolt M10X1.25 X 132 1
3 Flanged Hex. Bolt M10 X 1.25 X 52 2 10 Drop link Assy with bearing 2
4 Inner Race- Drag Link Back 1 11 Flanged Hex. Bolt M10X1.25 X 47 2
5 Inner Race- Drag Link Front 1 12 Inner Race- Drop Link 2
6 Flanged Hex. Bolt M10 X 1.25 X 66 1 13 Swing Arm with bearing-Assy 1

No. Instructions
12.1 Rear Wheel Chain &
Sprocket
 Ensure motorcycle is
placed on its centre
stand with the rear
wheel off the ground.
 Gently release brake
hose along with its
rubber grommets from
the locating clips on
swing arm.
 Loosen rear axle nut on Hex nut: M16

RH side and remove
along with washer. Ring Spanner: 24mm
 Loosen chain adjuster, Hex nut: M6

inner & outer lock nuts
on both LH and RH side Double end Spanner:
completely to increase 12mm
chain slack.
 Remove Chain Link

Lock.
 Remove Chain link plate,

Small Nose pliers.
‘O’ rings and link to
disconnect rear chain
from sprocket.

No. Instructions
12.1 Rear wheel, chain &
sprocket
 Pull out wheel axle from
CAUTION:
LH side, taking care not
to drop the spacers & Place a suitable spacer of 4
rear wheel sprocket. mm thickness, between the
brake pads to prevent them
from coming out too far,
incase brake pedal is
depressed accidentally.
Support caliper suitably, to
avoid damage to the brake
 Remove brake caliper hose.
assembly from the slot in
swing arm. NOTE:
Take care not to drop the
Cush rubbers from the
hub.
 Remove 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.

No. Instructions
12.2 Saree & Chain
guards
 Remove 2 hex socket Hex soc hd. cap screws: M6
head cap screws at the
top and 1 hex socket Allen Key: 5mm
head cap screw at the
bottom of saree guard.
 Remove saree guard and
chain guard from swing
arm.
12.3 Piece mudguard

 Remove 4 Hex bolts (2 at Hex Bolt: M6
the top & 2 at the bottom)
Socket spanner:10mm
 Remove piece mudguard

No. Instructions
12.3 Mud flap rear

Hex Soc. Hd cap screws:M5
head cap screws with
washers, holding mud Allen key: 4mm
flap to rear mudguard
bottom.
 Remove 2 hex bolts
Hex bolt: M6
holding mud flap to rear
mudguard top & remove Socket spanner:10mm
mud flap. (Ensure 2
rubber grommets & 2 NOTE:
faced spacers are
Support mud flap and
removed).
disconnect number plate
 Disconnect Trafficator illuminator coupler
couplers LH & RH.
12.4 Rear Mudguard
 Remove 2 each hex NOTE:

socket head cap screws
Couplers are color coded :
from saddle bag
mounting plates LH & LH side: Green
RH. RH side: Red
NOTE:
Support saddle mounting
plate LH to prevent damage
to seat latch cable.
 Support rear mudguard Hex Soc. Hd cap screws:
and remove 2 hex socket M5
head cap screws on LH &
RH side and remove rear Allen key:4mm
mudguard.

No. Instructions
12.5 Mono shock

absorber
 Ensure Air filter housing Hex nut: M10
and piece mudguard are
removed. Hex bolt M10
 Hold hex bolt and Double end spanner:17mm
loosen hex U nut at Ring spanner: 14mm
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.

No. Instructions
12.6 Drag & Drop Links
 Hold long hex bolt and Hex nut: M10

loosen nut, holding drop
links to drag link. Hex bolt M10
 Remove long hex bolt. Double end spanner:17mm

Ring spanner: 14mm
 Support swing arm and NOTE:

remove inner race – drag
link back, to separate It will be required to
drop links from drag link. dismantle centre stand
from frame for dismantling
 Remove the dust seals. drag link assembly.
 Hold hex bolt and

NOTE:
loosen nut holding drag
link to frame. The needle bearings
pressed into the drag and
 Support drag link and
drop links cannot be
remove hex bolt to replaced.
remove drag link from
frame along with dust In case of bearing worn out
seals. or damaged, the entire drop
links and/or drag link should
 Hold hex bolts and be replaced.
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
with dust seals and inner
race from swing arm.

No. Instructions
12.7 Swing arm
assembly
 Remove the 2 dust caps Hex nut: M12
from the swing arm
Spindle M12
mounting holes in the
frame. Socket spanner: 17mm
 Support the swing arm

suitably. NOTE:
 Hold swing arm spindle The needle bearings
from LH side and pressed into the swing arm
remove hex nut from RH cannot be replaced
individually.
side.
In case of bearing worn out
 Remove swing arm
or damaged, the entire
assembly along with the swing arm assembly should
spacers, dust seals and be replaced.
inner race from the frame
assembly.

INSPECTION
 Spokes for looseness / breakages
 Wheel out of trueness
 Tyre for uneven thread wear , cuts, cracks
 Wheel & sprocket bearings for sticky rotation, wear out , loose in hub
 Brake pads for uneven / completely worn out
 Needle bearings / inner races in drag link, drop links and swing arm assembly for damages rust stiff rotation
 Dust seals in swing arm, drag link and drop links for damages
TORQUE VALUES
Suggested
S. Min. Torque Max. Torque
Aggregate Fastener Torque
No.
1 Drop Link Bottom Hex Flanged Bolt M10X1.25X65 50.0 5.0 42.50 4.25 57.50 5.75
2 Drop Link Assy Hex Flanged Bolt M10X1.25X132 50.0 5.0 42.50 4.25 57.50 5.75
3 Shock absorber Top& Bottom Mtg Hex Flanged Bolt M10X1.25X55 50.0 5.0 42.50 4.25 57.50 5.75
4 Drag link to swing arm Mtg Hex 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 1.20
Hex Soc Screw M10X1.25X30 /
10 Rear Wheel Sprocket Mtg 50.0 5.0 42.50 4.25 57.50 5.75
Flange U Nut M10X1.25
11 Rear Number Plate Mtg Button Head M6X1X15 5.0 0.5 4.25 0.43 5.75 0.58
12 Tail lamp Illuminator Mtg Button Head M5 5.0 0.5 4.25 0.43 5.75 0.58
13 Mudguard to Mudflap Hex Socket Cap Screw M5X0.8X16 5.0 0.5 4.25 0.43 5.75 0.58
14 Rear Trafficator Mtg Button Head M6X1 5.0 0.5 4.25 0.43 5.75 0.58
15 Tail Lamp Bkt Mtg Hex Flange M6X1X20 10.0 1.0 8.50 0.85 11.50 1.15
16 Rear Mudguard Mtg Hex Flange M6X1X20 10.0 1.0 8.50 0.85 11.50 1.15

No. Instructions
12.8 Swing arm
 Ensure rear chain pad is NOTE:

assembled on the swing
arm RH side Ensure the needle bearing
and inner races are greased
 Locate the 2 inner races well before assembly.
inside the needle
bearing in the swing arm
 Locate new dust seals in
the swing arm on either
sides of the inner races
on the swing arm.
 Position the swing arm
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.
 Assemble spacer washer
Hex nut: M12
and hex nylock nut on
the spindle RH side and Spindle: M12
tighten to torque. Socket spanner: 17mm
 Ensure free and smooth Torque: 70Nm(7 KgM)
up and down movement
of swing arm.

No. Instructions
12.9 Drag & Drop Links

 Locate larger end of
drop link with inner race
and dust seal in place in
NOTE:
swing arm and assemble Ensure the needle bearings
hex bolt. and inner races are greased
 Assemble flange U nut well before assembly.
and tighten to torque
 Repeat above process to
assemble second drop Hex nut: M10
link in swing arm. Hex bolt M10
 Ensure free movement socket spanner:17mm
of both drop links.
Ring spanner: 14mm
 Ensure the drag link is
positioned such that the Torque: 50Nm(5 KgM)
longer side is facing
towards the mounting
hole in frame.
 Position drop links with
dust seals on either side
of the drag link, ensure
the holes are aligned and
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 Hex nut: M10
inner race – drag link Hex bolt M10
front and dust seals in
the mounting bracket in socket spanner:17mm
frame, ensure holes are
aligned and insert hex Ring spanner: 14mm
bolt to lock drag link to Torque: 50Nm(5 KgM)
frame.
 Assemble hex nut on
bolt.
 Tighten all fasteners of
drag and drop links to
torque.
 Ensure free movement
of swing arm, drag and
drop links.

No. Instructions
12.10 Mono shock

absorber
 Locate shock absorber
Hex nut: M10
in position between
drag link and frame. Hex bolt M10
 Align top mounting hole, Double end spanner:17mm
insert hex bolt, assemble
Ring spanner: 14mm
hex nut
Torque: 50Nm(5KgM.)
 Align bottom mounting
hole, insert hex bolt,
assemble hex nut
 Tighten top and
mounting fasteners to
torque.
 Assemble Air filter
housing
12.11 Rear Mudguards

Rear Mudguard
 Locate rear mudguard in
frame, assemble 2 hex Hex Bolt: M6
socket head cap screws Socket spanner:10mm
on LH & RH side frame
and tighten to torque
 Position saddle bag
mounting LH & RH on Hex Soc. Hd cap screws:
frame and tighten with 2 M6
each hex socket head Allen key: 5mm
cap screws to torque.

No. Instructions
12.12 Mud flap rear
 Position mud flap in

NOTE:
frame
Support mud flap and
 Locate the 2 spacers connect number plate
from the top of the illuminator coupler &
frame, position rear trafficators LH & RH
mudguard in frame,
ensure the rubber NOTE:
grommets are in place Couplers are color coded :
and tighten with 2 hex LH side: Green
bolts to rear mudguard RH side: Red
top & remove mud flap.
 Locate 2 hex socket Hex bolt: M6
head cap screws with
washers, on the rear Socket spanner:10mm
front end of mud flap
and tighten to rear Hex Soc. Hd cap screws:
mudguard bottom. M5
Allen key:4mm
12.13 Piece mudguard
 Locate piece mudguard

Hex bolt: M6
and tighten with 4 Hex
bolts (2 at the top & 2 at Socket spanner:10mm
the bottom)

No. Instructions
12.14 Saree & Chain

guards
 Position chain guard on Hex soc hd. cap screws: M6
swign arm top and saree
gurad over the chain Allen Key: 5mm
guard Torque:
 Assemble 2 hex socket
head cap screws at the
top and 1 hex socket
head cap screw at the
bottom of saree guard.
 Tighten all fasteners
diagonally and evenly to
torque.
12.15 Rear Wheel Chain &

Sprocket Assembly
 Ensure proper seating
NOTE:
of bearing and dust seal
in adaptor Apply Loctite 270 on the
Allen screws before
 Locate rear wheel assembling nuts.
sprocket on the adaptor.
 Ensure the 6 mounting
holes are aligned
 Locate six hex socket
head cap screws from
the sprocket end. Tightening Sequence
A-B-C-D-E-F
 Assemble 6 Nylock nuts
on the screws at the
adaptor end.
 Tighten the 6 bolts Allen screw: M10
diagonally and evenly to Allen key: M8
torque following the Hex nut: M10
sequence shown.
Ring spanner: 12mm
Torque: 50Nm (5Kg.M)

No. Instructions
12.16 Rear Wheel

Reassembly
 Ensure the cush rubber NOTE:
are located properly in
 Remove the spacer
the wheel hub.
between the brake pads.
 Position wheel  Ensure rear wheel
assembly between the sprocket lugs are
swing arms and locate located correctly in the
rear wheel sprocket with cush rubbers.
chain, on the rear wheel
correctly. CAUTION:
 Position the caliper  Ensure the axle mounting
correctly over the brake hole in the swing arm,
chain adjusters, wheel
disc and locate the
hub and caliper bracket
caliper bracket slot on
are all aligned.
the lug in the swing arm.
 Do not force the
 Position the respective spindle through as it will
spacers on the LH& RH damage the threads
sides of the wheel hub.
 Insert wheel axle from Hex nut: M16
LH side of swing arm and Socket Spanner: 24mm
gently tap it in, till it is Torque: 70Nm (7.0Kg.M.)
seated against swing
arm. NOTE:
Rotate rear wheel, apply
 Assemble washer and rear brake sharply and hold
Hex nut on RH side and the pedal depressed. DO
tighten NOT RELEASE TILL REAR
AXLE NUT IS TIGHTENED.
 Locate the brake hose
pipe in swing arm clips
properly. CAUTION:
 Ensure correct chain
 Check rear brake for tension and rear wheel
effectiveness and alignment with front
correct functioning wheel
before using the  Ensure brake hose is
motorcycle. correctly positioned on
the clips, without any
twist, sharp kinks or
damage as it will seriously
affect brake efficiency.

No. Instructions
12.17 Chain tension

adjustment
 Ensure vehicle is on its Hex nut: M16
centre stand on level
ground Socket Spanner: 24mm
Tommy Bar
 Loosen rear axle nut.
 Loosen the locknut on Hex nut: M8
chain adjuster LH.
Double end Spanner: 12mm
 Loosen / tighten inner
nut on chain adjuster LH NOTE:
to increase/ decrease Ensure chain slackness of
chain slackness. 20 to 25 mm on its top run.
12.18 Wheels alignment

 Check the matching
position of the CAUTION:
reference lines on the Ensure chain adjuster LH
chain adjuster LH and nut is not disturbed while
swing arm LH adjusting on the RH side.
 Loosen lock nut on chain Hex nut: M8
adjuster RH
Double end Spanner:
 Loosen/ tighten inner 12mm
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.
NOTE:
 Hold the inner nuts
Rotate rear wheel, apply
firmly and tighten the
rear brake sharply and hold
lock nuts on chain
the pedal depressed. DO
adjusters LH & RH NOT RELEASE TILL REAR
against the inner nuts AXLE NUT IS TIGHTENED
while ensuring they are
held firmly. Hex nut: M16
 Tighten the rear wheel Socket Spanner: 24mm
axle nut for torque. Torque: 70Nm (7.0Kg.M.)

SECTION 13 - HYDRAULIC DISC BRAKES

EXPLODED VIEWS
HYDRAULIC DISC BRAKE SYSTEM – FRONT
A1
A2
3 4 A4 A5
2 9
9 10 10 11 12
34 35 13
16 cb d
1 5 f
6
16 cb d
9 10 10
8 e a g
15 14
7
A3 A6 A7
Key Nos. Key Nos. Key Nos.
9 (2 Nos.), a to g a to c & e to g
10 (4 Nos.)
A1 Disc Brake System Assembly Kit Front 1 5 Major Kit Front M/C 1
Master Cylinder Assembly with Brake 6 Minor Kit Front M/C 1
A2 1
Lever - (BBI) 7 Clamp Kit Front M/C 1
A3 Banjo Bolt Kit 1 8 Oil Window Assembly Kit 1
Front Brake Hose Assy and Banjo Bolt Kit 9 Banjo Bolt 2
A4 1
Front M/C 10 Washer 4
A5 Caliper Assy Front 1 11 Pad Spring 1
A6 Major Kit Front Caliper 1 12 Disc Pad Kit - Front Caliper - (BBI) 1
A7 Minor Kit Front Caliper 1 13 Pad Pin Kit Front Caliper 1
1 Diaphragm Kit Front M/C 1 14 Wear pad 1
2 Reservoir Cover Kit Front M/C 1 15 Primary Pin Kit Front Caliper 1
3 Lever Kit Front M/C 1 16 Flanged Hex. Bolt M8 X 1.25 X 55 2
4 Front Brake Switch 1

EXPLODED VIEWS
HYDRAULIC DISC BRAKE SYSTEM – REAR
A3
Key Nos. 1
a to h A2
2
A6 3 4
Key Nos. A3
5
a to d, f, g & h
A6 a b cd e f g h
A1
Key Nos. 6 9
g to m 8
j k l
A7
Key Nos.
m
g to k & m
10
g h 7
A8 i
11 11
Key Nos. 12 12
A5
11 & 12
12 12

A1 Disc Brake Assembly Rear 1 3 Connector Kit Rear M/C 1
A2 Rear Master Cylinder Assembly 1 4 Boot Rear M/C 1
A3 Major Kit Rear M/C 1 5 Push Rod kit- Rear M/C 1
A4 Minor Kit Rear M/C 1 6 Pad Spring- Rear 1
A5 Rear Brake Hose Assy with Banjo bolt kit 1 7 Primary Pin Kit Rear Caliper 1
A6 Major Kit Rear Caliper 1 8 Brake Pad Kit Rear Caliper - BBI 1
A7 Minor Kit Rear Caliper 1 9 Pad Pin Kit Rear Caliper 1
A8 Banjo Bolt Kit 1 10 Wear pad 1
1 Reservoir Kit Rear M/C Threaded 1 11 Banjo Bolt 2
2 Reservoir Tube Kit Rear M/C 1 12 Washer 4

No. Instructions
13.1 Front Disc Brake
13.1.1 Master cylinder
from handle bar Double end spanner:
 Remove rear view mirror 14mm
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.
rubber cap on bleeder
nipple on the caliper.
 Loosen bleeder nipple

by about 2 turns. Ring Spanner: 10mm

No. Instructions
from handle bar
 Connect one end of a CAUTION:
transparent flexible
tube of length about 12" Brake fluid is extremely
(30cms.) firmly to the corrosive hence ensure it
bleeder nipple. does not spill on any
painted, rubber parts.
 Insert the other end of
the tube into a clean
glass or plastic container
to collect the brake fluid.
 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.

No. Instructions
from handle bar
 Place a clean tray below
brake caliper to collect Ring Spanner: 14mm
residual brake fluid from
the brake system. NOTE:
Loosen and remove the Ensure brake fluid does not
banjo bolt along with spill while removing the
sealing washers from the brake hose.
brake hose at wheel
caliper end.
 Loosen and remove the

banjo bolt along with Double end Spanner:
sealing washers from the 14mm
brake hose at master
cylinder end.
 Remove the brake hose
from vehicle.
 Remove 2 slotted screws
from the top cover. Philips screw driver
 Remove top cover

diaphragm plate and
rubber diaphragm from
master cylinder.

No. Instructions
from handle bar
 Remove the brake lever
pivot lock nut, brake Screw driver &
lever pivot from bracket. Double end spanner:
8mm
 Remove brake lever and
protective rubber boot
from master cylinder.
 Remove Circlip from the
Master cylinder body
slowly and carefully.
CAUTION:
 Remove conical spring
and piston with seals Spring loaded. Remove
with care.
from master cylinder
housing.
 Remove 2 hex bolts on Hex nut: M6

the clamp.
Ring spanner: 8mm
 Remove clamp and
master cylinder from the
handlebar

No. Instructions
13.1.2 Wheel caliper from
fork end LH
 Loosen the 2 hex bolts
holding brake caliper to Hex nut: M10
fork end. Ring spanner: 12mm
 Remove caliper
assembly from fork end.
13.1.3 Brake pads from

caliper
 Remove the 2 grub
screws on the caliper
body. Screw Driver
 Loosen and remove 2 Allen screws : 4mm

socket headed pin
screws from the caliper Allen key : M5
body.
 Remove the brake pad

from Caliper Assembly.

No. Instructions
13.1.3 Brake pads from
caliper
 Remove Mounting
Bracket from the Caliper
Assembly.
 Remove the Pad

tensioner spring plate
from caliper.

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
blunt and soft tool.

No. Instructions
13.2 Rear Disc Brake
13.2.1. Fluid draining
rubber cap on bleeder
nipple on the caliper.
 Connect one end of a
transparent flexible
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
to collect the brake fluid.
 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
drained from the brake
system.

with rubber grommets
from the swing arm.

No. Instructions
13.2.1. Fluid draining
banjo bolt along with
sealing washers from the Banjo bolt
brake hose at wheel
caliper end. Ring spanner: 12mm
 Disconnect the rear NOTE:

brake light switch
coupler (black) from Place a clean tray below
wiring harness near brake hose to collect
residual brake fluid.
battery.
 Using a double end

Brake light switch
spanner, loosen the hex
nut cum brake light Double end spanner:
switch and remove 14mm
from vehicle.
NOTE:
Remove the sealing washers
from either side of the brake
hose banjo.

reservoir
 Unscrew lid from master
cylinder reservoir and
remove lid along with
diaphragm.

No. Instructions
13.2.1. Master cylinder
reservoir
 Release metal clip and
disconnect hose from
reservoir to master
cylinder.
 Loosen and remove hex

Hex soc Hd screw : M4
socket screw holding
reservoir to frame and Allen key : 5mm
remove reservoir along
with hose.
 Remove split pin from

Split pin
the pin on brake pedal
Nose pliers
 Remove pin and
disconnect brake pedal
from the link rod in
master cylinder.
 Loosen 2 socket head

Hex soc Hd screw : M4
screws holding master
cylinder to frame. Allen key : 5mm

No. Instructions
13.2.3. Master cylinder
rubber boot from
master cylinder.
 Remove Circlip from the

Master cylinder body Circlip
slowly and carefully. Circlip pliers
 Gently pull out piston CAUTION:

with bush, seals, spring
guide and conical spring Do not use any sharp tool to
pull out the piston from the
from master cylinder
master cylinder.
housing.
Pull out gently with
minimum force.

13.2.4. Brake pads from
wheel caliper
 Remove 2 locking clips
from the brake pad
pivot in wheel caliper

No. Instructions

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
caliper.
 Separate the Mounting

Bracket from the Caliper
Assembly by gently
pulling them apart.

No. Instructions

13.2.5. Wheel caliper from
swing arm
 Remove the Pad
tensioner spring plate
from caliper and
mounting bracket.

13.2.5. Piston & seal from
caliper
 Hold the caliper body
with the piston facing CAUTION:
downwards. Do not use high pressure air.
 Blow low pressure Support piston while
compressed air with a removing from caliper.
nozzle into the oil
passage hole on the Ensure the bore in the
caliper, to drive out the caliper does not get scored
or damaged.
piston from the caliper
bore. Ensure piston outside
surfaces does not get
 Gently remove the scored or damaged.
piston with seal from
caliper using a blunt and
soft tool.

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

 Always replace brake pads as a set only.
 Always replace banjo union washers, ‘O’ rings, diaphragm washers, dust seals and piston seals whenever the
hydraulic disc brake system is overhauled.
 Always replace damaged parts like pistons, fixing pin etc. DO NOT 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
Thickness of the Minimum disc thickness
disc plate as engraved on the disc
Rear Disc
Brake Disc Flatness of the disc 0.1 mm

plate plate
Runout of the disc 0.3 mm

plate

Component What to Measure Service Limit Where to Measure
Brake pads Wear out of brake As marked in the brake

pads pads
Master
Wear out of the 12.76 mm
cylinder bore
cylinder
ID
Master
cylinder Wear out of piston 12.64 mm
Piston OD
Wheel caliper Wear out of the 25.46 mm

cylinder bore cylinders
ID
Wheel caliper Wear out of pistons 25.31 mm

Pistons OD
TORQUE VALUES
S. Suggested Torque
NM Kg.M
1 Master cylinder assembly clamp Hex Bolt M6 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 20.0 2.0
7 Grub screw, brake pad in bolts Grub screw 3.0 0.3
8 Bleeder nipple Hex nipple 10 0.1
9 Wheel caliper mounting on fork end LH Hex Nut M8X1.25 30.0 3.0

No. Instructions

13.3.1 Pistons & seals in
caliper
 Coat fresh brake fluid on
new dust seals and
piston seals.
NOTE:
 Install piston seals in the
inner groove and dust Do not apply force while
seals in the outer groove assembling the pistons into
in the bore in caliper the caliper. Press only with
assembly. minimal hand pressure.
 Coat the caliper Assemble pistons one at a

time into 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.

No. Instructions

13.3.1 Pistons & seals in
caliper
 Install the pad tension
spring plate in the Caliper
body.
 Assemble Bleed screw Ring Spanner: 8 mm

with the dust cap on the
caliper body. Torque: 10Nm (0.1Kgm)
 Assemble the Mounting

Bracket on the caliper
Body.

No. Instructions

13.3.2 Brake pads in
caliper
 Install brake pad on the
piston side first with its
friction material facing
outside. NOTE:
 Install the other brake Ensure pads are positioned
pad with the friction and locked correctly in the
material facing the mounting bracket lug.
opposite brake pad.
 Apply Silicon grease on
the pin OD and assemble
the Pin bolt by pressing
gently through the
brake pads into caliper
body.
 Tighten the pins to the Brake pad pins

caliper body.
Allen key: 5mm
Torque: 20Nm (2.0Kgm)
 Assemble Grub screws Grub screws

on the pins and tighten.
Screw driver
Torque: 3Nm (0.3Kgm)

No. Instructions

13.3.3 Wheel caliper on
fork end LH
 Locate caliper on fork
end LH and ensure the
brake disc is positioned
between the brake
pads. Hex bolt: M10
 Tighten caliper assembly Socket spanner: 12mm

to fork end with 2 hex Torque: 30Nm (3.0Kgm)
bolts.

13.3.4 Master cylinder on
handle bar
 Locate master cylinder
assembly on the handle
bar.
Hex Bolts : M6
 Locate clamp on handle
Socket spanner : 8mm
bar and tighten the
master cylinder assy. To Torque : 9Nm (0.9 KgM)
handle bar with 2 hex
bolts.
 Smear the piston, seals

and cylinder bore with
fresh brake fluid and
assemble piston sub-
assembly into the
master cylinder by gently
pushing it into the bore. NOTE:
Ensure the circlip is seated
correctly inside the groove.

No. Instructions

13.3.4 Master cylinder on
handle bar
 Locate the conical spring
on the piston, compress
and assemble Circlip into
the groove of the master
cylinder.
 Assemble the rubber

Boot. CAUTION:
Do not use tools with sharp
ends.
 Apply Silicon grease on

Hex Screw
the Lever pivot hole and
on the Piston surface. Hex nut : M5
Screw driver
 Position brake lever
inside the bracket, locate Spanner: 8mm
pivot screw from the top Torque: 6Nm(0.6 KgM)
and tighten to bracket.
 Assemble lock nut below
and tighten.
 Assemble the Brake
Switch on the bracket.
 Connect the brake light
switch.

No. Instructions

13.3.5 Brake hose on
master cylinder and
wheel caliper
 Position brake hose
against the mounting
hole on master cylinder
such that it is pointing
downwards correctly..
 Locate 2 new copper
washers on either sides Banjo bolt : M8
of the brake hose banjo Socket Spanner : 12mm
and tighten with banjo Torque : 38Nm (3.8 KgM)
bolt.
 Route the brake hose
correctly from the right
side towards the wheel
caliper in fork end LH.
hole on wheel caliper
correctly.
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 Slotted screws
 Assemble the diaphragm, Screw driver
plate and cover. Torque: 15Nm(.15KgM)
 Tighten screws gently.

No. Instructions

13.3.5 Brake hose on
master cylinder and
wheel caliper
 Assemble the rear view
mirror.
 Bleed the air out of the
hydraulic brake system.

13.4.1 Piston & seals in
caliper
 Coat fresh brake fluid on
new dust seals and
piston seals.
 Install piston seals in the
inner groove and dust
seals in the outer groove
in the bore in caliper NOTE:
assembly. Do not apply force while
 Coat the caliper cylinder assembling the piston into
and piston with fresh the caliper. Press only with
brake fluid. minimal hand pressure.
 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
caliper bore outer edge.

No. Instructions

13.4.1 Piston & seals in
caliper
 Install the pad tension
spring plate in the Caliper
body.
 Assemble Bleed screw

Ring Spanner: 8 mm
with the dust cap on the
caliper body. Torque: 10Nm (0.1Kgm)
 Position the guides on

the Caliper and
mounting bracket
correctly on the rubber
boot and assemble
caliper body in the
mounting bracket

No. Instructions

13.4.1 Wheel caliper on
swing arm
 Locate caliper with
mounting bracket on
the swing arm such that
the brake disc is
correctly positioned
inside the caliper.
 Assemble wheel axle
through the caliper
bracket on the swing
arm.
 Assemble axle nut and
tighten to torque.
13.4.2 Brake pads on

wheel caliper
 Locate the brake pads
inside the caliper on
either sides of the disc
with the friction material
facing the disc.
 Locate the pivot pin

caliper correctly.
 Assemble the 2 locking

clips on the brake pad
pivot pin.

No. Instructions

 Locate new O ring inside
the master cylinder CAUTION:
bore. Do not use any sharp tool
 Assemble the spring to assemble the O ring or
guide on the small end of piston in the master
the spring. cylinder.
 Locate the peg on the

piston, on the spring
guide
 Locate large bush over
the piston.
 Insert the large end of
the spring along with the
piston and guide bush
into the master cylinder
bore and hold it in
compressed position
inside the master
cylinder.
 Assemble Circlip in the
Circlip
master cylinder body
and ensure it is locked Circlip pliers
properly in the groove
 Assemble the protective
rubber boot on the
master cylinder.

No. Instructions

 Position Master cylinder
Hex soc Hd screw:M4
on frame and ensure the
mounting holes are Allen socket:5mm
aligned. Torque: 10Nm(0.1Kg.M)
 Assemble 2 socket head
screws on the mounting
holes and tighten master
cylinder to frame.x
 Insert link rod in master
cylinder and align
mounting eyelet with
brake pedal eyelet
correctly.
 Insert lock pin from Split pin
outside and assemble
split pin on lock pin on Nose pliers
the inside.

No. Instructions

reservoir
 Align reservoir mounting
hole to frame and Hex soc Hd screw : M4
tighten with hex socket Allen key : 5mm
head screw.
 Connect rubber hose to

reservoir and master
cylinder and lock metal
clip in place firmly at
both ends.
13.4.5 Brake hose

against the mounting Brake light switch
hole on master cylinder Double end spanner:
such that it is pointing 14mm
inwards correctly.
washers on either sides NOTE:
of the brake hose banjo. Ensure proper routing of
 Assemble Banjo bolt brake hose before
with brake switch on the tightening.
brake hose banjo, and
tighten banjo to master
cylinder.
 Connect brake light
switch coupler to main
harness.

No. Instructions

13.4.5 Brake hose
 Locate rubber
grommets on the brake
hose in the clips in swing
arm
hole on wheel caliper
correctly.

washers on either sides Banjo bolt
of the brake hose banjo Ring spanner: 12mm
and tighten with banjo
bolt.
 Fill fresh brake fluid in

the Master cylinder till
“MAX” mark
 Bleed the air out of the
hydraulic brake system.

No. Instructions
13.5 Disc brake bleeding

 Ensure the bleeding
screw is fully tight.
 Fix a transparent flexible
tube of length 12" (30
cms.) firmly on the
bleeder nipple and insert
the other end into a glass
or plastic container
containing about 100ml Screw driver
of fresh brake fluid.
 Ensure the tube end is
fully immersed in the
fluid. This will prevent
atmospheric air from
getting sucked into the
caliper unit during the
bleeding process.
 Ensure the master
cylinder reservoir is filled CAUTION:
with fresh brake fluid Fill only with DOT3 or DOT4
from a sealed container brake fluid.
up to “MAX” level. Do not mix DOT 3 & DOT 4
fluids.
 Fix the diaphragm, plate
and top cover and tighten
cover just sufficiently.
 Depress brake lever /
brake pedal completely
and release fully to allow
the brake fluid to fill up in
the brake system and NOTE:
caliper. Do not tighten the cover
 Repeat above step several fully since it may be required
times while periodically to top up fluid during
inspecting the fluid level bleeding process.
in the reservoir. Top as
required to maintain
level at “MAX”
 When a slight firmness is
felt on the lever / pedal
and travels only up to
halfway, hold the lever/
pedal firmly depressed
in that position. DO NOT
RELEASE THE LEVER.

No. Instructions

 Loosen the bleeder
Bleeder Nipple: M6
screw at caliper end by ½
to 1 turn to allow air Ring spanner: 10mm
bubbles in the brake Torque: 10Nm (0.1KgM)
system to escape into
the transparent tube
connected to the nipple.
 When the bleeder screw
is loosened and air
escapes from the brake
system along with brake
fluid through the
bleeder nipple, the brake
lever / pedal will 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,
till the brake lever / pedal
movement is minimal
and locks firmly without
any sponginess in
applied position.
 Also check and ensure
there are no more air
bubbles being carried
out by the fluid while
bleeding the system.

No. Instructions

 Ensure the bleeder
Slotted screw
screw is tightened fully
and fix the dust cap. Philips head Screw driver
 Check and top up brake Torque: 1.5Nm (0.015KgM)
fluid in the master
cylinder reservoir up to
For front brake master

cylinder
 Assemble diaphragm,
plate and top cover and NOTE:
tighten with 2 slotted Check and ensure there is no
screws on the front sponginess of the brake
brake master cylinder. lever / pedal when brakes
are applied.
Carry out a road test to
For front brake master
check the braking efficiency.
cylinder
Check for any leaks at the
 Tighten the cover firmly banjo or the bleeding screw
on the reservoir in the areas and ensure all
rear brake master tightness of all fasteners.
cylinder.

SECTION 14 – EVAPORATIVE EMISSIONS
HIMALAYAN MODEL
10
10
9
11
12
19
13 10
10
14
12
3
1
2
17
8
12 16 2 18
7 15
12 5
6
2
4
1 Skid plate with Canister pad 1 11 Hose- Canister to Purge valve 1

2 Flanged Hex Bolt M6 X 1 X 10 6 12 Hose-Clip 6
3 Hex.Socket Button Head Screrw M6 X 1 X 12 5 13 Purge Valve 1
4 Bracket Assy- Canister mounting 2 14 Grommet- Purge Valve 1
5 Rubber Strap- Canister 1 15 Hose- Canister to T Connector 1
6 Canister Assy 1 16 Bracket Assy- Purge Valve 1
7 Clip 1 17 T Connector 1
8 Hose- Air vent 1 18 Hose- T Connector to Purge Valve 1
9 Hose- Purge Valve to Throttle body 1 19 Hose- Fuel tank to Purge Valve 1
10 Hose-Clip 4

LOCATION OF EVAP IN MOTORCYCLE
The canister is connected to the fuel tank to trap all the fuel vapours that build up in the fuel tank .
HIMALAYAN
Location : Located on Skid Plate.

PURGE VALVE
The purge valve is a mechanically controlled one way valve. When the engine is off, the purge valve is closed. When the
engine is started, the vacuum created in the suction port is used to open this one way valve and allow the vapors to
go into the inlet port.
The Evaporative emission control system EVAP fitted in our motorcycles prevents gasoline vapors from escaping
into the atmosphere from the fuel tank.
As soon as the motorcycle is parked after riding or parked under the sun, the hot radiation from the engine / sunlight
causes the fuel in the tank to warm up and releases fuel vapors.
The EVAP system prevents these fuel vapors recycled to engine to avoid vapor into the atmosphere and stored in a
charcoal canister.
As soon as the engine is started, these vapours are purged from the canister, into the combustion chamber.
The system consists of a canister, purge valve, rubber hoses, connectors and a sealed fuel tank cap.

No. Instructions
1. Canister
 Loosen 6 hex. bolts

Hex Bolt : M6
mounted on skid plate
on LH, RH & Top Portion Socket Spanner : 8mm
of the skid plate.
 Loosen 5 hex. screws Hex Soc. Head Screw : M6
mounted on canister
assy. & Purge valve. Allen Key : 5 mm
 Gently remove the 2

canister bracket assy
along with rubber strap
 Gently remove the
canister from the skid
plate assy.with the
hoses.

INSPECTION
Inspect rubber hoses and joints periodically for any cuts cracks or fractures. Replace if damaged.
Inspect Canister periodically for any damage to its body cuts or cracks.
Replace all rubber hoses and connectors every 12,000 Kms.
TORQUE CHART
Torque Range
Aggregate Component Fastener
NM Kg-M
Canister Canister Assembly Bracket Hex. Flange bolt M6 X 1 X 20 10 1.0

No. Instructions
1. Canister
 Locate canister assy on

the skid plate along with
the hoses.
 Locatge the canister
bracket assy. on the skid
plate along with rubber
strap.
 Install 5 hex screws okn Hex Soc. Head Screw : M6

canister assy. & purge
valve. Allen Key : 5 mm
 Install 6 hex bolts on skid

plate LH, RH & Top Hex Bolt : M6
portion.
Socket Spanner : 8mm
Torque : 10 Nm

SECTION 15 -
ENGINE MANAGEMENT SYSTEM (EMS)

The EMS consists of an Electronic Control Unit (ECU) which constantly receives inputs like engine temperature,
ambient temperature, throttle position, manifold air pressure, exhaust emissions through the various sensors
provided to optimize the air fuel ratio AND crank position (from the crank position sensor) in relation to the engine
RPM to optimize the ignition advance for proper combustion of the air fuel mixture.
This is very essential for:
- Compliance with BS IV regulation related to exhaust emissions
- Optimum fuel efficiency and power output
- Excellent cold start ability and sustained high speed drive ability.
FUNCTIONAL DIAGRAM OF THE EMS
Provides
inputs TO
ECU.
Has a two
way
communi-
cation with
ECU
Receives
inputs from
ECU
In addition to optimizing engine performance, the ECU also has an inbuilt memory by which any EMS related
malfunctions will get stored and help diagnose the fault accurately.
There is also an inbuilt safety system, which, in the event of the motorcycle’s banking angle is below 60o OR is involved
in an accident causing the motorcycle to fall over on either of its sides with the gears engaged and the engine running,
both the fuel supply and ignition will be cut off to stop the engine and prevent any further damage from being caused.

SPECIFICATIONS / FUNCTIONS OF THE VARIOUS EMS PARTS
1. ELECTRONIC CONTROL UNIT (ECU)
LOCATION
The Electronic Control Unit (ECU) is located under the seat.
SPECIFICATION
Operating Voltage: 8 – 16 V
Sensor Supply Voltage: 5 V
Operating temperature: –10ºC to + 60ºC
Storage Temperature: –20ºC to + 80ºC
The ECU consists of a microprocessor with two memories Flash Memory and E2 PROM.
Flash memory is an exclusive recording unit. It collects different inputs from various sensors and calculates optimized
values and provides the outputs to the respective controlling devices.
E2PROM is an abbreviation for Electronically Erasable Programmable Read Only Memory. This memory records
information related to performance of the various sensors in the EMS on a real time basis AND also records any sensor
failures if it occurs during operation of the motorcycle.
The main advantage of E2PROM is it records data, even when the motorcycle’s electrical system is switched OFF.
This will help in diagnosing the motorcycle performance and also to view the history and defect codes, whenever the
Royal Enfield NACS II diagnostic tool is connected to the socket in the wiring harness of the motorcycle.
Once the defect is diagnosed and corrected, the history of the defect can be erased using the Royal Enfield NACS II
diagnostic tool.

ECU LAYOUT ECU PIN DETAILS
Pin No. Name Function
1 IGP Ignition Power
2 LG Logic Ground
3 HEGO HEGO Sensor
4. SG Sensor Ground
5 TH Throttle Position Sensor
6 VCC Sensor Power Output (+SV)
7 - -
8 FP Fuel Pump
9 PG1 Power Ground1
10 PG2 Power Ground2
11 IG Ignition Coil
12 CRK-P Crank Pulse Sensor
13 - -
14 TA Air Temperature
15 TEST Test Switch
16 INJ Injector
17 VSP Vehicle Speed Sensor
18 - -
19 - -
20 - -
21 - -
22 MIL Multi Indicator Lamp
23 CRK-M Crank Pulse Sensor GND
24 TW Engine Temp. Sensor
25 SSTAND Side Stand Switch
26 ROLL Roll Sensor
27 PM Manifold Pressure Sensor
28 EXAJ Exhaust Air Injection
29 NLSW Neutral Switch
30 K-LINE Diagnostic Tool
31 - -
32 - -
33 HEGO HT HEGO Sensor Heater

2. CRANK POSITION SENSOR
LOCATION
The crank position sensor sends an alternating voltage signal to the powertrain control module, which is used to
determine engine speed and ignition timing. Thus the speed of the engine is instantly known by the ECU.
SPECIFICATION
Output Voltage: 3 - 5 V AC.
Resistance : 200+20 Ω
It provides an alternating electrical pulse to the ECU, to determine crankshaft speed and TDC position by scanning
the 17 pips and 1 long gap between 2 particular pips on the rotor. This input helps the ECU to optimize both fuel
injection as well as Ignition advance required to suit the crankshaft rotation speed (RPM).
In the event the throttle is held wide open with gears in neutral, leading to crankshaft speed above 5500 RPM, the
high frequency electrical pulses from the crank position sensor will prompt the ECU to restrict fuel supply so that the
crank speed reduces below 5000 RPM. This is a safety aspect to prevent damage to moving engine parts.
3. ENGINE TEMPERATURE SENSOR

LOCATION
The engine temperature sensor (EOT) is located on the cylinder head, below the inlet manifold on the oil passage.
SPECIFICATION
Operating Temperature: -55°C to + 250°C
R e s i s t a n c e : 2 5 d e g ( 1 0 K Ω) 5% and Resistance at 80deg (1.63K Ω) 5%
Sensor Supply Voltage: 5V
It senses the oil temperature and provides the input to the ECU on a real time basis. The ECU can then determine the
fuel injector operating time to provide the required amount of vaporized fuel into the combustion chamber for
optimum performance of the motorcycle and also to meet the emission norms.

4. O2 SENSOR
LOCATION
The HEGO sensor is located on the exhaust down pipe, just after the cylinder head.
SPECIFICATION
Operating Voltage : 16V (Max)
Operating temperature: 600ºC - 950ºC
It detects residual oxygen in the exhaust gases versus the amount of oxygen in the atmosphere and provides the
data on a real time basis to the ECU based on which the fuel injection is metered continuously to control exhaust
emissions and for optimum performance of the motorcycle.
5. EXHAUST AIR INJECTION UNIT (SOLENOID)

LOCATION
The exhaust air injection unit (EXAI) is located underneath the fuel tank.
SPECIFICATION
Operating voltage : 10 V to 14.5 V
Operating Temperature: - 20°C to +120°C
In addition to the Hego sensor, the EXAI gets inputs from the ECU to supply filtered air into the exhaust end of the
cylinder head, primarily during idling RPM so as to meet exhaust emission specifications.

6. THROTTLE BODY
LOCATION
The throttle body is located below the fuel tank, between the intake side of the cylinder head & the air filter assembly.
SPECIFICATION
Operating Voltage: 5 V.
Out Put Voltage: 0 – 5V.
Throttle Angle : 0 – 80º
Resistance Maximum: 5 K Ω
Out Put at Idling: 0.6+0.2V.
Operating Temperature: –20ºC to +80ºC
It consists of a throttle plate (butterfly valve) to regulate the airflow into the cylinder head depending on the throttle
opening and a manual Bi Starter which helps control idling RPM in extreme cold conditions.
The throttle body also has a throttle position sensor (TPS) and manifold absolute pressure sensor (MAP).
7. THROTTLE POSITION SENSOR (TPS)

LOCATION
Throttle Position Sensor (TPS) is located on the throttle body at the end of the butterfly valve spindle to monitor the
position of the butterfly valve.
SPECIFICATION
Max Resistance : 5 K Ω
Operating Temp : - 20°C to +80°C
Supply Voltage : 5 V
The sensor consists of a potentiometer and provides a variable resistance depending upon the position of the
butterfly valve to the ECU. This helps the ECU to regulate the fuel injector opening duration to provide the required
amount of vaporized fuel into the combustion chamber for optimum performance of the motorcycle.

8. MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP)
LOCATION
The Manifold Absolute Pressure Sensor (MAP) is located on top of the throttle Body.
SPECIFICATION
Operating Temperature: -20°C to +80°C
Supply Voltage: 5 V
The MAP sensor monitors the manifold pressure at the intake end and provides data to the ECU on a real time basis.
This helps the ECU to calculate the air density and the air inflow rate and determines the fuel injector opening duration
to provide the required amount of vaporized fuel into the combustion chamber for optimum performance of the
motorcycle.
9. AMBIENT AIR (TA) SENSOR

LOCATION
The TA sensor is located on the rear side of the filter box assembly in Bullet EFI, Classic EFI, Thunderbird EFI models
and on the outlet pipe of the air filter housing in Continental GT models.
SPECIFICATION
Supply Voltage: 5 V+0.5 V
The ambient temperature input is provided to the ECU on a real time basis, based on which the ECU determines the
fuel injector operating time to provide the required amount of vaporized fuel into the combustion chamber for
optimum performance of the motorcycle.

10. FUEL PUMP ASSEMBLY
LOCATION
The fuel pump is located on the left side bottom of the fuel tank and submerged in the fuel so that it cannot ignite itself
due to any electrical short circuits. The fuel pump has an inbuilt micro filter which helps to filter even the minute dust
particles that may come in the fuel.
SPECIFICATION
Operating Voltage: 6 V to 15 V
Fuel Pressure: 294 Kpa
As soon as the Ignition switch and the engine kill switch are in ON position, the fuel pump creates a positive pressure
of 294KPa in the fuel line and up to the injector. The fuel pump operation is determined by the ECU so that there is no
excessive pressure in the fuel system to prevent damage to the fuel injector, fuel hose. Any excess pressure is bypassed
back into the fuel tank.
11. FUEL INJECTOR

LOCATION
The fuel injector is located at an angle on the intake side of the cylinder head so as to maximize fuel spray and minimize
wall wetting, for optimum performance of the motorcycle.
SPECIFICATION Injector
Operating Voltage : 10 V to 16 V
Operating Temperature : -30°C to +120°C
Fuel Pressure : 343 Kpa
Resistance : 10.3 +0.5 Ohms
The Fuel Injector is a solenoid operated electromagnetic valve, which enables the pressurized fuel delivered by the
fuel pump, to be atomized and sprayed into the cylinder head combustion chamber.
The fuel injector operation and duration to deliver vaporized fuel is controlled by the ECU based on the critical
operating inputs received from the crank position sensor, EOT sensor, ambient air temperature sensor, throttle
position sensor, manifold pressure sensor and HEGO sensor.

12. EFI ECU POWER & SIDE STAND RELAYS
LOCATION
There are two identical relays located under the seat.
SPECIFICATION
Operating Voltage : 10 V to 16 V
Operating Temp : - 30 ° C to + 120 ° C
Fuel Pressure : 343 Kpa
Resistance : 10.3+0.5 Ohms
The EFI ECU Power relay supports functioning of the ECU and fuel pump. The Side stand relay provides the inputs
regarding the position of the side stand to the ECU. In the event the side stand is NOT retracted and the motorcycle
is attempted to be started, it signals the ECU which cuts off the fuel supply thus preventing the engine from starting.
13. ROLLOVER SENSOR

LOCATION
The rollover sensor is located on the frame under the seat.
SPECIFICATION
Operating voltage : 10 V to 14.5 V
Operating Temp : - 20 ° C to + 120 ° C
The rollover sensor, also known as a “banking” sensor, is a safety feature. If the banking angle of the motorcycle goes
below 60o OR in the event of an accident causing the motorcycle to fall over on either of its sides with the engine
running, the rollover sensor will “command” the ECU to cut off both the fuel supply and ignition, thus stalling the
engine to prevent any further damage from being caused by the engine that may be running with a stuck open throttle
and the gears engaged.
To re activate the system, the motorcycle should be made upright in its centre stand position, the ignition switch and
stop switch must be switched OFF and switched back ON after a few seconds. This will help to RESET the rollover
sensor.

14. MALFUNCTION INDICATOR LAMP (MIL)
LOCATION
Malfunction Indicator Lamp (MIL) is located in the small meter on the Headlamp casing
When both the Ignition & Engine kill switch is “ON” and after vehicle
is started, MIL will glow for few seconds and switch OFF, this indicates
that all the functions of EMS are functioning correctly.
In the event of any malfunction the MIL will glow continuously. The
EMS should be checked using either the test pin method OR the
Royal Enfield NACS II diagnostic tool connected to the socket in the
wiring harness of the motorcycle.

S. Aggregate to Dismantle /
No. Instructions
4.1 Electronic Control
Unit (ECU)
Himalayan
 The ECU is located under
the fuel tank.
OFF position.
 Unlock side panel LH and
remove the panel LH.
 Gently pull seat latch
cable to release seat and
remove seat.
 Gently pull out the ECU
from the rubber housing
located in the frame.
 Gently release lock and
disconnect the wiring
coupler from the ECU.
 Remove ECU.

No. Instructions
4.2 Crank position
sensor
 The Crank position
sensor is located inside CAUTION:
the cover RH of the  Ensure stator coupler is
engine assembly. disconnected before
 Drain engine oil from the removing cover RH.
engine.  Gently tap on the tabs
 Ensure Ignition switch provided in the front
and stop switch are in and rear of Cover RH to
OFF position. release the cover from
 Disconnect Magneto the crankcase.
wiring coupler from the
electrical harness.
Hex Flange Bolt M6 X 1 X
85 from cover RH front.
70 from cover RH, top,
centre and bottom.
45 from cover RH rear.
 It may be necessary to
gently tap and remove
cover RH as the magnetic
forces in the rotor can be
acting on the stator and
making it difficult to
remove.
 Remove gasket.
 Remove 2 Hex Flange
Bolt M5 X 0.8 X 16,
holding Pulsar coil to
cover RH inside.
 Remove 3 Hex Socket
Head Cap Screw M5 X 30,
holding stator coil to
cover RH inside.

No. Instructions
4.3 Engine Temperature
Sensor
 The Engine temperature
sensor is located on the Deep Groove Socket bit:
cylinder head right side, 17mm
below the inlet manifold.

OFF position Disconnect
wiring harness coupler
from the sensor.
 Gently Loosen engine

temperature sensor and
remove along with ‘O’
ring.

No. Instructions
4.4 O2 Sensor
 The Hego sensor is

Deep Groove Socket:
assembled on the inner
21mm
side of the exhaust
down pipe near the
cylinder head.
OFF position.
the sensor.
 Loosen Hego sensor and
remove along with
copper washer from the
exhaust down pipe.

No. Instructions
4.5 Exhaust Air
Injection Unit (EXAI
Solenoid)
 The EXAI Solenoid is
located on the frame Gland Nut Double end
under the fuel tank spanner: 16mm
along with the reed
Soc Hd Cap Screw: M5X20
valve.
 Ensure Ignition switch Allen Key 4mm
Hex Screw M6 X 16
OFF position.
Socket spanner: 8mm
the EXAI solenoid.
 Release the 2 clips on the
Inlet and outlet pipes
connected to the EXAI
solenoid, and dis-
connect the pipes.
 Loosen Gland nut at

cylinder head end and
disconnect braided
hose connecting reed
valve to cylinder head.
 Remove the 2 Hex
Screws holding the reed
valve mounting bracket
to frame and remove
along with EXAI
solenoid.
 Remove socket head cap

screw holding the EXAI NOTE:
solenoid to the reed
Ensure spacer between the
valve bracket. EXAI solenoid & bracket is
removed.

No. Instructions
4.6 Throttle Body
 The throttle body is

located between the
cylinder head inlet and
the air filter outlet hose.
OFF position.
 Disconnect TPS and

MAP wiring couplers.
 Slacken the locknuts on

the adjusters and remove
throttle cables from the
throttle body. - Adjuster Nuts
 Disconnect rubber hose Double end spanner:
connecting throttle 12mm
body to the EVAP canister. - Hose clip screws: Flat
 Disconnect manual Bi screw driver
Starter cable from
throttle body by
loosening and removing
the plastic nut on LH
side.
 Loosen hose clip on air
inlet rubber hose. NOTE:
 Loosen hose clip on The throttle position sensor
Adaptor between (TPS) and Manifold
throttle body and Absolute Pressure Sensor
cylinder head. (MAP) are not serviceable
and hence should not be
 Remove throttle body
removed from the throttle
by gently sliding it out of
the inlet bellow and body.
adaptor.

No. Instructions
4.7 Ambient Air (TA)
Sensor
Himalayan Hex Soc Hd Cap Screws:

 The TA sensor is assembled M5 X 20
on the pipe outlet bet- Allen Key: 4mm
ween air filter housing
and Throttle body.
OFF position.
 Remove seat assembly
 Disconnect the wiring
coupler from the TA Philips head screws
sensor. Philips Screw driver
 Using a long reach Philips
head screw driver,
loosen and remove the 2
screws, holding TA
sensor to pipe outlet.
 Remove TA sensor along
with gasket, from pipe
outlet.

No. Instructions
4.8 Fuel Pump
Assembly
 The fuel pump assembly CAUTION:
is located inside the fuel
tank at the left side, rear  Store fuel in a tight
bottom. sealed container in a
well ventilated, cool
 Ensure Ignition switch and dry place.
OFF position.  Do not smoke or allow
open flame or sparks in
 Remove Seat assembly the vicinity.
and fuel tank.
 Loosen & remove 5 Hex NOTE:
Socket Button Head Cap Ensure Ignition switch and
Screws along with the engine kill switch are in OFF
copper & fibre washers. position
 Remove clamp plate. Drain fuel completely from
fuel tank before removing
 Pull out fuel pump from fuel pump.
the fuel tank.
 Take care to remove the
O ring from the fuel tank. Hex Soc Button Hd Cap
Screws: M6 X 12
Socket spanner: 8mm

No. Instructions
4.9 Fuel Injector
 The fuel injector is

Hex U nut: M6 X 1
assembled on the inlet
side of cylinder head Ring spanner: 8mm
below the fuel tank.
OFF position.
 Remove Seat assembly
and fuel tank.
coupler from the fuel
injector.
 Loosen worm clip on the
inlet fuel hose and
remove fuel hose from
cap injector assembly.
 Remove hex nut from
top of injector cap
assembly and remove
injector cap along with
“O” ring.
 Remove the spacer from
the stud.
Injector from the
cylinder head.

No. Instructions
4.10 EFI ECU Power &
Side Stand Relays
Himalayan
 Two identical relays are
located near the battery.
 Located in a rubber
holder on the side of the
battery carrier.
OFF position.
 Remove side panel LH.
 Gently pull out relay
from the rubber holder
and electrical socket.

No. Instructions
4.11 Roll Over Sensor
 Located below the seat

Hex Soc Hd Screw: M6
on the frame.
Allen Key: 5mm
and engine stop switch
are in OFF position.

coupler from the sensor.
hex socket screw holding
the sensor to the frame
and remove the sensor.

No. Instructions
4.12 Malfunction
Indicator Lamp
Himalayan
 Located in the RPM
meter in the instrument
cluster.
 The instrument cluster
does not have any
individual serviceable
parts.

S. Aggregate to Assemble /
No. Instructions
4.13 Electronic Control
Unit (ECU)
Himalayan
 Locate ECU under the
Fuel tank.
 Connect the wiring
coupler on the ECU and
gently lock.
 Gently push the ECU on
its rubber housing
located in the frame.
 The ECU is located under
the seat.
 Locate seat on the frame
and push it for proper
seating.
 Locate the side panel LH
and lock side panel LH.

No. Instructions
4.14 Crank position
sensor
 Locate Crank position
sensor inside the cover
RH of the engine
assembly.
CAUTION:
 Install 3 Hex Socket Head
Cap Screw M5 X 30, on  Ensure stator coupler
stator coil to cover RH is disconnected before
inside. removing cover RH.
 Install 2 Hex Flange Bolt  Gently tap on the tabs

M5 X 0.8 X 16, on Pulsar provided in the front
coil to cover RH inside and rear of Cover RH to
release the cover from
 Locate gasket. the crankcase.
 Install and tighten 1 Hex
Flange Bolt M6 X 1 X 45
on cover RH rear
on cover RH, top, centre
and bottom.
on cover RH front.
 Connect Magneto wiring
coupler in the electrical
harness.
 Fill engine oil.

No. Instructions
4.15 Engine Temperature
Sensor
 Locate engine
Deep Groove Socket bit:
temperature sensor
17mm
along with ‘O’ ring on the
cylinder head right side
below the inlet manifold.
OFF position, Connect
on the sensor.

No. Instructions
4.16 O2 Sensor
 Locate Hego sensor

Deep Groove Socket:
along with copper
21mm
washer on the exhaust
down pipe near the
cylinder head.
OFF position.
 Connect wiring harness
coupler on the sensor.

No. Instructions
4.17 Exhaust Air
Injection Unit (EXAI
Solenoid)
 Locate socket head cap
screw on the EXAI Gland Nut
solenoid to the reed Double end spanner:
valve bracket. 16mm
Soc Hd Cap Screw: M5X20
 Install the 2 Hex Screws
on the reed valve Allen Key 4mm
mounting bracket to Hex Screw M6 X 16
frame.
Socket spanner: 8mm
 Locate EXAI Solenoid on
the frame under the fuel
tank along with the reed
valve.
 Install Gland nut at

cylinder head end and
connect braided hose
connecting reed valve to
cylinder head.
 Connect 2 clips on the

Inlet and outlet pipes NOTE:
connected to the EXAI
solenoid. Ensure spacer between the
EXAI solenoid. & bracket is
 Ensure Ignition switch removed.
OFF position, Connect
in the EXAI solenoid.

No. Instructions
4.18 Throttle Body
 Locate throttle body

between the cylinder
head inlet and air filter
outlet house.
 Gently slide throttle
body on the inlet bellow
and adaptor.
 Locate hose clip on
Adaptor between
throttle body and cylinder
head.
 Locate hose clip on air
inlet rubber hose.
 Connect manual Bi
Starter cable on throttle
body by tightening and
locating the plastic nut
on LH side.
 Connect rubber hose
from throttle body to - Adjuster Nuts
the EVAP canister. Double end spanner:
12mm
 Locate the locknuts on
the adjusters and locate - Hose clip screws: Flat
throttle cables on the screw driver
throttle body.
OFF position.
 Connect TPS and MAP NOTE:
wiring couplers. The throttle position sensor
(TPS) and Manifold
Absolute Pressure Sensor
(MAP) are not serviceable
and hence should not be
removed from the throttle
body.

No. Instructions
4.19 Ambient Air (TA)
Sensor
Himalayan
 Locate TA sensor along

with gasket on pipe
outlet between air filter
housing and throttle
body.
Hex Soc Hd Cap Screws:
 Using a long reach Philips
M5 X 20
head screw driver, Install
2 screws, holding TA Allen Key: 4mm
sensor to pipe outlet.
and stop switch are in Philips head screws
OFF position. Philips Screw driver
coupler in the TA sensor.
 Assemble seat assembly

No. Instructions
4.20 Fuel Pump
Assembly
 Locate the O ring in the
fuel tank.
NOTE:
Ensure Ignition switch and
 Locate fuel pump engine kill switch are in OFF
assembly inside the fuel position.
tank at left side.
 Install clamp plate.
 Install 5 Hex Socket

Button Head Cap Screws Hex Soc Button Hd Cap
along with the copper & Screws: M6 X 12
fibre washers. Socket spanner: 8mm
 Assemble Seat assembly

and fuel tank NOTE :
In three times operation of
kill switch in ignition on
condition, 210 ml to 240ml
of fuel should get collected.

No. Instructions
4.21 Fuel Injector
 Locate fuel Injector on Hex U nut: M6 X 1

the inlet side of the
cylinder head below the Ring spanner: 8mm
fuel tank.
 Locate the spacer in the
stud.
 Locate hex nut from top
of injector cap assembly
and place injector cap
along with “O” ring.
 Locate worm clip on the
inlet fuel hose and locate
fuel hose on cap injector
assembly.
OFF position.
coupler from the fuel
injector.
 Assemble Seat assembly
and fuel tank.

No. Instructions
4.22 EFI ECU Power &
Side Stand Relays
Himalayan
OFF position.
 Gently push the two
identical relays in the
rubber holder and
electrical socket.
 Locate in a rubber holder
on the side of the battery
carrier.
 Locate side panel LH.

No. Instructions
4.23 Roll Over Sensor
 Locate the hex socket

Hex Soc Hd Screw: M6
screw on the sensor to
the frame and install the Allen Key: 5mm
sensor which is located
below the seat on the
frame.

coupler from the sensor.


No. Instructions
4.24 Malfunction
Indicator Lamp
Himalayan
 Locate the RPM meter in

the instrument cluster.
 The instrument cluster

does not have any
individual serviceable
parts.

EMS FAULT DIAGNOSIS & TROUBLE SHOOTING
NOTE:
 During diagnosis the motorcycle should be parked in its center stand, the side stand in fully retracted
position and with the gears in neutral .
 The battery should be in fully charged and proper working condition.
 There should be no external electrical sources or interferences near the motorcycle.
TYPES OF DIAGNOSIS
There are three levels of identifying a malfunction in the ECU or the sensors.
LEVEL 1 VISUAL
As soon as the ignition switch, engine stop switch are in ON position and the side stand is in fully retracted
position, the MIL will glow and will switch OFF after a few seconds after the engine is started. This indicates the
EMS system is in its auto diagnostic mode and the EMS is working perfectly.
In the event the MIL glows continuously and does not switch off, it indicates a malfunction in the EMS.
LEVEL 2 TEST PIN

In the event the MIL is continuously ON and does not switch OFF, the test pin method will help narrow down to
the sensor / electrical connection that caused the malfunction.
LEVEL 3 GENERIC SCAN TOOL (NACS II DIAGNOSTIC TOOL)

A generic scan tool supplied by Royal Enfield will help identify the exact cause of the malfunction in the EMS,
when connected between the motorcycle and a computer.
The tool will take inputs from the ECU and provide to the computer to display the defect code that will help
identify the specific sensor/connections.
In addition the generic scan tool can also help download the history of the vital parameters of the EMS, engine
performance and earlier defects for detailed analysis and records.
The generic scan tool will also be able to erase previous defects after the same has been rectified.
METHOD OF CHECKING
LEVEL 1 VISUAL
 Switch OFF the ignition and engine stop switch.
 Check for any loose coupler connections at the sensor end. Correct loose connections if any.
 Switch ON ignition and engine stop switch. Ensure side stand is fully retracted.
 Check for MIL Indication in the cluster/Console.
- Start the engine.
- Allow engine to run in idling RPM for about 30 seconds and switch off engine.

- Repeat the above process for 2 more times.
- Ensure MIL Indications goes off after above method.
- This will help to recalibrate the MIL and store the error code in the ECU.
 If in case the defect is not eliminated and the MIL glows continuously, proceed to level 2 test pin method
to resolve the defect.
LEVEL 2 TEST PIN METHOD

An open single pole connector is provided close to the UCE.
 Connect a piece of wire to this connector and suitably ground it to the motorcycle body.
 Switch ON ignition and engine stop switch and observe the MIL keenly for a series of short and long blinks
at different intervals, to identify the defective sensor / wiring connection as detailed in the table below,

MIL BLINK CODES DESCRIPTION
MIL BLINK MALFUNCATION INDICATION
MIL will glow continuous. Engine will start but not perform to its potential
Long 0 Short 6 Throttle position sensor Malfunction
Long 0 Short 9 Manifold Air Pressure sensor Malfunction
Long 1 Short 2 Engine oil temperature sensor Malfunction
Long 1 Short 3 Intake Air temperature sensor Malfunction
Long 1 Short 7 O2/HEGO Sensor Malfunction
Long 4 Short 5 O2 Sensor heater circuit Malfunction
Long 5 Short 4 EXAI Circuit Malfunction
MIL will glow continuous. Engine will NOT start but will crank
Long 6 Short 6 Crankshaft position sensor Malfunction
Long 1 Short 5 Roll over sensor Malfunction
Long 3 Short 3 Fuel Injector Circuit Malfunction
Long 3 Short 7 Ignition Coil Circuit Malfunction
Long 4 Short 1 Fuel pump relay circuit Malfunction
Long 7 short 0 Vehicle/Wheel speed sensor Malfunction( only for Continental GT Model)
LEVEL 3 GENERIC SCAN TOOL METHOD

When the fault is detected, the GST raises a flag to conform readiness Permanent/Confirmed/Pending DTC. If
some DTCs are defined for a sensor or device, a readiness for the sensor or device is judged as formed when
one of readiness for the DTCs is formed.
 NACS II Diagnostic Tool can read the error codes (P – codes in the adjacent table) to easily diagnose the
system causing the malfunction.
 It can also be used to capture engine data for future reference for saving data regarding issues of engine
malfunction before in the process of resolving engine malfunction.

DIAGNOSTIC TROUBLE CODES DESCRIPTION
Items Parameters Description DTC
Too low input voltage P0120

Throttle position sensor TH
Too High input voltage P0123

Manifold Air Pressure sensor PM

Engine Oil Temperature Sensor TW

Intake Air Temperature Sensor TA
Too low input voltage

Rollover Sensor RO P1630
Too High input voltage
Short circuit to ground or open

O2 Sensor HG
circuit (low or open) P0130
Short circuit to ground or open circuit

Fuel Injector IJ1 P0201
Short circuit to Battery

Ignition Coil IG1 P0351

Fuel Pump Relay FLR P0230

O2 sensor Heater HR P0030
(low or open)
Vehicle / Wheel speed sensor VSP The Sensor circuit malfunction P0500
AIR System Switching Valve EXAI Short circuit to ground or open circuit
P0412
“A” Circuit (low or open)
Crankshaft position sensor CRK The Sensor circuit malfunction P0335

INSTRUCTIONS (DO’S & DON’T’S)
1) DO NOT remove any of the sensor connections / couplers / Battery connections when the Ignition switch is ON OR
the engine is running.
2) DO ensure the battery is in good condition & Fully Charged Battery.
3) DO start the engine only when it is in centre stand or when rider sitting on the vehicle with both the stands
retracted. (Engine will NOT Start OR switch OFF if side stand is extended).
4) DO NOT rev the engine fully – immediately after starting OR just before shutting off the engine.
5) DO NOT remove the fuel hose (high pressure) from the fuel pump to fuel injector, when engine is running OR with
the ignition switch ON. Fuel flows at a very high pressure during these times.
6) DO NOT use a booster or high voltage-charging unit instead of a battery. Use only a good, correctly charged
battery to start OR check the motorcycle.
7) DO NOT use high pressure water jet to clean the ECU / Throttle Body / any of the sensors. Keep them well protected
while washing the vehicle.
NOTE :
Since this BS IV vehicle has AHO function, while using NACS II tool thehead lamp fusecan be removed to avoid the
battery drain.

SECTION 16 - ELECTRICAL COMPONENTS

STARTER MOTOR
TECHNICAL SPECIFICATIONS
System / Battery 12V DC / 12V 14 Ah
Starter Motor 0.9 KW
Solenoid Switch Magnetic Relay type
INSPECTION
Ensure earth terminal is located on the outside hex flange bolt of the starter motor before tightening both bolts.
RELAY STARTER
WIRING LAYOUT
Schematic Diagram - Relay

INSPECTION
1. COIL RESISTANCE CHECK
a. Set the Multimeter in Resistance check mode.
b. Keep the positive (Red) probe of the Multimeter on coil positive and Negative probe (Black) of the Multimeter on
coil negative.(Refer the below table for polarity identification).
c. Resistance Spec unit – 3.96 c
d. If resistance deviates from the specification or if coil is open/short, Relay starter to be replaced.
Sl.No. BS IV Coil Polarity & Wire Color

1. Classic 500 Coil +ve = Blue
Model Coil -ve = White
2. GT Coil +ve = Brown / Green

Model Coil -ve = Brown / Blue
1. TO CHECK - CONTACT CLOSURE AFTER ENERGISING:

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) using Multimeter. If the Multimeter indicates 0Ù with a beep sound, the contacts have got closed. If the
Multimeter indicates as open (OL) ,contacts have not closed and hence the Relay starter has to be replaced.
Starter motor +ve eyelet terminal
Energised the relay

Battery +ve terminal using battery

RR UNIT
INSPECTION
STEP 1 :
Check the condition of the six diodes used in the RR Unit.
Take the Multimeter and change the mode to diode check mode. Diode mode would be available in continuity mode.
NOTE :
Before checking the diode, internal capacitor of RR unit to be discharged. Else, the diode drop will not be correct. So
short the positive and negative terminal of RR Unit DC output(black and red wires) to discharge the capacitor.
STEP 2 :
To check the condition of 3 positive diodes of RR unit, keep the positive probe (Red) of the multimeter in any one of
the 3phase terminals (yellow wire inserted in black/red connector) and the negative probe (Black) of multimeter on
the positive terminal of DC output (red wire inserted in two pole connector) and check for the condition of diode as
shown in the below image.
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.
3 Phase AC Terminals

STEP 3 :
The positive probe of the multimeter shall be kept on all the 3 phase terminals one by one and the
condition of the 3 diodes to be checked as mentioned in Step 2.
STEP 4 :
To check the condition of other 3 negative diodes, positive probe (Red colour) of the multimeter shall be kept on the
negative 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.
STEP 5 :
All the three diodes to be checked by keeping the multimeter negative probe on all the 3 phase terminals one by one.
If the RR Unit is not working, replace with good working RR Unit.

SUPRESSOR CAP
INSPECTION
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.

FLYWHEEL MAGNETO
INSPECTION
A) PHASE TO PHASE RESISTANCE CHECK
1. Phase to phase resistance of the magneto shall be checked by setting multimeter in resistance mode.
2. Phase to Phase resistance – 1.5 +/-15% (0.59 to 0.79 ohms)
3. If the resistance deviates from the spec, then cover shall be opened and checked if stator coil has burnt. If stator
coil is burnt then replace the 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, keep the multimeter in continuity mode and check continuity between any
3 phase terminals and engine body. If there is a body short(insulation failure), multimeter will indicate 0ohms (or
resistance value ~ 50 ohms) with a beep sound.
If insulation failure is observed, failed magneto to be replaced with new magneto.
2. During visual inspection, if stator coil has burnt, magneto shall be replaced with new magneto.

SL
COMPONENT PART NOS SPECIFICATION
NO
1 IGNITION COIL(350cc) Ignition coil RH-1040217 Primary resistance – 4.5 + 10%
Ignition coil LH-581027 Secondary resistance – 13.5k + 10%
IGNITION COIL 1010013 – CLASSIC 500 Primary resistance – 2 + 10%
(500cc/535cc)- 1010022 – GT Secondary resistance – 13.5k + 10%
High energy coil
2 FLYWHEEL MAGNETO 572385 – (Varroc) Stator coil Phase to Phase resistance –
ASSY (350CC) 572384 – (Ducati) 500m + 15% (Varroc)
585m + 10% (Ducati)
FLYWHEEL MAGNETO 1040062 – (Ducati) Stator coil Phase to Phase resistance –
ASSY( 500CC/535cc 660m + 10%
COMPARISON
SL
SHUNT RR EXISTING SERIES RR
NO
In a shunt Rectifier and Regulator the control In a series Rectifier and Regulator the control
1
element is connected in parallel to the load. element is connected in series to the load.
The excess power from the magneto is returned The excess power will not be returned back to the
2
back to the source through the control element source
When magneto output voltage goes beyond The control device gets turned OFF when the
the setting voltage (Eg: 14.5±0.2V) the control magneto o/p volatge goes beyond the setting
3
element gets turned ON and shunts the voltage.
power to the source.
a) can start the vehicle in batteryless condition a) Cannot start the vehicle in Batteryless condition.
4
b) Bump/push start can be done b) Bump/push startability is not possible
Voltage controlled device, irrespective of the Current controlled device, control depends on the
5
current flowing through the device. current flowing through the device.
At higher current application large amount of heat is
6 Higher current capability can be achieved
generated and component life will be reduced.

FUSES
FUSE - USAGE LIST

For easy reference the individual fuse ratings and its function is mentioned inside the lid of the fuse box.
 Whenever a spare fuse is used, please ensure it is replenished at the earliest opportunity
 Always get the circuit checked to ascertain the cause of a fuse blowout and rectify to prevent fuses blowing
frequently.
BLADE FUSE USAGE LIST
F6
Spare-3 F5
F4
Spare-2 F3
F2
Spare-1 F1
ID No. Function Rating
F1 CHARGING FUSE 25A

F2 MAIN FUSE 25A
F3 IGNITION - EFI FUSE 15A
INSTRUMENT CLUSTER/
F4 10A
SIGNALLING FUSE
F5 HORN FUSE 10A
F6 LIGHTING FUSE 15A
SPARE-1 SPARE FUSE 1 25A

SECTION 17 - ELECTRICALS
No. Instructions
17.1 Battery
 Remove side panel on

the right side by
unscrewing 2 hex socket
button head screws.
 Unlock (turn the key
clockwise) and remove
the pillion seat.
 Remove front seat.

 Disconnect battery
terminals: positive
terminal first & negative
terminal next
 Remove flasher unit
holder from battery
strap.
 Disconnect starter relay
CAUTION:
couplers
Ensure starterrelay to starter
- White colour from wiring
motor wire is removed from
harness the slot in battery strap
- Red colour from Battery. before removing starter relay.
 Remove starter relay
holder from battery
strap.
 Remove Hex screw from Hex head screw: M6
battery strap front.
 Release battery strap
from the slot in the rear
and remove strap.
 Remove battery from
the housing.
218 ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL

No. Instructions
17.2 Headlamp
Assembly
head lamp.
 Remove 2 Allen screws Hex Socket cap screw M8

holding headlamp assy
Allen Key M6
to LH& RH Top bracket &
remove head lamp assy.
17.3 Instrument Cluster

Assy
 Disconnect Instrument
Hex Cap nut: M6
cluster wiring coupler
T spanner: 10mm
 Remove 3 Hex cap nuts
along with washers.
 Remove instrument
cluster from its
mounting bracket.
ROYAL ENFIELD HIMALAYAN BS III VEHICLE SERVICE MANUAL 219

No. Instructions
17.4 Trafficator front
LH& RH
 Disconnect Trafficator NOTE:
wiring couplers below
headlamp. The couplers are color
coded as:
 Remove Allen screw LH side: Green
mounting the trafficator
RH side: Red
to the side support
bracket.
 Pull out the decorative Hex Socket Cap screw M6

cover from the rubber
grommet in the side Allen key: 4 mm
support bracket.
17.5 Trafficator Rear

LH& RH
couplers red & green
 Remove the screw from
the trafficator housing
back side.
 Remove outer lens.
 Remove the fused bulb
by pushing and turning
anticlockwise.
17.6 Tail Lamp & Number

plate illuminator
 The tail lamp has a LED
lighting system. In the
event of failure, the
entire tail lamp assembly
should be replaced.

No. Instructions
17.7 Battery
Reassembly
 Position battery in the
battery carrier such that NOTE:
the terminals are facing Ensure wire terminals are
inside. free of corrosion.
 Ensure ignition switch is Apply petroleum jelly over
in “OFF” condition. the terminals after
connecting battery.
 Connect red wire to the
positive terminal of the
battery first.
 Connect black wire to
the negative terminal of
the battery.
 Locate starter relay
holder from battery
strap.
 Install Hex screw on
battery strap front.
 Locate battery strap
from the slot in the rear Hex head screw: M6
and remove strap. Socket Spanner: 10mm
 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

No. Instructions
17.8 Headlamp
Assembly
 Install 2 Hex cap screws
Allen screw: M8
holding headlamp assy
to LH& RH Top bracket & Allen Key: M6
locate head lamp assy.

head lamp
17.9 Instrument Cluster

Assy
 Locate instrument
Hex Cap nut: M6
cluster on its mounting
bracket. Allen Key: 5 mm
 Install 3 Hex cap nuts
along with washers.
 Connect Instrument
cluster wiring coupler.

No. Instructions
17.10 Trafficator front

LH& RH
 Push inside the
decorative cover on the
rubber grommet in the
side support bracket
 Install Allen screw
Hex Cap Screw M6
mounting the trafficator
to the side support Allen key: 5 mm
bracket.
wiring couplers below
NOTE:
headlamp. The couplers are color coded
as:
LH side: Green
RH side: Red
17.11 Trafficator Rear

LH& RH
 Locate the bulb by
pushing and turning
clockwise.
 Locate outer lens
 Install the screw on the
trafficator housing back
side.
couplers red & green

No. Instructions
17.12 Handle Bar Switch
LH
 Open cable straps to
NOTE:
release the wiring
harness. The straps fixed in the
handle bar are reusable
 Disconnect wire coupler hence do not remove them
from main cable harness from the handle bar if not
near Steering stem on required to be removed.
LH side.
 Remove 2 Philips head Screw driver
screw from bottom of
switch LH.

RH
 Open cable straps to
NOTE:
release the wiring
harness. The straps fixed in the
 Disconnect wire coupler hence do not remove them
from main cable harness from the handle bar if not
near Steering stem on required to be removed.
RH side.
 Remove 2 Philips head Screw driver
screw from bottom of
switch RH.
17.14 Clutch Switch
 Release coupler lock

from the switch on
Handle bar LH, bottom.
 Loosen 2 screws holding
clutch switch to switch
module LH and remove
clutch switch

No. Instructions
17.15 Front Brake Switch
 Remove wire connections

to the front brake switch
on handle bar RH bottom
 Release lock and gently
pull switch out of the
front brake bracket.
17.16 Ignition Switch

 Disconnect ignition
switch wiring coupler.
 Remove 2 Hex screws Hex Cap Screw: M6

from bottom of switch
housing and remove Allen key: 5 mm
switch.
17.17 Side stand switch

coupler
 Remove strap to frame
 Pull the bellow down
 Disconnect Red coupler
from LH side.

No. Instructions
LH
 Install 2 Philips head
NOTE:
screw on bottom of
switch LH The straps fixed in the
 Connect wire coupler on hence do not remove them
main cable harness near from the handle bar if not
Steering stem on LH side. required to be removed.
 Close cable straps to lock
the wiring harness. Screw driver

RH
 Install 2 Philips head
NOTE:
screw on bottom of
switch RH. The straps fixed in the
 Connect wire coupler on hence do not remove them
main cable harness near from the handle bar if not
Steering stem on RH required to be removed.
side.
 Close cable straps to lock Screw driver
the wiring harness.
17.20 Clutch Switch
 Install 2 screws holding

clutch switch to switch
module LH and locate
clutch switch
 Locate coupler lock on
the switch on Handle bar
LH, bottom.

No. Instructions
17.21 Front Brake Switch
 Locate lock and gently

push switch inside the
front brake bracket.
 Locate wire connections
to the front brake switch
on handle bar RH
bottom
17.22 Ignition Switch

 Install 2 Hex screws from
bottom of switch
housing and locate Hex Cap Screw: M6
switch.
Allen key: 5 mm
 Connect ignition switch

wiring coupler.
17.23 Side stand switch

coupler
 Connect Red coupler
from LH side.
 Push the bellow
upwards.
 Locate strap to frame

No. Instructions
17.25 Headlamp Bulb

 Remove the 2 screws
holding the head lamp
rim to the housing.
 Gently pull out the head

lamp rim along with
reflector assembly.

coupler.
 Remove the protective

rubber cap over the
bulb.
 Gently press the bulb

holding clip and release
it from the slot in the
reflector. NOTE:
Never touch the bulb with
 Remove the bulb from your fingers. Finger prints
the reflector. will etch the glass and
decrease bulb life.
Always hold the bulb with
clean dry cloth during
handling.
Don’t disturb the vent cap
X
provided in the inner body
mould.

No. Instructions
17.26 Trafficator bulbs
 Remove the 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.

No. Instructions
17.27 Head Lamp Bulb
 Locate the 3 lugs in the

bulb correctly in the
reflector.
 Locate bulb holding clip
over the bulb and lock it
in the slot in the reflector
X
 Locate protective rubber
cap over the bulb correctly
such that the vent pipe is
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
NOTE:
mounting holes at the
bottom of the rim are Do Not over tighten the
mounting screw as it can
aligned. Tighten with 2
cause damage to the
Philips head screws threads in the lens
firmly.

No. Instructions
17.28 Trafficator Bulb
 Position bulb in the

reflector, ensuring that
the pinsin the bulb,
match with slots in the
holder
 Locate bulb correctly in
the reflector, gently
press bulb and turn
clockwise to lock bulb
inholder.
 Refit trafficator cover
with reflector into the
housing and tighten the
screw.

No. Instructions
17.29 RR Unit
 Remove single pole

black connector (chassis
ground).
 Pull the bellow down on
middle RH side and
disconnect 2 pole T-type
connector to main
harness.
 Loosen 2 hex bolts
holding RR unit to frame.
 Remove RR unit
mounting from frame. Hex Flange Bolt : M6
Socket Spanner : 10 mm
17.30 HT Coil Assy
 Disconnect the white

coupler from the main
wiring harness HT coil.
 Loosen the 2 Hex flange
Hex Flange Bolt : M6
bolts mounted on the
welded nut in frame. Socket Spanner : 10 mm
 Remove HT Coil assy
from frame.

No. Instructions
17.31 RR Unit
 Position RR unit on the

frame and align the
mounting holes tighten
RR Unit to frameusing 2
hex bolts.
 Push the bellow
Hex Flange Bolt : M6
upwards on middle RH
side and connect 2 pole Socket Spanner : 10 mm
T-type connector to
main harness.
 Locate single pole black
connector (chassis
ground)
17.32 HT Coil Assy
 Position the HT coil on

the frame such that the
coupler is on the left side
and the HT coil is towards
the rear of the frame
 Assemble 2 Hex flange
bolts M6X14 into the Hex Flange Bolt : M6
welded nut in frame Socket Spanner : 10 mm
 Tighten the bolts using 8
mm socket spanner to a Torque : 10 Nm
torque of 10-12 Nm (1.0-
1.2 KgM)
 Connect the white
coupler on the main
wiring harness HT coil.

No. Instructions
17.33 Fuses
 Fuse carrier is located

under the rider seat.
 Remove pillion seat &
rider seat.
 Open the fuse carrier lid
& replace fuse as
Spare-3 F6
indicated inside the lid. F5
Spare-2 F4
 Replace the required F3
fuse with the spare fuse Spare-1 F2
F1
available in the fuse
carrier.
17.34 BLADE FUSE USAGE ID No. Function Rating

LIST
F1 CHARGING FUSE 25A
F2 MAIN FUSE 25A
F3 IGNITION - EFI FUSE 15A
INSTRUMENT CLUSTER/
F4 10A
SIGNALLING FUSE
F5 HORN FUSE 10A
F6 LIGHTING FUSE 15A

INSTRUMENT CLUSTER CLOCK
 Display in 12 hour format with AM/PM indication.
 Will reset to 12:00 AM when battery is
disconnected.
A. Main LCD E. Mode button

CLOCK SETTING
B. Speedometer F. Select button
Pressure
Function Switch Action
C. Tell tales G. Compass LCD time (sec)
SELECT & In ignition key ON position

D. Tachometer H. Fuel gauge MODE Enters into clock setting
pressed with > 3 sec
mode and hour digits starts
No Speed to blink
A. MAIN LCD input
Hours value shall increment
SELECT < 1 sec by 1 accordingly for no of
press
CLOCK Hour value saved and
SELECT > 3 sec
SETTING minute igits starts to blink
MODE
Minutes value will increase
SELECT < 1 sec by 1 by each press of the
“Select’ button
Minute value save and PM/
SELECT > 3 sec
AM digits starts to blink
PM / AM is interchangeable
SELECT < 1 sec by each press of the “Select’
button
PM / AM save and exit from
SELECT > 3 sec
clock set mode
1. Clock
Auto exit without saving
NO ACTION 20 sec changes and continue with
2. Ambient Temperature
previous setting
3. Service reminder
4. Odometer
WARNING
NEVER attempt to operate the select or reset buttons
5. Trip Value(A/B & F), AVG speed A/B while riding the motorcycle. Failure to do so may cause
loss of concentration and unstable riding, leading to a
6. Side Stand indication potential accident, resulting in serious injury to both
rider and other road users, besides causing severe
7. Gear position indication
damage to the motorcycle.

AMBIENT TEMPERATURE INDICATION SERVICE REMINDER
 Ambient temperature display can be changed  Service reminder is provided to remind about
from Celsius to Fahrenheit and vice versa.
service due.
 The temperature indication may increase during
vehicle riding/engine ON condition due to  Spanner symbol will flash till vehicle is serviced at
increase of engine temperature. service center.
 Ambient temperature indication tolerance is +
 Service reminder can be reset ONLY by authorized
2°C
personnel at service center after service is
completed.
 Service reminder symbol will flash on as per below
distance input from odometer.
i) 1 st service – 450 kms
ii) 2 nd service – 4900 kms
NOTE
The ambient temperature valve should be referred to iii) from there on for every 5000 kms from
only when the engine is switched “OFF” and the engine previous value (ex: 9900, 14900 etc.)
is in cold condition.
The temperature displayed will be higher if the engine
in running or immediately after it is switched “OFF”
since the sensor will only pickup the higher
temperature surrounding it.
TEMPERATURE UNIT CHANGEOVER
WARNING
DO NOT use high pressure water jet directly on
instrument cluster for cleaning. Use only water spray
cleaning and wipe it with soft dry cloth.
Temperature sensor push button management.
Required button
 Mode
Pressure ODOMETER
Function Button time Action
(sec)
In ignition key ON  Displays the cumulative kilometers the vehicle
position, long press has covered.
TEMPERA- and hold MODE
TURE
MODE > 10 secs button for period >
UNIT 10 secs to reset
ODO
CHANGE temperature units
OVER from degree Celsius
to Fahrenheit and
vice versa.

TRIP A/B & AVG SPEED A/B  Trip F mode would come into function
automatically.
 Trip A/B indicates distance travelled in particular
trip.  Trip F mode would de-activate automatically if
fuel is filled above 5.5+0.5 lts.
 Avg A/B indicates average speed of vehicle in
particular trip mode.  During Trip F mode rider can toggle between Trip
A/B but mode will return automatically to Trip “F”
after 25+5 secs.
Pressure
Function Switch time Action
(sec)
In ignition key ON
SELECT < 1 sec position, Move to: NOTE
TRIP A AVA A
 Trip “F” will stop displaying at approximately 90 +
5 seconds AFTER fuel level in tank is above 5 + 0.5
SELECT > 2.5 sec TRIP A/AVG A RESET
litres, side stand is fully retracted AND Ignition is
SELECT < 1 sec Move to: TRIP B switched ON.
AVG A
SELECT > 2.5 sec TRIP A/AVG A RESET
WARNING
SELECT < 1 sec Move to: AVG B
TRIP B NEVER attempt to operate the select or reset buttons
SELECT > 2.5 sec TRIP B/AVG B RESET while riding the motorcycle. Doing so may cause loss
of concentration and unstable riding, leading to a
SELECT < 1 sec Move to: TRIP A potential accident, resulting in serious injury to both
AVG B rider and other road users, besides causing severe
SELECT > 2.5 sec TRIP B/AVG B RESET damage to the motorcycle.
TRIP “F” MODE 6. SIDE STAND INDICATOR

 The word, Trip “F” will flash when the Trip “F”
mode is active  Indicates when side stand is extended.
 Trip “F” is provided to measure distance travelled

by the vehicle when fuel level in the vehicle is
5.5+0.5 lts. in the fuel tank so that the rider can
plan fuel filling accordingly based on his trip
requirements, Trip “F” will get activated when SIDE STAND
needle on fuel gauge enters the red zone. INDICATOR

GEAR POSITION INDICATION CAUTION
 Displays the gear position in which the vehicle is DO NOT run motorcycle incase the malfunction
traveling. remains ‘ON’ continuously as it can cause severe
damage to the ECU & Sensors. Please visit the nearest
 When in neutral the indication will be “0”. autorise Royal Enfield dealer to diagnose & rectify the
 When in gear the appropriate number between 1 defect in the EMS.
to 5 will be displayed.
D. TACHO METER
C. TELL TALES
1. Indicates the RPM at which engine is working.
2. Useful for right selection of gear with respect to
TURN LEFT TURN RIGHT
EMS MALFUNCTION
engine RPM.
NEUTRAL INDICATION
LOW BATTERY
INDICATION WARNING
HI BEAM INDICATION
 Do not run engine with gears in neutral as RPM
will go beyound red zone.
 Do not ride motorcycle in lower gears with high
1. Turn Left : Left turn signal ON. acceleration as it will cause RPM to start to red
2. Turn right: Right turn signal ON. zone & affect the main parts inside engine.
3. Neutral : Transmission is in Neutral. G. COMPASS LCD

4. Low Battery Indication: Indicator will glow
continuously if ignition switch is ON & engine is
not running. Indication will switch off as soon as
engine is started. If battery voltage is below 12 V,
indicator will glow continuously indicating a low
battery.
5. High Beam Indication: Head lamp high beam ON.
 Useful for Navigation during riding.
6. EMS Malfunction Indication :
 Text indicates heading direction of vehicle. (N, S,
 Will be illuminated as soon as ignition & stop E, W, NE, NW, SE, SW)
switch are ‘ON’ and will go ‘OFF’ after the
 Arrow will always point to North.
engine is started.
 Eg. if heading Northwest, text will display NW and
 Will remain continuously ‘ON’ incase of any arrow will be in top right corner to indicate
malfunction of the EMS. North.

CAUTION
1. Avoid using magnetic key chains, magnetic/
ferrous materials or electronic components with
interference around cockpit area to avoid
malfunctioning of digital compass.
2. If compass LCD enters into calibration mode(“CA”
flashing) ride vehicle in “8” direction slowly to
calibrate the compass or approach nearest
authorized service center for assistance and
proper calibration.
3. Indication 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
injury to both rides & other road users besides causing
severe damage to the motorcycle.
H. FUEL GAUGE
 Indicates fuel level in tank
WARNING
Do not use the motorcycle for long duration with the
fuel indication in red zone. Refuel at the earliest.
Failure to do so may cause the motorcycle to run out
of fuel and get stranded, in addition to causing serious
damage to the fuel pump.

SECTION 18- NACS II DIAGNOSIS
1. HARDWARE COVERAGE 2. NACS II-ROYAL DIAGNOSTIC TOOL

KIT
NACS II-ROYAL Interface

1. NACS II- 2. Main cable 3. Diagnostic cable
ROYAL Interface (Transfer cable) (6 PIN)
USB Hi-speed cable connector
4.USB Hi-speed 5. Cigarette 6. SD memory

cable lighter cable Card
Reset Button
SD memory card
7. SD card reader 8. Carrying Box 9. Installation CD Diagnostic connector

10. User Manual
(Included on CD)

3. PRODUCT SPECIFICATION 2. PC
PC  USB Hi-Speed Cable  NACS II-ROYAL
Dimension L:173.78mm x interface  Main Cable  Diagnostic Cable 
W:134.66mm x Motorcycle (IG ON)
H:60.91mm
Weight 660g
Operating Voltage DC 8~18V
Operating Current 300mA
Operating Temperature 00C~+700C
Dust and water resistance IP55 Standard
4. HARDWARE CONNECTION
DIAGRAM
Connect NACS II-ROYAL diagnostic tool kit as below
before performing diagnosis.
1. HAND-HELD
NACS II - ROYAL interface Main cable Diagnostic
cable Motorcycle (IG ON)
5. WARNING
 When NACS II is already connected to the
motorcycle, do NOT plug in AC Adaptor.
 Do not remove SD card when you are using
NACS II.
 The failure caused by the use of unapproved
cables, accessories is out of warranty.
 The warranty will become void if NACS II is
disassembled or altered.
 We recommend you to back up the SD-card data
to avoid data loss due to various reasons.

6. TROUBLE SHOOTING s There is a warning message showing on the
screed. Wht’s wrong?
s Why I can not install the software successfully?
A: It means communication breakdown. Please
A: If you are using Windows 7, 8, 10, please check
check whether the cables are connected well.
whether you have turned UAC off before
installation. (Please refer to item No. 8, PC
settings.)
s I have already installed the software. Why the
software can not be opened?
A: Check whether you have run the software as
administrator. Right click ICM logo on the
desktop. Choose ‘Run as admministrator”.
7. PC REQUIREMENTS
Operating system Windows XP, Vista,
Windows 7 /8 / 10
CPU CPU 1.6 GHz or higher
RAM 2GB or larger
Display Resolution 1024*768
Hard Disk Space Free space more than 1GB
(on C driver)
Notes When you use Windows Vista
or Windows 7/8, you need to
close “User Account Control
(UAC)” first. Please refer to
s Why there is a pop-up-window displaying item No. 7. PC Settings.
“cannot find COM port”.?
8. PC SETTINGS
A: Check whether the driver of USB Hi-speed cable
is installed. If USB port is not recognized, please When you use Windows 7 /8 / 10, please finish the
install USB driver. setting below to run out software successfully.
First, you need to disable “User Account Control
(UAC)” before installing our software. The way to
disable UAC is as follows.
8.1
Click ‘Start button’
and select ‘Control
Panel’.

ROYAL ENFIELD NACS II DIAGNOSIS 9. SOFTWARE INSTALLATION
8.2. 9.1. Start the computer.
Click ‘User Accounts’ 9.2. Insert installation CD to CD-ROM drive and install
following software.
a. Main software: NACSII_ROYAL_V0.03_install.exe
b. Recording data analyzing software: NACSII-
RECORD_ROYAL-V0_01_setup
8.3.
Click ‘Changer User’ Account Control Settings”.
9.3.
Click ‘Finish’ to complete the installation
8.4.
Move the slider to the Never notify position, Click “OK”
to make the change effective.

ROYAL ENFIELD NACS II DIAGNOSIS
9.4. 9.7.
Click ‘Finish’ to exit installation Click ‘Finish’ to complete the installation
9.5. 10. SOFTWARE REMOVAL

After installing Firmware program, USB high speed 10.1.
driver will start installation. Click ‘Extract’ to install. Click ‘Star Menu’ - ‘All Programs’ - ‘Control Panel’
9.6. 10.2.
Click ‘Next’ to continue Click ‘Uninstall’ a program’

10.3.
11. DIAGNOSTIC SOFTWARE FOR
Find ‘NACSII_ROYAL’ and click ‘Change / Remove’. HANDHELD TOOL
11-A.
Diagnosis
11-A1.
Please connect your NACSII-ROYAL diagnostic tool
kit with your motorcycle. NACSII-ROYAL interface-
maincable  Diagnostic cable  Motorcycle
Orange light indicates whether the system is
communicating.
10.4.
When ‘Unistalling NACSII_ROYAL’ window pops up.
please click ‘Next’.
10.5.
11-A2.
Click ‘Finish’ to exit uninstall.
When the IG of the motorcycle is ON, the system
starts to run, entering welcome page ‘ROYAL
ENFIELD’. Press F1 Diagnosis.

11-A3. 11-A6.
Select ‘Royal Enfield Press to C exit
534 EFI’. Press OK to ‘Vehicle Info’
continue. page. The page
will return to the
main menu.
11-A4.
NACS II will 11-A7.
automatically detect Using and to
which system the move the cursor.
vehicle is. Select Move the cursor to
‘KEIHIN Engine select ‘Diagnostic
System’ or ‘BOSCH Trouble Code’.
ABS System’. Press OK to see the
Press OK to content.
continue.
11-A5.
11-A8.
Take ‘KEIHIN Engine System’ as an example. After
Diagnostic trouble
pressing OK the system will display ‘Vehicle Model
code page includes
Data’. Press to view the 2nd page of vehicle ‘F1 Current’, ‘F2
information. Press to return to last page. History’ and ‘F4
Erase’. ‘Current’ is
for the DTC occurred
at the time and
‘History’ is for DTC
occurred in the past.
‘Erase’ is for erasing
current DTC and
History DTC. Press OK
to view ‘Current’
DTC.

11-A9. 11-A11.
Press F2 to view Erace DTC. It’s the
function to erace
‘History ‘ DTC.
Diagnostic Trouble
Press to view next Code in both
‘Current’ and
page and press
‘History’.
to view last page.
After viewing all the Press F4 to erace.
current DTC. To confirm erasing
Press C to exit. The DTC. Press F1 ‘Yes’.
screen will return to
the previous page.
When showing on the screen, it means the DTC

11-A10. has been erased. Press to go back to the main menu.
Freeze Data. ‘Freeze Data’ is the data recorded when
First DTC occured, and one time only record One DTC
freeze data. It’s for saving the engine dynamic data for
further analysis.
When displays on the screen, press OK to view

freeze data. Press and to view next page and
last page. After viewing all content, press C
to exit. The screen will return to the previous page.
11-A12.
When the screen
returns to the main
menu, move the
cursor to ‘Live Data’
and Press OK to
view the content.

11-A13. 11-A16.
Press and to view all the content. Back to the main
menu, move the
cursor to ‘Special
Function’ and
Press OK
‘Special function’ is
customized functions
provided to specific
vehicles.
11-A17.
Select “CO
11-A14. Adjustment”, press
Record data. ‘F2 and to adjust
REC’ is for
the CO value. is for
recording Live data.
When viewing ‘Live increasing fuel
injection value. is
Data’, click to
for decreasing fuel
record current
injection value.
values. Press C to
After finish
stop recording
adjustment, press OK
to save. Press to
exi t. If you want to
go back to the main page, press unti l the page
return to the top of the page.
11-B.
11-A15. 11-B1.
Press F1 to save “F2 Setup” page contains setting Language, viewing
the file. System Information and setting Date / Time.

11-B2. 11-C.
Press to view System Information. ABS Functions
11-C1.
Select ‘BOSCH ABS
System’. Press OK
to continue.
11-C2.
Select ‘Special Function’. Then, select ‘Repair Air
Bleed’.
11-B3.
Press to set
Date and Time.
11-B4.
Using and to move the cursor. Press OK to
select the item. Change figure using or
11-C3.
and press OK to confirm the item. At this time, the
pink block will return to white. Press to apply the Read the warning first before start operating air
bleeding.
setting.

11-C3. 11-C6.
Read the warning first before start operating air Front Channel
bleeding. Activation
11-C4. 11-C7.
Follow each step on thescreen to finish the Follow the instructions on screen to finish the
procedure. activation.
11-C5. 11-C8.
SILA Lamp Blinking Test Follow the instructions on screen to finish the
Follow the screen guide to finish the test. activation.

12. Diagnostic software for PC base 12-3.
When the first time
12-1. you use software,
the software will
Before diagnosis, please connect your NACSII- enter register
ROYAL diagnostic took kit with your motor cycle. process
PC  USB Hi-Speed Cable  NACSII-ROYAL automatically.
interface  Main Cable  Diagnostic Cable  ‘Please make sure
Motorcycle (IG ON) your PC is connected
to the internet.
When the window
displays ‘Product
key’, click ‘NEXT’.
Software will get the
password by itself.
12-4.
Registration is
completed. Click
‘EXIT’.
12-2.
Double click NACSII_ROYAL onthe desktop to open
diagnostic software.
12-5.
This is the page
showing your
connected system.

12-6. 12-9.
Click to show There are various

Interface info and green buttons on
Contact info of I.C.M. the right.
button is for
displaying all the
vehicle info.
12-7. 12-10.
Click to switch Click to read the
language. Diagnostic Trouble
After selecting code. Click
language. ‘Current’ toread
Click to confirm current DTC. Click
setting ‘History’ to read
Click to continue. history DTC.
12-11.
12-8.
If you want to
Connecting to
engine system. print trouble
Please wait... code, click

to print DTC
data. It will
take a
moment.

12-15.
12-12.
To erase the
The window will pop Diagnostic Trouble
up for selecting
printer. Code, click
Note : if you click the
erase button, all
Diagnostic Trouble
Code in ‘Current’ and
‘History’ will be
erased!
12-13.
If you want to freeze
DTC data, select the
code which has 12-16.
mark. Click to
Click to see
freeze data specification of live
data.
12-14.
This is the page of
freeze data. ‘Freeze
Data’ is the data
racorded when 12-17.
FIRST Diagnostic
Trouble Code Click to see the
occurred, and one live data. You can
time only record one
select ‘All Data’ to
Diagnostic Trouble
Code freeze data, it’s view all live data or
for saving the engine select the item which
dynamic data for used often. Selected
further analysis. items will be listed in
Click to return to
the block of ‘Live
Diagnostic Trouble
Code page. Data Item’.

12-17-A. 12-17-D.
Click to erase ALL selected live data. If you want
Click to view selected data values. to erase only one item, please press and hold ‘Shift’
key and select the item that you want to delete.
Then, click button. The selected item will be
erased.
12-17-B.
Click to view wave chart.
12-18.
This button is
for special function.
Functions depend
on ECU type. Take
‘CO adjustment’ as
an example. Select
the item and click
12-17.
Click to view chart of 2 live data items at the

same time. 12-19.
The page will display
‘What to do’ for
next step. Click
to continue.

12-20. 13-2.
Adjust CO value Select Record Date
by clicking and File name, then
and click click
to save
adjusted value.
13. RECORD ANALYZING SOFTWARE 13-3.

This software is for reading NACS II handheld Select the items
recorded data. Please take out SD card from NACS II which used often.
handheld tool and insert SD card to PC. Selected items will be
listed in the block of
‘Live Data Item’.
Click to view
wave chart of
selected items.
13-4.
Wave chart starts running until press ‘Stop’ button.
13.1. Drag Yellow line forward and back to view recorded
Open the live data values.
software of
‘NACSII_Record_Royal’.
Select ‘Analyze
Record Data’.

13-5. 13-8.
For example, setting Engine speed grater than 3150,
To slow down the playing speed of wave chart,
enter 3150 in the right block. Click to confirm
please drag the slider down.
the setting value.
13-6.
To view different sections of wave chart, please click 13-9.
to select page number. Click the 2nd to go When window pops up ‘Setting OK’, the setting is
completed.
back to last page.
13-7. 13-10.
Select items to set breakdown point for analysis. The setting value will display in the blockunder
After selecting items, click ‘Break’ Click to view wave chart.

13-11. 13-14.
Click to quickly find matched point of setting value. Back to Live data selection page, click to view
wave chart of the 2 setting values.
13-12.
Sometimes, setting only one value still can not find the
13-15.
main problem which causes malfunction. In this case,
setting the 2nd value or more values can help user to Click to quickly find the 2 matched conditions.
find satisfied conditions. To set the second value
please select Live data item. Take throttle position as
an example. Enter throttle position grater than 9.8 in
the right block and click to finish setting.
13-16.
13-13. Back to Live data selection page, setting the 3rd
After Setting 2 values of the 2 items, the 2 items will
value as the same way as step 18-8. Click to
be listed in the block of ‘All value match’ Click to
go back to Live data selection page. finish setting.

13-17. 13-18.
The 3 setting items will be listed in ‘All value match’
block. To analyze conditions and differences of Click to quick find matched conditions.
values, it’s necessary to select match items. Select
the items and then The selected items will be
listed in ‘Any of value match’ block. Continue to set
match conditions : AND, OR &&, AND : All conditions
of setting items must be satisfied.
OR : One of or any of selected items must be
satisfied. && : Setting items listed in ‘All value match’
and ‘Any of value match’ must be satisfied. If there
isno matched condition, the window will pop up
showing condition can’t match.
After setting condition, click to go back to Live

data selection page.
13-18.
Click to wave chart.

SECTION 19 - WIRING HARNESS

WIRING DIAGRAM COMPLETE - LS 410

SECTION 20.1 - VEHICLE TROUBLE SHOOTING
WARNING
The trouble shooting section of this Owner’s Manual is intended solely as a guide for diagnosing problems. Carefully
read the appropriate sections of this manual before performing any work.
CAUSES REMEDIES
I. ENGINE FAILS TO START
1) Stop switch in ‘OFF’ Position Push stop switch to ‘ON’ position.
2) Side stand not retrieved Retrieve side stand.
3) Vent hole clogged in fuel tank cap Clean vent hole.
4) Spark plug cap / lead not connected Fix cap / lead firmly
5) Spark plug electrode dirty / fouled Clean spark plug
6) Spark plug insulation cracked Replace spark plug
7) Clutch slipping Adjust clutch cable free play
8) Main or EFI Fuse failed................... Replace with new fuse
II. ENGINE MISFIRING

1) Loose spark plug cap Fix cap / lead firmly
2) Spark plug fouled Clean spark plug or non specified heat range plug.
3) Any sensor loose connections Check MAP or EOT or TPS sensor wiring / coupler loose
connections
4) Water in petrol tank Clean petrol tank. Fill tank with fresh petrol.
III. POOR PICKUP

1) Brake pedal adjusted too tight Re-adjust properly
2) Choked air filter Clean / Replace air filter
3) Rear chain adjusted too tight Re-adjust properly
4) Under inflated tyres Inflate to correct pressure
5) Accelerator cable free play excessive Adjust cable free play
6) Clutch Slipping Adjust clutch cable free play
7) Faulty fuel supply Remove fuel pump & clean.
Fuel pump, filter / injector blocked

CAUSES REMEDIES
IV. WHITE/BLUE SMOKE
1) Oil level in sump above the Top line. Check and drain excess oil
in the oil level window
V. ENGINE OVERHEATING
1) Low engine oil level Check and top-up if necessary
2) Clutch slipping Check and correct
3) Cylinder fins not clean Clean the cylinder fins at regular intervals
VI. EXCESSIVE FUEL CONSUMPTION
2) Choked air filter Clean / Replace
3) Fuel leakage Check and rectify, tank float unit, drain pipe, breather
pipe, fuel line / pump.
VII. BRAKES POOR
1) Brake pad worn / Uneven wear Replace Brake pads
2) Oil/grease on disc. Clean and refit
3) spongy brake fill brake fluid & remove air from the system.
VIII. MOTORCYCLE WOBBLES
2) Loose / Broken spokes Tighten / Replace spokes
3) Wheels misaligned Ensure proper alignment
4) Wheel rim runout Rectify
5) Tyres not fitted correctly Refit tyres correctly
IX. ELECTRICALS
Bulbs do not 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

CAUSES REMEDIES
Brake light remains on
1) Switch not adjusted properly Adjust connecting links properly
2) Switch sticky Replace switch
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 Replace switch
X. ELECTRONIC FUEL INJECTION (EFI)
Malfunctioning Indicator Lamp (MIL) glowing continuously
(1) Sensor Coupler Loose Connection Check for any EFI sensor coupler loose connection
and correct them
(2) Any EFI Sensor Failure Check & replace the same
XII. ABS (ANTI LOCK BRAKING SYSTEM)
1) ABS lamp continuously ON. Take the vehicle to service center for diagnosis

1. ENGINE CRANKS BUT DOES NOT START
Symptom Probable Cause Remedy
Battery voltage low Recharge/ replace battery
Spark plug cap / high tension wire Check & correct
loose / shorted / defective
Spark plug incorrect Replace with correct spark plug
A. Ignition spark weak
Spark plug sooty / wet Check &clean spark plug
Spark plug gap incorrect Correct spark plug gap
Spark plug insulator cracked Replace spark plug
No spark from Ignition coil Check & Replace Ignition coil
Pulsar coil defective Check & Replace
Battery dead Recharge/ replace battery
Spark plug cap / high tension wire Check & correct
shorted / defective / disconnected
B. No Ignition spark
Spark plug insulator cracked Replace spark plug
No spark from Ignition coil Check & Replace Ignition coil
Pulsar coil defective Check & Replace
No Fuel in fuel tank Fill fuel tank.
Stale / adulterated fuel Clean fuel tank
Fill with fresh fuel
C. Fuel related Air vent blocked in fuel cap Clean air vent/s
Fuel filter clogged Clean fuel filter
Fuel line pinched Check & correct fuel line
Ambient temperature too low for Use Bi starter for starting in
engine to start cold conditions
Spark plug loose Tighten spark plug to torque
Tappets adjusted too tight Check & adjust tappets to specn
Cylinder head gasket blown Check & replace
Cylinder head nuts loose Check & tighten to torque
D. Compression related
Cylinder head warped Check & replace
Valve stem bent, seating area Check & replace
burnt, excess carbon deposit on
seating area, Valve springs broken
Piston rings sticky / worn-out Check & replace
Cylinder barrel / Piston excess Check & replace
clearance.

2. ENGINE DOES NOT CRANK
Ignition key not in ON position Switch ON ignition key
Engine Kill switch in OFF position Switch ON engine Kill switch
Gears not in neutral (neutral lamp Depress clutch / shift to correct
not glowing) neutral & start
Battery voltage low Check battery. Recharge
replace battery
Starter circuit Fuse blown Check all fuses & replace blown
A. Starter motor does not rotate fuse
Starter motor connections loose Check & tighten connections
Starter relay connections loose Check & tighten connections
Ignition Switch defective Check & replace Ignition switch
Starter button defective Check & replace RH switch.
Starter relay failed Check & replace starter relay
Starter motor failed Check & replace starter motor
Major short in Wiring harness Check & correct wiring harness
Motor rotates slowly due to low Check & correct battery /
B. Starter motor rotates battery / worn out starter motor starter motor
BUT engine does brush
not crank Magneto rotor woodruff key broken Check & replace woodruff key
Starter clutch assembly slipping Check & replace starter clutch
assy
Inlet / Exhaust rocker arm seized in Investigate cause of seizure,
rocker shaft check & correct as required
Cam shaft seized in cylinder Investigate cause of seizure,
head / cover check & correct as required
Cam chain jammed in sprocket Investigate cause of seizure,
gears check & correct as required
C. Engine does not crank and Piston Seized in cylinder barrel Investigate cause of seizure,
sounds locked. check & correct as required
Piston Pin seized in connecting Investigate cause of seizure,
rod small end check & correct as required
Big end bearing seized in Crank Investigate cause of seizure,
pin / connecting rod big end check & correct as required
Crankshaft bearings in LH / RH Investigate cause of seizure,
crankcases seized check & correct as required

3. IDLING ERRATIC / ENGINE MISFIRING AT LOW RPM
Attribute Probable Cause Remedy
Battery voltage low Recharge/ replace battery
Suppressor cap / H T lead loose Check & correct as required
Suppressor cap / H T lead defective Check & correct as required
A. Ignition related
Spark plug fouled / wet Replace / clean spark plug
Electrode gap too less / excessive Check and correct electrode gap
Spark plug wrong specifications Replace with correct spark plug
Ignition coil defective Check & replace
Pulsar coil / Magneto defective Check & replace
Adulterated / Bad fuel Clean fuel tank.
Air vent holes in Fuel tank cap Check & clean air vents
partially blocked
B. Fuel / Induction related
Fuel flow partially blocked Check & clean Fuel filter
Air filter dirty / clogged Check & clean / replace
Pulse air valve pipe connections Check & correct
loose / cracked
Spark plug loose Check & tighten to torque
Inlet / Exhaust tappets adjusted Check & correct
wrongly
Cylinder head gasket blown Check & correct
Cylinder head studs loose Check & tighten to torque
Cylinder head seating area warped Check & replace
C. Compression related
Cam shaft sticky rotation /seized Check & correct
in cylinder head
Valve spring broken or weak Check & replace
Valve not seating properly (stem Check & replace
bent. Heavy carbon deposit on
seating surface)
Piston rings worn out/ broken / Check & replace
stuck in ring groove
Cylinder / piston worn Check & replace

4. PICKUP POOR / SLUGGISH
A. Ignition related Spark plug fouled / wet Replace / clean spark plug
Electrode gap too less / excessive Check and correct electrode gap
B. Fuel / Induction related Fuel flow partially blocked Check & clean Fuel filter
loose / cracked
Spark plug loose Check & tighten to torque
Inlet / Exhaust tappets adjusted wrongly Check & correct
Cylinder head gasket blown Check & correct
Cylinder head studs loose Check & tighten to torque
Cylinder head seating area warped Check & replace
C. Compression related Cam shaft sticky rotation /seized Check & correct
in cylinder head
Valve spring broken or weak Check & replace
Valve not seating properly (stem Check & replace
bent. Heavy carbon deposit on
seating surface)
Piston rings worn out/ broken / Check & replace
stuck in ring groove
Cylinder / piston worn Check & replace
Rear chain tension too slack / tight Check & correct
No free play in clutch / clutch release sticky Check & correct
D. Transmission related
Engine oil quantity too high Check & correct
Engine oil wrong grade/ high viscosity Check & correct
Clutch plates worn out / warped / Check & correct
sticky release / burnt
Front / rear brakes jamming Check & correct
E. Others
Front / rear wheel bearing jammed Check & correct

5. ENGINE MISFIRING AT HIGH SPEEDS/ HIGH RPM.
Spark plug electrode gap too less/ Check and correct electrode gap
excessive

A. Ignition related Spark plug insulator cracked Check & replace
Suppressor cap / H T lead loose Check & correct as required
Ignition coil defective Check & Replace
Adulterated / stale fuel / water Check, Clean fuel tank.

content in fuel Fill with fresh fuel
Fuel flow partially blocked Check & clean Fuel filter
B. Fuel / Induction related Inlet manifold loose / cracked Check & tighten / replace inlet
manifold
Tappets adjusted too tight Check & adjust tappets

correctly
Cylinder head bolts loose Check & tighten to torque
Cylinder head gasket damaged Check & Replace
Cylinder head warped Check & Replace

C. Compression Related
Valve spring broken or weak Check & Replace
Valve not seating properly (valve Check & Replace

bent, worn, carbon accumulation
on the seating surface.)
Excessive Carbon in combustion Check & Clean

chamber
Piston ring bad (worn, weak, Check & Replace

broken, or sticking)
Piston rings clearance excessive Check & Replace
Cylinder, piston worn Check & Replace

6. EXHAUST SMOKE EXCESS
Adulterated / Bad fuel Clean fuel tank
Spark plug Electrode gap too less Check and correct electrode gap
A. Black smoke Spark plug wrong specifications Replace with correct spark plug
Air Filter element clogged Check & Clean

loose / cracked

B. Brown smoke Fill with fresh fuel
Air filter box poorly sealed / Check & correct

element partially clogged
Engine oil level too high Check & Maintain Oil level as
Recommended
Valve stem seal damaged Check & correct

C. Bluish / White smoke Excess clearance between valve Check & correct
stem & guide
Oil scrapper ring worn out Check & correct
Cylinder barrel / piston clearance Check & replace

high

7. ENGINE HEAT EXCESSIVE
Prolonged driving in low gear at High Ride in appropriate gear as
speeds / High gear at Low speeds required by traffic conditions
Engine in Idling RPM for prolonged Switch off Engine if required to
periods be in standstill traffic for more
A. Driving / traffic related than 2 minutes.
Vehicle in standstill with gear engaged and Shift to neutral & release clutch
clutch depressed for prolonged periods
Engine RPM high when vehicle at Allow engine to run in idling
standstill position RPM when in neutral
Riding in traffic with brakes partially Release both brakes and drive
engaged for prolonged periods at appropriate speeds
Spark plug electrode gap too less/excessive Check and correct electrode gap
Spark plug insulator cracked Check & replace
B. Ignition Related Suppressor cap / H T lead loose Check & correct as required
Ignition coil defective Check & Replace
Adulterated / Bad fuel Clean fuel tank
C. Fuel / Induction related Fill with fresh fuel
Tappets adjusted too tight Check & adjust tappets correctly
D. Compression Related
Excessive Carbon in combustion chamber Check & Clean
Poor compression due to cyl. head gasket Check & correct
blown, Valve seating improper, Piston rings
worn out / broken, Piston / Cyl. worn out
Engine oil less viscous / wrong Check & correct
specification / level too low
E. Others Oil cooler fins dirty / blocked Check & clean oil cooler fins
Clutch slipping Check & correct
Front / Rear brakes jammed Check & correct
Engine oil pressure less Check & correct
Silencer choked Check & clean

8. ENGINE NOISY
Prolonged driving in low gear at High Ride in appropriate gear as
speeds / High gear at Low speeds required by traffic conditions
Excessive Engine heat Check & correct
Fill fresh fuel
A. Knocking noise Incorrect plug gap. Wrong spec spark plug Check & correct gap
Excessive carbon in combustion chamber Check & correct
Pulse air valve pipe connections loose / Check & correct
cracked
Exhaust pipe & cylinder head joint not Check & tighten exhaust flange
sealed correctly nuts / replace gasket
Engine oil less viscous/wrong specification Check & correct
/ level too low
B. Lubrication related Oil filter element blocked Replace filter element
Oil pressure low Check & correct
Tappets clearance excessive Check & adjust tappets
correctly
Camshaft sticky rotation Check & correct
C. Top End noise Cam lobes in camshaft uneven wear Check & replace
Cylinder head gasket blown Check & replace
Valve spring broken / weak Check & replace
Valve stem squeaky noise Replace stem seals
Valve stem to guide clearance high Check & replace
Piston rings broken Check & replace
Cylinder / Piston scored Check & replace. Check air filter
/ housing also for damages
D. Cylinder barrel / central Excess clearance between piston / barrel Check & replace
(Piston slap)
portion noise Cam chain pads worn out Check & replace
Auto chain tensioner jammed Check & replace
Excessive clearance between Cam chain / Check & replace
sprockets
Connecting rod small end / piston pin Check & replace
clearance excess
Connecting rod bent Check & replace crankshaft
Excess clearance between connecting rod Check & replace crankshaft
E. Bottom end noise big end / crank pin
Crankshaft / balancer shaft support Check & replace
bearings worn
Crankshaft run out excessive Check & replace
Balancer shaft / crankshaft gears backlash Check & correct
Clutch housing/friction plate clearance Check & replace
excessive
F. Transmission noise Clutch housing gear / crank gear backlash Replace matched gears
Drive / counter gears backlash Check & replace
Drive / Countershaft bearings worn out Check & replace
Gears / bushes seized in drive / counter shaft Check & replace

9. GEAR SHIFTING HARD / SLIPS
Routing improper Check & correct
Strapped too tight to frame Check & correct
A. Clutch cable related
Inner cable sticky Check & replace
Inner / outer cable damaged Check & replace
Free play excess Correct free play to 2-3mm
Oil less / more viscous. Wrong specification Check & correct
B. Oil related
Oil level too high / too low Check & correct
Gear lever position incorrect Check & correct
Shift lever sticky / jammed on pivot pin Check, clean & lubricate pivot pin
C. Shift lever / linkage / Gear shift linkage ball joint stuck/worn out Check & correct
shifting Mechanism Return spring weak / broken Check & replace
related Indexing pawl pins worn out Check & replace
Shift forks sticky in pin / selector drum Check & correct
Shift forks / pins worn out Check & replace
Selector drum grooves worn out Check & replace
Clutch pad sticky / worn out Check & replace
Clutch plates movement sticky Check & correct
D. Clutch assembly related Springs weak / broken Check & replace
Friction plates worn out / burnt Check & replace
Steel plates warped Check & replace
No end float of clutch assembly in shaft Check & correct
Shift forks sticky in pin / selector drum Check & correct
E. Gears does not engage Selector drum rotation sticky Check & correct
Sliding gear movement sticky in shaft Check & correct
Gears / bushes partially seized in shaft Check & correct
Shift forks / pins worn out Check & replace
Selector drum grooves worn out Check & replace
F. Gears overshifts Sliding Gear dogs worn out Check & replace
Drive shaft/counter shaft splines worn out Check & replace
Drive / counter shaft bearings wornout Check & replace

SECTION 20.2 - EMS TROUBLE SHOOTING
ISSUE DESCRIPTION EMS COMPONENT CHECK POINTS

ECU Check for P codes/blink pattern as mentioned in previous slide
for ECU internal error or any other internal issues.
Fuel Injector, * Check for Connector loose fitment, terminal back out or wire
cut etc.
Roll Over Sensor * Check for supply voltage, battery voltage etc.
Vehicle not starting Ignition Coil * Check for Connector loose fitment, terminal back out or wire
cut etc.
* Check for supply voltage, battery voltage etc.
* Check for harness continuity.
* Check for suppressor cap loose connection
* Check for sparkplug contamination
Crank Position Sensor * Check for Connector loose fitment, terminal back out or wire
cut etc.
* Check for crank shaft position sensor resistance.
Flywheel Magneto Assy * Check for stator short circuit.
* Check for connector loose fitment.
DTC History not ECU Clear DTC using only scan tool, do not re-set ECU by test pin
able to clear method
Fuel pump ECU ECU internal short, replace ECU

Continuous ON
Fuel Pump Fuel Pump Check for Connector loose fitment, terminal back out or wire
Not working cut etc.
Check for supply voltage, battery voltage etc.
Fuel pressure loss/ Fuel Pump Check for leakage near connectors
no fuel supply Check for clogged filter
Fuel pump short Pulse Fuel Pump Fuel pump Primes for 2 Sec, If priming cycle is less than 2 sec
check for Ignition coil Connector.
Fuel dripping through Fuel Pump Check for Pressure Lock in tank, if pressure lock is not there
Pump Nipple replace the pump
If Pressure Lock is there check for Tank Cap and EVAP Purge
valve.

ISSUE DESCRIPTION EMS COMPONENT CHECK POINTS
Poor Feeling of Fuel Injector Check for Injector Block
acceleration, Check if Pressure is built by pump,
hesitation, Vehicle Check for any Kinks in Fuel hose.
Could not reach Max
Speed
Vehicle mis-firing/ Crank Position Sensor Check for crankshaft position sensor mounting
tachometer fluctuation Throttle Position Check for supply voltage, battery voltage etc.
Sensor
Low battery Flywheel * Check for stator short circuit.
Magneto Assy * Check for connector loose fitment.
Heater Circuit Failure HEGO Sensor Check for Connector loose fitment, terminal back out or wire
cut etc.
Sensor Circuit Failure HEGO Sensor Check for Connector loose fitment, terminal back out or wire
cut etc.
Engine Oil * Check Connectors for loose pin
Temperature (TE) * If the issue still persists Replace Sensor
Sensor
TA Sensor Check for Connector loose fitment, terminal back out or wire
cut etc.
Sensor Circuit MAP Sensor Check for Connector loose fitment, terminal back out or wire
Malfunction cut etc.
EXAI Sensor * Check for Connector loose fitment, terminal back out or wire
cut etc.
* If terminals are in good condition replace Solenoid.
Throttle Position * Check for Connector loose fitment, terminal back out or wire
Sensor cut etc.
* Check for Supply Voltage
MIL distance not Vehicle Speed Sensor * Check for Connector loose fitment, terminal back out or wire
showing in diagnostic cut etc.
tool * Check for Supply Voltage

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EFI Model

With warm regards

Part No: 1040333/A / May ’17

ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL 011

ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL 03

SL.NO. DESCRIPTION PG.NO. SL.NO. DESCRIPTION PG.NO.

1. Technical Specifications ........................................ 6 12. Rear Suspension

12.1 Rear Wheel ..................................................... 107

12.3 Rear Mudguard .............................................. 109

12.5 Drag & Drop Links .......................................... 111

5. Rider & Pillion Seat ................................................. 45

6. Control Cables ........................................................ 48

7. Air Filter .................................................................... 53

8. Pulse Air Valve ......................................................... 59

9. Fuel Tank .................................................................. 63

10. Exhaust Pipe & Silencer ......................................... 67

11. Front Suspension

11.2 Front Wheel ................................................... 82

ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL 05

VEHICLE & VEHICLE SYSTEMS

ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL 07

A : Adjust C : Clean I : Inspect L : Lubricate R : Replace

ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL 09

21 Cam Chain / Chain Pads / Auto chain Tensioner I I I I I I I I I I I&R

22 Inlet / Exhaust valve seating (compression test) * I I

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

28 Hydraulic Brake Fluid - Front & Rear # I I R I R I R I R I R

29 Hydraulic brake hose & Washers - Front & Rear # I I I I R I I I R I I

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

31 Tyre wear pattern (Front & Rear)# (1) I I I I I R I I I I R

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

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

41 Evaporative Emission Equipment rubber hoses * I I I R I I R I I R I

A : Adjust C : Clean I : Inspect L : Lubricate R : Replace

10 ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL

PART NO. DESCRIPTION PHOTOS APPLICATION

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

ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL 11

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

12 ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL 13

14 ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL

4.1 Skid plate

 Loosen & remove 6 Flanged Hex Screw: M6

 Remove the spacers and NOTE:

4.2 Oil Cooler Banjo Union Bolts: M14

ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL 15

4.3 Wind Shield

4.4 Trafficator front LH,

 Remove hex socket

Hex socket hd. Screw: M5

16 ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL

 Remove the dust caps

4.6 Top frame LH & RH

ROYAL ENFIELD HIMALAYAN BS IV VEHICLE SERVICE MANUAL 17

4.7 Pillion & Rider Seat

 Unlock pillion seat by

4.8 Fuel Tank

 Remove 2 Hex screws