1st Service (500kms/1month) @447kms on 27-06-2016
As the bike was nearing the 500km mark, I thought it's a good day to get the 1st service done.
Issues noted -
1. Slight Oil stain after yesterday's ride on top of the cylinder head
2. Tappet noise seemed to have increased
3. Slight gasp in acceleration at speeds of around 80~90 while closing and opening the throttle was also noticed yesterday
The Service Head and the Head Mechanic listened to my issues patiently and as I had already informed the Service Head that I was coming for 1st service in the morning, he was 'armed' and ready with a 4 page 1st Service Checklist for the Himalayan. This was the 1st Himalayan they were servicing. The Head Mechanic (Technician) had also just returned from his 2nd training schedule of the Himalayan and he informed me that the slight gasp in acceleration is also due to tappet adjustment and not due to any fuel mixture issue of the carburetor.
So first and foremost the tappet covers were opened
A close-up of the tappet
Both the tappet covers were opened and left open to cool down as the tappets need to be adjusted 'only' in a cold engine
The engine oil was drained. Notice that not only the drain plug but a larger portion was removed to access the oil strainer
This is the stainless steel mesh oil strainer that needs cleaning on every oil change. Don't avoid this at any cost.
The oil filter was also removed and replaced
Notice the oil strainer goes into this slot
2 to 2.1L oil is needed for a refill. Oil Grade is HP Racer 4 Plus 15W/50 Grade and costs 350/- per liter
The Head Bolts were tightened to solve the oil stain issue. They were found to be a bit loose.
The cylinder block bolts were also tightened
As were the Timing Cover and Clutch Cover bolts
This is the timing cover adjustment nut. On flashing light inside, the engine crank has to be rotated to a point where 'T' is marked inside and then the tappets are needed to be adjusted.
Timing Cover opened to rotate the crank
In the meanwhile the spark plug was removed. You can see a soot deposit of brownish color on it's tip signifying a perfect combustion for best mileage. It was then cleaned by a automatic machine. Gap was set at 0.7mm.
The air filter cover was also opened which sits under the left 'Himalayan' side cover
To reveal the Air Filter Inside
Quite a good quality one with a large surface area
It was then cleaned by compressed air
Now adjusting the tappet was not such a simple job as I had initially thought and it requires this special tool. It is best left to the professionals.
Both pieces combine to become one tool
The tappet being finally adjusted with a clearance tool. Inlet tappet clearance to be set between 0.08 - 0.10 mm and exhaust tappet clearance to be set to 0.23 - 0.25 mm and is to be checked in a cold engine only. Both tappet clearances had increased, hence causing extra engine and tappet noise. Both were tightened back to these specs.
This is the complete Checklist for the 1st Service of the Himalayan which has been specially sent to all dealerships with instructions that they are to be strictly adhered to. All points are self explanatory.
Fuel filter in fuel tap was also cleaned. Front Forks were also checked for any oil leakage. None found.
The chain tension was tightened to a 25~30mm play with both tyres on the ground
Kindly insist that all points in this checklist are properly adhered to during your respective servicing.
The bike was finally given a nice gentle pressure wash
Then a proper dry down with compressed air
The final Bill was just 807 bucks which includes 700 for the oil and 107 for the oil filter. This will be economical bike to maintain.
Some Himalayan Parts had arrived. So picked up a spare spark plug (a Bosch M10) for just 161 bucks, a couple of frame plastic dust caps that are prone to fall off (8 bucks) and a few original cable ties (6 bucks each)
The bill of the spares
The bike has become much smoother after the service. The tappet noise has disappeared and the engine has become smoother and quieter. Overall a satisfying experience and a big Thumbs Up for my Service Dealership for being so pro-active. I am also hearing news that RE is initiating a gradual recall to solve this tappet issue once and for all, by replacing some parts in the engine head. It is short of the required parts and hence are proceeding gradually. It will be a 3 hour process and the head will need to be opened to replace those parts. Let us see when the official information and parts reaches my dealership. For now the bike is running like a dream.
Cheers...