Has anyone removed and replaced a Himalayan engine?

[jrhyins]

A few weeks ago my engine blew on my Himalayan 411 2021. I have since found and purchased a Himalayan 411 2022 at auction for parts (it's a salvage title so I can't just start riding that). Does anyone have experience removing and replacing the engine on their 411? Thanks in advance, Jo (NYC)

 

[Roy Gavin]

Important thing is to support the motor and frame so all the bolt holes line up as close as possible and everything is as stress free as possible after assembly
Some other makes have a complex sequence and procedure and some havemore sophisticated fixing points.
The 452 has the improved fixing points, so there might be better instructions in the factory 452 manual , if you can find it.

 

[Dool2]

 

[Dool2]

I imagine that the whole engine can be removed as a unit but in this case it appears they were stripping the engine also.

 

[Roy Gavin]

Usually not as daunting as it seems, I could swap cams in a Pre Unit Triumph easily in a day and that involved motor removal and splitting the crankcases .
After the first one, of course. And with a speedbrace on the sockets!

 

[Eatmore Mudd]

Do you have the Factory Service Manuals ?

 

[OldGuy]

I have the 2020 engine service manual if you want them - PM me. They aren't great, but better than nothing. They may be too big to email, but I'm sure we can work something out.

 

[Bluestrom13]

Euro 4 Engine Manual is available online to view or download, HERE.

Euro 4 Service Manual is available online to view or download, HERE.


Being in the US, will the 2022 engine be "Euro 5", and the '21 a Euro 4?
They can be identified by the air injection fitting over the exhaust port on the cylinder head,
The Euro4 has an open hole, the Euro5 just the blank casting,


Mechanically they will be interchangeable, but I recall a member discovering the electrical harness connections being different.
It may be necessary for OP to re-use his old magneto? (Which also controls ignition timing???).

 

[Roy Gavin]

First magneto change was before 2021, don't know if there were any more.
Parts numbers might not help--!
Easiest fix for incompatible connectors is Posiloks, they have been tested to work better than most sliding connectors, and if sealed with heat shrink probably more weather resistant too.

 

[Dool2]

A few weeks ago my engine blew on my Himalayan 411 2021. I have since found and purchased a Himalayan 411 2022 at auction for parts (it's a salvage title so I can't just start riding that). Does anyone have experience removing and replacing the engine on their 411? Thanks in advance, Jo (NYC)

Any reason for the engine blowing up that you are aware of?

 

[Turbofurball]

Have you ever done a motorcycle engine swap before? How much experience you have is going to greatly affect the sort of guidance you need. Also, if the engine failure was due to a problem outside of the engine itself you're going to need to resolve that or you'll blow up another engine!

 

[tom_d]

At about 7 minutes in, they begin removing the engine in this video and I hope it is helpful. It's not detailed instruction, but they capture lots of details on the way to a visual inspection of the entire engine's internals after 55k of life.

 

[RD52]

Never done it on a Himalayan, but for most bikes it's not too hard to R/R motors. Basic steps are:

Remove everything attached to the engine:
fuel tank
airbox
carburetors/throttle bodies (stuff a clean rag in the intake tract to prevent anything from falling into engine.)
exhaust
radiator and oil cooler, if applicable
hoses
electrical connections (often just the spark plug caps, wires from the stator/generator and ground strap, but sometimes other sensors)

If there's a frame rail or down tube that can be removed to make access easier, do that. (like in the video)
Support the engine. (like in the video)
Remove all mounting bolts that hold engine in place and ease engine out.

When it gets hung up and won't come out, go back and remove ground strap bolt that you forgot. I have a, um, friend who does that a lot.

Not a bad idea to record yourself with phone or GoPro, with a running commentary on what you're removing and any thoughts on what to watch out on re-install.

 

[RD52]

Hmm, no way to edit on this site?? Anyway, a couple of clarifications/corrections.

Put a rag in the exhaust port also! You can reduce the chances of a problem with FOD by turning the engine to TDC on compression stroke before starting.

When I say "everything" attached to the engine, use a little common sense there. Usually the intake boots between carb and head can stay. And on some V-Twins, the rear exhaust will have a short stub between the head and the main part of the exhaust, that can typically stay also.

 

[Dool2]

The Noob has not responded to any posts, which could indicate many things but does not show, to me, an interest in participating just a desire to take and not give back.
Just my opinion.