My Mods Thread - Royal Enfield Himalayan

[wachuko]

Folks, I do no have a Himalayan yet... I am planning on buying one. A 2023 (or 2022) in Gravel Gray or Granite Black.





In the meantime, I wanted to start documenting the changes that I want to make in the pursue of making the bike as light as possible. Knowing that I will be adding weight to it for the trips I have planned, I need to off-set some of that weight gain as much as possible.

Please, please, those that have made changes towards lighter parts, please chime in.

So far, this is the list that I have:

A. Performance:

1. TEC Performance Camshaft
2. Hitchcock's Air injection delete kit
3. For better brake performance (I did the same on my GT 650) - EBC HH brake pads for front and rear
4. For additional brake performance, replace front caliper with Harley Davidson HD Street 750 Front Brake Caliper 41300158A - Uses the same brake pads as stock. Difference is that the cylinders are 28mm vs 26 mm in the stock Himalayan caliper. Idea from this video
5. Another option, is installing different size sprockets... some good suggestions from fellow forum members.
6. Guessing I will need something like a FuelX with all the mods done...

B. Weight reduction (still researching, all these numbers from other owners or product websites):

1. RK Takasago 520 pitch chain and sprocket set - 3 lbs lighter than stock
2. YSS rear suspension - 4 lbs lighter than stock and would allow a 5mm drop in height (I know that is not much, but anything that helps me have my feet planted on the road is a plus)
3. Lithium (LiFePO4) battery - 5.5 lbs lighter than stock - one option IMP08-X
4. Delkevic carbon fiber complete exhaust system - 10 lbs lighter than stock - also need a spark arrester baffle
5. Wheels - replace stock rims with aluminum replacements - 10 lbs - I will replace with a set from Bart Factory
6. Tubeless setup - I think, have not weighted this, that getting rid of the inner tubes would save another 3lbs
7. Going solo so will be removing passenger pegs - ? lbs ?
8. Removing bumper peak. I really do not get why RE added that... just for looks I am guessing - ? lbs ? Or, leave the peak and remove the lower fender
9. Remove EVAP system - ? lbs ?
10. Hitchcock's Brake disc contoured for rear wheel. They claim it is lighter than the stock unit - ? lbs?
11. Replace all hardware (nuts and bolts) with titanium hardware. On this one, the cost is not worth the amount of weight loss.... but wanted to add it to the list...
12. Bar ends - ? lbs ?
13. Royal Enfield Adventure handle bar in aluminum - they claim it is 20% less weight than stock handlebar another option is to go with Renthal Handle bars.
14. Remove license plate mount. Relocate plate between turn signals - ? lbs ?
15. If not using, remove front pannier racks. Not sure yet on this. Yes, those are heavy and high up but they do provide some level of protection (if only minimal) - 6.5 lbs
16. Solo rider. So I really do not need the passenger pillion seat. I can replace that with the LUGGAGE PANEL, to replace pillion seat, Himalayan PART No. 91481 from Hitchcock's or some home made aluminum panel... and with that I can also remove the rear rack as this modification gives me a place to have the rolls with tent, chair, table, sleeping bag, etc. - ? lbs ?

C. Additional modifications:

1. Change headlight to LED. Proper LED headlight, not just swapping to a LED bulb.
2. Better seat. I like the one @Norton.Rider added to his bike... Seat Concepts ... I do hope this one is lower and lighter than stock. EDIT: Not lighter and not lower than stock... so I will stay with the stock seat
3. Replace all relays as preventive measure
4. Royal Enfield black side panniers - I do not need the third/top box.
5. Engine guard with better coverage
6. A set of RAM Arm mirrors - similar to these
7. Auxiliary LED driving/fog lights
8. Hand guards
9. Side stand larger foot plate - This clamps to the bottom of the existing side/prop stand to give an increased surface area to help prevent sinking in soft ground.
10. Rear brake cylinder guard
11. Larger foot pegs
12. Front fender raisers - if I keep the front fender...
13. When replacing the tires, compare also their weight. Considerable differences between brands.
14. Foldable gear shifter arm/peg - like this one
15. Replace all bearings with better quality units. Similar to what I did on my Continental GT 650
16. Replace the original starter relay with a Yamaha starter relay and the power/ground cables with 8 gauge cables.. What @Old Man Himmie did - link to post

• New Starter Relay Compatible With/Replacement For YAMAHA V-Star 1300 Deluxe XVS13BG 15 16 3D8-81940-00-00 12V https://a.co/d/96DQr0x
• Starter Solenoid Relay Plug... https://www.amazon.com/dp/B085NL656T?ref=ppx_pop_mob_ap_share

17. Enfield Accessories Himalayan Midi Mount - to mount the old Garmin Zumo 550 that I have

D. Spare parts for common problems:

1. Fuel pump assembly - common issue. Good insurance to have it handy.
2. Relays - I have spares from when I bought them for the GT 650. So in addition to changing them when I get the bike, I will keep a few spares in the bike.
3. Kawasaki brake light switch - better copper contacts instead of the steel contact in the stock switch.

E. Useful links:

1. New Himalayan FAQ Thread - outstanding thread and pdf with documented issues/recommendations
2. Adventurising your Himalayan

I will update the list as I go...

 

[Andyb]

Adding the RE panniers will put back the weight you saved elsewhere! There must be lighter options.
Crash bars can also be surprisingly heavy.
Easiest and cheapest way to save a little weight is to remove the bar ends. And the EVAP.
Some of the mods you suggest like alloy rims are not cheap.

 

[wachuko]

Adding the RE panniers will put back the weight you saved elsewhere! There must be lighter options.
Crash bars can also be surprisingly heavy.
Easiest and cheapest way to save a little weight is to remove the bar ends. And the EVAP.
Some of the mods you suggest like alloy rims are not cheap.

Thank you for your suggestions! The EVAP delete!!! I had the EVAP system removal on my notes but never made it to the post... Added to the list now .

On the panniers... I agree, there has to be a lighter alternative. I just need the ability to have storage. I was spoiled with the ones on the GSA... I had everything for a long trip in them. And because they were hard cases, everything kept well organized.

Crash bars... researching those now as well.

Also, I see a lot of folks having issues with the shifter when they go down. There has to be a way to protect the shifter... so need to see if there is a crash bar alternative that extend enough to protect the shifter???

Bar ends, I tend to keep those. I do not want issues with the steering from not having them. They do work.

 

[Andyb]

By bar ends I meant the handlebar end weights - they are meant to absorb vibration and do not effect the steering - I took mine out early on and no vibration. They also allow hand guards to sit inboard by about 1” each side so narrow the bike down.
I think someone makes a gear change lever with a hinge in it so it is less likely to get broken? Hitchcocks?
Storage - soft bags on the tank sides / tank bag / bag on a Hitchcocks rear seat replacement platform?

 

[Norton.Rider]

I'll have to measure the seat mate I'm quite curious I'll get dad to hold the bike tomorrow and try measure from a spirit level for you, I think Nathan Milward said in his latest video stock is about 860 when he measured it an the crf300 rally is 950!
I can rig something up to measure my Seat Concepts seat to the base is stock Himalayan so don't expect to much of a change on that it's interesting though I was saying to dad it'd be good lighten it off I saw someone posting about a battery that was 2kg lighter that could totally negate the weight of carrying a tent. I think the biggest change that could be felt Is unsprung weight as thatl improve handling, acceleration and stopping, the wheels were something I was considering doing further down the line

 

[wachuko]

By bar ends I meant the handlebar end weights - they are meant to absorb vibration and do not effect the steering - I took mine out early on and no vibration. They also allow hand guards to sit inboard by about 1” each side so narrow the bike down.
I think someone makes a gear change lever with a hinge in it so it is less likely to get broken? Hitchcocks?
Storage - soft bags on the tank sides / tank bag / bag on a Hitchcocks rear seat replacement platform?

Correct, I meant to say vibration in the handlebars. Great to see that you have not experience vibration after removing them. I will do the same. Let me update the list again.

I will add the to the search that shifter... need to be proactive on those changes... Same with some of the spare parts to keep handy, like a fuel pump...

 

[wachuko]

I'll have to measure the seat mate I'm quite curious I'll get dad to hold the bike tomorrow and try measure from a spirit level for you, I think Nathan Milward said in his latest video stock is about 860 when he measured it an the crf300 rally is 950!
I can rig something up to measure my Seat Concepts seat to the base is stock Himalayan so don't expect to much of a change on that it's interesting though I was saying to dad it'd be good lighten it off I saw someone posting about a battery that was 2kg lighter that could totally negate the weight of carrying a tent. I think the biggest change that could be felt Is unsprung weight as thatl improve handling, acceleration and stopping, the wheels were something I was considering doing further down the line

I just do not want to go that route if it increases reach significantly... appreciate checking.

 

[Manzaneeto]

I believe RE sells a lighter handlebar, which is confusing. Why don’t they just start with that one? Anyways, check out the parts catalog on RE’s website. Also, on their YouTube page they released this video, if money is no object

 

[wachuko]

I believe RE sells a lighter handlebar, which is confusing. Why don’t they just start with that one? Anyways, check out the parts catalog on RE’s website. Also, on their YouTube page they released this video, if money is no object

Very cool video. But I do not want to make such drastic changes.



That bike looks to be built for a taller guy... at 5'6", I need to keep it all stock height.

Wished there was an equivalent aluminum tank replacement... that has to be lighter than the stock unit. It would have to look just like the stock tank since I like the looks of it.



Anyway... looking at the photo above... I can remove the mount for the license plate and just place the plate higher. Between the turn signals when the rack kit is installed. I know, minimal savings...



Thank you for letting me know on the availability of an aluminum handle bar directly from Royal Enfield. Added to the list.

 

[Andyb]

I raised my bike’s number plate and the light above it onto the mudguard - which to me looks much better - but the raised light meant I had to cut away some of the transverse bracing bracket for the RE pannier frames (whch I don’t now have fitted).
Renthal make a range of good quality handlebars of much lighter / stronger alloy.
You can save a little weight removing the ‘choke’ lever and cable - personally never use it and it is not actually a choke.
If you are not going to fit tank mounted panniers, removing the tank side frames and converting the headlamp so it rotates with the forks would loose a lot of weight. And the rear rack can go.

 

[wachuko]

Thank you Andyb.

I do need the panniers and the rear rack for my gear... this is why I thought about placing it in the center area, between the turn signals





This is me next to my, now gone, F 850 GSA... great bike but it was very top heavy (well, it was heavy overall!! ) and also, I was too short for it... but what a great motorcycle for long distances! Loved that aspect of it.




Link to Renthal Handle bars. I will give the aluminum Royal Enfield handlebars a try first. Will switch to Renthal if those RE do not work out.

Choke (or what? High-idle?) cable removal. Good idea. Will add it to the list.

Removing the front racks did not even occurred to me... they look very cool but in reality, not sure if I will need those. I read that they are more for storage than for protection. If I replace them, I will need to see if there are aftermarket options for upper crash bars. Sorry to go back to the BMW, but it was the only bike I ever got to go out camping and off-roading... Some bars like these would be nice:




Thanks again for the suggestions. Let me update the list.


On another note, earlier today, I updated the link to the Delkevic exhaust system as I need one that could accommodate a flame arrester baffle. Required for riding on forest roads/trails...

.

 

[Andyb]

Unfortunately it is not possible to simply remove the tank racks as they support the headlamp and instrument panel. Someone in Europe was making a nice CNC set of brackets to do this job but I am not sure if they are still available?

 

[wachuko]

Unfortunately it is not possible to simply remove the tank racks as they support the headlamp and instrument panel. Someone in Europe was making a nice CNC set of brackets to do this job but I am not sure if they are still available?

Found another Himalayan owner that made modifications to the front using off the shelf parts... Weight savings of about 6.5 lbs





Here is the link to the article.

Again, not sure at this moment if this is something I want to do... I would definitely not modify the height of the windshield... I want the wind protection the new windshield provides. Modifying the bottom of it to contour to the new headlights is not an issue, I would be willing to do that.

 

[wachuko]

Unfortunately it is not possible to simply remove the tank racks as they support the headlamp and instrument panel. Someone in Europe was making a nice CNC set of brackets to do this job but I am not sure if they are still available?

I wonder if these are the brackets you were talking about? Does not fits 2022-2023 bikes plus looks these are sold out...

Street Himalayan Conversion Kit | Ride The Himalayan

himalayan-tools.com

 

[wachuko]

Another approach...

 

[Andyb]

Could well be the CNC made ones on the bike with the black / yellow / red tank that I was thinking of. If I could get hold of a set I have someone with CNC cutting / bending equipment…and the design could be tweaked. But I now have side panniers for the tank racks so those are staying on.
Windscreen - save judgement until you ride the bike a few miles. Most find the standard screen very noisy and the best solution seems to be to fit a much lower one, just to the top of the instruments. There is also safety to think of - I would not like to head butt the original.

 

[Bikeguy]

This company sells parts to convert a Himalayan in to a Scrambler style bike. Expensive though...

Kit conversion SCRAMBLER Himalayan 411 | hedgehogmotorcycles (hdghmotorcycles.com)

Another french site selling a complete kit

Kit Scrambler Himalayan 411 Hedgehog Motorcycles – blackpines.fr

 

[Triumph Thaiger]

If I was you I'd wait modifying,stripping, buying goodies etc until you have experienced throughly how the bike rides as stock. Running in period is useful for that .Also if you during that running in period find that after all the bike is not what you expected and hoped for you are likely to get a better price for a lightly used stock bike then a heavily modified one. I did modify mine as whilst doing many km's, I found , but this is entirely personal, that I hated the windscreen and thoroughly disliked the front frame /headlight holder arrangement.
Whilst, more so when the windscreen is ditched , the front frame looks the part I disliked my view right in front of the front wheel being obstructed . I searched for "motorcycle head light holder" on our local version of Ebay and bought one for the princely (equivalent ) sum of 5 EUR. I only used the clamps which go around the fork stanchions. The rest I made of 3mm thick 1 inch wide aluminium flatbar. The cradle for the instrument cluster I also made of alu flat bar . The latter needs shimming a bit to get into the right position, the shims I once again made of alu flat bar. Only further things needed were longer bolts for the handle bar clamps and a number of 5x 20 roundhead bols, springwashers and nuts . The entire project cost less then 15 Eur and a pleasant afternoon's work.

 

[Triumph Thaiger]

picture

 

[Bal Ra]

Are you trying to save all this weight to regain horsepower and torque? IF so maybe buy a Himalayan that has the big bore done to it or wait for the 450 newer version. BMW 1200cc to 411cc is a huge difference from where you were, I am coming from a Suzuki 650cc and I am more concerned with resolving small reliability issues. I can relate to you tho cause modding motos were made to keep men busy and sane