Himalayan Relay Upgrade and Headlight Update

[@coldpizza2.7k26]

Always looking for a good video on Himalayan repair. You explained the problem and solution clearly and the sound was good. I would suggest better lighting on the actual repair work as that’s crucial for understanding the steps needed to replace the parts. Thanks.

[@MidgardSurvival]

I have to same annoying rattle in my front end. I thought it was the cluster too, but now I am going to check the headlight! Thank you!

[@On2Feet]

I hope that you are able to solve your rattle as well.

[@johnbaker7626]

I had a cold start problem on my Euro 5 2021 Himalayan. I fitted Hitchcocks relay’s, 5 on the 2021 model, 4 under the seat and one under the side panel, right hand side. The old relays hadn’t failed, just the copious amount of thick grease that Royal Enfield uses, a bit like old tractor grease. However, Hitchcocks relays have a good reputation for reliability. Love the bike, big smile every time I get out on it. All the best, John

[@chuckwilliams6294]

Really enjoyed your Grand Canyon video. Regarding this video, the "grease" that you encountered on the relay pins, may in fact be a dialectic grease. If so, it facilitates conductivity, ie. current flow, and is best left in place. I have used it in Amateur Radio antenna applications where a conductive cylindrical aluminum antenna element slides into a slightly larger I.D. clamped element, and also on numerous vehicle connectors. I recently solved an intermittent front right turn signal anomaly on my 2020 BS-IV Himalayan that was driving me nuts, by simply adding a SMALL amount of this "dialectic grease" on the male pins of the turn signal connector, as well as the corresponding internal female pin slots. I also store my docs in a freezer bag under the seat as well, and have the same tank rail bags as you. Apparently, great minds think alike. Pics of my bike can be seen on the Himalayan USA users group.

[@On2Feet]

Ironically, dielectric grease is actually an insulator and does NOT conduct electricity. It's put on to help keep the pins from corroding. Too much though, and it can actually cause current flow issues. At least that's what the internet tells me ;-) ¯\_(ツ)_/¯

[@Hutchie2112]

These videos really are gold, thanks. Mine is a BS6, I think there are 4 (FOUR!) of those relays on mine for some reason. I'll make sure I get a couple of these from hitchcocks and keep them in my toolkit.

[@On2Feet]

I'm so glad to hear you are getting something out of these videos Hutchie. Just tonight my Signal/Hazard Flasher Relay stopped working (my blinkers stopped blinking!). After much digging I found the relay, but now need to order a replacement. There'll likely be a video on that at some point ;-)

[@chrisshelly1265]

Any bike shop should be able to get you a 65/100 watt H4 bulb. Very bright and inexpensive.

[@CoroElToro]

I've got 2 hima's with different brand headlights and i have bent the clips so they fit tighter. No problem at all

[@On2Feet]

I went back to the standard bulb and it's been totally fine. I actually ordered a high-output halogen from the UK and it's plenty bright.

[@Diakos-1821]

Thanks for the video. I made exactly the same experience. I’ll also go back to the standard configuration, but I will try other lamps like the “night breaker” or others. 👍

[@abhisheknegi2030]

I faced same issue, i upgraded to 24 Amp Denso Relay, also I have done Throttle position sensor adjustments, now she is smooth like butter :)

[@Sherlock_Ohms]

What did you adjust your throttle position sensor to?

[@abhisheknegi2030]

@@Sherlock_Ohms setting the tpfc voltage output to 6 volts

[@On2Feet]

Great to hear this. I honestly have not had any notable stalling issues since...

[@abhisheknegi2030]

@@On2Feet Stalling issue major reasons - 1- TPS sensor retired (set it to 6 Volts). 2- Relay (20 AMP) cuts. need to upgrade it to 24 25 AMP. 3- Fuel Tank cap (if GAS is forming inside the tank). 4- There is a charcoal canister in bottom of the engine, if it catches dirt, it then needs to replaced. 5- Finally fuel Pump. I faced same issue, I cleaned and calibrated these units, which actually fixed missing issue.

[@hasanshafiq]

Please share link for the product ✌️

[@OGrobdeo]

Much Thanks!💯🤙

[@adarshgajarajan7887]

Good Video. Would recommend to try a 130/100 H4 Bulb. It works flawless. I've had it on my Classic 500 and using the same on my Interceptor 650 as well.

[@CoastlinesCollide]

wouldnt the wattage be to high to run other accessories?

[@antonyross9957]

cheers for that, i have the same problem, best i check my relays !

[@gadibob]

Thank you for your excellent videos... Al of what I see! Regarding the relays, is this also good idea for 2022 model? Thank you!

[@marcvanheugten9472]

So if the bulb can move will that cause the lenses to let loose?

[@inigor-ac]

Hi, I was having the same issues and I have changed them today. Let's hope that fixes the problem. Quick question, I have seen in other similar videos Himalayan with 5 relays (4 under the seat and one near the battery), any idea why is that and when they changed the configuration? (I've buy my Himalayan this January in Peru). Thanks

[@slammermx]

Good information, did the swap fix the problem?

[@On2Feet]

I haven't had a single stall issue since swapping out the relays....so I definitely think it fixed the issues I was having.

[@thudtheace]

Did you get the fuel pump relay(I believe) that is clipped next to the battery? (accessible by removing the right side panel). I have a 2019 model that had the 2 under the seat and the 1 clipped next to the battery. Of course your model might not have it... Cheers!

[@danielben-avraham1539]

Changed out my relays using 30 amp automotive relays. My 2021 stalls usually at idle, hot and cold. I installed the relays while traveling with a hot engine. It had stalled several times in the city and as soon as I replaced the relays, the bike tried to stall but recovered. So now the hot stalling turned into hiccups. Still irritating but not nearly as dangerous when in heavy traffic. The cold stalling has not changed at all. I bypassed the EVAP which was plugged and not working anyhow, and no change in regard to the cold stalling. Although the bike runs much smoother and peppier with that fix. I tried bumping up the TPS voltage and no change to the stalling. Could it be a CPU issue? Who knows? RE?

[@JamesJohnson-ov5ct]

What Philips bulb did you put in? Been looking to upgrade the stock bulb but not with an led.

[@On2Feet]

I ordered the one from Hitchcocks as the European H4 bulbs are brighter: accessories.hitchcocksmotorcycles.com/accessory-shop/Bulbs-Lighting/21016

[@Lostandwondering]

Hey John thanks for replying i got my REH same colour as yours :O) today was my first day on the road after passing my written test and bike stalled twice excatly like you explained so i would like to ask do you think if i take the relays out clean the grease and then put them back in..and also please always post links for the products use i wanna buy the mount for helmet and the ram mount whatever you use so you can get a little bit bemnfit off of that once again thanks for amazing detailed vlogs mine is gonna be comming soon.

[@On2Feet]

Congrats on the new Bike! Sorry you are also having some stalling issues. I did what you said initially. I re-set the OEM relays and that seemed to temporarily fix the problem (I may have swapped them too). Then I also had the Throttle position sensor adjusted to help with cold start-stalling. Eventually, I bought these upgraded relays from Hitchcocks. The link for the relays is in the video description. I'll keep an eye out for your videos as well!

[@PubRunner]

I had one of those LED headlights and I found that I was out riding the beam at 60kph so I put the old headlight assembly back in with an LED bulb and it was so much better. The high beam leaves a bit to be desired tho so I am going to put in some driving lights to resolve that. I think one of the issues with the LED assembly is I had the headlight guard installed and because the source of light is so much smaller the shadows cast by the black grill are so much bigger...

[@On2Feet]

Yep...I had all of the same issues you note, and also ended up putting my old housing back in and just upgrading the light itself to something much brighter. I also found this LED housing vibrated a lot and caused the light to spin around while driving. I guess there was a reason it was cheap on Amazon!

[@PubRunner]

@@On2Feet the designers of the OEM headlights knew what they were doing when they designed them the OEM bulb sucked tho. The LED makes a Huge difference to low beam and I can safely ride at 100kph just using low beam.

[@chuckchase3395]

Hey John, your video is very well informed and user friendly, thank you. I like your tool kit and its canister, may I ask where you obtained these. Thank you

[@On2Feet]

I got them here: www.thetooltube.com/ToolTube.html

[@chuckchase3395]

Muchas, muchas gracias, Amigo

[@CristianoGabrielPereiraAlves]

Thanks for your videos and tips. Already subscribed! Could you share more info on the light bulb and the relays? Part numbers and where to buy them? Thanks

[@On2Feet]

I added the links to the video description

[@nihalahammed9137]

1 sec delay in starting even if started without pulling the choke bi starter ??

[@On2Feet]

My bike is definitely still a little temperamental from time to time....but once started, stays going (and doesn't stall)...which is the big thing I suppose

[@Kemrer]

Thank you

[@On2Feet]

sure thing. Hope this helps

[@asitpurohit_108]

Can you tell , why there is lot of current consumption when I started my himalayan , means like if I cold start the bike in winter , and after 5 times self start , bike didn't start , then battery goes down ...is it starter issue ??? I have installed new battery ...

[@rayhernandez4382]

I noticed comments about north American or Indian models, how can I find out what model is my Himalayan?

[@JasonKambak]

Did you refresh that dielectric grease? Its there for a reason.

[@yodab0y]

have you had any stalling issues after since replacing the relays?

[@On2Feet]

It's been a couple years now and so far, so good. No stalling issues other than the occasional cold start stall if it's been sitting for an extended period of time.

[@yodab0y]

@@On2Feet have you experienced any battery issues that seem to come up a lot when researching himalayan's pre-2021? ran into a guy with one who said the hitchcock's add on loom is a must-add. hopefully pulling the trigger on a 2021 shortly!

[@On2Feet]

@@yodab0y Congrats on the new bike! I have really enjoyed my Himalayan.I have not had battery issues, but I also keep my bike plugged into a trickle charger any time it's parked (and still on original batter). I have also taken multi-day camping trips and the battery has been fine. I know the issue you speak of and have seen the loom on Hitchocks. I have a US 2021 model but Hitchcocks also says the issue doesn't effect Euro 5 versions. Not sure if my 2021 has this issue or not, but as of now, it would seem that it doesn't. ¯\_(ツ)_/¯

[@yodab0y]

@@On2Feet do you know if the loom needs to be plugged in when the bike isn't in use (ie. parked at home)? or if it's even necessary until I experience any battery issues, or if upgrading the battery from the get-go would be best. I'd be keeping the bike covered outdoors during the season (don't have a garage unfortunately)

[@complexbentsimpler]

Hey can you give an update about the issue. It's been an year since you uploaded this. Is the issue sorted?

[@On2Feet]

Not a single problem since I've replaced these relays...and over 9000 miles now. I still have the stock headlight as well (although with a brighter bulb than factory).

[@shajik.damodaran8156]

Greetings from india, Very vital information brother, thanks, by the way what's the amperage of the new relays ?

[@On2Feet]

I ordered these. They are listed as 30/40 Amp. accessories.hitchcocksmotorcycles.com/accessory-shop/ignition/39317

[@shajik.damodaran8156]

Thanks for the quick response.

[@hansbachtold1966]

40AMP i guess

[@vikaspatel1987]

Hi sir. Whwre5do you get that c spanner from ?

[@On2Feet]

The link is the video description. I got it from Hitchcocks in the UK

[@jacksondiraviam]

Hey Great information Thank you

[@DatG-sx1co]

So, you are using 30/40 A relay while the stock is 20/10 A? Is not that relay you got too high ?

[@chrislmcnair]

Have you had any wobble issues at highway speeds?

[@On2Feet]

The only time my bike wobbled a little, was when I adjusted the chain and didn't exactly balance the tire. As soon as I noticed it, I readjusted the rear axle nuts/bolts and it was fine.

[@chrislmcnair]

@@On2Feet thank you!

[@thelastjourney2196]

Why does there two relau

[@On2Feet]

The two relays in my 2021 North American Model are fitted under the primary seat next to the battery. I think in the Indian and European model they are located elsewhere

[@gcprost]

I really appreciate you doing this video. I’m sure I won’t have any problems replacing the relays; however, it was difficult to see exactly what you were doing. I wonder how powerful the Himalayan’s charging system is. Is it up to the increased draw of the new bulb? Please let us know if you have any issues. I considered replacing all my bulbs with LED’s so that I could add accessory driving lights and USB outlet but I haven’t made a move yet. kzbin.info/www/bejne/baa6ZaCZbsSaj7c Actually I couldn’t locate the relays. Is your bike a 2021? Perhaps you could throw some light on that area under the seat.

[@On2Feet]

Sorry for the poor lighting Gerald. I realized that after I shot the video. I have a 2021 North American model. From what I understand, the relays are located in different places on the Euro models and the new Indian models (I think behind the side panels maybe?). I forget the total wattage that the Himalayan can support, but I know it comes with the halogen light, so the only thing I've really added as of now is a very small USB charger for my phone. If I ever do add the accessory lights, I'll need to check the draw to make sure the bike can support them for sure.

[@gcprost]

@@On2Feet Mine is also the North American model.

[@rupjyotikakati2458]

Where can i order these relay?

[@On2Feet]

I ordered them here: accessories.hitchcocksmotorcycles.com/accessory-shop/ignition/39317

[@hansbachtold1966]

Any 5pin Relay will do the trick. Look for a 40 Amp switching power.

[@hansbachtold1966]

Bosch or Hella. I dont trust does China Stuff.