We plan to cross from India to Nepal (via Banbassa-Uttaranchal crossing)with our Enfield (Nov 2003). What are the formalities? Do they request vehicle insurance (we don't have?). How much do they charge to bring in the bike? Anything else we should know about the road from the border to Kathmandu?

We crossed into Nepal (at Sonauli) last March and it was very easy and some friends crossed this week and had no problems.
You don't need proof of insurance.
If your Enfield is Indian registered then you don't need a carnet but you do have to pay a small amount to import the bike temporarily. This is the same for any locals crossing the border, so it won't be expensive and the amount you pay depends on how long you want to be in Nepal.
You can get a visa on the border easily.
I don't know about the roads from the western border crossing, but understand that they're okay.
From Sonauli, there are two routes to Kathmandu:
Route one - head north on a paved highway which follows a very pretty river valley until you reach Mugling. There you turn east and just follow the main highway all the way to Kathmandu. This route can be busy, but Nepalese drivers are very poilte and it's not a problem - you can easily ride this in a day.
Route two - head east on a paved highway which skirts Chitwan National Park as far as Hetauda. Then head north on a rough track for about 100km that winds through the foothills and is full of switch backs. You get some great views this way, but it is hard work and tiring. At the end of this road, turn east on the main highway and it's about 25 km or so into Kathmandu. If you set off early from Sonauli you can ride this route in a day, but it's a long one!
Hope this helps.
Harvey

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no pipe, no slippers
www.chasingthesun.org

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no pipe, no slippers
www.chasingthesun.org