Manual de Emsamble RE4S

ASSEMBLY MANUAL
RE 4 - STROKE (FACE LIFT)
SKD TO CBU
ASSEMBLY MANUAL
RE 4 - STROKE (FACE LIFT)
SKD TO CBU
Prepared by : Vipin Wagholikar
Checked by : Sampath Kumar
Approved by : Pramod Shahane

THIS PHOTOGRAPH AND INDUSTRIAL PROPERTY RIGHTS PERTAINING TO THIS PHOTOGRAPH , INFORMATION ARE EXCLUSIVE
PROPERTY OF " BAJAJ AUTO LTD. PUNE , INDIA".UNAUTHORISED USE OF THIS INFORMATION AND PHOTOGRAPH IS LIABLE TO
ATTRACT SUITABLE LEGAL ACTION
OPN NO. REV . NO OPERATION DESCRIPTION
10 0 LOCATION OF PARTS
20 0 GENERAL INFORMATION ( ABBREVIATION USED IN OPERATION SHEET )
30 0 UNPACK CRATE
40 0 ASSEMBLE REAR WHEEL LH & RH
50 0 ASSEMBLE STEERING COLUMN
60 0 ASSEMBLE FRONT WHEEL
70 0 POSITION MAT FRONT & REAR
80 0 ASSEMBLE CHARGED BATTERY
90 0 ASSEMBLE HANDLE BAR ASSEMBLY
100 0 CONNECT HYDRAULIC BRAKE HOSE & BRAKE OIL BLEEDING
110 0 ASSEMBLE REAR MUDFLAP LH & RH ASSLY
120 0 ASSEMBLE REAR MUGUARD LH & RH
130 0 ASSEMBLE TAIL LAMP LH & RH
140 0 ASSEMBLE BUMPER ASSEMBLY
150 0 ASSEMBLE PASSENGER SEAT
160 0 ASSEMBLE PASSENGER BACK REST
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
REV. DATE SIGN REVISION SHEET OPN.NO
OPN DESC: 1 OF 3
INDEX
PART NAME : RE 4 - STROKE PART NO.
VEHICLE ASSEMBLY
INTERNATIONAL BUSINESS
170 0 ASSEMBLE WIND SHIELD
180 0 FIT PIPE B PILLAR & ASSEMBLY BACKREST SUPPORT TOP
190 0 ASSEMBLE DRIVER BACK REST
200 0 ASSEMBLE BKT WIPER MOTOR MOUNTING
210 0 ASSEMBLE WIPER MOTOR ASSEMBLY
220 0 ASSEMBLE TRIM LH & RH
230 0 ASSEMBLE COVER WIPER MOTOR
240 0 ASSEMBLE PIPE SIDE HOOD FRAME LH & RH
250 0 ASSEMBLE HOOD COMPLETE
260 0 ASSEMBLE HOLDER BOTTLE
270 0 ASSEMBLE TOP COVER FOR HANDLE BAR
280 0 ASSEMBLE DASHBOARD COVER
290 0 ASSEMBLE FRONT NUMBER PLATE
300 0 ASSEMBLE REAR NUMBER PLATE
310 0 ASSEMBLE MIRROR LH & RH
320 INSPECT VEHICLE
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 2 OF 3
INDEX
VEHICLE ASSEMBLY
330 0 CO CHECKING
340 0 BATTERY CHARGING
350 0 SUB ASSEMBLY MUD FLAP FRONT
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 3 OF 3
INDEX
VEHICLE ASSEMBLY
9
6
3 8
10
1
7 5
2
4
SNO. PART DESCRIPTION

1 FRONT MUDGAURD ASSEMBLED WITH STEERING COLUMN
2 FRONT WHEEL
3 FRONT INDICATOR LH
4 REAR WHEEL LH
5 REAR MUDGAURD LH
6 HOOD COMPLETE
7 SPARE WHEEL
8 DRIVER SEAT
9 DRIVER BACK REST
10 PASSANGER SEAT
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 1 OF 4 10
LOCATION OF PARTS
VEHICLE ASSEMBLY
16 17
13
15
11
14
12

11 REAR MUDGAURD RH
12 REAR WHEEL RH
13 MAT REAR
14 BATTERY
15 MAT FRONT
16 HANDLE BAR
17 FRONT INDICATOR RH
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 2 OF 4 10
LOCATION OF PARTS
VEHICLE ASSEMBLY
18 19
21 20
22

18 MIRROR ASSLY RH
19 MIRROR ASSLY LH
20 WIPER BLADE
21 WIND SHIELD ASSLY
22 FRONT NUMBER PLATE
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 3 OF 4 10
LOCATION OF PARTS
VEHICLE ASSEMBLY
23 24
25
26
28
27

23 TAIL LAMP ASSLY LH
24 TAIL LAMP ASSLY RH
25 REAR NUMBER PLATE
26 BUMPER ASSLY
27 MUD FLAP REAR LH
28 MUD FLAP REAR RH
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 4 OF 4 10
LOCATION OF PARTS
VEHICLE ASSEMBLY
Following 'abbreviation' are used in operation sheet.
Abbreviation used in operation sheet are as follows :
A ) ' Comp ' --------- Component
B ) ' Assly ' --------- Assembly
C ) ' LH ' --------- Left hand side
D ) ' RH ' --------- Right hand side
E ) ' OPN. NO ' --------- Operation number
F ) ' OPN. DESC ' --------- Operation description
G) ' Sr' --------- Serial number.
H) ' No ' -------- Number.
I) ----------------- Grey colour is used in operation sheet to indicate

TORQUE VALUE .
J) ----------------- Green colour is used in operation sheet to indicate
CHECK POINT .
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: GENERAL INFORMATION 1 OF 2 20
( ABBREVIATION USED IN OPN. SHEET )
VEHICLE ASSEMBLY
General tightening torque values for various size of hardwares are

as follows:
1 ) M5 X 0.8 ------------------ 0.3 TO 0.4 KGM
2 ) M6 X 1 ------------------ 0.6 TO 0.8 KGM
3 ) M8 X 1.25 ------------------ 2 TO 2.5 KGM
4 ) M10 X 1.5 ------------------ 3.2 TO 3.8 KGM
USE DIAL INDICATING TORQUE WRENCHES IN CASE OF TIGHTENING

BY HAND TOOLS.
1 ) DIAL INDICATING TORQUE WRENCH - UPTO 2 KGM TORQUE VALUE.
2 ) DIAL INDICATING TORQUE WRENCH - UPTO 7 KGM TORQUE VALUE.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: GENERAL INFORMATION 2 OF 2 20
( ABBREVIATION USED IN OPN. SHEET )
VEHICLE ASSEMBLY
Pneumatic tools
Hydro pneumatic nut runner -
UL- 90
Socket : 1/2" SQ X 17 A/F
Optional Hand tools
T- spanner - 17 mm
Open end- spanner - 17 mm
Cutter for strap
Wrench for socket
1 ) As shown in the above photograph the Steel crate used for the packing of 3-WH RE 145.
2 ) Dimension of Steel crate is 1320 ( Length) x 915 ( Width ) x 2500 ( Height ) mm.
Extended polythene sheet
3) Take out extended polythene sheet by removing the cello tape used to join with main
polycover .
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 1 OF 15 30
UNPACK CRATE
VEHICLE ASSEMBLY
Take out rear side cross bar
4 ) Take out Rear side cross bar by removing 2 nos. left & 2 nos. right hand side bolts & nuts
using 17 mm socket with wrench & keep aside.
Extension frame
5 ) Take out Extension frame by removing 4 nos. left & 4 nos. right hand side bolts & nuts
using 17 mm socket with wrench & keep aside.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
6 ) Remove the polythene cover from the Steel crate & keep aside.
Take out front
7 ) Take out Front side cross bar by removing 1 no. left & 1 no. right hand side bolt using 17
mm socket with wrench & keep aside.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
Lock trailing arm
8 ) Go to Rear side of crate & take out Lock trailing arm left & right hand side by removing 1 no.
each bolt using 17 mm socket with wrench & keep aside.
Provide soft support below
9 ) Position the Steel crate horizontally & provide soft support having 400 mm height below the
scudo of vehicle.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
Cut the plastic strap & cotton rope
10 ) Cut the plastic strap & cotton rope using cutter, remove wheel assly placed at top side from
vehicle & keep on trolley.
11 ) Cut the plastic strap & band using cutter, remove Bumper assly, Backrest support top, Pipe
B pillar, Pipe side hood frame LH & RH ,tied at top side of body assly's cross bar & keep on
trolley.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
12 ) Cut the plastic strap used to tied the Steering colomn box placed at passanger leg room
using cutter.
Steering colomn box
13 ) Cut the plastic strap used to tied the hood frame assly , windshield assly ,hood complete
box at driver's leg room using cutter, tilt hood frame assly towards body rear side, remove
steering colomn box from vehicle & keep aside.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
14) Take out passanger seat & passanger backrest from passager legroom of the vehicle &
keep on trolley.
Rear mudgaurd box Hood complete box

15) Take out Rear mudgaurd box from passager legroom of the vehicle & keep aside.
16) Take out Hood complete box placed over windshield assly in driver legroom of the vehicle &
keep on trolley.
Driver backrest
Windshield assly
17) Take out Windshield assly packing from driver legroom of the vehicle & keep on trolley.
18) Take out driver backrest placed over the driver seat of the vehicle & keep on trolley.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
SA box
19) Take out SA box from driver legroom of the vehicle & keep aside.
20 ) Tilt Hood frame assly towards driver's leg room.
21) Take 2 - nos. Screw jacks & position one Screw jack below the main member of the chassis
at left hand side & another one below the main member of chassis at right hand side as shown
above.
22) Lift the vehicle from rear side by screwing the jack up to 90 mm height from left & right
hand sides equally.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
23 ) Press the vehicle gently from Scudo side as shown above & take out steel crate carefully
from the vehicle.
24 ) Cut the strap used to tie the Handle bar assly & key on the dashboard of the vehicle using
cutter. Remove the straps.
25 ) Collect key & keep aside.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
26 )Take out Steering plates assembled on dashboard's 2 nos. studs & keep the flange nuts in
a bin.
27 )Tilt Handle bar towards driver seat side.
28 )Remove plastic block positioned over upper race.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
Steering colomn box
Steering colomn assly
Mat front
Polythene bag no. - 1 contents Polythene bag no. - 3 contents
Polythene bag no. - 2 contents
29 ) Collect Steering colomn box, open it , take out & arrange it's contents on trolley / table /
bins.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
Contents of Steering colomn box are as belows:-

1 ) Wheel assly - 2 nos.
2 ) Mat front
3 ) Mat Rear
4 ) Steering colomn assly with front mudgaurd
5 ) Polythene bag containing Hardwares for :-
5a ) Bag no. -1 :- Hardwares for Handle bar
5b ) Bag no. -2 :- Hardwares for Rear & Front wheel assemblies.
5c ) Bag no. -3 :- Ball cage lower & upper for Steering colomn fitment.
30 ) Remove the hardwares prefitted on steering colomn assly & keep in bins.
Rear mudgaurd box
31 ) Collect Rear mudgaurd box, open it , take out 2 nos.Rear mudgaurds from it, remove
polythene bags packing from the items & arrange in trollies.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
SA box
32 ) Collect SA box, open it , take out 23 types items, unpack & arrange in partition bin / bins.
Details of SA box items are shown below & next page.
1
2 3
9
4
8
6 7
5
13 14
10 11
12
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
15
17
16
19
18
23
21
20
22
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
Details of SA box items
S.no. Item detail Qty

1 Pouch for Grommet & spacer 1
2 Joint plate LH 1
3 Joint plate RH 1
4 Cover wiper motor 1
5 Hardware pouch for hood,windshield,seats 1
6 Sleeve bumper side 2
7 Sleeve bumper center 1
8 Number plates 2
9 Wiper motor box 1
10 Front number plate bracket 1
11 Bracket for wiper motor mounting 1
12 Polythene bag for mud flap front & rear 1
13 Tail lamp assly LH 1
14 Tail lamp assly RH 1
15 Trim small RH 1
16 Trim small LH 1
17 Dash board cover 1
18 Wiper blade assly 1
19 Mirror assly box 1
20 Holder bottle 1
21 Strip aluminium Bigger 1
22 Strip aluminium small 1
23 Tool kit 1
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
UNPACK CRATE
VEHICLE ASSEMBLY
SNO. PART NO DESCRIPTION QTY / VEH REMARK
1 52AP0214 Rear wheel assly 2

2 39182812 Spring washer 8
3 39095615 Nut hex.M8 X 1.25 8
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 1 OF 3 40
ASSEMBLE REAR WHEEL LH & RH
VEHICLE ASSEMBLY
Pneumatic tools
UL- 90
Optional Hand tools
T- spanner - 17 mm
Torque wrench :
Tohinichi 900 QSP.
Tightening sequence
4
1
2 3
Assembly sequence
1 ) Collect Rear wheel assly ( Sr.no -1 ) 1- no. & locate on 4 - nos. studs of the drum assembled
on Trailing arm assly left hand side.
2 ) Prefit Spring washer ( Sr.no -2 ) 4 -nos. & Nut hex.M8 X 1.25 ( Sr.no -3 ) 4 -nos. on studs &
tighten in cross sequence.Apply torque wrench & confirm torque value of 4 nuts.
3 ) Hold Rear wheel assly & tighten the Nuts in cross sequence to a snug fit.
4 ) Apply torque wrench & confirm torque value of 4 nuts.

CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 2 OF 3 40
VEHICLE ASSEMBLY
Tightening sequence
4
1
2 3
5 ) Repeat the Assembly sequence no. from 1 to 4 for Rear wheel assly right hand side
fitment.
* Torque value for Rear wheel Nut (Sr. no.- 3 )- 4.0 to 5.0 kgm.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 3 OF 3 40
VEHICLE ASSEMBLY
7 6 5 4 1 3
1 AB181017 Ball cage upper 1

Steering colomn assly with front mudgaurd
2 ************* 1
& mudflap
3 AB181012 Ball cage lower 1
4 24161443 Dust cap 1
5 AB181019 Bearing race upper outer 1
6 AB181020 Spacer Washer bearing 1
7 24181047 Nut Lock ring 1
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 1 OF 4 50
ASSEMBLE STEERING COLOMN
VEHICLE ASSEMBLY
Pneumatic tools
Nil
Hand tool
Fork spanner
Wrench
Anti lock spanner
Torque wrench
Tohinichi -225 QSP
Tohinichi -900 QSP
Consumables
Grease MP-3
Brush - 1/2 "
Assembly sequence
1 ) Apply Polythene bag on Front mudguard assembled on Steering colomn.
2 ) Apply grease MP-3 on upper bearing race pressed on progressive vehicle.
3 ) Collect Ball cage upper ( Sr.no -1 ) & position on upper bearing race.
4 ) Apply grease MP-3 on bearing race lower pressed on Steering colomn assly with front
mudgaurd & mudflap ( Sr.no -2 ) & position Ball cage lower( Sr.no -3 ) on it.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 2 OF 4 50
VEHICLE ASSEMBLY
5 ) Insert Steering colomn assly with front mudgaurd & mudflap through steering pipe of
vehicle.
6 ) Position Dust cap( Sr. no - 4 ) & Prefit Bearing race upper outer ( Sr. no - 5 ) on the steering
pipe threads of the Steering colomn assly with front mudgaurd & mudflap.
7 ) Tighten the Bearing race upper outer using fork spanner manually to a snug fit.
Tighten the Bearing race upper outer using torque wrench to achieve torque value
from 0.6 to 0.7 kgm. .
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 3 OF 4 50
VEHICLE ASSEMBLY
8 ) Prefit Spacer Washer bearing ( Sr. no - 6 ) & Nut lock ring ( Sr. no - 7 ) on the steering pipe
threads of the Steering colomn assly with front mudgaurd & mudflap.
Antilock spanner for holding bearing race upper
outer
9) Hold the Bearing race upper outer using Antilock spanner & tighten Nut lock ring using fork
spanner on threads of the Steering colomn assly with front mudgaurd & mudflap to a snug fit.
Hold the Bearing race upper outer using Antilock spanner, tighten the Nut lock using
torque wrench to achieve torque value from 4.5~5.0 kgm.
Check the freeness of Steering colomn assly with front mudgaurd & mudflap .
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 4 OF 4 50
VEHICLE ASSEMBLY
1 52AP0214 Front wheel assly 1

2 39182812 Spring washer 4
3 39095615 Nut hex.M8 X 1.25 4
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 1 OF 3 60
ASSEMBLE FRONT WHEEL
VEHICLE ASSEMBLY
Pneumatic tools
UL- 90
Optional Hand tools
T- spanner - 17 mm
Torque wrench :
Tohinichi 900 QSP.
Assembly sequence
1 ) Collect Front wheel assly ( Sr.no -1 ) & locate on 4 - nos. studs of the drum assembled on
Steering column assly.
2 ) Prefit Spring washer ( Sr.no -2 ) 4 -nos. & Nut hex.M8 X 1.25 ( Sr.no -3 ) 4 -nos. on studs.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 2 OF 3 60
VEHICLE ASSEMBLY
Tightening sequence
1
3
4
2
3 ) Hold Front wheel assly & tighten the Nuts in cross sequence to a snug fit.
4 ) Apply torque wrench & confirm torque value of 4 nuts.
* Torque value for Front wheel's Nuts (Sr. no.- 3 )- 4.0 to 5.0 kgm.
5 ) Remove the plastic cover from Front fender assly.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 3 OF 3 60
VEHICLE ASSEMBLY
1 2
1 24165215 Mat front floor FL 1

2 24231473 Matting rear 1
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 1 OF 2 70
POSITION MAT FRONT
VEHICLE ASSEMBLY
Pneumatic tools
Nil
Hand tools
Open end spanner - 14 mm.
Assembly sequence
1 ) Collect & position Mat floor front (S.No -1) in driver's leg room.
2 ) Collect & position Matting rear (S.No -2) in Passanger's leg room.
3 ) Apply key on battery lock , take out battery lock from clamp , take out battery lock nut from
clamp , open battery clamp , take out dry charge battery from vehicle & arrange on trolley to
sent to battery charging area.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 2 OF 2 70
POSITION MAT FRONT
VEHICLE ASSEMBLY
1 BA201067 Charged battery 12V 32AH 1
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 1 OF 6 80
ASSEMBLE CHARGED BATTERY
VEHICLE ASSEMBLY
Pneumatic tools
Nil
Hand tools
T - Spanner - 10 mm.
Consumables
petroleum jelly
1/2" Brush
Assembly sequence
1 ) Collect Charged battery (S.No -1) & position on base battery.
2 ) Prefit & then tighten Charged battery on base battery using battery arrester & lock nut.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 2 OF 6 80
VEHICLE ASSEMBLY
3 ) Fix Battery lock on the lock nut.
4 ) Collect positive terminal harness ( Red colour) & Remove the Square bolt, nut from it &
keep aside.
5 ) Connect positive terminal harness connector on Charged battery LH side terminal.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 3 OF 6 80
VEHICLE ASSEMBLY
6 ) Tighten positive terminal harness connector on Charged battery LH side terminal using
Square bolt & Nut.
7 ) Position red colour cap on Charged battery LH side terminal.
8 ) Collect negative terminal harness ( Black colour) & Remove the Square bolt, nut from it &
keep aside.
9 ) Connect negative terminal harness connector on Charged battery RH side terminal.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 4 OF 6 80
VEHICLE ASSEMBLY
10 ) Tighten negative terminal harness connector on Charged battery RH side terminal using
Square bolt & Nut.
11 ) Position Black colour cap on Charged battery RH side terminal.
Connect positive connector first & then negative connector of main harness on
Charged battery terminals.
Apply petroleum jelly on negative & positive terminals of Charged battery.
12 ) Following cautions to be followed during charged Battery installation.
a) Ensure that in all cells the level of electrolyte is near the maximum level mark.
b) To clean & dry the surface, wipe the top of the battery with a clean cloth. Fasten the battery
firmly with bracket and allied fasteners.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 5 OF 6 80
VEHICLE ASSEMBLY
c) Connect cables to the positive and negative terminals properly. Reverse connections will
damage the charging system permanently.
d) Always connect the “negative (earthing) terminal last”.
e) Clean the battery terminals and cable connections. Smear them with petroleum jelly to avoid
corrosion (NEVER USE ORDINARY GREASE).
f) Route the battery vent tube properly. Do not fold or crimp as it may cause damage to the
battery.
g) Check that the battery cables connections are firm and cables do not rub against any metal
components.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 6 OF 6 80
VEHICLE ASSEMBLY
6 2
1 7
Steering plates
3 4
1 52AA0341 Handle bar assly 1

2 39069415 Nut hexagon M8 2
3 39137704 Bolt hex with collar 1
4 39020111 Plain Washer 1
5 39029615 Nut flange M10 1
6 21180307 Knob 1
7 21180308 Spring 1
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 1 OF 4 90
ASSEMBLE HANDLE BAR ASSLY
VEHICLE ASSEMBLY
Pneumatic tools
UL- 70
Ring spanner - 14 mm
Optional Hand tools
Ring spanner - 13 mm
Open end spanner - 14 mm
Torque wrench :
Tohinichi 450 QSP.
Assembly sequence
1 ) Tilt Handle bar upside & Position lower side steering plate on dash board's 2 welded studs .
2 ) Insert Handle bar (S.No -1) on steering colomn & Position upper side steering plate on dash
board's 2 welded studs .
* Allign the Handle bar's bolt hole with the relieve of Steering column assly while
positioning the Handle bar.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 2 OF 4 90
VEHICLE ASSEMBLY
3 ) Prefit & tighten Flange nut (S.No -2 ) 2 -nos. on dash board's welded studs.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 3 OF 4 90
VEHICLE ASSEMBLY
4 ) Prefit Handle bar assly on steering colomn using Hexagonal bolt (S.No -3)along with Plain
washer (S.No -4) from LH side & Nut flange M10 (S.No -5) from RH side.
5 ) Hold the Bolt head with spanner & tighten the nut.
* Torque value for the Hexagonal bolt - 4 to 4.5 kgm.
6 ) Assemble Knob (S.No -6) along with Spring (S.No -7)on 2 nos. steering plates.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: 4 OF 4 90
VEHICLE ASSEMBLY
1 Hydraulic brake hose 1
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: CONNECT HYDRAULIC 1 OF 5 100
BRAKE HOSE & BRAKE OIL BLEEDING
VEHICLE ASSEMBLY
Pneumatic tools
Nil
Hand tools
T - spanner - 17 mm.
Take out brake hose pipe routed in steering colomn outside
Assembly sequence
1 ) Take out Brake hose pipe (S.No -1) routed in steering colomn to out side.
2 ) Take out plastic plug fixed on Brake hose pipe end side connector.
3 ) Insert the Brake hose pipe end side connector through Scudo hole.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
4 ) Fix the grommet provided on Brake hose pipe on Scudo hole.
Place cotton cloth below the Cylinder comp. tandem master & Brake oil container
area.
5 ) Take out 1 - no. Benjo bolt & 2- nos. Copper washers assembled on Cylinder comp. tandem
master & keep aside.
6 ) Prefit Brake hose pipe end side connector on Cylinder comp. tandem master using 1 - no.
Benjo bolt & 2- nos. Copper washers as shown in above photographs.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
7 ) Tighten the Benjo bolt.
8 ) Fill brake oil DOT - 3 or equlvalent 375 ml in the brake oil container.
9 ) Open the air bleeding screws mounted on the Front & rear wheel's master cylinder of wheel
assemblies.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
10 ) Operate the brake pedal continuously & remove air entrapped in the hydraulic brake pipe &
wheel cylinders. Tighten the air bleeding screw using open ended spanner 8 mm as soon as
the oil splashing starts coming out from mounting hole of air bleeding screw.
11 ) After completion of brake oil bleeding operation, operate brake pedal & inspect visually at
joints & fittings for leakage of brake oil.
12 ) Tighten the cap on brake oil container.
CAUTION
Brake fluid may ruin the painted surface. Care must be taken while filling the brake
fluid not to spill it on the painted parts.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
1b 1a
1 52AA0362 Mud flap assly set 1

1a ************ Mud flap rear RH assly 1
1b ************ Mud flap rear LH assly 2
2 39007104 Hex head screw M5 4
3 KCGA0505 Nut hex flanged 4
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE REAR MUDFLAP LH & RH
VEHICLE ASSEMBLY
RH side mud flap assly Pneumatic tools

Nil
Hand tools
T - Spanner - 8 mm.
LH side mud flap assly
Assembly sequence
1 ) Collect & insert Bolt flange (S.No -2) 2- nos. Body assly right hand inner side 2 - holes for
Mud flap rear RH assly fitment.
2 ) Hold the 2 nos.Bolt flange from Body assly right hand inner side & prefit Mud flap rear RH
assly (S.No -1a) on outer side of Body assly using Nut flange (S.No -3) 2- nos.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
3 ) Hold the Bolt flange from Body assly right hand inner side using T spanner & tighten the Nut
flange from Body assly outer side .
4 ) Repeat the Assembly sequence no. from 1 to 3 for Mud flap rear LH assly (S.No -1b)
fitment on Body left hand side.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
1 24231757 Rear mudguard 2

2 25231064 Beading for mudgaurd 2
3 KCDA0504 Nut hex 8
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE REAR MUDGUARD LH & RH
VEHICLE ASSEMBLY
Pneumatic tools
Nil
Hand tools
T - Spanner - 8 mm.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
Assembly sequence
1 ) Collect Rear mudgaurd(S.No -1) & fix Beading (S.No -2) on it.
2 ) Position Rear mudgaurd on Body assly left hand side, insert it's 4 - nos. studs through body
holes as indicated in above photographs & prefit using Nut hex (S.No -3) 4 - nos. from Body
assly inner side.
3 ) Tighten the Nut hex.
4) Repeat the Assembly sequence no. from 1 to 3 for Rear mudgaurd fitment on Body from
right hand side.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
2 1
1 24201473 Tail lamp assly RH 1

2 24201472 Tail lamp assly LH 1
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE TAIL LAMP LH & RH
VEHICLE ASSEMBLY
Pneumatic tools
Nil
Hand tools
Assembly sequence
1 ) Collect Tail lamp assly RH (S.No -1), reverse it , remove 4 nos. flange nuts & 2 nos.
brackets from it & keep side.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
2 ) Position Tail lamp assly RH on Body assly RH side & prefit 2 nos. brackets & 4 nos. flange
nuts on it's studs from inner side of Body assly.
3 ) Tighten the flange nuts.

Torque Value for Tail lamp flange nut - 0.4 to 0.5 kgm.
4 ) Connect Tail lamp assly RH coupler with main harness coupler.
5 )Repeat the Assembly sequence no. from 1 to 4 for Tail lamp assly LH(S.No -2) fitment.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
1 1
1 24165274 Sleeve bumper mtg side FL 2

2 24165273 Sleeve bumper mtg mid FL 1
3 24165137 Bumper assly 1
4 KAAG0885 Bolt-KAA ST-G dia-08 L-85 2
5 KAAG0875 Bolt-KAA ST-G dia-08 L-75 1
6 KDAB1018 Washer plain small 3
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE BUMPER ASSLY
VEHICLE ASSEMBLY
Pneumatic tools
1. Pneumatic Nut Runner UL-
70
2.Socket :1/2" SQ X 12 A/F
Hand tools
Assembly sequence
1 ) Collect Sleeve bumper mtg side FL (S.No -1) 2- nos. & insert 1- no. each in LH & RH rear
side holes of Body & Chassis assly.
2 ) Collect Sleeve bumper mtg mid FL (S.No -2) & insert in middle rear side hole of Body &
Chassis assly.
3 ) Collect Bumper assly (S.No -3) & locate it's 3 holes on Sleeves.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
4 ) Prefit Bumper assly on Body assly using Bolt-KAA ST-G dia-08 L-85 (S.No -4) 2- nos. along
with Washer plain small (S.No -6) 2- nos. on LH & RH side holes.
5 ) Prefit Bumper assly on Body assly using Bolt-KAA ST-G dia-08 L-75 (S.No -5) along with
Washer plain small (S.No -6) on middle hole.
6 ) Tighten the Bolts.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
1 AA231110 Passenger seat 1

2 Plain washer 2
3 39079815 Nut hexagon with flange M6 2
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE PASSANGER SEAT
VEHICLE ASSEMBLY
Pneumatic tools
Welded bkts on body for passanger seat mounting
Nil
Hand tools
Assembly sequence
1 ) Collect & position Passanger seat (S.No -1) on Body assly.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
2 Studs on passanger seat for mounting as indicated below
2 ) Insert the Passanger seat studs in Body assly's welded brackets & prefit Plain washer (S.No
-2)1-no. & Hex nut (S.No -3) 1-no. on each stud.
3 ) Tighten the nuts.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
1 24211009 Passenger backrest 1

2 24231421 Spacer behind back rest 3
3 Plain washer 3
4 39079815 Nut hexagon with flange M6 3
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE PASSANGER BACK REST
VEHICLE ASSEMBLY
Pneumatic tools
Nil
Hand tools
Assembly sequence
1 ) Collect & position Passanger backrest (S.No -1) on Body assly.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
3 Studs on passanger back rest for mounting as indicated below
Insert spacers on 3 Studs of passanger back rest as shown below
2 ) Collect Spacer (S.No -2) 3- nos. & insert in Passanger backrest studs.
3 ) Insert Passanger backrest 3 studs in Body assly holes.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
4 ) Collect & prefit Plain washer (S.No -3) & Hex nut (S.No -4 )1-no. each on 3 studs from inner
side of Body assly.
5 ) Tighten the 3 - nos. Nuts.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
6 7
8
3
4 9
5
10
1 24231641 Packing Wind shield 1

2 52240684 Single piece wind shield assly with utility box 1
3 KAAA0522 Bolt hexagon 11
4 39025811 Plain washer 22
5 39248415 Nut flange - M5 11
6 24231615 Joint plate left hand side. 1
7 24231616 Joint plate right hand side. 1
8 KAAA0516 Bolt-KAA ST-A dia-05 L-16 8
10 39032615 Nut nyloc M5 X 0.8 8
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE WIND SHIELD
VEHICLE ASSEMBLY
Pneumatic / Electrical tools
Hydro pneumatic nut
runner 2 RLNS
Optional hand tools
Open end spanner- 8 mm
T spanner- 8 mm
Assembly sequence
1 ) Collect Rubber packing (S.No -1 ) & position over the Scudo of the vehicle alligning the 11
nos. holes.
2 ) CollectSingle piece wind shield assly with utility box (S.No -2) & position over the Scudo of
the vehicle alligning the 11 nos. holes.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
1
11 10
9 8
6
7
5 4
3 2
3 ) Follow the below mentioned sequence for Windshield assly prefitting & tightening on Scudo
of the vehicle.
1. 1 (Bolt in the center)
2. 2 – 3
3. 4 – 5
4. 6 – 7
5. 8 – 9
6. 10 – 11
e.g. Collect & insert Bolt (S.No -3 ) 1-no. along with Plain washer (S.No -4 ) 1 - no. into center
hole ( 1st ) of Scudo, rubber packing ,Windshield assly from lower side & prefit Nut flange - M5
(S.No -5 ) 1 - no. along with Plain washer (S.No -4 ) 1 - no. on Bolt from upper side.Follow the
same for remaining holes.
4 )Connect LH & RH side Front indicator harness couplers with Main harness couplers & route
in pocket provided on Dashboard.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
5 )Collect Joint plate right hand side(S.No -7 ) & locate on Wind shield assly & Scudo.
6 ) Prefit Joint plate right hand side using Bolt-KAA ST-A dia-05 L-16 (S.No -8 ) 4 -nos. along
with Plain washer (S.No -9 ) 4 -nos. from inner side holes & Plain washer (S.No -9 ) 4 -nos. &
Nut nyloc M5 X 0.8 (S.No -10 ) 4 -nos. from outer side holes of Wind shield & Scudo.
7 ) Hold the Nuts & tighten the bolts.
8 ) Repeat the Assembly sequence no. 5 to 8 for Joint plate left hand side fitment.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
1 24231742 Pipe B pillar 1

2 24231620 Assembly backrest support top 1
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: FIT PIPE B PILLAR & 1 OF 2 180
ASSEMBLY BACKREST SUPPORT TOP
VEHICLE ASSEMBLY
Pneumatic tools
Nil
Hand tools
Nylon hammer
Assembly sequence
1 ) Collect Pipe B pillar (S.No -1) & Assembly backrest support top (S.No -2).
2 ) Insert the Pipe B pillar in Assembly backrest support top tubes.
3 ) Locate & fit the Pipe B pillar & Assembly backrest support top assly on Body assly.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
OPN DESC: FIT PIPE B PILLAR & 2 OF 2 180
ASSEMBLY BACKREST SUPPORT TOP
VEHICLE ASSEMBLY
1 24231566 Driver back rest 1

2 Nut flange 4
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE DRIVER BACK REST
VEHICLE ASSEMBLY
Pneumatic tools
Pneumatic nut runner -Ux 612
Optional hand tools

T- spanner - 8 mm.
Assembly sequence
1 ) Collect & position Drive back rest (S.No -1) on Support top & Body assly's cross bar welded
brackets by inserting it's 4 studs.
2 ) Prefit Nut flange (S.No -2) 4 - nos. on 4 studs of Driver back rest.
3 ) Tighten the nuts in cross sequence.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE DRIVER BACK REST
VEHICLE ASSEMBLY
1 24231625 Bracket wiper motor mounting 1

2 KADA0512 Bolt flanged M5 L12 2
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE BKT WIPER MOTOR MTG
VEHICLE ASSEMBLY
Pneumatic tools
Optional hand tools

T- spanner - 8 mm.
Assembly sequence
1 ) Collect & position Bracket wiper motor mounting (S.No -1) on Wind shield from inner side.
2 ) Prefit Bolt flanged (S.No -2) 2 - nos. as shown.
3 ) Tighten the Bolt flanged.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE BKT WIPER MOTOR MTG
VEHICLE ASSEMBLY
1 AA201263 Wiper motor big FL 1

2 KADA0620 Bolt flange-KAD ST-A dia-06 L-20 3
3 24201525 Grommet wiper motor big FL 1 Prefit on Wiper motor
4 BH111071 Cap wiper motor big FL 1
5 AL241023 Wiper blade assly 1
6 *********** Nut flange 1 Prefit on Wiper motor
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE WIPER MOTOR ASSLY
VEHICLE ASSEMBLY
Pneumatic tools
Pneumatic nut runner
- 2 RLNS
Socket : 3/8 " X 10 mm.
Optional hand tools
T- Spanner - 10 mm.
Open end- Spanner - 10 mm.
Assembly sequence
1 ) Collect Wiper motor (S.No -1) & takeout Flange nut, Grommet wiper motor big FL from it &
keep aside.
2 ) Insert Wiper motor harness coupler through dash board pocket & route downward side.
3 ) Insert Wiper motor shaft through Windshield hole & prefit using Bolt flange-KAD ST-A dia-06
L-20 (S.No -2) 3 - nos. on Bracket wiper motor mounting.

CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
5 ) Connect Wiper motor harness red colour coupler with main harness.
6 )Collect Cap wiper motor big FL(S.No -4) & fix on Wiper motor & Wind shield assly.
7 ) Collect Grommet wiper motor big FL (S.No -3) & fix on Wiper motor shaft over the Grommet.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
8 ) Collect & prefit Wiper blade assly (S.No -5) on Wiper motor shaft using
Nut flange (S.No -6).
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
2 1
1 AA161219 Trim small RH 1

2 AA161218 Trim small LH 1
3 39152401 Screw pan cross M5X28 5
4 39183911 Washer plain 5
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE TRIM LH & RH
VEHICLE ASSEMBLY
Pneumatic tools
Philips head bit no. - 2
Optional hand tools

Philips head screw driver
Assembly sequence
1 ) Collect Trim small RH (S.No -1) & locate on Wind shield & scudo joint by alligning it's 2 -
holes with welded bracket holes of Scudo at RH side.
2 ) Prefit Trim small RH using Screw pan cross M5X28 (S.No -3) 2 - nos. along with Washer
plain (S.No -4) 2 - nos. on welded bracket of Scudo.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
3 ) Collect Trim small LH (S.No -2) & locate on Wind shield & scudo joint by alligning it's 3 -
holes with welded bracket holes of Scudo at LH side.
4 ) Prefit Trim small LH using Screw pan cross M5X28 (S.No -3) 3 - nos. along with Washer
plain (S.No -4) 3 - nos. on welded bracket of Scudo.
5 ) Tighten all the Screws.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
1 AA231223 Cover wiper motor 1

2 24231475 Nut dome cap -M5 2
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE COVER WIPER MOTOR
VEHICLE ASSEMBLY
Pneumatic tools
Optional hand tools

T- spanner - 8 mm.
Assembly sequence
1 ) Engage wiper motor earthing connector on RH side stud of Wiper motor.
2 ) Collect & prefit Cover wiper motor (S.No -1) on 2- nos. studs of Wiper motor using Nut dome
cap -M5 (S.No -2) on 2- nos.
3 ) Tighten the nuts.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE COVER WIPER MOTOR
VEHICLE ASSEMBLY
3 2
7 10
9 4
1 24231770 Pipe side hood frame LH 1

2 24231771 Pipe side hood frame RH 1
3 ************ Handle passanger 2 Part of Hood comp.
4 39206004 Bolt flanged M5 10 Packed with pipes
5 39023911 Plain washer 20 Packed with pipes
6 39032615 Nut nyloc M5 X 0.8 10 Packed with pipes
7 KAAA0825 Bolt 2
8 KDAC0816 Washer plain 4
9 KCHB0809 Nut nyloc 2
10 24231737 Bracket outer B pillar 4 Packed with pipes
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE PIPE SIDE HOOD FRAME LH & RH
VEHICLE ASSEMBLY
Pneumatic tools
Optional hand tools
T- spanner - 8 mm.
Hardware pouch packed along
T- spanner - 13 mm.
with Pipe side LH & RH
Assembly sequence
1 ) Unpack Pipe side hood frame LH & RH & take out hardware pouch for assembling it with
hood frame assly.
2 ) Move Hood frame assly from horizontal to vertical Position.
3 ) Collect Pipe side hood frame LH (S.No -1) & Handle passanger (S.No -2) 1- no.
4 ) Insert the Handle passanger in Pipe side hood frame LH & locate Pipe side hood frame LH
on Hood frame bracket LH side.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
5 ) Prefit Pipe side hood frame LH on Hood frame bracket LH side using Bolt flanged M5 (S.No -
4) 1- no. along with Plain washer (S.No -5) 1- no. from outer side & Plain washer (S.No -4) 1-
no. & Nut nyloc M5 X 0.8 (S.No -6) 1- no. from inner side.
6 ) Prefit Pipe side hood frame LH on Wind shield bracket LH side using Bolt (S.No -7) 1- no.
along with Washer plain (S.No -8) 1- no. from inner side & Washer plain (S.No -8) 1- no. along
with Nut flange M6 (S.No -9) 1- no. from outer side.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
7 ) Collect Bracket outer B pillar (S.No -10) 1- no. & locate on Pipe side hood frame LH from
inner side.
8 ) Collect Bracket outer B pillar (S.No -10) 1- no. & locate on Pipe B pillar LH from outer side.
9 ) Insert Bolt flanged M5 (S.No -4) 4- nos. along with Plain washer (S.No -5) 4- nos. on 2 - nos.
Bracket outer B pillar's 4 holes from outer side & prefit Plain washer (S.No -5) 4- nos. along with
Nut nyloc M5 X 0.8 (S.No -6) 4- nos. from inner side.
10 ) Repeat the Assembly sequence no. 2 to 8 for Pipe side hood frame RH fitment.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
1a
1b
1
1c
1d
2
5 9
6
7 3
4
8
1 24231605 Hood complete - Black 1

1a ************* Belt hood 2 Part of Hood comp.
1b ************* Rexene hood cloth assly 1 Part of Hood comp.
1c ************* Cover for hood & top 1 Part of Hood comp.
1d ************* Tape hood 1 Part of Hood comp.
2 24231762 Strip aluminium Bigger 1
3 24231761 Strip aluminium small 1
4 24231630 Screw self drill BH 3.5X16X15 13
5 39037118 Tekus 15
6 39155704 Screw hex head M6 2
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE HOOD COMPLETE
VEHICLE ASSEMBLY
1a
1b
1
1c
1d
2
5 9
6
7 3
4
8
8 39081715 Nut nyloc M5 X 0.8 2

9 39037216 Button red 11
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
Pneumatic tools
Optional hand tools
T- spanner - 8 mm.
T- spanner - 10 mm.
Steel hammer - 250 Grams
Philips screw driver
Electrical tools
Portable drilling m/c
Drill bit 3 mm.
Assembly sequence
1 ) Go to rear side of progressive vehicle, remove the left hand side hardware for hook
assembled on Body assly rear side as shown above.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
2 ) Collect Belt hood (S.No -1a ) 1 -no., insert in the Body assly left hand side hook & tighten
the hardware again.
3 ) Repeat the Assembly sequence no. from 1 to 2 for Right hand side Belt hood fitment on
Body assly.
4 ) Pass right hand side Belt hood over the hood frame assly's links ,Pipe B pillar.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
5 ) Pass left hand side Belt hood over the hood frame assly's links ,Pipe B pillar.
Hood stick
6 ) Pull the right hand side Belt hood over the Wind shield assly & fix the Belt on Hood stick
using Tekus (S.No -5 ) 2- nos.
7 ) Fold the excess right hand side Belt hood over the Wind shield assly & fix the Belt on Hood
stick using Tekus (S.No -5 ) 2- nos.
8 ) Repeat the Assembly sequence no. from 6 to 7 for left hand side Belt hood fitment on
Hood stick.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
9 ) Spread the hood frame assly's links to increase the Belt hood tension.
10 ) Collect Rexene hood cloth assly (S.No -5b ), open it & spread over the Hood frame assly
links, Pipe B pillar starting from Body assly rear side.
11 ) Collect Strip aluminium Bigger (S.No -2 ), unfold & straight it using steel hammer.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
12 ) Insert the Strip aluminium Bigger in the Rexene hood cloth assly's pocket from left hand to
right hand side.
13 ) Collect & Insert Strip aluminium small (S.No -3 ) in the Rexene hood cloth assly's pocket
from right hand side.
14 ) Collect portable drilling machine, fix drill bit on it.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
15 ) Locate Rexene hood cloth assly along with Strip aluminium on body assly left hand end
side & drill holes on body assly along with Hood & strip at 13 locations.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
16 ) Tighten Rexene hood cloth assly along with Strip aluminium on body assly holes using
Screw self drill BH 3.5X16X15 (S.No -4 ) 13-nos.
17 ) Spread the Rexene hood cloth assly over the wind shield assly.
18 ) Pull the Rexene hood cloth assly over the hood stick assembled on windshield assly & fix
using Tekus (S.No -5 ) 7-nos. from right hand side to left hand side.
19 ) Fold the excess Rexene hood cloth assly over the hood stick assembled on windshield
assly & fix using Tekus (S.No -5 ) 4-nos. from right hand side to left hand side.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
20 ) Position Rexene hood cloth assly in stretched condition on wind shield assly's LH side
bracket hole, make a hole on Hood cloth with he help of screw driver.
21 ) Insert Bolt flange (S.No -6 ) 1-no. along with Plain washer (S.No -7 ) 1-no. in Rexene hood
cloth assly & wind shield assly's LH side bracket hole from outer side & prefit Nut (S.No -8 ) 1-
no. flange from inner side.
22 ) Hold Bolt flange & tighten the Nut.
23 ) Repeat the Assembly sequence no. from 20 to 22 for Right hand side Rexene hood cloth
assly fitment on bracket.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
24 ) Position the Cover for hood & top (S.No -1c ) over the hood stick assembled on windshield
assly & fix using Button red (S.No -9 ) 6-nos. from right hand side to left hand side.
25 ) Position the Tape hood (S.No -1d ) over the hood stick assembled on windshield assly &
fix using Button red (S.No -9 ) 5-nos. from right hand side to left hand side.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
Hood frame link

positioning
26 ) Spread the Hood frame links & position over the stitching mark from inner side to eliminate
the wrinkles on hood.
For wrinkle free fitment of Rexene hood cloth assly shown above the hood frame
links should match with stitching marks.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
1 24161446 Holder bottle 1

2 39168004 Bolt flange 2
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE HOLDER BOTTLE
VEHICLE ASSEMBLY
Pneumatic tools
Hand tools
T- Spanner - 10 mm.
Open end Spanner - 10 mm.
Assembly sequence
1 ) Collect & locate Holder bottle (S.No -1) on Rh side of Chassis scudo below dash board &
prefit using Bolt flange (S.No -2) 2 - nos.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE HOLDER BOTTLE
VEHICLE ASSEMBLY
1 AP161047 Top cover for handle bar 1

2 KBUC0410 Screw truss M4 X 0.7P 3
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE TOP COVER FOR HANDLE BAR
VEHICLE ASSEMBLY
Pneumatic tools
Hand tools
Assembly sequence
1 ) Collect & locate Top cover for handle bar (S.No -1) on Handle bar assly & prefit using Screw
truss M4 X 0.7P (S.No -2) 3 - nos.
2 ) Tighten the Screws.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE TOP COVER FOR HANDLE BAR
VEHICLE ASSEMBLY
1 52AP0216 Dash board cover 1

2 *********** Clip nut 2 Packed along with
3 *********** Screw 2 Dash board cover
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE DASHBOARD COVER
VEHICLE ASSEMBLY
Pneumatic tools
Hand tools
Assembly sequence
1 ) Collect & fix Clip nut (S.No -2) 2- nos. on Dashboard assly's middle portion.
2 ) Collect & locate Dashboard cover (S.No -1) on Dashboard assly's middle portion & prefit
using Screw (S.No -3) 2 - nos.
3 ) Tighten the Screws.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
2
1
1 24165132 Bkt. No. plate mtg. 1

2 AF161090 Plate number - Black 1 Yellow colour shown
3 39168004 Bolt flange M6 4
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE FRONT NUMBER PLATE
VEHICLE ASSEMBLY
Pneumatic tools
Hand tools
T- Spanner - 10 mm.
Assembly sequence
1 ) Collect & locate Bkt. No. plate mtg. (S.No -1) on Scudo of chassis assly & prefit using Bolt
flange M6 (S.No -3 ) 2 - nos.
3 ) Collect & locate Plate number (S.No -2) on Bkt. No. plate mtg. & prefit using Bolt flange M6
(S.No -3 ) 2 - nos.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
VEHICLE ASSEMBLY
1 AF161090 Plate number - Black 1 Yellow colour shown

2 39168004 Bolt flange M6 2
3 39081715 Hex nut flange M6 2
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE REAR NUMBER PLATE
VEHICLE ASSEMBLY
Pneumatic tools
Hand tools
T- Spanner - 10 mm.
Open end spanner - 10 mm
Assembly sequence
1 ) Collect & locate Plate number (S.No -1) on Body assly rear RH side & prefit using Bolt
flange M6 (S.No -2 ) 2 - nos. from outer side of Body assly & Hex nut flange M6 (S.No -3 ) 2 -
nos. from inner side of Body assly.
2 ) Hold the Nuts tighten the Bolts.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE REAR NUMBER PLATE
VEHICLE ASSEMBLY
1b 1a
1 52AA0251 Mirror assly set 1

1a ************* Mirror assly RH 1
1b ************* Mirror assly LH 1
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
ASSEMBLE MIRROR LH & RH
VEHICLE ASSEMBLY
Pneumatic tools
Nil
Hand tools
T- Spanner - 17 mm.
Open end Spanner - 17 mm.
Assembly sequence
1 ) Collect Mirror assly RH (S.No -1a), take out 1 - no. each Nut, Plain washer & Spring washer
from it.
2 ) Position Mirror assly RH on Windshield assly right hand side & prefit Plain washer, Spring
washer & Nut on it. Tighten the Nut.
3 ) Repeat the Assembly sequence no. from 1 to 2 for Mirror assly LH (S.No -1b) fitment.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
FIX MIRROR LH & RH
VEHICLE ASSEMBLY
After the completion of vehicle assembly following activities to be carried out to inspect the
vehicle.
Sr no. Activities to be carried out for vehicle inspection

1 Check & correct tyre inflation pressure including that of spare wheel.
Check all important nuts , bolts for tightness especially , Handle bar bolt , engine
2
foundation bolt , shock absorber nuts etc.
3 Check trasmission & Engine oil level & top up, if necessory.
4 Check steering lock & other locks for proper operation.
5 Check for smooth operation of fuel cock lever, choke lever & all control cables.
6 Check front , rear brakes for efficient working.
7 Check & adjust steering.
8
Check all lights , horn , switches , speedometer, wiper motor for satisfactory working.
9 Check & adjust engine idling.
10 Check & top up Hydraulic brake system.
11 Initial charging of the battery.
12 Check electrolyte level in battery.
13 Test drive the vehicle.
14 Clean the vehicle before delivery.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
INSPECT VEHICLE
VEHICLE ASSEMBLY
Following product verification card is used in Bajaj auto for vehicle inspection purpose.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
INSPECT VEHICLE
VEHICLE ASSEMBLY
1 ) Apply the key on petrol tank door lock, open the door & take out petrol tank cap.
2 ) Fill 500 ml. petrol in the tank , fix petrol tank cap & lock the door.
3 ) Start the vehicle & warm up the engine by running at speed < 50 kmph for about 4 to 5
minutes on Dynometer / road till the engine oil temperature reaches 60 ~ 65 deg.C.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
CO CHECKING
VEHICLE ASSEMBLY
4 ) Set the engine on idling speed @ 1400 ± 300 rpm with the Equipment
help of idling screw on the carburettor. (Open out to reduce the Dynometer
speed ). CO checking m/c
Confirm idling speed using Pulse Engine Tachometer. Pulse engine tachometer
Temp. sensor
Screw driver
5 ) Bring the started vehicle nearer to CO checking machine & insert machine's probe in to
silencer tail pipe. Observe the reading on machine's display Set idle CO with the help of air
screw on the carburettor. (Open out to reduce CO)
* CO value for RE COMPACT 4S vehicle should be - 1.5% ~ 2.0%
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
CO CHECKING
VEHICLE ASSEMBLY
DRY CHARGED BATTERY CHARGING PROCEDURE:
Remove small plastic cap from exhaust Flush air into exhaust vent passage
Flush air on battery terminals
1 ) Remove the small plastic cap from the exhaust vent outlet and replace it with the long open
tube provided with battery.
2 ) Clean the exhaust vent passage by flushing air so that acid will drop down in the cell of
battery (As shown in Photo).
3 ) Clean the terminals by flushing air on it to remove acidic water traces.
Do not crimp or bend the exhaust tube. This is a safety device to remove fumes.
Blockage of this tube may cause damage to the battery.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
BATTERY CHARGING
VEHICLE ASSEMBLY
Equipment
Battery charger
Hydrometer
Multimeter
Remove gang plug from the battery
4 ) Check the acid sp.gravity & Temprature of acid which is to be filled in the battery.
5 ) Open the gang plug of battery by pulling from one side as shown in above photograph.
6 ) Fill each cell with dilute sulphuric acid of 1.240 specific gravity (1.24 at room temp. for use
above 100C and 1.28 at room temp for use below 100C).
7 ) Keep the battery as it is for half an hour for soaking the acid.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
BATTERY CHARGING
VEHICLE ASSEMBLY
2A
8 ) Connect the Battery charger to battery terminals , set the battery charger on 2A current
setting & charge for 24 to 30 hours.
9 ) After the battery charging is over, charge indicator LED will lit.
10 ) The Terminal voltage with battery connected to charger, when measured with multi meter
should show voltage between 14.5 to 15.2 V, when the battery is fully charged.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
BATTERY CHARGING
VEHICLE ASSEMBLY
11 ) Stop Charging when Charging is over. For a fully charged Battery, open circuit voltage
should be greater than 12.3 V, measured after one hour of charging.
12 ) Specific gravity of individual cells, should be > 1.22 when measured after one hour of
charging
13 ) If Specific gravity of any one or more cells is lower than 1.18, then Battery may be
defective.
14 ) After charging, gang cap firmly into place and wash off acid spillage with water and dry the
battery.
CHECKING THE SPECIFIC GRAVITY:
15 ) The charged condition of the individual cell can be checked by measuring specific gravity
of electrolyte in that cell. The specific gravity of electrolyte can be checked by using Hydrometer
having small diameter spout.
16 ) For measuring the specific gravity bring the electrolyte in the hydrometer to eye level and
read the graduations on the float scale bordering on the lower meniscus (i.e. curved down
portion of electrolyte surface) as shown in the fig.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
BATTERY CHARGING
VEHICLE ASSEMBLY
1 52240508 Mud flap assly front 1

2 ************ Steering colomn with Front mudguard 1
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
SUB ASSEMBLY MUD FLAP FRONT
VEHICLE ASSEMBLY
Pneumatic tools
Hand tools
T- Spanner - 8 mm.
Assembly sequence
1 ) Collect Mudflap assly front (S.No -1), remove Strip, 2 - nos. bolts, 2- nos. Hex. Nut & 2- nos.
Spring washer from it.
2 ) Position Mudflap assly front strip on front fender holes, prefit using removed items in
Assembly sequence no. - 1.
3 ) Hold Nut & Tighten the bolt.
CHECKED SK
PREPARED VGW
0 22/10/2013 DATE 22/10/2013
SUB ASSEMBLY MUD FLAP FRONT
VEHICLE ASSEMBLY
Bajaj Auto Limited
Akurdi Pune 411035 India
Tel +91 20 27472851

Fax +91 20 27407385
www.bajajauto.com
Item code : 71111374

Manual de Emsamble RE4S

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual de Emsamble RE4S

Uploaded by

Copyright:

Available Formats

ASSEMBLY MANUAL

RE 4 - STROKE (FACE LIFT)

RE 4 - STROKE (FACE LIFT)

Prepared by : Vipin Wagholikar

Checked by : Sampath Kumar

Approved by : Pramod Shahane

OPN NO. REV . NO OPERATION DESCRIPTION

20 0 GENERAL INFORMATION ( ABBREVIATION USED IN OPERATION SHEET )

40 0 ASSEMBLE REAR WHEEL LH & RH

50 0 ASSEMBLE STEERING COLUMN

60 0 ASSEMBLE FRONT WHEEL

70 0 POSITION MAT FRONT & REAR

80 0 ASSEMBLE CHARGED BATTERY

90 0 ASSEMBLE HANDLE BAR ASSEMBLY

100 0 CONNECT HYDRAULIC BRAKE HOSE & BRAKE OIL BLEEDING

110 0 ASSEMBLE REAR MUDFLAP LH & RH ASSLY

120 0 ASSEMBLE REAR MUGUARD LH & RH

130 0 ASSEMBLE TAIL LAMP LH & RH

140 0 ASSEMBLE BUMPER ASSEMBLY

150 0 ASSEMBLE PASSENGER SEAT

160 0 ASSEMBLE PASSENGER BACK REST

OPN NO. REV . NO OPERATION DESCRIPTION

170 0 ASSEMBLE WIND SHIELD

180 0 FIT PIPE B PILLAR & ASSEMBLY BACKREST SUPPORT TOP

190 0 ASSEMBLE DRIVER BACK REST

200 0 ASSEMBLE BKT WIPER MOTOR MOUNTING

210 0 ASSEMBLE WIPER MOTOR ASSEMBLY

220 0 ASSEMBLE TRIM LH & RH

230 0 ASSEMBLE COVER WIPER MOTOR

240 0 ASSEMBLE PIPE SIDE HOOD FRAME LH & RH

250 0 ASSEMBLE HOOD COMPLETE

260 0 ASSEMBLE HOLDER BOTTLE

270 0 ASSEMBLE TOP COVER FOR HANDLE BAR

280 0 ASSEMBLE DASHBOARD COVER

290 0 ASSEMBLE FRONT NUMBER PLATE

300 0 ASSEMBLE REAR NUMBER PLATE

310 0 ASSEMBLE MIRROR LH & RH

320 INSPECT VEHICLE

OPN NO. REV . NO OPERATION DESCRIPTION

340 0 BATTERY CHARGING

350 0 SUB ASSEMBLY MUD FLAP FRONT

SNO. PART DESCRIPTION

SNO. PART DESCRIPTION

SNO. PART DESCRIPTION

SNO. PART DESCRIPTION

Following 'abbreviation' are used in operation sheet.

Abbreviation used in operation sheet are as follows :

A ) ' Comp ' --------- Component

B ) ' Assly ' --------- Assembly

C ) ' LH ' --------- Left hand side

D ) ' RH ' --------- Right hand side

E ) ' OPN. NO ' --------- Operation number

F ) ' OPN. DESC ' --------- Operation description

G) ' Sr' --------- Serial number.

H) ' No ' -------- Number.

I) ----------------- Grey colour is used in operation sheet to indicate

General tightening torque values for various size of hardwares are

1 ) M5 X 0.8 ------------------ 0.3 TO 0.4 KGM

2 ) M6 X 1 ------------------ 0.6 TO 0.8 KGM

3 ) M8 X 1.25 ------------------ 2 TO 2.5 KGM

4 ) M10 X 1.5 ------------------ 3.2 TO 3.8 KGM

USE DIAL INDICATING TORQUE WRENCHES IN CASE OF TIGHTENING

1 ) DIAL INDICATING TORQUE WRENCH - UPTO 2 KGM TORQUE VALUE.

2 ) DIAL INDICATING TORQUE WRENCH - UPTO 7 KGM TORQUE VALUE.