SCHEME

ELECTRICLE

A.HARNESS
ROUTING

COMPACT 4S PET

FRONT HARNESS ROUTING AND CLIPPING

CLIPPING
WITH PVC
COATED CLIP

CLIPPING
WITH PVC
COATED CLIP

Horn branch routing & Grommet

fitment in Shield hole

HORN
GROMMET

Harness clipping on upper

terminal & Dashboard assembly

SNUG
CLIPPING

SNUG
CLIPPING

ROIUTING OF
UPPER PART
HOLE
CLIPPING
WITH PVC
COATED CLIP

Front
Harness

CLIPPING
WITH PVC
COATED CLIP

Horn
Branch
Handlebar
switch
harness
branch

Harness clipping on
Upper part , lower part and HL housing

Snug Clipping

Clipping with PVC coated clip

Routing

SNUG
CLIPPING

REAR HARNESS + BATTERY CABLE ROUTING AND CLIPPING

COMPACT 4S PET

Battery
Harness

Battery
Harness

Rear
Harness

Rear
Harness
ROUTING THROUGH
FCM HOLE

ROUTING THROUGH
WIRE CLIP

RH TAIL LAMP BRANCH

CLIPPING
SNUG
CLIPPING

Battery
Harness

SNUG
CLIPPING

SNUG
CLIPPING

SNUG
CLIPPING

SNUG
CLIPPING

SNUG
CLIPPING

Snug Clipping

Routing

Rear
Harness

SNUG
CLIPPING

SNUG
CLIPPING

REAR HARNESS + BATTERY CABLE ROUTING AND CLIPPING

Rear Harness Routing on LH main
member

Starter motor
Harness branch
PVC Coated
Clipping on Rear
Eng. Mtg.
member Rear

Rear Harness Routing on Body

mounting member Rear

Snug Clipping

Routing through wire clamp

COMPACT 4S PET

D COUPLER CONNECTIONS BETWEEN FRONT AND REAR HARNESS & COUPLER BOX FITMENT

COMPACT 4S PET

Complete
Pressing of
rivet

** Harness should not be

pinched in Coupler box and
cover

** Complete Pressing of
rivet_2 no's

Rear
Harness
Front
Harness
Front
Harness

Battery
cable

Bolt
Flanged
KADA061
2

Battery
cable

**Front and Battery cable

**Front and rear harness

**Washer
lock
toothed
LDF0000
1

** Tightening Torque Of Earthing Bolt

OIL PRESSURE SWITCHG HARNESS BRANCH CLIPPING

COMPACT 4S PET

**OIL PRESSURE SWITCHG BRANCH TO CLIPPED ON

CLIPPING BRACKET PROVIDED ON ENGINE
TO OIL PRESSURE
SWITCH

OIL PRESSURE SWITCH

BRANCH IN REAR
HARNESS

HT COIL ASSEMBLY FITMENT AND BODY HARNESS ROUTING

Coupler for
cabin lamp
Clipping
02

RH side HT
coil assembly
LH side HT
coil
assembly

Tightening
torque 1.11.3Kgm

COMPACT 4S PET

Clipping
01

Clipping
01

Clipping
03
Fuel tank
coupler

Clipping
04

Loop of
harness

Tightening torque 1.1-1.3

Kgm

HT Coil assembly mounting on

Body

Clipping
05

Body harness routing & Snug

clipping at 5 location

Rear harness
Clipping on Body
panel at one

HEADLAMP SCREW AND HEADLAMP ASSEMBLY

G
1

Headlamp Screw fitment

COMPACT 4S PET

Headlamp fitment and connection

Front
Front harness
harness
connection to
connection
to
Headlamp
Headlamp

HL Screw and
Spring
assembly

Headlamp
assembly
LH

Headlamp
assembly
RH

**Headlamp keyhole position in screw

FRONT ELECTRIC PLATE ASSEMBLY AND CONNECTIONS

**Tightening
torque 0.64-0.72
Kgm)
To
Speedometer
assembly
Flange
nut

MODEL :COMPACT 4S PET

Front electric
plate
assembly

To Indicator
assembly
Reverse
switch
connection

2 Position
switch
connection

Fuse box
assembly
connection
Relay Flasher
Hazard
connection

Hazard
switch
connection

Ignition
switch

HL Relay
connectio
n

MODEL :COMPACT 4S PET

REAR ELECTRIC PLATE ASSEMBLY AND CONNECTIONS
**Tightening
**Tightening
Rear harness
torque 0.64-0.72
torque 0.64-0.72
Earthing
Starter
Kgm)
Kgm)
Snug
rely
Metallic
clipping
connectio
Clipping
n
Neutral
switch
Rear harness

Regulat
or

CCU coupler
connection
Starter Rely
Snug
clipping

Battery
cable +
magneto
coupler
connection

Battery
cable

Magneto

REAR ELECTRIC PLATE COVER ASSEMBLY

MODEL :COMPACT 4S PET

Rear Harness +
batter cable +
magneto Harness
Routing

Rear Harness
Routing

Flange
Nut

Electric Plate
Cover

**Tightening
torque 0.64-0.72
Kgm)

**Tightening
torque 0.64-0.72
Kgm)

Flange
Nut

INSTALLCONTR
OL SYSTEM

SCHEME OF PARKING
BRAKE

FITMENT EQUALIZER BRACKET ASSEMBLY AND CABLE ROUTING

COMPACT 4S PET

Front handbrake Cable

routing through Splash
guard

Routing
through clip on
RH main
member

Pre-fitment and tightening of

flange nuts

**Tightening Torque :
Flange Nut =1.66~2.07
Kg.m

ASSEMBLY OF HANDBRAKE LEVER AND CONNECTION OF FRONT HANDBRAKE CABLE

Handbrake
lever
assembly

Pre-fitment and
tightening of lock
nuts
Pre-fitment and
tightening of
flange nuts

**Tightening Torque :
Flange Nut =1.66~2.07
Kg.m

Connection of cable and

fitment of plain washer

COMPACT 4S
PET

HANDBRAKE CABLE ROUTING & FITMENT

MODEL :COMPACT 4S PET

LH Handbrake Cable
Routing through
Engine mount

Handbrake
cable LH

Handbrak
e cable
RH

**RH Handbrake cable

to be routed above
brake pipe

REVERSE LEVER
FITMENT

ASSEMBLY OF REVERSE LEVER MOUNTING PIN UPPER

AND LOWER

COMPACT 4S PET

Pin upper rev.

lever
(AA191120)A

Pivot pin rev.

lever
(AA191119)

Tightening Torque :
Upper & lower Pins (M10) _3~3.2 Kgfm

FITMENT

Assembly of
reverse lever on
Mtg pin

**Tightening Torque :
Upper & lower Nuts (M8) 2~2.2
Kgfm

OF REVERSE LEVER ASSEMBLY

Pre-fitment
and tightening
of nuts

COMPACT 4S PET

ROUTING & CONNECTION OF REVERSE CABLE ON VEHICLE

COMPACT 4S PET

*Rout Reverse
Cable from
outside of Spare
wheel resting
bracket

Reverse
Cable
routing 01

*Grommet to be fitted after

cable assembly with 4-5mm
overlap
Reverse
Cable
routing

Reverse
Cable
routing 04

Reverse
Cable
routing 05

Reverse
Cable
Clipping
Reverse
Cable
routing 02

Band

*Cable to be tied firmly with guide clip after

routing Control cable set through same Clip

Reverse
Cable

REVRSE GEAR CABLE CONNECTIONS AND PLAY SETTING

*Grommet to be
fitted after
cable assembly
with 4-5mm
overlap

COMPACT 4S PET

REVERSE CABLE

REVERSE
SECTOR ON
ENGINE

REVRSE GEAR CABLE CONNECTIONS AT

ENGINE END

*Tighten of
upper and lower
nut
REVRSE GEAR CABLE CONNECTIONS AT
ENGINE END

REVERSE
CABLE

REVERSE
PLAY
ADJUSTER
REVRSE GEAR CABLE
CONNECTIONS TO REVERSE LEVER

***Ensure complete fitment of

Rubber boot after connection

CONTROL CABLE
SET

FITMENT OF ASSEMBLY KNOB MOUNTING BRACKET WITH CHOKE CABLE & CABLE
ROUTING
Bolt

COMPACT 4S PET

(39168004 )

Knob mounting
bracket

Choke Cable

Choke cable
routing Guide clip
on cross tube

**Knob mounting bracket tightening torque

1.8-2 Kgm

Choke cable
routing

Choke cable
routing Guide clip
on TA cross tube

Choke cable
routing

Choke cable
routing through
Sleeve

B CONTROL CABLE SLEEVE POSITION AFTER CONTROL CABLE SET ROUTING

Sleeve marking to be Positioned Outside FCM

COMPACT 4S PET

COMPACT 4S PET

CONTROL CABLE SET ROUTING

GEAR
CABLE

GEAR CABLE
GEAR CABLE

CLUTCH CABLE

GEAR
CABLE

CLUTCH
CABLE
ACCELRATOR
CABLE

ACCELRATOR
CABLE

*Hose
routing
should be
bellow cable
set

CONTROL CABLE ROUTING THROUGH GUIDE CLIP ON CHASSIS

*Cable Routing bellow
cross tubes Through
Guide Clip
1.
2.
3.
4.
5.
6.

Accelerator cable
Choke Cable
Clutch cable
Reverse Cable
Gear cable white
Gear cable Black

COMPACT 4S PET

*Cable Routing bellow

cross tubes Through
Guide Clip
1. Accelerator cable
2. Choke Cable

** Accelerator & choke Cable to

be tied firmly with guide clip
(No relative motion between
cable and Clip)

**All routed Cables to be tied

firmly with guide clip (No
relative motion between cable
and Clip)

CLUTCH CABLE CONNECTION AND PLAY SETTING

COMPACT 4S PET
CLUTCH PLAY
SETTING

CLUTCH CABLE CONNECTION TO HANDLE BAR

ASSEMBLY

CLUTCH
CABLE

**Clutch Play 13mm

* Ensure Guide of cable outer inserted

& butted in clutch lever bracket bush
guide firmly

CLUTCH PLAY
SETTING

Clutch cable connection to engine

end

Rout clutch cable

through wire
guide clip on
handle bar
assembly

Gromme
t

** Fold complete lug of

clutch holding bracket

**Grommet to be fitted after

cable assembly with 4-5mm
overlap

Clutc
h
Cable
Adjuster
nuts

GEAR CABLE CONNECTIONS & PLAY

SETTING

GEAR CABLE CONNECTION TO

HANDLE BAR ASSEMBLY

GEAR PLAY
SETTING

GEAR CABLE
BLACK

COMPACT 4S PET

ADJUSTERS FOR GEAR PLAY

SETTING

GEAR
CABLE
WHITE
GEAR
CABLE
BLACK

GEAR CABLE
WHITE

* MATCH MARKING LINE ON

INDICATOR RING WITH DOT ON
HANDLE BAR

ACCELRATOR CABLE CONNECTIONS & PLAY SETTING

ACCELRATOR CABLE
CONNECTION

COMPACT 4S PET

ACCELERATOR AND CHOKE

PLAY

**Ensure free play 1

to 2 mm for inner
at rear End

ACCELRATOR
CABLE

ACCELARTOR CABLE CONNECTION TO

ENGINE END
TIGHTEN ADJUSTER
AND LOCK NUT
COMPLETELY

**ENSURE GROMMET
LOCKED IN GROOVE
CARBURETOR ADJUSTER

ACCELRATOR
CABLE

CHOKE CABLE CONNECTION TO

ENGINE END

TIGHTEN ADJUSTER
AND LOCK NUT
COMPLETELY
**ENSURE GROMMET
LOCKED IN GROOVE
CARBURETOR ADJUSTER

CHOKE CABLE

ACCELRATOR & CHOKE CABLE CONNECTION TO CARBURETOR

ACCELRATOR CABLE
CONNECTION
ADJUSTER

ACCELARATO
R CABLE
LOCK

COMPACT 4S PET

ACCELRAT
OR CABLE

CARBURETO
R CAP

ADJUSTER
LOCK NUT
CHOKE
CABLE

CHOKE CABLE
CONNECTION

ADJUSTER

ADJUSTER
LOCK NUT
ADJUSTER
LOCK NUT

CHOKE
CABLE
LOCK

**Tighten Carburetor
Cap

GEAR CABLE CONNECTION AND COVER FITMENT

F
A

Gear cable connection

White Gear
cable

Gear cable holding bracket fitment

COMPACT 4S PET

Gear shifter Cover fitment

black Gear
cable

Bolt
Screw

Bolt

Gear cable
Holding bracket
Gear sector

** Gear cable position in

Gear sector

Screw

Holding bracket tightening

torque 4-4.5 K-GM

Gear shifter Cover

Gear shifter cover tightening

torque 4-4.5 KGM

SPEEDOMETER CABLE ROUTING

SPEEDOMETER CABLE ROUTING

*SPM Cable routing

through gap
between Dashboard
& Scudo
*SPM Cable routing
from inside of
ratchet

*SPM Cable routing

from side of

*routing through
FCM Hole

*SPM Cable clipping

on floor board

COMPACT 4S PET

*Spm cable
routing bellow
cross tubes
Through Guide
Clip

**Cable to be tied firmly with guide

clip ((No relative motion between
cable and Clip)

SCHEME OF WHEEL AND

BRAKES

INSTALL BRAKE PADDLE MODULE

*Ensure
proper
folding of
locking of
Split pin

COMPACT 4S PET

96 mm from
floor

*Ensure Free rotation

of brake Paddle after
pivot bolt tightening
Brake paddle module

INSTALL BRAKE PADDLE MODULE

COMPACT 4S PET

**Ensure
Grease HP
LithonRR3 (Qty.
1-2 gm) applied
Pivot Bolt
**Tightening
torque 4.5-5
Kgm
Tightening
**Tightening
torque 4.5-5
2.5-3
kgm
Kgm
**Hose routing
should be bellow
cable set

BRAKE PIPE ROUTING & CLIPPING

COMPACT 4S PET

Brake pipe
Clipping

Brake pipe
should be from
front side of
Starting tube
Bracket

Brake pipe
should be
below reverse
and SPM cable

3
4
1
Brake
pipe

2
6

5
Brake pipe
should be
Below sleeve

Brake pipe
routing on RH
side

Brake pipe should

be from rear side
of TA Bracket

Brake
Brakepipe
pipe
clipping
clipping
Brake pipe
routing on LH
side

Brake pipe and

Rear Hose
connection

Brake pipe
Clipping on RH
main member

INSTALL WHEELS

INSTALL FUEL SYSTEM

FUEL PIPE ROUTING

INSTALL FUEL SYSTEM

COMPACT 4S PET

**Fuel pipe to be routed

below duct

**Fuel pipe to be routed

through hook clip

*****Fuel pipe to be
inserted in Carburetor
inlet pipe up to end
*** Clips to be clipped on
joint

FUEL TANK FITMENT

**Fuel tank fitment on

front side By Flange nut
(Torque 1.8-2Kgm )

**Fuel tank fitment on

RH side By Flange nut
(Torque 1.8-2Kgm )

**Fuel pipe Should be

inserted up to end
** Clips should be clipped
on joint

**Orientation of tap
with Pulley should be
as shown

**Orientation of
fuel filter

**Fuel tank fitment on

Rear side by Flange bolt
(Torque 1.8-2Kgm)

ROUTING OF FUEL TAP CABLES

COMPACT 4S PET

FUEL COCK FITMENT ON FRONT

SIDE OF BODY

Fuel
cock

**Fuel cock
tightening torque
0.65-0.75 Kgm

Fuel cock
position

Fuel tap cables to be

routed through this guide
and clip

FUEL TANK
CAP

Fuel tank cap

should be tied
with rope

INSTALL FRONT SUSPENSION

ASSEMBLY STEERING COLUMN

COMPACT 4S PET

ASSEMBLY STEERING COLUMN

**Tightening
torque 4.5-5
Kgm

Nut Lock ring

Nut lock
ring
**Tightening
torque 4.5-5
Kgm

Spacer

**Grease 2-3
gm
Race Upper
bearing

Nut Lock ring

Washer

Washer
Dust cover top
Dust Cover
top

Bearing race
upper outer

Cover dust
lower

Spacer

Nut Lock ring

Ball steel with

Nylon cage
upper
**Grease 8-10
gm
Bearing
race lower
outer

Cover dust
lower

Steering column
assembly

Bearing
race lower
Ball steel with
Nylon cage
Lower

**Tighten the lower lock nut ring with torque 4.5-5 Kgm place washer and tighten upper locknut with torque 4.5-

BEARING RACE FITMENT

**Grease 2-3
gm
Bearing race
upper outer

Bearing race
upper outer

**

Spacer

Bearing
race lower
outer
Space
r

Cover dust
lower

Bearing
race lower
outer
Cover dust
lower

COMPACT 4S PET

FRONT HOSE ROUTING AND CONNECTION TO TMC

ASSEMBLY

Grommet
fitment

COMPACT 4S PET

HANDLEBAR ASSEMBLY AND TIGHTENING

COMPACT 4S PET

Handlebar
assembly
Hex Nut M10
Palin washer

Spring Washer
Bolt Hex with collar
M10

Handlebar tightening torque 44.5 Kgm

INSTALL REAR SUSPENSION

COMPACT 4S PET

INSTALL REAR SUSPENSION

Trailing arm assembly RH

Trailing arm assembly LH

Trailing arm assembly LH

Nut
Spring
washer

Pivot bolt

Trailing arm
assembly LH

Spring
washer
Trailing arm
assembly RH

Nut
Pivot bolt

B ASSEMBLY OF SHOCK ABSORBER AND TRAILING ARM AND TIGHTENING

LH
Tightening Torque ofside
sock absorber top nut
3-3.5 Kgm

Tightening
torque of check
Nut 3-3.5 Kgm

RH
1
Tightening Torque of side
sock absorber top nut
3-3.5 Kgm

** Presence of check nut

**Tightening Torque of
trailing .arm Nut 7-9 Kg-m
**Tightening Torque of
bottom Bolt 4-4.5 Kg-m
** Tightening Torque of
sock absorber top nut 7-9
Kg-m

Trailing arm
bolt
Tightening Torque
of bottom Bolt 4-4.5
Kgm

Bottom
bolt

3
Tightening Torque
of bottom Bolt 44.5 Kgm

COMPACT 4S PET

Tightening torque
of check Nut 33.5Kgm

Sock
absorber
assembly

Tightening
Torque of
trailing .arm
Nut 7-9 Kgm
Nylock
nut

Trailing
arm
assembly

BRAKE PIPE CLIPPING ON TRAILING ARM ASSEMBLY AND BANJO BOLT TIGHTENING

LH
side

**Tightening
torque of banjo
bolt 2.2-2.5Kgm
Copper
Washer
Banjo
bolt

Brake
Pipe

COMPACT 4S PET

RH
side

Brake pipe Clipping

on Trailing arm
assembly

Brake pipe Clipping

on Trailing arm
assembly

**Tightening torque
of banjo bolt 2.2-2.5
Kgm
Banjo
Copper
bolt
Washer

Brake
Pipe

LH
side

ASSEMBLY OF SHOCK ABSORBER

COMPACT 4S PET
RH
side

Nut
Lock Washer
Cushion
Rubber

Shockabsorber
assembly

Sleeve

Sleeve

Cushion
Rubber
Lock
Washer

Spring rear
Suspension
Shockabsorber
assembly

INSTALL ENGINE MOUNT

ASSEMBLY REARENGINE MOUNTING CROSS MEMBER

Engine
mounting
cross member

Flange
Nut

Bolt
Bolt

Flange
Nut

Flange
Nut

Flange
Nut

INSTALL EXHAUST SYSTEM

MODEL :COMPACT 4S PET

INSTALL EXHAUST SYSTEM

Nut hex
Flanged +
Plain washer +
Spring washer

Cylind
er
head

Cylinder
head
mount

Combinati
on bolt

Cross
member
FR mount

Flange
Nut

Cross
member
RR mount

Bolt + Plain
washer

Flange
joint
Gaske
t

Nut +
Plain

Combinati
on bolt

Silencer
assembly

Engine
mounti
ng
cross
membe
Damp
r
er
Damp
Sleeve
er

SILENCER ASSEMBLY &

PRE FITMENT
Locate Silencer on engine.
Pre fit cyl head side fasteners
i.e. gap closed but no torque
applied.
Pre fit cross member rear
mount fasteners.
Cross member rear mount is
expected to be fitted with rubber
bush.
Steel bushes should be
inserted from top & bottom side.
Bolt with washer to be
inserted from bottom side.
Nut to be pre fitted from top
side.
Pre fit cross member front
mount bolt in the clip nut In
the Install
Silencer and
clip nut
assembly

INSTALL EXHAUST SYSTEM

Tightening
torque 1.8-2.2
Kgm

Tightening
torque 1.8-2.2
Kgm
Cylinder
head
mount

Tightening
torque 1.8-2.2
Kgm

Flange joint

Cross
member
FR mount

Tightening
torque 3.5-4
Kgm

Cross
member
RR mount
Tightening
torque 1.8-2.2
Kgm

MODEL :COMPACT 4S PET

SILENCER ASSEMBLY
TIGHTENING :
Tighten cross member rear
mount to specified torque
of 1.8-2 Kgm
Tighten cross member
front mount to specified
torque of 3.5-4 Kgm
Tighten Cyl head mount to
specified torque. of 1.8-2
Kgm .
Ensure that there is no
abnormal gap between
triangular flanges after
above 3 steps.
Tighten triangular flange
mount to specified torque's
of 1.8-2 Kgm.

PROPELLER SHAFT
ASSEMBLY
Q pints :
Bellow should not be getting
pinched .
Clamp should not be getting
clamped in tilted condition.
Clamps should be as shown
Propeller shaft
Wheel side is White
marking on bellow

Omega
Clamp

Strap
Clamp

Strap
Clamp

Propeller shaft
Wheel side is White
marking on bellow

Omega
Clamp

INSTALL HANDSTART MECHANISAM

COMPACT 4S PET
Long connecting tube fitment

Starting tube fitment

Long connecting
tube connection to
starting tube

R clip

**fill grease
through grease
nipple

After adjustment
tighten this nut
at torque 2+0.5

Long connecting
tube
Long connecting
tube connection
to starting
Handle
Tightening
torque 1.8-2.2
Kg.m

INSTALL HANDSTART MECHANISAM

SUPPORT ASSEMBLY

STARTING HANDLE FITMENT

Startin
g
handle

Flange
bolt

**apply Grease
to Starting
handle Pin

Support
assembly
Tightening
torque 1.8-2.2
Kg.m

COMPACT 4S PET

Copper
Washer

INSTALL HANDSTART MECHANISAM

COMPACT 4S PET

SHORT CONNECTING TUBE ASSEMBLY

** Match flat
portion of pin
cotter with
lever
Support
assly

Cotter pin

Short connecting
tube

Split
Pin

**Fold split
Pin on both
end up to
90degeree

After adjustment
tighten this nut
at torque 2+0.5

**Fold split
Pin on both
end up to 90
degeree

** Match flat
portion of pin
cotter with
lever

INSTALL BATTERY

COMPACT 4S PET

HANDSTART MECHANISAM SETTING

**After
After
adjustment
adjustment
tighten this nut at
torque 2+0.5

**After
adjustment
tighten this nut
at torque 2+0.5

COMPACT 4S PET

Dog of
support
assembly

**When Rubber Damper on assembly starting

handle is touched with floorboard adjust long
connection tube till the dog of support assembly
and starting tube mate with each other without
change in angle 40 degree marked with #

Dog of
support
assembly

40degree
#

40degree
#

**While adjusting length of the short

connecting tube ensure that there is no
deflection of engine lever of support
assembly

Battery
Connection

0.4-0.5 kgm.

torque
1.551.74

Battery MTG BKT on

Chassis

Battery Base
fitment

Wheel assembly Complete

(24151109)

Spring Washer
(39182912)

Nut Hex (39031215) Torque 4

to 5 Kgm

RH side bolt
Tightening

RH side bolt
Tightening
RH side bolt
Tightening

LH side bolt Tightening

RH side bolt
Tightening

Cross member Fitment

FITMENT OF BATTERY & CABLE

CONNECTIONS

MODEL :COMPACT 4S PET

COMPACT 4S PET

INSTALL ENGINE MOUNT

Engine
mounting front

Hex Nut
M10
Reinfo Plate

Rubber
plug

Plain
Reinfo Plate
washer
Hexagonal
bolt

Flange
Nut

Bolt
Bolt

Flange
Nut

Assly Engine
mounting Cross
member Rear

Bolt
Flange
Nut
Bolt
Flange
Nut

Thank
You