Tomos A35 Workshop Manual
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Tomos A35 Workshop Manual

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TOM OS
workshop manual
TOM OS
&
TWOWHEELERS
COMPONENTS
PROOUCTION,SLOVENIJA

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Summary of Contents for Tomos A35

  • Page 1 TOM OS workshop manual TOM OS & TWOWHEELERS COMPONENTS PROOUCTION,SLOVENIJA...

  • Page 2: Table Of Contents

    TOM OS CONTENTS TECHNICAL DATA 3- 5 STANDARD ELEMENTS SPECIAL TOOLS INTRODUCTION FUNCTION OF ENGINE/A35 11 - 15 TROUBLE SHOOTING 16 -21 TRANSMISSION REPAIRS 22-27 MAGNETO REPAIRS 28-29 CARBURETOR REPAIRS 30-31 WIRING HARNESS SPRINT, TARGA 32-33 CYLINDER, PISTON, REED VALVE REPAIRS...

  • Page 3: Technical Data

    TOM OS TECHNICAL DATA single cylinder. two cycle with reed valve, coo l e• Engine: Bore Stroke: Piston displacement: Compression ratio: 1,45 Brake horse power: (5200 min-1) min·') Torque: (3500 with automatic 2-steps, two centrifugal cluthes Gearbox: Valvomatic type A Suffix A SAE 10 30/ccm 3 Gearbox oil/quantity:...
  • Page 4 TO MOS TECHNICAL DATA TRANSMISSION Z= 17 Z•72 Za66 Main shall Za26 Chain transmission 96101tors 3.8823 (66/17) Gear ratio 1 speed •1 (53/24) I: 2.4615 2"" Gear ratio speed (3.88. 72/11) •=25.4117 Gearbox ratio 1•1speed (2.46 • 72111) • = 16.1189 Gearbox ratio 2""speed (22126)

  • Page 5: Technical Data

    A 3 5 TOM OS TECHNICAL D A T A TORQUE silio Thread Pound per foot Ml 4><1.25 1,83 13,27 plug Spar!< Cylinder cover 1,22 8,85 1,53 Cylinder stud bolts 11,06 M10x1 3.0S 22.12 Magneto flywheel M10x1 Clutch of 1" speed 2.55 16,44 2""sp;ied driven gear...

  • Page 6: Standard Elements

    035.070x 2 6203-C3 17x40x12 Crankshaft 035.202 Bx 22x 7 035.072 Countershaft 035.031 6201 12x32x 10 035.037 6006 30x55x13 Wheel axle 044.225x 2 6201-Z 12x32x10 Seal ri n gs TOMOS Dimensions lati pcs. Code. No. b(mm) 17x35x7 Crankshaft 036.554 nshaft 036.620 35x47x7...

  • Page 7: Special Tools

    TOM OS SPECIAL TOOLS 732.746 MAGNETO FLYWHEEL PULLER 732.202 FLYWHEEL HOLDER 011.008 GAUGE PIN 732.193 DIAL GAUGE SUPPORT 735.888 CRANKCASE DIS -ASSEMBLY TOOL...
  • Page 8 TO MOS SPECIAL TOOLS 735.753 CRANKSHAFT MOUNTING FORK 731.155 CRANKSHAFT BEARING PULLER 702.856 DIS -ASSEMBLY CRANKSHAFT BEARINGS 737.535 CLUTCH SPRING SETIING TOOL 737.536 ROLLER CLUTCH INSTALLER...

  • Page 9: Special Tools

    TOM OS SPECIAL TOOLS 732.367 MAINSHAFT NEEDLE BEARINGS INSTALLER 706.485 EXTRACTOR 706.472 EXTRACTOR BRIDGE 736.913 ------- BRAKE SHOES SPRING INSTAWNG PUERS 714.011 ENGINE REPAIR STAND...

  • Page 10: Introduction

    TO MOS INTRODUCTION This manual is intended as a help in "trouble shooting" and equent repair procedure, which cons occou rs exploatation due to normal wear, but in most due to inproper maintenance of vehicle or engine. cases For a dependable and prompt repair, follow the general rules as: Always use adequate tools.
  • Page 11 TO MOS FUNCTION OF ENGINE TRANSMISION PARTS clutch drum 1111 SJ}eed clutc h crankshat1 roller clutcti 2"" speed clutch 1 t� speed gear r' speed gear stancr shaltlpodal s h aft Legenda rotating pcwerod elements • free rotating ete n 1enls •...
  • Page 12 TO MOS FUNCTION OF ENGINE Starting...

  • Page 13: Function Of Engine/A35

    TO MOS FUNCTION OF ENGINE Idle...
  • Page 14 TO MOS FUNCTION OF ENGINE 1� speed...
  • Page 15 TOM OS FUNCTION OF ENGINE 2"' speed...

  • Page 16: Trouble Shooting

    TOM OS TROUBLE SHOOTING SPARK PLUG CONDITIONS ENGINE DOES NOT START ENGINE RUNS OVER BUT STALLS, ENGINE RUNS IRREGULARY, STOPS OR IDLES ROUGHLY. POWER LOOS ENGINE MISFIRES...
  • Page 17 TOM OS SPARK CONDITIONS PLUG b<own, tan i s indicative gray firing corr ect deposits engine running conditions and the selection of have m ulated excessive White accu from the use of in the oombustio n or through appropri a te heat ra plug.
  • Page 18 TO MOS ENGINE DOES NOT START Source coil Defective. Checic resistance Replace Contact breaker Not insulated. Not connected. Adjust or poin�s Incorrect gap. Pitted. Bumt. Replace Fuel hoses eakage Flattened, Broken Replace Worn . (piping) in fuel Clogged Clean Fuel fitt e r Condenser Weak.
  • Page 20 TO MOS ENGINE DOES NOT START Source coil Defective. Checic resistance Replace Contact breaker Not insulated. Not connected. Adjust or poin�s Incorrect gap. Pitted. Bumt. Replace Fuel hoses eakage Flattened, Broken Replace Worn . (piping) in fuel Clogged Clean Fuel fitt e r Condenser Weak.
  • Page 21 � Clogged Clean, ai r blow "' Clogged Ae-s1an Clean zamazano Fuet lank Fuel Is de1oriora1ed or dirty Replace luet FUEL SPARK gnltion liming Checlc limi n g Adjusl "Tl Ignition check reslslance coll Oelective, Replace Plug cap Faulty. No coniact Replace Incorrect gap.
  • Page 22 TO MOS TRANSMISSION REPAIRS TROUBLES IN GEARBOX When starting, engine runs in neutral gear and also with higher number of revs clutch does not engage: • off . - Throttle down and restart engine (oil is still cool and dense). When driving throttle up gradually to reduce jerks.
  • Page 23 A 3 5 TOM OS TRANSMISSION REPAIRS 1" Slacken the protective clutch washer with a socket and with special tool 732.202 remove speed clutch nut 1 ). (fig. hand or by means of an standard extractor in case of bushing seizure (fig. 2). Detach clutch drum...

  • Page 25: Transmission Repairs

    TOM OS TRANSMISSION REPAIRS 737.536 Fig.
  • Page 26 A 3 5 TO MOS TRANSMISSION REPAIRS If ls necessary to replace chain sprocket or claw collar on pedal shaft of kick shaft, first remove ring protective the thinner part of collar in mounted for­ g washer (fig. 8/2). Du assembly take care that (fig.
  • Page 27 TOM OS TRANSMISSION REPAIRS • Fig. Fig. 9 Fig.

  • Page 28: Magneto Repairs

    TO MOS MAGNETO REPAIRS In case of any magneto faulty part replacement actuate with dismantling at sequent parts as follows: - starting/lever pedal (wrench 1 1 . plastic mallet) side protection shield fixed on swinging arm (wrench 10) - engine cover (flat screwdriver) - flywheel nut (socket wrench 17, flywheel holder= special tool 732.202=fig.

  • Page 29: Magneto Repairs

    TO MOS MAGNETO REPAIRS • Fig. Note: contact breaker points gap between advance, ignition For a good ignition must be provided a proper correlation and abns.

  • Page 30: Carburetor Repairs

    TOM OS CARBURETOR REPAIRS carburetor troubles enti ed in trouble shooting chapters No: 3, 4 and on pages 19-21 proceed case of with dismalling at sequent parts as follows: area (detach the e screwsfl a t screwdriver) - carburetor protection shield rubber protection sheet, slackes th 1 O mm) rubber elements-box wrench...

  • Page 31: Carburetor Repairs

    TOM OS CARBURETOR REPAIRS DELLORTO FIG.
  • Page 32 lllilll FR!JIT li&IKE !.C.RBUATl!l SWITCH lMf' S�1Cll 11V 60W 11'.liN l&lltll. NJICATOR lMf' 11V 1.1W IWi BfAIC lt(JICATOR 11V 1,ZW STOP lMf' l.Mf' 11V fll liCAI! lfW(( I.All' SMTOI 8.fCTRll>'TC BOX �If� �Jf°�l:i:-:1 E NGllE LIGHT LIGHTING IKlRN DIMM ER SWITCM ST OP SWITCH...
  • Page 34 TO MOS CYLINDER, PISTON, REED VALVE REPAIRS on pages 18-20 proceed with In case of mentionated parts troubles in trouble shootlng chapters No. 2, 3 and dismantling at sequent parts follows: carburetor - exhaust pipe - head cover and cylinder (box wrench 1 1 mm) - piston (suitable pliers and gudgeon pressing pin) Check piston and cylinder surfaces for possible damages.
  • Page 35 TOM OS CYLINDER, PISTON, REED VALVE REPAIRS Upon the request of the market there is available one different pistons: 50 km/h (30 m.p.h.) - fig.19 with its own function diagram. T.D.C. IGNITION ADVANCE INTAKE TRANSFER 26 . 0 . � Fig.
  • Page 36 TOM OS CYLINDER, PISTON, REED VALVE REPAIRS r �20. ass y . parts - Damage to reed valve may be caused also by steel material run-down (see function on r ig.211. PISTON A T T.D.C. PISTON A T B.D.C. Fig. 20...

  • Page 37: Cylinder, Piston, Reed Valve Repairs

    TO MOS CYLINDER, PISTON, REED VALVE REPAIRS NOTE.: Replacement of cpl. reed valve is suggested. Fig. 21 Check conrod bending by help of two calippers (Fig. 22). Check the needle bearing clearance and bearing rol· ling surface lor damage. Fig. 22...
  • Page 38 TOM OS CRANKSHAFT AND MAINSHAFT REPAIRS Fig. 23 connecting Unscrew the crankcase halves screws. 735.888 with the three Install on the magneto side a case splitter o base plate fixing screw. With (fig. 23 wrench mm screw on device A and detach both halves Detach the AH crankcase half with mallet (fig.
  • Page 39 TO MOS CRA.NKSHAFT AND MAINSHAFT REPAIRS Crankshaft Inspection Check clearance of the conrod small and big end bearing assemblies. Check the crankshaft between the center of a horisontal alignment tool and measure the out-of round on all the p oi indicated in fig.
  • Page 40 TOM OS CRANKSHAFT AND MAINSHAFT REPAIRS Check both crankcase halves for possible damages or distorsions, particularly the joint surfaces, to avoid later leaking of oil from gearbox. Check all bear ings. i f clearance is noticed, the bearings must be replaced.
  • Page 41 TOM OS CRANKSHAFT AND MAINSHAFT REPAIRS t nul by a wrench 30 mm and using In case mainshaft toothing damage repl.Pce Slacken the chain s tool 732.202 (fig. c mallet. special 31 ). Knock out lhe mainshaft by pl Fig. case of needle bearings or seal g (incorporated in first...

  • Page 42: Frame And Suspension 4

    A 3 5 TOM OS FRAME AND SUSPENSION Fig.33 The front fork lower leg be removed as It is shown In fig. 33. - by unscrewing remove lower leg from the front fork (fig. 33/ 1) will remain attached either to the upper or to the lower screwed plug - remove by unscrewing spring - the upper plug should be removed after taping out the elastic pin (fig.33/2) - the lower plug can be removed with longer alien key...

  • Page 43: Wheels And Brakes

    TOM OS WHEELS AND BRAKES alloy Wheels are aluminium type. No special maintenance is usual ball bearings greasing and ca st wear checking. 34) thus Brakes are drum type (fig. there is a periodically need of linings dust (non asbestos) ;...

  • Page 44: Oil Pump

    TOM OS OIL PUMP After assembly or repair of models with oil pump you must keep to the following instructions: The pump is connected to the magneto nut on the crankshaft by a special clutch. Unscrew the bleed screew on the pump and wait until oil from the tank under the seat flows to the pump.
  • Page 45 MOTORCYCLE PARTS & ACCESSORIES Click on links below Tomos Motorcycle History & Technical Specifications Motorcycle Parts & Accessories Dirt Bike Parts & Accessories Harley Davidson Parts & Accessories Motorcycle Helmet Closeout Sale Japanese Motorcycle Original Equipment Parts Save On All Motorcycle Tires...

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