TOMOS

workshop manual

TOMOS
TWOWHEELERS & COMPONENTS
PROOUCTION,SLOVENIJA
 A35
TOMOS CONTENTS
2

TECHNICAL DATA 3-5

STANDARD ELEMENTS 6
SPECIAL TOOLS 7-9
INTRODUCTION 10
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 34-37
CRANKSHAFT AND MAJNSHAFT REPAIRS 38-41
FRAME AND SUSPENSION 42
WHEELS AND BRAKES 43
OIL PUMP 44

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 A35
TOMOS TECHNICAL DATA
3

Engine: single cylinder. two cycle with reed valve, air coole•

Bore x Stroke: 38 x 43 mm

Piston displacement: 49 ccm

Compression ratio: 9, 1 : 1

Brake horse power: 1,45 kW (5200 min-1)

Torque: 3,5 Nm (3500 min·')

Gearbox: automatic 2-steps, with two centrifugal cluthes

Gearbox oil/quantity: Valvomatic type A Suffix A • SAE 10 W 30/ccm 3

Ignition: Flywheel magneto

Ignition advance: 15+

, 0,2 mm B.T.D.C.

Contact breaker gap: 0,35·0,45 mm

Spark plug: BOSNA F 80. BOSCH W 4A2. CHAMPION L82,

NGK HS. EYQUEM 755, AC.C.42F

Spark plug gap: O,Smm

Fuel: MIXTURE OF GASOLINE 98 oct AND •

TWO STROKE OIL

 A35
TOMOS TECHNICAL DATA
4

TRANSMISSION

Z= 17

Z a 24

Z•72

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Chain transmission 96101tors

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22

(66/17) I=3.8823
Gear ratio 1•1 speed
(53/24) I: 2.4615
Gear ratio 2"" speed
(3.88. 72/11) •=25.4117
Gearbox ratio 1•1speed
(2.46 • 72111) •=16.1189
Gearbox ratio 2""speed
(22126) i � 0,846
Chain transmission ratio
(25.4117'0,846) i= 21.502
Total transmission ratio 1•• speed
(16.11/0.846) i- 13.631
Total transmission ratio 2"0 speed
 A35
TOMOS TECHNICAL DATA
5

TORQUE
Posilion Thread Nm Kpm Pound
per foot

Spar!< plug Ml 4><1.25 18 1,83 13,27

Cylinder cover M7 12 1,22 8,85

Cylinder stud bolts M7 15 1,53 11,06

Magneto flywheel M10x1 30 3.0S 22.12

Clutch of 1" speed M10x1 25 2.55 16,44

2""sp;ied driven gear Ml 4><1 80 9, 15 59.0

Engine-frame fastening bolts M8x1 25 2.55 16.44

RH engine cover MS 7 0.71 5.1S

LH engine cover MS 6 0,61 4.42

Crankcase MS 10 1.02 737

Mainshaft chain sprocket M22 60 6.11 44,23

Swinging arm fastening screw Ml 2x1 .25 35 3,57 25,61

Rear shock absorber M10 25 2,25 16,44

Top fork lug M12 35 3.57 25,81

Front and rear wheel spindle M11x1 32 3.2S 23,SO

 A35
TOMOS STANDARD ELEMENTS
6

Ball bearings

TOMOS
Dimensions
Installation: B earing No.
Code. No. d x 0 x b(mm)

Crankshaft 035.070x 2 6203-C3 17x40x12

Crankshaft 035.202 608 Bx22x 7

035.072
Countershaft 035.031 6201
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Mainshaft 035.037 6006 30x55x13

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Wheel axle 6201-Z 12x32x10

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Seal rings
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TOMOS
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Dimensions
Ins t a l lation pcs.
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Code. No. d x D x b(mm)

Crankshaft 036.554 17x35x7 2

Ma inshaft 036.620 35x47x7 1

 A35
TOMOS SPECIAL TOOLS
7

732.746
�·-·-- I-.. , ._ . _
,

MAGNETO FLYWHEEL PULLER

732.202
0
FLYWHEEL HOLDER

011.008
... -1
GAUGE PIN

732.193

DIAL GAUGE SUPPORT

735.888
4f--�-·-· -
CRANKCASE DIS -ASSEMBLY TOOL

a---8--E-+ B
 A35
TO MOS SPECIAL TOOLS
8

735.753
CRANKSHAFT MOUNTING FORK

731.155
CRANKSHAFT BEARING PULLER

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702.856
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--- -- - DIS-ASSEMBLY CRANKSHAFT

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BEARINGS
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737.535

CLUTCH SPRING SETIING TOOL

-1--1 - - ---j- 737.536

ROLLER CLUTCH INSTALLER

 A35
TOMOS SPECIAL TOOLS
9

.
I �
732.367
.
--0 MAINSHAFT NEEDLE BEARINGS
INSTALLER

-� I I B3��1- - -·3:3- 706.485

EXTRACTOR

/
- 706.472
�-
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--
-=H EXTRACTOR BRIDGE

736.913
\ ,QI
- -------
BRAKE SHOES SPRING INSTAWNG
L PUERS

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714.011
<=.
ENGINE REPAIR STAND

.. . -I . -

...
 A35
TOMOS INTRODUCTION
10

This manual is intended as a help in "trouble shooting" and consequent repair procedure, which occours in
exploatation due to normal wear, but in most cases due to inproper maintenance of vehicle or engine.

For a dependable and prompt repair, follow the general rules as:
- Always use adequate tools.
- Where necessary, use a plastic mallet when dismantling individual assemblies,
- Clean Individual parts prior to each check.
- Carefully clean all parts, oil movable parts, which are fitted by embossing them, and replace gaskets and
sealing rings prior to re-assembly.
- Observe torque figures table when screwing on screws and nuts.

The manual shows only the execution of dis-assembly operations in which necessary special toots are needed.
Dis-assembly of other parts (see explosion view in Spare parts catalogue) is meant like a common knowledge
of an aualified mechanic to whom this manual is dedicated.

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 A35
TOMOS FUNCTION OF ENGINE
11

TRANSMISION PARTS

clutch drum

1111 SJ}eed clutch

crankshat1

roller clutcti
LJ

2"" speedclutch

1 t� speedgear

LJ
e Shaf1
count r
SCllfoc ktng 10
U er clu t ch

r' speed gear

Sl a r1 1 ng e
. h a1n lrainsm 1 ssion

mal nsfl all

stancr shaltlpodal shaft

drive chain sprocket

Legenda

• rotating pcwerod elements

• free rotating eten1enls

4 s1and sll'I clements

 A35
TOMOS FUNCTION OF ENGINE
12

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Starting
 A35
TO MOS FUNCTION OF ENGINE
13

Idle run
 A35
TOMOS FUNCTION OF ENGINE
14

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1� speed
 A35
TOMOS FUNCTION OF ENGINE
15

'
2"' speed
•
 A35
TOMOS TROUBLE SHOOTING
16

1 SPARK PLUG CONDITIONS

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2 ENGINE DOES NOT START

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ENGINE RUNS OVER BUT STALLS,

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ENGINE RUNS IRREGULARY,

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STOPS OR IDLES ROUGHLY.

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4 POWER LOOS

5 ENGINE MISFIRES
 A35
TOMOS SPARK PLUG CONDITIONS
17

A b<own, tan or gray firing end i s indicative of correct

engine running conditions and the selection of the White deposits have accumulated from excessive
appropriate heat rating plug. amount of oil in the oombustion or through the use of
low quality oil. Remove deposits or a hot spot may
from.

Black sooty deposits indicate an over-rich luet /air Wet, oily cartx>n deposits form an electrical leakage
mixture, or a malfunctioning ignition system. If no Im­ path along the insulator nose, resultin g in a misfire.
provement Is obtained, try one grade hotter plug. The cause may be a badly worn engine or a malfunc·
tloning ignition system.

A blistered white insulator or melted electrode lndlca· A worm spark plug not only wastes fuel but also over ­

tes over advanced Ignition timing or a malfunctioning loads the whole ignition system because the increa­
cooling system. If oorrection does not prove effectl· sed gap requ ire s higher voltage to Initiate the spark.
ve, try a colder grade plug. Adjust spark plug gap or replace.
TOMOS 2 ENGINE DOES NOT START

-,.
I Source coil Defective. Checic resistance Replace

11
II

III I
- .
Contact breaker Not insulated. Not connected. Adjust or
I poin�s Incorrect gap. Pitted. Bumt.
----
. - Replace
Fuel hoses Leakage , Flattened, Broken Replace Worn .
(piping)

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Fuel fitter in fuel Clogged Clean

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tank Condenser Weak. Shorted, Bad contact Replace
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,. Piston, Cylinder Worn, Broken, Scuffed, Replace
Fuel filter in carburetor
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Clogged Clean -

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,. wall, Piston ring. Roasted.

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Ignition coil Defective, check resistance Replace
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,. Oil seal Worn, cracked Replace I

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Fuel tank Empty or low fuel level Add fuel
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Plug cap

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Ponovni zagon

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Re-start '
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NO OK Cylinder or
crankcase gasket
Afr leakage Replace

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1
Re-start

NO
. NO OK
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Spat1c plug

NO�
Incorrect gap. Garboo deposit. Replace
Dirty. Oily. Bumed.

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Reed valve Leakage, broken Replace
'

I FUEL
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I SPARK
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COMPRESSION I

� Is spark blue and

1s mere rue1 1n carouretor! strong?
YES I

Is compr1�ssion
pressure correct?

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Fuel tank Fuel is deteriorated or dirty Replace fuel
Re:start

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 A35
ENGINE RURNS OVER BUT STALLS. ENGINE RUNS
TOMOS 3 IRREGULARLY, STOPS OR IDLES ROUGHLY.
19

-
Adjust
,. Carburetor Needle valve is worn.
Pilot passages are dogged. Clean
Ignition timing Check timing Adjust

Choke is dosed. Replace

�
-

Water is mixed. Piston, Cylinder Worn, Broken, Scuffed, Replace

wall, Piston ring. Roasted.

Replace
Fuel hoses Leakage, Flattened, Broken
(piping) Oil seal Worn, cracked Replace
Contact breaker Not insulated. Not connected. Adjust or replace
points Incorrect gap. Pitted. Burnt.
Worn.

• 1"
-
1

.
Fuel filter Clogged
Clean
n 'It I it -
Cylinder or Air leakage Replace
crankcase gasket
Re- start

Re-start
NO OK

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...
NO OK
- '
I-
Spark plug Incorrect gap. Carbon deposit. Replace
... Add fuel Dirty. Oily.
Burned.
Replace

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It Reed valve Leakage, broken
Fuel tank Empty or fuel level is low

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����-
FUEL SPARK .l COMPRESSION

Is compression
pressure correct?
TOMOS 2 ENGINE DOES NOT START

-,.
I Source coil Defective. Checic resistance Replace

11
II

III I
- .
Contact breaker Not insulated. Not connected. Adjust or
I poin�s Incorrect gap. Pitted. Bumt.
----
. - Replace
Fuel hoses Leakage , Flattened, Broken Replace Worn .
(piping)

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Fuel fitter in fuel Clogged Clean

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tank Condenser Weak. Shorted, Bad contact Replace
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,. Piston, Cylinder Worn, Broken, Scuffed, Replace
Fuel filter in carburetor
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Clogged Clean -

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,. wall, Piston ring. Roasted.

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Ignition coil Defective, check resistance Replace
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,. Oil seal Worn, cracked Replace I

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Fuel tank Empty or low fuel level Add fuel
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Plug cap

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Ponovni zagon

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Re-start '
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.

1 I
NO OK Cylinder or
crankcase gasket
Afr leakage Replace

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1
Re-start

NO
. NO OK
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Spat1c plug

NO�
Incorrect gap. Garboo deposit. Replace
Dirty. Oily. Bumed.

I
Reed valve Leakage, broken Replace
'

I FUEL
I
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I SPARK
I
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COMPRESSION I

� Is spark blue and

1s mere rue1 1n carouretor! strong?
YES I

Is compr1�ssion
pressure correct?

-
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Fuel tank Fuel is deteriorated or dirty Replace fuel
Re:start

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�art>ure1or Clogged Clean, air blow

0
"'
-ue1 fiher Clogged Clean Ae-s1an

NO OK
01
zamazano
Fuet lank Fuel Is de1oriora1edor dirty Replace luet

I FUEL
I: I SPARK
I···
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gnltion liming Checlc liming Adjusl z
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-
(/)
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-
::0
Ignition coll Oelective, check reslslance Replace m
(/)
I

Plug cap Faulty. No coniact Replace I

Spar1< plug Incorrect gap. Cerbon deposll.

Olny. Olly. Burned.
Replace

N :t>
(,)

1:
.....

I
01
•••
SPARK Arst checlc spark plug 10 find
cause.
 A35
TOMOS TRANSMISSION REPAIRS
22

TROUBLES IN GEARBOX

• When starting, engine runs in neutral gear and also with higher number of revs clutch does not engage:
- Throttle down and restart engine (oil is still cool and dense). When driving off. throttle up gradually to reduce
jerks.
- Loosen or broken retain spring of 1" speed gear selllocking clutch.
- 1•1 speed gear selflocking clutch cage damaged.
• When starting, the engine joggle:
- Not enough oil in the gearbox- fill up to the required level.
- Clutch drum or 151 speed clutch shoe elements damage.
- 1•1 speed clutch retaining nut slackened (noise at engine idle run).
* Clutch skidding (especially in cool weather):
- Uncorrect oil in gearbox replace oil with standard.
Clutch not shifting from the 1" into 2"" or nol engaging at all:
·

- Engine not powerful enough-see chapter 3 · Power loss

- Excessive oil in gearbox- check level.
- Brakes not disengaging grease control cables.
•

- Clutch blocked - try to operate clutch at higher number of revs with motorized bicycle supported by stand.
Countershatt and 1•1 speed gear selflocking clutch seized - check the slide bearing surface.
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- Chain sagged · tighten chain.
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- Nol enough oil in the gearbox · fill up to the required level.

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• With engine disengaged, the motorized bicycle is difficult to move forward · rearward:
- Check the 1" speed gear selflocking clutch for damage.
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With engine in idle run in rearward motion blows:

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- Check the starter shaft brake spring proper function.

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• Transmission not disengaged by idle run:

- Clutch drum incorporated roller clutch blocked.
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When starting the engine does not turn over:

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- Starter shaft holding clamp do not engage the inner chain transmission.
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- Clutch drum incorporated roller clutch damaged.

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In case of transmission part damage or failure is necessary to disassemble, only the RH engine cover and pre­
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cede with disassembling and checking the parts as shown further.

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Prior of operation drain the oil from the gearbox, dismantle the exhaust pipe (box wrench 10 mm, wrench 13
mm), the lateral protection shield fixed at swinging arm (wrench 10 mm), and slacken the cover screws. Atten­
tion at distance washers on starter shaft and countershaft.
 A35
TOMOS TRANSMISSION REPAIRS
23

Slacken the protective clutch washer with a socket 19 and with special tool 732.202 remove 1" speed clutch nut
(fig. 1 ).
Detach clutch drum by hand or by means of an standard extractor in case of bushing seizure (fig. 2).

Fig. 1 Fig. 2

The starter shaft and the countershaft are connected by a starter chain, so both shafts will have to be taken out
together (fig. 3).
Remove the standard washers on the crankshaft and on the mainshaft (fig. 4).

Fig. 3 Fig. 4
 A35
TOMOS TRANSMISSION REPAIRS
24

Remove the sg·circlip and separate clutches 1" and 2"" speed.
Dismantle both clutches, spring is removed with a screwdriver.
In this manner brake strips are realeased, and all three shoes can be removed.
Press pins out of shoes and check brake strips, spring inside of shoes and clutch hub for excessive wear (Fig. 5).
Clutch shoes must slip freely on clutch hub. In case of use of prescribed oll quantity and quality the wear of
clutch shoes linings is reduced at minimum.

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Fig. 5 Fig. 6
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At first, assemble the 1'" speed clutch at reversed order of dismantling. Particular care should be taken of brake
strips, they must protect each other against falling out.
Fix the main pin of the device 737.535 with the thinner part facing upwards. The spring joint must be placed in
the middle of one shoe. With the lever of the device insert the spring in the shoes groove. (Fig. 6).
To assemble the 2"" speed clutch tum the device over. The clutch hub with gear must be placed in the way the
gear Is on bottom and the gap between two shoes fits with the pin. The manner of mounting the spring is lhe
same as mentioned before for the 1" speed clutch.
Remove and inspect the 111 speed driven gear selflocking clutch in case of transmission troubles mentionated
on page 24. Remove the sg·circlip at the countershafts toothing. Unfasten the wire spring (Fig. 9) and separate
a small chain sprocket with roller cage. Remove the selflocking clutch and the rollers (Fig. 10).
In case of sliding surface damage of selflocking clutch replace the body (223.463). Check the sliding surface of
selflocking clutch on countershaft.

Dismantling of the needle clutch is necessary only in case of replacement.

A new needle clutch is pressed with special tool no. 737.536 (Flg. 7).
The needle clutch must be pressed with the signed side towards the center of the clutch drum, if not it may ope·
rate in the reverse direction.

Clearance between shoes and clutch drum rim is approx. 0,4 mm. Axial clearance of the clutch drum is from 0.1
m to 0.3 mm by means of inserting in the adjusting thrust washer of 0.3 mm or 0.5 mm under the clu1ch (fig. 5/A).
 A35
TOMOS TRANSMISSION REPAIRS
25

737.536

0 0

0 0 0 0
0 0

Fig. 7
 A 35
TOMOS TRANSMISSION REPAIRS
26

If ls necessary to replace chain sprocket or claw collar on pedal shaft of kick shaft, first remove protective ring
(fig. 8/1) and spring washer (fig. 8/2). Du ring assembly take care that the thinner part of collar in mounted for­
ward or else, the brake spring slides across the chain sprocket Check the chain for overtension or some other
.

damage.

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Fig. 8

A damage of sliding surface of 1 •1 speed driven gear and countershaft may be caused due to low oil quantity in
the gearbox. Fix the countershaft into a vice and unscrew the nut with wrench 19 and remove the 2"" speed gear
with an extractor. Replace damaged parts.

Reassemble the countershaft in the reversed order of dismantling.

Use of grease is not suggested because it may impede the function of the selflocking clutch. Put the chain
sprocket with cage so that the beginning of wire spring is turned 90" left-ward from spring nose. (fig. 9). Lock the
wire spring to riveted nose on the selflocking clutch body.

Before tightening nut, it is necessary to check the proper function of the assy. Firmly hold 2"" speed driven gear
with the left hand and the clutch drum with the right hand When clutch drum rotates counterclockwise, both clut­
.

ches idle, when it rotates clockwise the motion is tran� mited to the crankshaft (fig. 1 1 ).
 A35
TOMOS TRANSMISSION REPAIRS
27

.•I
•
'. .

Fig. 9 Fig. 10

Fig. 11
 A35
TOMOS MAGNETO REPAIRS
28

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. 12)
- flywheel (wrench 32 and 19, flywheel extractor=special tool 732.746=1ig. 13)
- stator plate (flat screwdriver)

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Fig. Fig. 1 3
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For proper function of the engine is essential a correct ignition timing. The ignition advance should be 1 ,5 '0
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The most common cause of incorrect timing is due wear or damage of contact breaker points. wear of cam ac­
tuated breaker nose lever, damage of condenser. To provirte the exact timing is necessary to replace faulty
parts and proceed (fig. 14) as follows:

- Screw the special tool 732.193 and dial gauge 975.709 wi1h gauge pin 011 .008 into the spark plug hole. 8y
rotating the flywheel put the piston to the T.D.C. and set the dial gauge to zero.
- With the flywheel in T.D.C. set the contact breaker points gap between 0,35 to 0,45 mm
- With a test light, buzzer or Ohm meter determine when contact breakerpoints connection is made. The te-
sting device must be connected to the short circuit (black) wire and to the ground of the engine. At the mo­
ment of connection of the points the test battery light will glow brightly, lhe buzzer will change the acoustic
frequence or the Ohm tester will show approx. zero Ohms.
- Rotate the flywheel in the clockwise direction until the dial gauge will show the value of 1,5 mm
- By means of oblong fixing openings rotate the stator base plate and find a contact breaker points connection -

opening position (test indication).

- Tighten the stator base plate and recheck the ignition advance which should be max. 1 ,7 mm
- In case of excessive advance, the stator base plate should be rotated in the direction of entine rotation (see
arrow of flywheel). fn case of insufficient advance turn the plate in the opposite direction.
- In case of uncapable timing setting with a stator base plate rotation provide with the contact breaker points
gap setting but under prescribed limits.
- For efficient spark intensity or high ignition voltage is essential a proper abris adjustament. As a matter of fact,
it is the distance between the edge of the ignition coil pole shoe and the receeding magnet pole edge at the
opening point of the contact breaker and it should be within the range of 12 ± 2 mm (0.473 + 0,079 in). The
gap should be measured the moment the Intensity of light or sound frequency is changed on the gauge (fig.
14).
 A35
TOMOS MAGNETO REPAIRS
29

12 mm''

Fig. 14

Note:
For a good ignition must be provided a proper correlation between ignition advance, contact breaker points gap
and abns.
 A35
TOMOS CARBURETOR REPAIRS
30

In case of carburetor troubles mentioned in trouble shooting chapters No: 3, 4 and 5 on pages 19-21 proceed
with dismalling at sequent parts as follows:
- carburetor area protection shield (detach the rubber protection sheet, slackes the screwsflat screwdriver)
- fuel tank (screw on bottom side near horn attachment on frame and on rubber elements-box wrench 1 O mm)
- carburetor cpl. with air filter and rubber dust protection (screw of fixing claw flat screwdriver) fig. 15.
-

The intake silencer remains between the angle supports and engine thus is necessary to remove the engine to
replace it.

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Fig. 15

Dismantle the carburetor Into component parts (fig. 17). Clean the parts in gasoline (petrol) and blow them by
compressed air.
Replace if necessary worn parts and carefully reassemble, especially the needle valve and float. Sligthly oil the
air filter
.
 A35
TOMOS CARBURETOR REPAIRS
31

DELLORTO

FIG. 17
 FR!JIT li&IKE lllilll
SWITCH !.C.RBUATl!l
lMf' S�1Cll
11V 60W

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NJICATOR lMf'
11V 1.1W

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lt(JICATOR

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11V 1,ZW

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STOP lMf'

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 A35
TOMOS CYLINDER, PISTON, REED VALVE REPAIRS
34

In case of mentionated parts troubles in trouble shootlng chapters No. 2, 3 and 4 on pages 18-20 proceed with
dismantling at sequent parts as 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. With micrometer check piston dia on points d1, d2,
d3 at right angles to gudgeon pin and compare the readings with the corresponding group on piston and in the
table (fig. 18).

Skuplna d1 d2 d3
ovalnos1
Group ound-<lff
r

A 37.955 37,8
65 37,775 0,045 mm
37,965 0,045

es
B 37,875 37,785

A 1.4954 1 .4919 rc
1 .4883 0.001 8
in PISTON
ou

B 1.4958 1 .4923 1.4887 0.001 8

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Slcupina A B
()lwp CYLINDER
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Fig. 18 38,01 o+<>·0

' 38,020•0.oio
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1.soo•o.OCM 1.504 • 0.000 in

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Bore taper and come-shaped:

o, max. 0,012 mm (0,473 · 10·3 in)
=
 A35
TOMOS CYLINDER, PISTON, REED VALVE REPAIRS
35

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.

13

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-
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� R 5
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T.D.C.

IGNITION ADVANCE
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INTAKE

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TRANSFER

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8
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 A35
TOMOS CYLINDER, PISTON, REED VALVE REPAIRS
36

Damage to reed valve may be caused also by steel material run-down (see function on r�20. assy. parts -
rig.211.

PISTON AT T.D.C.

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PISTON AT B.D.C.

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Fig. 20
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 A35
TOMOS CYLINDER, PISTON, REED VALVE REPAIRS
37

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
 A35
TOMOS CRANKSHAFT AND MAINSHAFT REPAIRS
38

..

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Fig. 23
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Unscrew the crankcase halves connecting screws.

C

Install on the magneto side a case splitter tool 735.888 with the three magneto base plate fixing screw. With
wrench 13 mm screw on the device A and detach both halves (fig. 23 ) .
Detach the crankshaft from the AH crankcase half with a plastic mallet (fig. 24 ) . In case of remaining ball bea­
ring on the crankshaft remove it with the extractor 731.155 (fig. 25).

Fig. 24 Fig. 25
 A35
TOMOS CRA.NKSHAFT AND MAINSHAFT REPAIRS
39

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 poi nts indicated in fig. 26.
Permissible out-of-round snould be within 0.02 mm (0,008 in) at check points 2 and 0.01 mm (0.004 in) at check
points 1 and 4. Check ii the crankshaft conical part is damaged, inspect the thread on semiaxles and the key·
way.

Fig. 26

Note
As required centering is only carried out with a copper hammer, grip pliers and two levers.
,
 A35
TOMOS CRANKSHAFT AND MAINSHAFT REPAIRS
40

Check both crankcase halves for possible damages or distorsions, particularly the joint surfaces, to avoid later
leaking of oil from gearbox.
Check all bearings. if clearance is noticed, the bearings must be replaced.
Remove seal rings by screwdriver. For disassembly of ball bearings and seal rings assembly alternatively use a
pressing pin 702.856 (fig. 27 and28).

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Crankshaft is impressed in crankcase halves by extractor 735.888 actuating with screw B (fig. 29 and 30) -

wrench 24 and 13. In case of machine press assembly is necessary a use of crankshaft insert forks 735.753 to
prevent crankshaft deflection.

Fig. 29 Fig.30
 A35
TOMOS CRANKSHAFT AND MAINSHAFT REPAIRS
41

In case of mainshaft toothing damage repl.Pce ii. Slacken the chain sprocket nul by a wrench 30 mm and using
the special tool 732.202 (fig. 31 ). Knock out lhe mainshaft by plastic mallet.

Fig. 31

In case of needle bearings or seal r ing (incorporated in first needle bearing, code 035.502.) damage knock out
them by suitable tool but pay attention not to damage bearing lying surface on mainshaft.
Pay attention on sequence assembly of needle bearings (fig. 32) by mach ine press tool and special tool
732.367.

035.503

035.502

seal ring

Fig. 32
 A 35
TOMOS FRAME AND SUSPENSION
42

I 1

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2

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Fig.33

The front fork lower leg can be removed as It is shown In fig. 33.
- by unscrewing remove lower leg from the front fork (fig.33/ 1)
- the spring will remain attached either to the upper or to the lower screwed plug - remove by unscrewing
- 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 (9 mm), (fig.33/3)

Checking:
Lenght of new spring: L = 215 mm
Wear limit: L = 200 mm
Check the outer and inner surfaces of the stanchions for sign of excessive wear.
Check for excessive play and for the straightness of the fork legs.
Reassemble in reverse order of dismantling.
The spring and sliding surfaces should be greased with water resistant grease (LIS 2)
 A35

TOMOS WHEELS AND BRAKES

43

Wheels are cast aluminium alloy type. No special maintenance is required as usual ball bearings greasing and
wear checking.
Brakes are drum type (fig. 34) thus there is a periodically need of linings dust (non asbestos) cleaning; cable
controls, brake operating cam and brake shoes support pin greasying. Disassembly of brake shoes is easier
with pliers - special tool 736.913.

Fig. 34

,
 A35
TOMOS OIL PUMP
44

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 oil pump and wait until oil from the tank under the seat flows to the pump.
The screw is lhen screwed on (fig. 35).
- Pour approx. 1 I gas mixture in the ratio od 1 :50 (2% oil) into the fuel tank and start lhe engine. Let the engine
run of for approx. 5 min so as to make the oil pump push oil to the engine.
- Fill up the fuel lank with regular gas.
Take care lest oil level in the oil tank does not fall under the marking MIN. Pay special attention to the routing
of the oil IiIles to and from the oif pump. If the outflow line is crimped, oil will not reach lhe carburetor causing
severe engine damage.

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Fig. 35
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