TOMOS Colibri A 35 Moped Workshop manual
The Colibri A 35 is a moped with a single-cylinder, two-stroke engine with a reed valve, air-cooled. It has a bore and stroke of 38 x 43 mm, a piston displacement of 49 ccm, a compression ratio of 9.1:1, and a brake horsepower of 1.45 kW (5200 min-1). The gearbox is automatic 2-step with two centrifugal clutches. The ignition system is a flywheel magneto with an ignition advance of 1.5 + 0.2 mm B.T.D.C. and a contact breaker gap of 0.35-0.45 mm.
advertisement
TOMOS
^
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TOMOS
A 35
workshop manual
www.1977mopeds.com
1.800.965.1977
colibri
TOMOS A 3 5
workshop manual
TOVARNA MOTORNIH VOZIL
TOMOS KOPER
SLOVENIA
www.1977mopeds.com
1.800.965.1977
TOMOS
CONTENTS
TECHNICAL DATA
STANDARD ELEMENTS
SPECIAL TOOLS
INTRODUCTION
FUNCTION OF COLIBRI ENGINE/A35
TROUBLESHOOTING
TRANSMISSION REPAIRS
MAGNETO REPAIRS
MAGNETO AND ELECTRICAL EQUIPMENT CHECKING
WIRING HARNESS
CARBURETOR REPAIRS
EXHAUST SYSTEM
CYLINDER, PISTON, REED VALVE REPAIRS
CRANKSHAFT AND MAINSHAFT REPAIRS
FRAME AND SUSPENSION
WHEELS AND BRAKES
OIL PUMP
A35 - SPECIAL FEATURES
COLIBRI A35
Page
3 - 5
6
7 - 9
10
11 - 15
1 6 - 2 1
2 2 - 2 7
2 8 - 2 9
30
31 - 3 2
3 3 - 3 4
35
3 6 - 4 0
41 - 4 4
4 5 - 4 7
48
49
50 www.1977mopeds.com
1.800.965.1977
COLIBRI
TOMOS
Engine:
Bore * Stroke:
Piston displacement:
Compression ratio:
Brake horse power:
Torque:
Gearbox:
Gearbox oil quantity:
Ignition:
Ignition advance:
Contact breaker gap:
Sparkplug:
Spark plug gap:
Fuel:
T E C H N I C A L D A T A single cylinder, two cycle with reed valve, air cooled
38 x 43 mm
49 ccm
9,1 : 1
1,45 kW (5200 min-
1
)
3,5 Nm (3500 min"
1
) automatic 2-steps. with two centrifugal cluthes
Valvomatic type A Suffix A - SAE 10 W 30 ccm 300
Flywheel magneto
1,5 + 0,2 mm B.T.D.C.
0,35-0,45 mm
BOSNA F 80, BOSCH W 4A2, CHAMPION L82,
NGK HS, EYQUEM 755, AC.C.42F
0,5 mm
Mixture of gasoline 86-oct. and two stroke oil. www.1977mopeds.com
1.800.965.1977
TOMOS
TECHNICAL DATA
COLIBRI A35
T R A N S M I S S I O N
Z = 26 i speed
2" a
speed
Z = 66
Mamshaft
Chain transmission 96 rollers
G e a r r a t i o 1 s t
speed
Gear ratio 2 ncl
speed
Gearbox ratio 1
5 , speed
Gearbox ratio 2" r t speed
Chain transmission ratio
Total transmission ratio 1 s
' speed
Total transmission ratio 2 n
" speed www.1977mopeds.com
1.800.965.1977
( 6 6 / 1 7 ) i = 3.8823
( 5 3 / 2 4 ) i = 2.461 5
( 3 . 8 8 * 7 2 / 1 1 ) 1 = 25.4117
( 2 . 4 6 * 7 2 / 1 1 ) 1=16 1189
(22/26) i = 0.846
(25,4117*0.846) i - 21.502
(16.11 0.846) i = 13.631
TOMOS
Position
Spark plug
Cylinder cover
Cylinder stud bolts
Magneto flywheel
Clutch of 1 s t
speed
2 nd speed driven gear
Engine-frame fastening bolts
RH engine cover
LH engine cover
Crankcase
Mainshaft chain sprocket
Swinging arm fastening screw
Rear shock absorber
Top fork lug
Front and rear wheel spindle
TECHNICAL DATA
COLIBRI A35
5
Thread
TORQUE
Nm Kpm
2,25
3,57
3,26
0,61
1,02
6,11
3,57
1,83
1,22
1,53
3,06
2,55
9,15
2,55
0,71 M6
M6
M6
M22
Mil 4x1,25 18
M7 12
M7
M10x1
15
30
M10x1
M14x1
M8x1
25
80
25
10
60
7
6
M1 2x1,25 35
25 M10
M12
M l 1*1
35
32
Pound per foot
13,27
8,85
11,06
22,12
18,44
59,0
18,44
5,16
4,42
737
44,23
25,81
18,44
25,81
23,60 www.1977mopeds.com
1.800.965.1977
TOMOS
Ball bearings
Installation:
Crankshaft
Crankshaft
Countershaft
Mainshaft
Wheel axle
Seal rings
Installation
Crankshaft
Mainshaft
STANDARD ELEMENTS
COLIBRI A35
6
TOMOS
Code. No.
035.070 x 2
035.202
035.072
035.031
035.037
044.225x2
Bearing No.
6203-C3
608
6201
6006
6201-Z
Dimensions d x D x b (mm)
1 7 x 40 x 1 2
8 x 22 x 7
1 2 x 3 2 x 10
30 x 55 x 1 3
1 2 x 3 2 x 1 0
TOMOS
Code. No.
036.554
036.620
Dimensions d x D x b (mm)
1 7 x 3 5 x 7
35 x 47 x 7 pes.
2
1 www.1977mopeds.com
1.800.965.1977
TOMOS
SPECIAL TOOLS
COLIBRI/A35
732.746
MAGNETO FLYWHEEL PULLER o
732.202
FLYWHEEL HOLDER
«=€
3=>
I—
- <
—'
I> www.1977mopeds.com
1.800.965.1977
975.709
DIAL GAUGE
011.008
GAUGE PIN
732.193
DIAL GAUGE SUPPORT
735.888
CRANKCASE DIS-ASSEMBLY TOOL
TOMOS
SPECIAL TOOLS
C O L I B R I A35
8
735.753
CRANKSHAFT MOUNTING FORK
•:•:•:•..'.'
731.155
CRANKSHAFT BEARING PULLER
702.856
DIS-ASSEMBLY CRANKSHAFT
BEARINGS
*ZZ7 v., t
I
I 1
1
1
737.535
CLUTCH SPRING SETTING TOOL d www.1977mopeds.com
1.800.965.1977
737.536
ROLLER CLUTCH INSTALLER
TOMOS
A
\|
SPECIAL TOOLS
v. f
COLIBRI/A35
9
732.367
MAINSHAFT NEEDLE BEARINGS
INSTALLER
E B O = g
3 706.485
EXTRACTOR
706.472
EXTRACTOR BRIDGE
736.913
BRAKE SHOES SPRING INSTALLING
PLIERS a = C o = C www.1977mopeds.com
1.800.965.1977
714.011
ENGINE REPAIR STAND
TOMOS
INTRODUCTION
COLIBRI/A35
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 tools are needed.
Dis-assembly of other parts (see explosion view in Spare parts catalogue) is meant like a common knowledge of an qualified mechanic to whom this manual is dedicated. www.1977mopeds.com
1.800.965.1977
Technical Service Department
TOMOS
TOMOS
FUNCTION OF COLIBRI ENGINE
COLIBRI/A35
11
TRANSMISSION PARTS
crankshaft
•
countershaft starter shaft/pedal shaft
. f r j
ID CfcOD
ucFcin
Legenda
rotating powered elements free rotating elements
- stand still elements www.1977mopeds.com
1.800.965.1977
clutch drum
I s 1
speed clutch roller clutch
2 nd
speed clutch
I s t
speed gear seltlocking rollerclutch
2 " speed gear starting chain transmission malnshaft drive chain sprocket
TOMOS
FUNCTION OF COLIBRI ENGINE
COLIBRI/A35
12
ir
I
8
n—
r=
l""
^™p
Starting www.1977mopeds.com
1.800.965.1977
TOMOS
FUNCTION OF COLIBRI ENGINE
COLIBRI/A35
13
Idle run www.1977mopeds.com
1.800.965.1977
HCFDD
1
i—T^
TOMOS
FUNCTION OFCOLIBRI ENGINE
COLIBRI/A35
14
• CFDD
1
S|
Speed www.1977mopeds.com
1.800.965.1977
TOMOS
1
SPARK PLUG CONDITIONS
COLIBRI
17
A brown, tan or gray firing end is indicative of correct engine running conditions and the selection of the appropriate heat rating plug.
White deposits have accumulated from excessive amount of oil in the combustion or through the use of low quality oil. Remove deposits or a hot spot may from.
Black sooty deposits indicate an over-rich fuel /air mixture, or a malfunctioning ignition system. If no improvement is obtained, try one grade hotter plug.
Wet, oily carbon deposits form an electrical leakage path along the insulator nose, resulting in a misfire.
The cause may be a badly worn engine or a malfunctioning ignition system.
A blistered white insulator or melted electrode indicates over advanced ignition timing or a malfunctioning cooling system. If correction does not prove effective, try a colder grade plug.
A worm spark plug not only wastes fuel but also overloads the whole ignition system because the increased gap requires higher voltage to initiate the spark.
Adjust spark plug gap or replace. www.1977mopeds.com
1.800.965.1977
TOMOS
ENGINE DOES NOT START
Is there fuel in carburetor?
YES
Fuel hoses
(piping)
Leakage, Flattened. Broken Replace
Fuel filter in fuel Clogged tank
Clean
Fuel filter in carburetor Clogged Clean
Fuel tank Empty or low fuel level Add fuel
"1'
I 1
Ponovm zagon
Re-start
NO OK
Fuel tank Fuel is deteriorated or dirty Replace fuel
SPARK
Is spark blue and strong?
NO OK
Re-start www.1977mopeds.com
1.800.965.1977
Source coil Defective. Check resistance Replace
Contact breaker Not insulated. Not connected. Adjust or replace points Incorrect gap. Pitted. Burnt.
Worn.
Condenser Weak, Shorted, Bad contact Replace
Ignition coil Defective, check resistance Replace
Plug cap Faulty, No contact Replace
Spark plug Incorrect gap. Carbon deposit. Replace
Dirty. Oily. Burned.
COLIBRI
18
1 \ | ! I l
Re-start
NO OK
I
B
COMPRESSION
Is compression pressure correct?
Piston, Cylinder Worn, Broken, Scuffed, Replace wall, Piston ring. Roasted.
Oil seal Worn, cracked Replace
Cylinder or Air leakage crankcase gasket
Replace
Reed valve Leakage, broken Replace www.1977mopeds.com
1.800.965.1977
TOMOS
ENGINE RURNS OVER BUT STALLS. ENGINE RUNS
IRREGULARLY, STOPS OR IDLES ROUGHLY.
FUEL www.1977mopeds.com
1.800.965.1977
Carburetor Needle valve is worn.
Pilot passages are clogget
Choke is closed
Water is mixed
Fuel hoses
(piping)
Leakage, Flattened, Broke
Fuel filter Clogged
Fuel tank Empty or fuel level is low
Re-start
NO OK
1
SPARK
Ignition timing Check timing Adjust
Contact breaker Not insulated. Not connected. Adjust or replace points Incorrect gap. Pitted. Burnt.
Worn.
Spark plug Incorrect gap. Carbon deposit. Replace
Dirty Oily. Burned. i_t a Re-start
NO OK
I
COMPRESSION
Is compression pressure correct? www.1977mopeds.com
1.800.965.1977
Piston, Cylinder Worn, Broken, Scuffed, wall. Piston ring. Roasted
Replace
Oil seal Worn, cracked Replace
Cylinder or Air leakage crankcase gasket
Reed valve Leakage, broken
Replace
Replace
COLIBRI
19
TOMOS
POWER LOSS
COLIBRI
20
FUEL
Is compression pressure correct
-
?
COMPRESSION
Carburetor Needle valve is worn. Adjust
Pilot passages are clogged.
Choke is closed. Clean
Water is mixed. Replace
Fuel filter Clogged Clean
Fuel hoses (piping) Leakage, Flattened, Broken Replace Test ride
Fuel tank Fuel is deteriorated or dirty Replace fuel ^ \
ISKRA
SPARK
Piston,
Cylinder wall,
Piston rings
Worn, Broken, Scuffed,
Roasted.
Oil seal Worn, cracked
Cylinder gasket Air leakage
Lamelni ventil Ne tesni.zlomljen
Reed valve Leakage, broken
Replace
Replace
Replace
Zamenjati
Replace
Ignition timing Check timing Adjust
Spark plug Incorrect gap. Carbon deposit. Replace
Dirty. Oily. Burned.
' Check:
- brakes do not disengage = oil or grease control cabl&s
- exhaust pipe clogged = clean cylinder exhaust port and exhaust pipe
- intake filter clogged = clean
J
NO
Test ride
COMPRESSION www.1977mopeds.com
1.800.965.1977
1 r
/ h
H
Carburetor
Fuel filter
Fuel tank
Clogged
Clogged
Clean, air blow
Clean zamazano
Fuel is deteriorated or dirty Replace fuel
FUEL
• • •
SPARK r
Ignition timing Check timing Adjust
Ignition coil Detective, check resistance Replace
Plug cap Faulty, No contact Replace
Spark plug Incorrect gap. Carbon deposit.
Dirty. Oily. Burned.
Replace www.1977mopeds.com
1.800.965.1977
First check spark plug to find cause.
I
Re-start
NO OK
1
SPARK
. . .
m
O
z m
Z
CO
-n m
o
O
O l
PO
O o
I
-
CD
J3
TOMOS
TRANSMISSION REPAIRS
COLIBRI A35
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 sl
speed gear selflocking clutch.
- 1 s
' 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 1 s
' speed clutch shoe elements damage.
- 1 sl
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 st
into 2 n6
or not 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.
- Countershaft and 1 s
' speed gear selflocking clutch seized - check the slide bearing surface.
When shifting to 2 nd
gear, clutch joggle.
- Chain sagged - tighten chain.
- Not enough oil in the gearbox - fill up to the required level.
With engine disengaged, the motorized bicycle is difficult to move forward - rearward:
- Check the 1 sl
speed gear selflocking clutch for damage.
With engine in idle run in rearward motion blows:
- Check the starter shaft brake spring proper function.
Transmission not disengaged by idle run:
- Clutch drum incorporated roller clutch blocked.
When starting the engine does not turn over:
- Starter shaft holding clamp do not engage the inner chain transmission.
- Clutch drum incorporated roller clutch damaged.
In case of transmission part damage or failure is necessary to disassemble, only the RH engine cover and procede with disassembling and checking the parts as shown further.
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. Attention at distance washers on starter shaft and countershaft. www.1977mopeds.com
1.800.965.1977
TOMOS
TRANSMISSION REPAIRS
COLIBRI A35
23
Slacken the protective clutch washer with a socket 19 and with special tool 732.202 remove 1 sl
speed clutch nut
(fig- D.
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). f 1 1 f \
•*
Fig. 3 www.1977mopeds.com
1.800.965.1977
Fig. 4
TOMOS
TRANSMISSION REPAIRS
COLIBRI A35
24
Remove the sg-circlip and separate clutches 1 st
and 2 nd
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 oil quantity and quality the wear of clutch shoes linings is reduced at minimum.
' t I \
Fig. 6
Fig. 5
At first, assemble the 1
M
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 nd
speed clutch turn 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 the same as mentioned before for the 1 s
' speed clutch.
Remove and inspect the 1 st
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 (Fig. 7).
The needle clutch must be pressed with the signed side towards the center of the clutch drum, if not it may operate 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 clutch (fig. 5 A). www.1977mopeds.com
1.800.965.1977
TOMOS
TRANSMISSION REPAIRS
COLIBRI/A35
25
737.536 marking
I 1
Fig. 7 www.1977mopeds.com
1.800.965.1977
TOMOS
TRANSMISSION REPAIRS
COLIBRI A35
26
If is 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). During assembly take care that the thinner part of collar in mounted forward or else, the brake spring slides across the chain sprocket. Check the chain for overtension or some other damage.
®
PTT
\
7
©
®
'O
Fig. 8
A damage of sliding surface of 1 st
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 nd
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 nd
speed driven gear with the left hand and the clutch drum with the right hand. When clutch drum rotates counterclockwise, both clutches idle, when it rotates clockwise the motion is transmited to the crankshaft (fig. 11). www.1977mopeds.com
1.800.965.1977
TOMOS
TRANSMISSION REPAIRS
COLIBRI/A35
27
K
]
Fig.
9 y j ^ ^ f c l
U*
#c
>
Fig.
10
Fig.
11 www.1977mopeds.com
1.800.965.1977
TOMOS
MAGNETO REPAIRS
COLIBRI/A35
28
In case of any magneto faulty part replacement actuate with dismantling at sequent parts as follows:
- starting lever pedal (wrench 11, 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=fig. 13)
- stator plate (flat screwdriver)
1 ^ \ \ jfl H^H
&cs3
; ^ ^ * ™ " j f
Fig. 12
1
Fig. 13
For proper function of the engine is essential a correct ignition timing. The ignition advance should be i 5 '
0
-
2 m m
*
The most common cause of incorrect timing is due wear or damage of contact breaker points, wear of cam actuated breaker nose lever, damage of condenser. To provide 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 with gauge pin 011.008 into the spark plug hole. By 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 testing device must be connected to the short circuit (black) wire and to the ground of the engine. At the moment of connection of the points the test battery light will glow brightly, the 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). In 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). www.1977mopeds.com
1.800.965.1977
TOMOS
MAGNETO REPAIRS
COLIBRI/A35
29
r\
BTDC
12 m m
2
' 0,35-0,45
Fig. 14
Note:
For a good ignition must be provided a proper correlation between ignition advance, contact breaker points gap and abris. www.1977mopeds.com
1.800.965.1977
TOMOS
MAGNETO AND ELECTRICAL
EQUIPMENT CHECKING
COLIBRI/A35
30
The flywheel should be checked by visual inspection for mechanical damage and proper cone. Check deflection by help of the crankshaft.The maximum permissible axial deflection amounts to 0.1 mm and radial deflection to 0.3 mm.
The ignition coil both internal and external can only be checked if a special monotester is available. The chekking procedure is laid down by the mototester's manufacturer. If there is no mototester available, a possible fault can be established by replacing a truly good sample coil for the existing coil.
The lighting coil should be checked with engine in operation (2000-3000 r.p.m.) To check the coil, use a Voltmeter and an appropriate bulb of the same rated power (W) as magneto. If there is no bulb of adequate power available, interconnect an appropriate number of bulbs of an inferior power. If a bulb of an inferior power is used it may blow at high revs.
Contact breaker: Check the contacts and the cam nose for wear. Insert an insulating mass between the two breaker contacts and by an OHM-meter make sure the parts are electrically disconnected (there exist a possibility of uncture on the bearing bush or fixing bolt insulation).
Fig. 15
To check the capacitor it should be separated from other electrical components of the magneto.
Check the capacity by means of a capacitance meter and the ability of the capacitor to retain an electric charge.
Measurements and checking are carried out under the instruction of the meter's manufacturer.
Note
Caution is recommended in handling the noninsulated parts since there is a possibility of an electric shock. The capacitor should, therefore, be discharged by connecting the two contacts.
COLIBRI:
Detach the fairing (cross screwdriwer) and the headlamp assy, (wrench 10) fig. 15 to achieve to the main electric wire harness and tachometer's leads.
Remove the carburetor protection shield and fuel tank to easily work on HT igniton coil and horn (fig, 16).
Replacement of voltage regulator is obtainable with exhaust pipe and RH protection shield dismantling (fig. 4).
A35: The ignition coil and voltage regulator are placed under side protection shields, as on A3.
Electric wiring and combination switches are checked according to the wiring diagram.
The voltage regulator should be checked when bulbs blow frequently. During the check the engine should be operating and the lights switched on, alternatively. The voltage should always read 12 ± 0.5 V. Before replacing the regulator, make sure the improper operations is not due to poor earth connection contact.
The direction indicator relay should be checked within in the wiring system. Previously check the bulbs and direction indicators switch.
The STOP switch should be checked by a pilot bulb or OHM-meter. www.1977mopeds.com
1.800.965.1977
RH FRONT
INDICATOR
12V 10W
INDICATOR WARNING
LAMP 12V 1,2W
—>-
-=>-
NEUTRAL IDICATOR
LAMP 12V 1.2W
-
HIGH BEAM
LAMP 12V I.2W
®y-
HEAD LAMP
12V 25/25W
EL.
o n
FRONT BRAKE
LAMP SWITCH
LIGHT ENGINE STOP
SWITCH SWITCH
B w
INDICATOR
RELAY
LH FRONT
INDICATOR
12W 10W
M V
- £ > -
REAR BREAK
LAMP SWITCH
\l
LIGHTING INDICATOR HORN
DIMMER SWITCH SWITCH
SWITCH
H
O o—o o o
#
•
ENGINE
STOP
SWITCH o o
— . 0
LIGHT
SWITCH
01
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O O-MD r*
LIGHTING
DIMMER
SWITCH
•
O
O — O O o o
C ^ K )
O O O o o o
HORN
SWITCH
C ^ ^ > O
INDICATOR SWITCH www.1977mopeds.com
1.800.965.1977
, I I
IGNITION
COIL
1
A . C . REGULATOR
12V 60W
A A
RH REAR
INDICATOR
12V 10W
STOP LAMP
12V 10W
I M , tg)
TAIL LAMP
12V 4W
GENERATOR
12V fiOW
LH REAR
INDICATOR
IcV 10W
RH FRONT
INDICATOR
12V IOW
INDICATOR WARNING^
LAMP IZV I . 2 W
NEUTRAL INDICATOR
LAMP 12V l , 2 W
HIGH BEAM
INDICATOR 12V l.Z'
HEAD LAMP
IZV Z5/Z5W
AA
ENGIN
LIGHT
S T 0 P
FRONT BRAKE SWITCH SWITCH
LAMP SWITCH ^ ^ m
HORN v y
LH FRONT
INDICATOR
IZV IOW
-
REAR BREAK
LAMP SWITCH
If
LIGHTING INDICATOR HORN
DIMMER SWITCH SWITCH
SWITCH
INDICATOR
RELAY
« C ^ ^ 3
• 0 o 01 o - o o
O C ^ K ) o o o
# c^^>
ENGINE LIGHT
3
STOP SWITCH DIMMER
SWITCH
LIGHTING
SWITCH
• o O CN—o
O 0 ^ 3 T*
0 o o o o o
HORN
C ^ ^ D O
SWITCH o c^«o o o o
C ^ ^ D
INDICATOR SWITCH www.1977mopeds.com
1.800.965.1977
A . C . REGULATOR
IZV 60W
GENERATOR
IZV BOW
¥?
= ^ C -
IGNITION
COIL
U U
A A
RH REAR INDICATOR
IZV IOW
STOP LAMP
IZV IOW
TAIL LAMP
IZV 4W
LH REAR INDICATOR
IZV IOW
TOMOS
CARBURETOR REPAIRS
COLIBRI
33
In case of carburetor troubles mentioned in trouble shooting chapters No: 3, 4 and 5 on pages 1 9 - 2 1 proceed with dismatling 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 10 mm)
- carburetor cpl. with air filter and rubber dust protection (screw of fixing claw - flat screwdriver) fig. 16.
The intake silencer remains between the angle supports and engine thus is necessary to remove the engine to replace it.
Fig. 16
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. www.1977mopeds.com
1.800.965.1977
TOMOS
CARBURETOR REPAIRS
COLIBRI A35
34
w
0
M l i ^
/ » i
JkJ^
®9k
j * i w%
®
S
1 r^N f^K F
' l^
DELLORTO
www.1977mopeds.com
1.800.965.1977
TOMOS
EXHAUST SYSTEM
COLIBRI
35
The exhaust system is one-piece welded steel pipe with removable baffle (flat screwdriver) fig. 18. The oil residue in exhaust gases tends to condense in the exhaust system, becoming a hard carbon deposit over a certain time period. The baffle could be cleaned with a steel brush. The exhaust pipe could be cleaned with a chemical solution. Highly effective and relatively cheap solution is caustic soda dissolved in water in ratio 1 : 3.
1
Fig. 18
ATTENTION
Caustic soda is very dangerous chemical. Always wear protective clothing with eye protection!
Retain to the chemical producer's warnings and use routine!
Caustic soda-especially at above recommended strength reacts violenty with aluminium alloy and will cause severe damage. Avoid the contact of caustic soda solution with engine aluminium alloy parts!
Carefully pour the solution into the one end plugged exhaust pipe. Do not plug the open end of quite fully filled exhaust pipe! The solution should be left for its dissolving action to take place. Note that the soluton will give off noxious fumes throughout its disolving process - the system must therefore be placed in well ventilated area.
After the required time has passed, carefully pour out the solution and flush the system through with clean, fresh water. www.1977mopeds.com
1.800.965.1977
TOMOS
CYLINDER, PISTON, REED VALVE REPAIRS
COLIBRI/A35
36
In case of mentionated parts troubles in trouble shooting 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 11 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. 19).
- -
• e -
-<3 d
2
* l
Fig. 19
Skupina
Group
A
B
A
B d1
37,955
37,965
1.4954
1.4958 d2
37,865
37,875
1.4919
1.4923
Skupina
Group
D
A B
38,010'
0 0 1
1 5 0 0
» 0.004
38,020' ooi2
°
1.504'
0008 in d3
37,775
37,785
1.4883
1.4887 ovalnost round-off.
0,045
0,045
0.0018
00018 mm in
PISTON
CYLINDER
CD
^ ± 0 , 2
3 * 4 ± 0 , ^ 50+0,5
Bore taper and come-shaped:
D, = max. 0,012 mm (0,473 • 10'
3
in) www.1977mopeds.com
1.800.965.1977
TOMOS
CYLINDER, PISTON, REED VALVE REPAIRS
COLIBRI/A35
37
Upon the request of the market there are available two different pistons: 50 km/h (30 m.p.h.) - fig. 20 and 40 km/ h (25 m.p.h.) - fig. 21 with their own function diagram.
13
•nl r~\ m to m
(*->
H
1
O
C5LR
f
T.D.C.
IGNITION ADVANCE
INTAKE
TRANSFER
EXHAUST
Fig. 20
*?/
«V|/ w <y p TTv' o
— 1
• ^ « J h<r
p
)
Z6.0
•o j
|
( l J 1 S
: : tf"5
C"J so
*• www.1977mopeds.com
1.800.965.1977
8
_ t e _
- i I V I
TOMOS
CYLINDER, PISTON, REED VALVE REPAIRS
COLIBRI/A35
38
Fig. 21 www.1977mopeds.com
1.800.965.1977
u
IGNITION ADVANCE
INTAKE
TRANSFER
EXHAUST
TOMOS
CYLINDER, PISTON, REED VALVE REPAIRS
COLIBRI A35
39
Damage to reed valve may be caused also by steel material run-down (see function on fig 22, assy, parts fig-23).
1 PISTON AT T.D.C.
Fig. 22 www.1977mopeds.com
1.800.965.1977
PISTON AT B.D.C.
TOMOS
CYLINDER, PISTON, REED VALVE REPAIRS
NOTE:
Replacement of cpl. reed valve is suggested.
COLIBRI/A35
40
Fig. 23
Check conrod bending by help of two calippers (Fig. 24). Check the needle bearing clearance and bearing rolling surface for damage. n www.1977mopeds.com
1.800.965.1977
Fig. 24
TOMOS
CRANKSHAFT AND MAINSHAFT REPAIRS
COLIBRI A35
41
In case of mentionated repairs is necessary to dismantle the engine from the fixing supports of swinging arm assy. (fig. 25).
Upon previously described procedure dismantle magneto, transmission parts, carburetor and cylinder.
Fig. 25. Fig. 26
Unscrew the crankcase halves connecting screws.
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. 26).
Detach the crankshaft from the RH crankcase half with a plastic mallet (fig. 27). In case of remaining ball bearing on the crankshaft remove it with the extractor 731.155 (fig. 28). lib.
Fig. 27 www.1977mopeds.com
1.800.965.1977
Fig. 28
TOMOS
CRANKSHAFT AND MAINSHAFT REPAIRS
COLIBRI/A35
42
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 points indicated in fig. 29.
Permissible out-of-round should 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 if the crankshaft conical part is damaged, inspect the thread on semiaxles and the keyway.
Fig. 29
Note
As required, centering is only carried out with a copper hammer, grip pliers and two levers. www.1977mopeds.com
1.800.965.1977
TOMOS
CRANKSHAFT AND MAINSHAFT REPAIRS
COLIBRI/A35
43
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. 30 and 31).
Fig. 30 Fig. 31
Crankshaft is impressed in crankcase halves by extractor 735.888 actuating with screw B (fig. 32 and 33) 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. 32 www.1977mopeds.com
1.800.965.1977
Fig. 33
TOMOS
CRANKSHAFT AND MAINSHAFT REPAIRS
COLIBRI A35
44
In case of mainshaft toothing damage replace it. Slacken the chain sprocket nut by a wrench 30 mm and using the special tool 732.202 (fig. 34). Knock out the mainshaft by plastic mallet.
<& iL.**'*'
Fig. 34
In case of needle bearings or seal ring (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. 35) by machine press tool and special tool
732.367.
035.503
035.502
0 seal ring www.1977mopeds.com
1.800.965.1977
TOMOS
FRAME AND SUSPENSION
COLIBRI
45
The frame is rectangular steel tube construction type (fig. 36). Engine is peculiarly incorporated with supports in rear swinging arm with hydraulic monoshock absorber (fig. 37 and 25). Front forks are common telescopicspring type (fig. 38).
Fig. 36
For a safe riding is necessary that here is none excessive clearance in front and rear forks assy, which is obtainable with tightening of steering bearings and replacement of sliding bushing at swinging arm.
In case of hydraulic monoshock absorber damage do not try to open the hydraulic part of assy, because is under high pressure thus replace the monoshock absorber cpl. www.1977mopeds.com
1.800.965.1977
TOMOS
FRAME AND SUSPENSION
COLIBRI
46
Fig.
37 www.1977mopeds.com
1.800.965.1977
TOMOS
FRAME AND SUSPENSION
COLIBRIA35
47
The front fork lower leg can be removed as it is shown in fig. 38.
- by unscrewing remove lower leg from the front fork (fig. 38/1)
- the spring will remain attached either to the upper or to the lower screwed plug
- the upper plug should be removed after taping out the elastic pin (fig. 38/2)
- the lower plug can be removed with longer alien key (9 mm), (fig. 38 3) remove by unscrewing
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) www.1977mopeds.com
1.800.965.1977
TOMOS
WHEELES AND BRAKES
COLIBRI A35
48
Wheels are cast aluminium alloy type. No special maintenance is required as usual ball bearings greasing and wear checking.
Brakes are drum type (fig. 39) 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.
/
Mi o >J1
^ ^ ^ ^
Fig. 39
BRAKE DRUM (front and rear wheel)
Inside diameter (new one)
Max. wear diameter
•0.5
-1.5
90 "" mm
90,10 mm
BRAKE SHOES (front and rear brake)
Breaking surface 28,8 cm
2
Brake lining thickness (new one) 4 mm
Max. wear thickness 2.2 mm www.1977mopeds.com
1.800.965.1977
TOMOS
OIL PUMP
COLIBRI
49
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, (fig. 42 1)
- 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 then screwed on (fig. 40).
- Pour approx. 1 I gas mixture in the ratio od 1:50 (2% oil) into the fuel tank and start the 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 tank 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 lines to and from the oil pump. If the outflow line is crimped, oil will not reach the carburetor causing severe engine damage.
Fig. 40 www.1977mopeds.com
1.800.965.1977
TOMOS
A35 - SPECIAL FEATURES
A35
50
Special features
The A-35 motorcycle is a combination of the A-3 models (frame and swinging leg), Fig. 42 and the A-5 (Colibri) (driving unit). The front suspension is identical for all 3 models. (A-3, A-5 and A-35).
There is no functional difference in the electrical system of both models, with the only exception that the cable harness with the A-5 is of a single piece while it consists of two parts with the A-35 (front and rear). www.1977mopeds.com
1.800.965.1977
PROMO, D.O.O. KOPER, PROIZVODNJA DVOKOLES - TWOWHEELERS PRODUCTION, SLOVENUA
6000 KOPER, SMARSKA C. 4, TEL: 066/31-111, FAX: 066/33-207, TELEX: 34-118 www.1977mopeds.com
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Key Features
- Single-cylinder, two-stroke engine with reed valve
- Air-cooled
- Automatic 2-step gearbox with two centrifugal clutches
- Flywheel magneto ignition system
- 1.45 kW (5200 min-1) brake horsepower
Frequently Answers and Questions
What is the compression ratio of the Colibri A 35 engine?
What type of ignition system does the Colibri A 35 have?
What is the spark plug gap for the Colibri A 35?
What type of gearbox does the Colibri A 35 have?
How much brake horsepower does the Colibri A 35 engine produce?
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