tomos - Motor-Talk
Contents
1. POWER LOSS Carburetor Needle valve is worn Adjust Pilot passages are clogged Choke is closed Clean Water is mixed Replace r Fuel filter Clogged Clean Fuel hoses piping Leakage Flattened Broken Replace Korn av Fuel tank Fuelis deteriorated or dirty Replace fuel kan Piston Worn Broken Scuffed Replace Cylinder wall Roasted Piston rings Oil seal Worn cracked Replace Cylinder gasket Air leakage Replace Ne tesni zlomljen Leakage broken Lamelni ventil Reed valve Zamenjati Replace J Test ride OK ISKRA SPARK COLIBRI Check timing Ignition timing Test ride Replace Spark plug Incorrect gap Carbon deposit Dirty Oily Burned COMPRESSION Check brakes do not disengage oil or grease control cables exhaust pipe clogged clean cylinder exhaust port and ex haust pipe intake filter clogged clean www 1977mopeds com Carburetor Fuel filter Clogged Clean air blow Clogged Fuel tank zamazano Fuel is deteriorated or dirty Replace fuel Ignition timing Check timing Ignition coil Defective check resistance Replace Plug cap Spark plug Faulty No contact Replace Incorrect gap Carbon deposit Replace Dirty Oily Burned www 1977mopeds com 1 800 965 1977 Re start NO OK First check spa2. The A 35 motorcycle is a combination of the A 3 models frame and swinging leg Fig 42 and the A 5 Colib ri 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 0 0 0 KOPER IROIZVODNJA D KOLES TW NHEELERS PRODUCTION www 1977mopeds com 1 800 965 1977
3. TITT 274 speed 2 53 SN Mainshaft Chain transmission 96 rollers 66 17 3 8823 Gear ratio 1 speed 53 24 i 2 4615 Gear ratio 27 speed 3 88 72 11 i2 25 4117 Gearbox ratio 1 speed 2 46 72 11 i 16 1189 Gearbox ratio 2 dspeed 22 26 i 0 846 Chain transmission ratio 25 4117 0 846 i 21 502 Total transmission ratio 1 speed 16 11 0 846 13 631 Total transmission ratio 27 speed 1 800 965 1977 COLIBRI A35 TECHNICAL DATA TORQUE Position Thread Nm Pound per foot Spark plug M14x1 25 13 27 Cylinder cover Oylinder stud bolts Magneto flywheel Clutch of 1 speed 2 speed driven gear Engine frame fastening bolts RH engine cover LH engine cover Crankcase Mainshaft chain sprocket Swinging arm fastening screw M12x1 25 Rear shock absorber Top fork lug Front and rear wheel spindle 1 800 965 1977 COLIBRI A35 STANDARD ELEMENTS Ball bearings TOMOS Installation i nstallation Code No Bearing No Dimensions d x D x b mm Crankshaft 035 070 x 2 6203 C3 17x40x12 Crankshaft 035 202 035 072 Countershaft 035 031 12x32x10 Mainshaft 035 037 30x 55 x 13 Wheel axle 044 225 x 2 12x32x10 L Seal rings TOMOS i Dimensions lI Code No d x D x b mm Crankshaft 036 554 17x35x7 Mainshaft 036 620 35
4. TOMOS Ss collb TOMOs 35 workshop manual www 1977mopeds com 1 800 965 1 colibri tomos 35 workshop manual TOVARNA MOTORNIH VOZIL TOMOS KOPER SLOVENIA 1977mopeds com 1 800 965 1977 CONTENTS TECHNICAL DATA STANDARD ELEMENTS SPECIAL TOOLS INTRODUCTION FUNCTION OF COLIBRI ENGINE A35 TROUBLE SHOOTING 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 1 800 965 1977 OLIBRI A35 Engine Bore x Stroke Piston displacement Compression ratio Brake horse power Torque Gear box Gearbox oil quantity Ignition Ignition advance Contact breaker gap Spark plug Spark plug gap Fuel COLIBRI TECHNICAL DATA single cylinder two cycle with reed valve air cooled 38 x 43 mm 49 ccm 9 1 1 1 45 kW 5200 min 3 5 Nm 3500 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 00 965 1977 TECHNICAL DATA TRANSMISSION 15 speed Be
5. 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 transmited to the crankshaft fig 11 www 1977mopeds com 1 800 965 1977 TRANSMISSION REPAIRS www 1977mopeds com 1 800 965 1977 MAGNETO REPAIRS 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 For proper function of the engine is essential a correct ignition timing The ignition advance should be 1 5 92 mm 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 provide the exact timing is necessary to replace faulty parts and proceed fig 14 as follows Screw the special tool 732 193 and dial g
6. 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 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 COLIBRI A35 CYLINDER PISTON REED VALVE REPAIRS 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
7. 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 pro cede 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 Atten tion at distance washers on starter shaft and countershaft 1 800 965 1977 TRANSMISSION REPAIRS 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 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 www 1977mopeds com 1 800 965 1977 TRANSMISSION REPAIRS Remove sg circlip and separate clutches 1 and 27 speed Dismantle both clutches spring is remove
8. 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 B 37965 37875 37785 y ERN B 14958 1493 14887 38 010 38 0200020 L CYLINDER Bore taper and come shaped D max 0 012 mm 0 473 10 in www 1977mopeds com 1 800 965 1977 COLIBRI A35 CYLINDER PISTON REED VALVE REPAIRS 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 T D C IGNITION ADVANCE EXHAUST 1 800 965 1977 IGNITION ADVANCE INTAKE TRANSFER EXHAUST NWW 19 moped om 1 800 965 1977 COLIBRI A35 CYLINDER PISTON REED VALVE REPAIRS am Damage to reed valve may be caused also by steel material run down see function on fig 22 assy parts fig 23 PISTON AT T D C NE 2 SS SINS SSS i PISTON AT B D C 1 800 965 1977 COLIBRI A35 CYLINDER PISTON REED VALVE REPAIRS NOTE Replacement of cpl reed valve is suggested Fig 23 Check conrod bending by help of two calippers Fig 24 Check the needle bearing clearance and bearing rol ling s
9. 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 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 1 800 965 1977 COLIBRI A35 CRANKSHAFT AND MAINSHAFT REPAIRS 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 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 seal ring 5 1977 COLIBRI FRAME AND SUSPENSION 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 telescopic spring
10. type fig 38 D Fe Lum k L o Fig 36 For a safe riding is necessary that here is none excessive clearance in front and rear forks assy which is obtai nable 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 un der high pressure thus replace the monoshock absorber cpl E 800 965 1977 FRAME AND SUSPENSION 1 800 965 1977 COLIBRI A35 FRAME AND SUSPENSION 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 remove by unscrewing the upper plug should be removed after taping out the elastic pin fig 38 2 the lower plug can be removed with longer allen key 9 mm fig 38 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 1 800 965 1977 COLIBRI A35 WHEELES AND BRAKES Wheels are cast aluminium alloy type No special maintenance i
11. 12V 10W TAIL LAMP 12 4W d GENERATOR LH REAR INDICATOR 12 10W i INDICATOR HORN it o nh DIMMER SWITCH SWITCH INDICATOR RELAY SS3NHVH DNIHIM IGNITION COIL Ka ENGINE LIGHT LIGHTING STOP SWITCH DIMMER SWITCH SWITCH INDICATOR SWITCH 1 800 965 1977 COLIBRI CARBURETOR REPAIRS In case of carburetor troubles mentioned in trouble shooting chapters No 3 4 and 5 on pages 19 21 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 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 COLIBRI A35 TOMOS CARBURETOR REPAIRS DELLORTO peds com 1 800 965 1977 EXHAUST SYSTEM The exhaust system is one piece welded steel pipe with removable baffle flat screwdriver fig 18 The oil resi due in exhaust gases tends to
12. art www 1977mopeds com 1 800 965 1977 COLIBRI Piston Cylinder Worn Broken Scuffed wall Piston ring Roasted Replace Oil seal Worn cracked Replace Oylinder or crankcase gasket ASA ee 00 Air leakage Replace NO oK COMPRESSION Is compression pressure correct Reed valve Leakage broken Replace www 1977mopeds com 800 965 197 ENGINE RURNS OVER BUT STALLS ENGINE RUNS IRREGULARLY STOPS OR IDLES ROUGHLY Carburetor Needle valve is worn Pilot passages are clogge Choke is closed Water is mixed Fuel hoses Leakage Flattened Broke piping Fuel filter Clogged Fuel tank Empty or fuel level is low www 1977mopeds com COLIBRI Ignition timing Check timing Piston Cylinder Worn Broken Scuffed Replace wall Piston ring Roasted Oil seal Worn cracked Replace Contact breaker Not insulated Not connected Adjust or replace points Incorrect gap Pitted Burnt Worn JL L Cylinder or crankcase gasket Air leakage Replace Re start NO OK Spark plug Incorrect gap Carbon deposit Replace Dirty Oily Burned fuel Reed valve Leakage broken Replace COMPRESSION 5 compression pressure correct www 1977mopeds com FUEL 15 compression pressure correct COMPRESSION
13. auge 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 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 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 ignitio
14. d 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 Fig 5 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 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 speed clutch Remove and inspect the 1 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 selflocki
15. hed 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 RH FRONT INDICATOR 12V 10W INDICATOR WARNING LAMP 12V 1 2W NEUTRAL IDICATOR LAMP 12V 1 2W HIGH BEAM LAMP 2V 1 2W HEAD LAMP 12V 25 25W INDICATOR RELAY LH FRONT INDICATOR 12W 10W FRONT BRAKE SWITCH LIGHT SWITCH ENGINE STOP SWITCH REAR 60W INDICATOR 12 10 IGNITION A C REGULATOR COIL 12V STOP LAMP 12 10W REAR BREAK LAMP SWITCH DIMMER SWITCH SWITCH R ojejo o Q o o ENGINE LIGHT STOP SWITCH SWITCH LIGHTING DIMMER SWITCH INDICATOR SWITCH LIGHTING INDICATOR HORN SWITCH 1 800 965 1977 TAIL LAMP 12V 4W LH REAR INDICATOR GENERATOR tA 10 12V 80W SS3NHVH DNIHIM ENGINE LIGHT STOP FRONT SWITCH SWITCH RH FRONT INDICATOR SITE 12V 10 RH REAR INDICATOR INDICATOR wa IS LAMP 12V 1 2W 12V 10 NEUTRAL wan Le d LAMP 12V 1 2 3 gt STOP LAMP HIGH BEAM INDICATOR 12V 1 2 12V 10W HEAD LAMP gt 12V 25 25 4 x LH FRONT INDICATOR
16. ior 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 Technical Service Department TOMOS COLIBRI A35 FUNCTION OF COLIBRI ENGINE TRANSMISSION PARTS clutch drum 15 speed clutch crankshaft roller clutch 2 d speed clutch 15 speed gear countershaft selflocking rollerclutch starting chain transmission mainshaft starter shaft pedal shaft drive chain sprocket Legenda rotating powered elements free rotating elements stand still elements www 1977mopeds com 800 9 9 COLIBRI A35 FUNCTION OF COLIBRI ENGINE Starting www 1977mopeds 1 800 965 1977 COLIBRI A35 FUNCTION OF COLIBRI ENGINE Idle run 1 800 965 1977 COLIBRI A35 FUNCTION OF COLIBRI ENGINE 1 Speed www 1977mopeds com 1 800 965 1977 SPARK PLUG CONDITIONS A brown tan or gray firing end is 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 combustion or through the use of low quality oil Remove deposits or a hot spot may from Black sooty deposits i
17. n 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 MAGNETO REPAIRS Note For a good ignition must be provided a proper correlation between ignition advance contact breaker points gap and abris 1 800 965 1977 COLIBRI A35 MAGNETO AND ELECTRICAL EQUIPMENT CHECKING The flywheel should be checked by visual inspection for mechanical damage and proper cone Check deflec tion by help of the crankshaft The maximum permissible axial deflection amounts to 0 1 mm and radial deflec tion to 0 3 mm The ignition coil both internal and external can only be checked if a special monotester is available The chek king 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 Volt meter 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 Con
18. ndicate an over rich fuel air Wet oily carbon deposits form an electrical leakage mixture or a malfunctioning ignition system If no im path along the insulator nose resulting in a misfire provement is obtained try one grade hotter plug The cause may be a badly worn engine or a malfunc tioning ignition system A blistered white insulator or melted electrode indica 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 correction does not prove effecti sed gap requires higher voltage to initiate the spark ve try a colder grade plug Adjust spark plug gap or replace ENGINE DOES NOT START Source coil Defective Check resistance Replace Contact breaker Notinsulated Not connected Adjust or replace po nts Incorrect gap Pitted Burnt Fuel hoses Leakage Flattened Broken Worn piping m Glogged Condenser Weak Shorted Bad contact Replace Fuel filter in carburetor Clogged Ignition coil Defective check resistance Replace Fuel tank Empty or low fuel level Add fuel Plug cap Faulty No contact Replace Ponovni zagon Re start NO OK NO Spark plug Incorrect gap Carbon deposit Replace Dirty Oily Burned FUEL Is spark blue and 15 there fuel in carburetor YES strong Fuel tank Fuel is deteriorated or dirty Replace fuel Re st
19. ng 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 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 clutch fig 5 A 965 1977 COLIBRI A35 o lt a 2 9 o o z lt TOMOS TRANSMISSION REPAIRS 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 for ward or else the brake spring slides across the chain sprocket Check the chain for overtension or some other damage A damage of sliding surface of 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
20. rk plug to find cause IH8I 102 COLIBRI A35 TRANSMISSION REPAIRS 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 selflocking clutch 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 1 speed clutch shoe elements damage 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 274 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 speed gear selflocking clutch seized check the slide bearing surface When shifting to 2 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 speed gear selflocking clutch for damage With
21. s 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 BRAKE DRUM front and rear wheel 0 5 Inside diameter new one 907 mm Max wear diameter 90 10 mm BRAKE SHOES front and rear brake Breaking surface Brake lining thickness new one Max wear thickness 1 800 965 1977 COLIBRI n mm 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 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 1 800 965 1977 A35 SPECIAL FEATURES Special features
22. tact 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 possibi lity of uncture on the bearing bush or fixing bolt insulation 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 meters 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 elec tric 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 switc
23. urface for damage 5 1977 1 800 96 CRANKSHAFT AND MAINSHAFT REPAIRS 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 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 bea ring on the crankshaft remove it with the extractor 731 155 fig 28 1 800 965 1977 COLIBRI A35 CRANKSHAFT 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 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 key Way Note As required centering is only carried out with a copper hammer grip pliers and two levers 1 800 965 1977 COLIBRI A35 CRANKSHAFT AND MAINSHAFT REPAIRS Check both crankcase halves for
24. x47x7 1 800 965 1977 COLIBRI A35 SPECIAL TOOLS 732 746 MAGNETO FLYWHEEL PULLER 732 202 FLYWHEEL HOLDER 975 709 DIAL GAUGE 011 008 GAUGE PIN 732 193 ER ER DIAL GAUGE SUPPORT LEITEN 735 888 CRANKCASE DIS ASSEMBLY TOOL 1 800 965 1977 COLIBRI A35 SPECIAL TOOLS 735 753 CRANKSHAFT MOUNTING FORK 731 155 CRANKSHAFT BEARING PULLER 702 856 DIS ASSEMBLY CRANKSHAFT BEARINGS 737 535 CLUTCH SPRING SETTING TOOL 737 536 ROLLER CLUTCH INSTALLER 1 800 965 1977 COLIBRI A35 Ki 732 367 MAINSHAFT NEEDLE BEARINGS INSTALLER 706 485 EXTRACTOR 706 472 EXTRACTOR BRIDGE 736 913 BRAKE SHOES SPRING INSTALLING PLIERS 714 011 ENGINE REPAIR STAND www 1977mopeds com 1 800 965 1977 COLIBRI A35 INTRODUCTION 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 pr
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