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Tomos A3 1988 Workshop Manual 

 

CONTENTS 

Technical Data

 ………………………………………………………………………………………………………………………………………..2 

 

Nuts, Bolts, and Torque Specs

 …………………………………..…………………………………………………………………………..3 

 

Special Tools

……………………………………………………………………………………………………………………………………………3 

Image..……………………………………………………………………………………………………….………………….….……….4 

 

Engine Removal

…………………………………………………………………………………………………….…………………………..……5 

 

Engine Disassembly

…………………………….……………………………………………………………….…………………………….…..8 

 

Checking Engine Parts and Assemblies

 ………………………………………………………………………………………………..11 

 

Checking, Dismantling, and Assembling of the Clutch

 ……………………………………………………….………………..13 

 

Dismantling, Checking, and Assembling of the Countershaft

 ………………………….…………………………………..15 

 

Checking Pedal Shaft and Transmission Chain 

.……………………………………………………………………………….……17 

 

Carburetor Checking

……………………………………………………………………..………………………………………………………18 

 

Encarwi Image………………………………………………………..………………………………………………………………..18 

 

Dellorto Image……………………………………………………………………………………………………………………….…19 

 

Reassembling the Engine .

……………………………….………………………………………………….……………………………….20 

 

Adjusting the Contact Gap and Ignition Advance

 ……………………….……………………………………………………….23 

 

Oil Pump

……………………………………………………………………………………………………………………………………………….24 

 

Magneto Settings and Electrical Equipment

…………………………………….…………………………………………..……..25 

 

Wiring Diagrams

 (COLOR!) 

 

European without turn signals………………………………………………………………………………………………….26 

 

European with turn signals……………………………………………………………………………………………………….27 

 

U.S. without turn signals…………………………………………………………………………………………………………..28 

 

U.S. with turn signals………………………………………………………………………………………………………….…….29 

 

The following is a modified and English-only version of the A3 manual found at 

www.classiccycles.org

 

Please note that this version is NOT guaranteed to be a perfect reproduction of the original; if you have 

any doubts as to what you are reading, please check the original to be sure. 

 

Содержание A31988

Страница 1: ...Image 18 Dellorto Image 19 Reassembling the Engine 20 Adjusting the Contact Gap and Ignition Advance 23 Oil Pump 24 Magneto Settings and Electrical Equipment 25 Wiring Diagrams COLOR European without...

Страница 2: ...35 0 45 mm 0 014 0 018 inches Spark plug gap 0 5 mm 0 020 inches Spark plug NGK B6HS Champion L86 Bosch W 4 AC Fuel Mixture of 86 octane gasoline and two stroke oil 2 or 50 1 Gearbox oil quantity Val...

Страница 3: ...garm fastening screw M12 x 1 25 35Nm Rear shock M10 25Nm Top fork lug M12 35Nm Front and rear wheel spindle M11 x 1 32Nm SPECIAL TOOLS 011 008 Gauge pin 702 856 Crankshaft bearings fitting tool 708 25...

Страница 4: ...C l a s s i c C y c l e s T e c h n i c a l R e s o u r c e s 4...

Страница 5: ...otrest screw with 17mm wrench fig 2 With 11mm wrench unscrew the nut and drive out lever pin fig 3 For pedal versions refer to figures 3a and 4a Remove the hub cups and springs fig 4 Unscrew the three...

Страница 6: ...PUMP Remove the chain by removing master link fig 7 Unscrew the crown nut and extract control cable along with throttle piston fig 8 Unscrew bottom screw on control cable cover and release the spark p...

Страница 7: ...Unscrew all three engine screws with two 13mm wrenches fig 12 Hold the engine by hand Extract top screw 3 and remove the engine out of the frame fig 13 Take the intake silencer out of the frame fig 1...

Страница 8: ...d bush fig 18 The pedal shaft and the countershaft are connected by a starter chain so both shafts will have to be taken out together fig 19 Remove the standard washers on the crankshaft and on the ma...

Страница 9: ...nd lift the stator assembly from the engine fig 23 Slacken the chain sprocket nut Using the flywheel and clutch holder tool and a 30mm wrench remove the sprocket nut fig 24 Using an 11mm socket unscre...

Страница 10: ...onnecting rod The bush as a spare part has inner diameter 9 80 0 1 mm and it is necessary to ream it out to increase the inner diameter to 10mm Remove the crankshaft and gasket and knock out the mains...

Страница 11: ...tool and measure out of round on all the points indicated in figure 35 Permissible out of round should be within 0 01 mm at check pints 2 and 3 and 0 02 mm at check points 1 and 4 Check if the cranks...

Страница 12: ...024 in D D1 max 0 012 mm Ma x permissible bore taper 0 006mm PISTON D1 D2 D3 D4 A 37 95 0 01 37 91 0 01 37 87 0 01 37 85 0 01 B 37 96 0 01 37 92 0 01 37 88 0 01 37 86 0 01 L 50 mm L 52 5 mm L 55 mm Pi...

Страница 13: ...order of dismantling Particular care should be taken of brake shoes they must protect each other from falling out fig 40 Fix the main pin of the clutch spring fitting tool with the thinner part facin...

Страница 14: ...the needle clutch is necessary only in case of replacement A new needle clutch is pressed with special tool roller clutch installer The needle clutch must be pushed with the signed side towards the c...

Страница 15: ...and separate a small chain sprocket with roller cage fig 47 Remove the 1st speed gear and shake the rollers out fig 48 If troubles appear in the self locking clutch consisting of rollers with 1st spe...

Страница 16: ...der of dismantling Use of grease is not suggested because it may impede the function of the self locking clutch Put the chain sprocket in with cage so that the beginning of the wire spring is turned 9...

Страница 17: ...the protective ring fig 50 1 and the spring washer fig 50 2 During assembly take care that the thinner part of the collar is mounted forward or else the brake spring will slide across the chain sprock...

Страница 18: ...or 52a Dellorto Clean the parts with carb cleaner and blow them out with compressed air Check the parts In case of wear throttle slide or leakage of float replace with a new one When reassembling the...

Страница 19: ...19 FIGURE 52a DELLORTO CARBURETOR...

Страница 20: ...er Through the splitter screw the device on the crankshaft With an 11mm and a 24mm wrench place the crankshaft in the crankcase fit 54 Place the mainshaft and a washer on the mainshaft needle bearing...

Страница 21: ...g 59 Handle the roller clutch carefully and if it is necessary turn the drum only counterclockwise direction of free rotation Place the trust washer under the clutch fig 60 Incorporate 1st speed clutc...

Страница 22: ...piston rings are installed properly by aligning them with the stationary pins mounted in the ring grooves of the piston Compress the piston rings and mount oiled cylinder fig 65 Mount the cylinder hea...

Страница 23: ...a test light buzzer or Ohm meter determine when a connection is made The testing device must be connected to the short circuit black wire and to the ground of the engine fig 67 At the moment of conne...

Страница 24: ...e oil level in the oil tank does not fall under the marking MIN fig 70 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...

Страница 25: ...haft The maximum permissible axial deflection amounts to 0 1 mm and radial deflection to 0 3 mm To check the capacitor it should be separated from other electrical components of the magneto Check the...

Страница 26: ...C l a s s i c C y c l e s T e c h n i c a l R e s o u r c e s 26...

Страница 27: ...27...

Страница 28: ...C l a s s i c C y c l e s T e c h n i c a l R e s o u r c e s 28...

Страница 29: ...29...

Страница 30: ...C l a s s i c C y c l e s T e c h n i c a l R e s o u r c e s 30 White Yellow Brown Black Brown...

Страница 31: ...Accessories Harley Davidson Parts Accessories Motorcycle Helmet Closeout Sale Japanese Motorcycle Original Equipment Parts Save On All Motorcycle Tires Motorcycle Jacket Closeout Sale High Visibility...

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