YOUNGST 'R SPARE PARTS MANUALS Tomos d.o.o., motoindustrija

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1 YOUNGST 'R SPARE PARTS MANUALS 2010 Tomos d.o.o., motoindustrija

2 Contents CRANKCASE, CYLINDER, PISTON... 4 CRANKSHAFT, CLUTCH... 6 COUNTERSHAFT, MAINSHAFT... 8 STRARTER MECHANISM -PEDAL STRARTER MECHANISM- KICK MAGNETO ASSEMBLY, ELECTRIC STARTER OIL PUMP, OIL TANK CARBURATOR, INTAKE SILENCER EXAUST, SEAT, COVERS DECALS MUDGUARDS FRAME, REAR FORK, CENTRAL STAND FRONT FORK GRIPS, CABLES HANDELBAR, SPEEDOMETER, MIRROR FRONT WHEEL REAR WHEEL ELECTRIC PARTS... 38

3 TYPE-MODEL A26BAC YOUNGST'R 45 -XL A26DAC YOUNGST'R 25 XL A26DAC YOUNGST'R 20 XL PEDAL MODELS B C D Vin-nr. is denominated from 4 to 11. nr. for EU directive LEGEND FOR ADDITIONALY MARKED PARTS a,b option..(genuine parts) 1,2 various parts, which have same part nr. as parts on group picture G base coat (ground coat) painted parts L color painted parts C chromed parts M optional parts (parts which are used for another type of motor vehicle) N unprotected parts (plastic parts) P parts used in case of need (not mandatory by Bill of Material-BOM) Z Interchangeable parts (parts which could be used instead of listed parts in case listed ones are not on stock) PAINTED PARTS (PROTECTED) PARTS LAK color painted parts; please provide information of color X91 black painted parts; black-temperature resistant color C51 - chromed - lights EXAMPLE FOR CHANGE 01/00 do - parts was built on vehicle till januar /01 od - parts we built on vehicle from november 2001 Colour code Typ of protection Colour Colour LAK all all ALL GRU basis gray gray KOM all combin. combin. Colour tone M71 metal silver silver standard 9006 S91 normal black black standard 9017 S92 normal black black mat 9017 S01 normal white white standard 9003 C51 CROMED BLU Cr LIGHT Z51 ZINCED BLU Zn LIGHT RAL similar

4 CRANKCASE, CYLINDER, PISTON

5 No. * Part No. Denomination B C D ENGINE 45-XL ENGINE 25-XL ENGINE 20-XL CRANKCASE-CPL (with parts 2-8,18,60,47 and bearings) CRANKCASE GASKET CENTERING BUSH 9,8X RIGHT COVER GASKET SCREW M6X SEAL RING A6X SCREW M8X SEAL RING A8X ELASTIC PIN 8x MAGNETO COVER BLACK RUBBER RING ALLEN SCREW M6X ALLEN SCREW M6X SCREW M8x1X SCREW M8x1X WASHER NUT M8X1-SELFLOCKING SS CYLINDER STUD BOLT M7X CYLINDER GASKET-0,4 mm CILINDER CPL (with part 26)-BLACK STUD BOLT CYLINDER HEAD CYLINDER HEAD SPARK PLUG (BOSNA- F75, BOSCH-W7AC,CHAMPION-L86) NUT M WASHER PISTON 38,0 X 50 mm (with part 28-30) PISTON RING 38,0 mm WRIST PIN 12 mm SPRING CIRCLIP 12 mm SPRING CIRCLIP 12 mm CYLINDER HEAD GASKET ALLEN SCREW M6X ALLEN SCREW M6X INTAKE MAINFOLD (OIL PUMP) - 45 km/h INTAKE MAINFOLD (OIL PUMP) REED VALVE REED VALVE GASKET SCREW M5X20(ISO 7380) WASHER BARRIER PIPE- UPPER BARRIER PIPE- BUTTOM RUBBER OIL PUMP COVER -PLASTIC SCREW M5X GASKET SET (A5-A) 1 1 1

6 CRANKSHAFT, CLUTCH

7 No. * Part No. Denomination B C D CRANKSHAFT - A NEEDLE BEARING 12X15X P SHIM 0,10MM P SHIM 0,15MM P SHIM 0,20MM BALL BEARING 6203 C SEAL RING A17X35X THRUST WASHER 14X20X BEARING BUSH GEAR WITH DRUM CPL. - A ROLLER CLUTCH SHIM 0,30MM P SHIM 0,50MM CLUTCH SEGMENT 1ST. GEAR CLUTCH SEGMENT 2ND. GEAR CLUTCH PIN CLUTCH HUB 1ST. GEAR SPRING PLATE BRAKE STRIP CLUTCH SPRING CLUTCH SPRING DRIVE GEAR (2.ND GEAR) CLUTCH CPL. 2.ND GEAR (REV CLUTCH CPL. 1ST. GEAR (REV CIRCLIP Z SPRING RING B THRUST WASHER B NUT M10X BALL BEARING CONNECTING ROD CPL. (12MM)...

8 COUNTERSHAFT, MAINSHAFT

9 No. * Part No. Denomination B C D COUNTERSHAFT WOODRUFF KEY 5X5X BALL BEARING CIRCLIP CAGE ROLLER D5X CAGE COUNTERSHAFT SPRING BEARING BUSH ST. SPEED GEAR - A ND. SPEED GEAR - A PROTECTIVE WASHER NUT M14X THRUST WASHER 2,0MM P SHIM 0,20MM P SHIM 0,50MM BALL BEARING FRONT SPROCKET Z= PROTECTIVE WASHER NUT M22X DISTANCE BUSH SEALING RING A35X47X BALL BEARING DRIVE SHAFT CPL. - KICK NEEDLE BEARING SCE 109P NEEDLE BEARING SCE O RING O RING 1 1 1

10 STRARTER MECHANISM -PEDAL

11 No. * Part No. Denomination D STARTER SHAFT-pedal THRUST WASHER BRAKE SPRING CLAW COLLAR CHAIN SPROCKET Z= CHAIN (32 ROLLERS) DISTANCE BUSH STARTERSHAFT RING SHIM 0,50MM 1 10 P SHIM 0,02MM 3 10 P SHIM 0,50MM WASHER 7,4X14X NUT M PEDAL ARMS-par,black PEDAL-par PIN SEAL RING THRUST WASHER 1,0 mm SPRING CUP-bright DISTANCE TUBE 1

12 STRARTER MECHANISM- KICK

13 No. * Part No. Denomination B C STARTER SHAFT THRUST WASHER BRAKE SPRING CLAW COLLAR CHAIN SPROCKET Z= CHAIN (32 ROLLERS) DISTANCE BUSH STARTERSHAFT RING SHIM 0,50MM P SHIM 0,02MM P SHIM 0,50MM KICK START LEVER CPL. (with parts 11 to 20) KICK START RETURN SPRING HUB KICK START LEVER THRUST BOLT KICKSTART SPRING KICKSTART PIN DISTANCE BUSH WASHER 7,4X14X NUT M7 1 1

14 MAGNETO ASSEMBLY, ELECTRIC STARTER

15 No. * Part No. Denomination B C D MAGNETO ASSEMBLY CPL. (with parts 1-4) FLYWHEEL BASE PLATE CPL RUBBER INSERT PIECE PICK UP CLIP ALLEN SCREW M5x LOCTITE WASHER M ROLLER D3x WASHER d10,4 D 17,5 s 1, OIL PUMP NUT M10x DISTANCE TUBE SCREW FOR PICK UP ELECTRICAL STARTER 12v 170w STARTER GEAR SCREW M6x WASHER M GROUND WIRE ELECTRONIC SPARK PLUG CABLE (430mm) m m m RUBBER PROTECTOR SPARK PLUG CAP SCREW M5x12 (ISO 7380) WASHER M

16 OIL PUMP, OIL TANK

17 No. * Part No. Denomination B C D OIL PUMP CPL. (with parts 2,3,4) BANJO BANJO BOLT SEALING WEASHER 6X SCREW M5X16 (ISO 7380) WASHER B P SHIM 0,50mm FERRULE OIL LINE (320 mm) m m m OIL LINE (250 mm) m m m OIL LINE (530 mm) m m m CONNETCING CLAMP OIL TANK OIL TANK CAP BANJO TRUBBER WASHER WASHER CUP NUT M OIL LEVEL SENZOR OIL TANK PROTECTOR 1 1 1

18 CARBURATOR, INTAKE SILENCER

19 No. * Part No. Denomination B C D CARBURETOR CARBURETOR JET JET FLOAT VALVE FLOAT FLOAT PIN FLOAT CHAMBER GASKET FLOAT CHAMBER WASHER SCREW M4X THROTTLE SLIDE CARBURATOR COVER CPL. with parts (12-15) PIN SPRING CHOKE LEVER RETURN SPRING CARBURATOR COVER GASKET SCREW M4X NUT ADJUSTING SCREW RUBBER BUSH FUEL FILTER FUEL CONNECTION LID SEAL RING SCREW M5X NUT M SCREW M6X ADJUSTING SCREW SPRING GASKET CHOKE LEVER RETURN SPRING SCREW LEVER CHOKE SPRING CHOKE LEVER CONNECTION NUT M WASHER PLASTIC REDUCING BUSH SEALING RING CLAMP CARBURATOR GASKET SET CPL INTAKE SILENCER CPL INTAKE SILENCER CPL AIR FILTER (FOAM) FILTER COVER FILTER PIECE FILTER SUPPORT SHEET SCREW 4,2X SILENCER INSERT PIECE JUNCTION SLEEVE INSERT RUBBER 1 1 1

20 SCREW M6X WASHER NUT M

21 EXAUST, SEAT, COVERS

22 No. * Part No. Denomination B C D 1 L LAK RNNING BOARD PAINTED RH L LAK RNNING BOARD PAINTED RH L LAK RUNNING BOARD PAINTED LH SCREW M6X50 (ISO 7380) DISTANCE TUBE SCREW M6X14 (ISO 7380) WASHER RUBBER INSERT PIECE RH SIDE COVER SUPPORT DISTANCE TUBE (L=10,5MM) SCREW M6X25 (ISO 7380) WASHER NUT M6-SELFLOCKING CONTROL CABLE COVER PAINTE SHEET SCREW 4,2X WASHER CHAIN GUARD (BLACK) SHEET SCREW 4,8X WASHER SEAT (with part 24) SCREW M8X55(ISO 6921) WASHER NUT M BAG SEAT L S92 SEAT HOLDER SCREW WASHER EXHAUST SILENCER EXHAUST SILENCER EXHAUST SILENCER EXHAUST GASKET SPRING RING B SCREW M5X SCREW M8X20 (ISO 7380) WASHER NUT M8-SELFLOCKING SCREW WASHER S91 EXHAUST SHIELD 1 1 1

23 DECALS No. * Part No. Denomination B C D DECAL YOUNGST'R CPL DECAL RES'ON'OFF 1 1 1

24 MUDGUARDS

25 No. * Part No. Denomination B C D 1 L LAK FRONT MUDGUARD SCREW M6X12 (ISO 7380) WASHER L LAK REAR MUDGUARD-FRAME SCREW M6X12 (ISO7380) WASHER A6, NUT M6 SELFLOCKING CABLE HOLDER SCREW PT KA30X REAR MUDGUARD REAR MUDGUARD HOLDER SCREW M8X20 (ISO7380) WASHER 8, NUT M8 SELFLOCKING MIDLE MUDGUARD WASHER A6, NUT M6 SELFLOCKING RECLECTOR RED WITH PROTECTIVE RING MUD FLAP PLASTIC SCREW 2 2 2

26 FRAME, REAR FORK, CENTRAL STAND

27 No. * Part No. Denomination B C D 1 L FRAME BEARING BUSH FUEL TANK CAP FUEL FEED TAP FUEL TUBE 0,1m m m m SPRING CLAMP RELEASE VALVE SEALING WASHER L S91 CENTRAL STAND SPRING SPRING SUPPORT SCREW M8x1X WASHER NUT M8x1 SELFLOCKING L LAK REAR FORK DISTANCE BUSH SCREW M12x1,25X WASHER HV NUT M12x1,25 SELFLOCKING SHOCK ABSORBER-RED SCREW M10X45 (DIN 6921) NUT M10 SELFLOCKING L S91 BRACKET SUPPORT FOOT SUPPORT CPL (with parts 24, 25) L FOOT SUPPORT FOOT SUPPORT RUBBER SCREW M10X25 (ISO 7380) WASHER B CHAIN GUIDE CHAIN GUIDE HOLDER SCREW M5X10 (ISO7380) FUEL FILTER RELAY PROTECTOR MUD PROTECTOR 1 1 1

28 FRONT FORK

29 No. * Part No. Denomination B C D FRONT FORK CPL. grund (with parts 1 to 21 and 27) L RH FRONT FORK SILVER L LH FRONT FORK SILVER SEAL RING OIL SEAL RING CABLE GUIDE G FORK LUG grund SCREW M8X NUT M G UPPER YOKE GRUND G HANDLEBAR CARRIER grund SCREW M6X NUT M CROWN NUT BEARING SET (with parts 21-30) STEERING BEARING CONE STEERING BEARING CONE COVER (BRIGHT) GROOVED NUT P WASHER (S= 2MM) WASHER (S= 0,7MM) BALL BEARING STEERING BEARING CUP (TOP) STEERING BEARING CUP (BOTTOM) L LAK LAMP HOLDER SCREW M6X WASHER A6, NUT M FRONT SIDE REFLECTOR SET OF LOCKS (with parts 41-43) KEY (must to notify number) FRONT FORKS LOCK (with part 41) IGNITION LOCK (with part 41)...

30 GRIPS, CABLES

31 No. * Part No. Denomination B C D HYDRAULIC BRAKE CPL. (with parts 2 to 7) BRAKE LEVER RH CALIPER (with part 5) BRAKE PAD SCREW SEAL RING LINE BRAKE BUSH SCREW M8X BRAKE BUSH SCREW M8X LEVER CPL HOUSING BRAKE LEVER SPRING HOUSING HOLDER SCREW M5X LEVER GRIP THROTTLE CABLE SCREW M5X BRAKE CABLE REAR GRIP CPL 1 1 1

32 HANDELBAR, SPEEDOMETER, MIRROR

33 No. * Part No. Denomination B C D SPEEDOMETER- km/h (with parts 2-3) BULB 12V 2W BA7S BULB HOLDER SPEEDOMETER HOLDER SPEEDOMETER CABLE OS L=780 mm C C51 SPEEDOMETER HOUSING C C51 SPEEDOMETER HOUSING BOTTOM C C51 SPEEDOMETER HOUSING HOLDER SCREW*PT*KA50X SPEEDOMETER WIRING (with parts 16 and 17) SPEEDOMETER WIRING (with parts 16 and 17) BULB 12V 1,2W -W2x4,6d BULB HOLDER C C51 HANDLEBAR LH MIRROR-CHROME 1 1 1

34 FRONT WHEEL

35 No. * Part No. Denomination B C D LAK FRONT WHEEL BEARING 12X32X10(6201-2Z) SCREW FOR DISC 'YA WHEEL SET ( with parts 2, 11 in 21) BRAKE DISC FRONT WHEEL AXLE M12X DISTANCE TUBE'D18/12L75, DISTANCE TUBE'D24/12L19, DISTANCE BUSH 18x13x75, TYRE'120/70-12 TUBELESS VALVE TUBELESS (2 pcs in set ) SPEEDOMETER DRIVE'YA

36 REAR WHEEL

37 No. * Part No. Denomination B C D 1 L LAK REAR WHEEL HOLDER CHAIN TENSIONER SCREW M10X80 (DIN931) NUT M10-5 ZN5GLCB SELFLOCKING WASHER A10, L LAK REAR WHEEL REAR WHEEL AXLE'YA BEARING RSR 20X47X DISTANCE TUBE D25x2L WASHER d24,5d30s WASHER A NUT M16x1,5 SELFLOCKING SPOCKET Z26-Gd SPOCKET Z20-Gd SPOCKET Z31-Gd SPOCKET Z37-Gd PROTECTIVE PLATE NUT M22X1 H8-S BRAKE SHOE YA-CPL SPACE BRAKE CAM BRAKE LEVER BOLT WASHER A6, NUT M AXLE WASHER A8, NUT M8-5 SELFLOCKING CONTROL CAP TYRE 120/70-12 TUBELESS VALVE TUBELESS SPRING ADJUSTMENT SCREW M6X CHAIN 98 (with part 41) CHAIN 95 (with part 41) CHAIN 100 (with part 41) CHAIN 100 (with part 41) CHAIN WASHER LINK 1 1 1

38 ELECTRIC PARTS

39 No. * Part No. Denomination B C D HEADLAMP (with parts 2-6) HEADLAMP INSERT PIECE BULB 12V 35/35W BA 20D BULB 12V 5W S HORN HOLDER CLAMP SCREW ST 2,9X SCREW M8X35 (DIN 6921) WASHER DISTANCE TUBE SWITCH RIGHT WITH CABLE SWITCH LEFT WITH CABLE SCREW M5X22 black CABLE WEB FRONT CABLE WEB MIDDLE CABLE WEB REAR CABLE WEB FOR REGULATOR NUT FOR IGNITION LOCK REAR LIGHT (with part 24) REAR LIGHT GLASS BULB 12V 21/5W BAY 15D SCREW ST 4,2x HORN HORN HORN CAP-chrome SCREW M6X12(IS0 7380) WASHER WINKER F.R./R.L. (with part 37) WINKER F.L./R.R. (with part 37) BULB12V 10W SCREW M5X12 (ISO 7380) WASHER NUT M5 SELFLOCKING WINKER RELAY WINKER RELAY HOLDER WASHER FOR IGNITION LOCK WOLTAGE REGULATOR WOLTAGE REGULATOR SCREW M6X14 (IS0 7380) WASHER B BATTERY TERMINAL CAP FUSE FUSE HOUSING STARTING RELAY 70A BATTERY HOLDER...

40 TOMOS D.O.O. MOTOINDUSTRIJA ŠMARSKA CESTA 4 SLOVENIJA

FLEXER SPARE PARTS MANUAL Tomos d.o.o., motoindustrija, Tomos Nederland B.V, Tomos USA Inc.

FLEXER SPARE PARTS MANUAL Tomos d.o.o., motoindustrija, Tomos Nederland B.V, Tomos USA Inc. FLEXER SPARE PARTS MANUAL 2010 Tomos d.o.o., motoindustrija, Tomos Nederland B.V, Tomos USA Inc. Contents CRANKCASE,CYLINDER,PISTON... 4 CRANKSHAFT, CLUTCH... 6 COUNTERSHAFT, MAINSHAFT... 8 STRARTER MECHANISM