SPRINT SPARE PARTS MANUALS Tomos d.o.o., motoindustrija, Tomos Nederland B.V, Tomos USA Inc.

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1 SPRINT SPARE PARTS MANUALS 2011 Tomos d.o.o., motoindustrija, Tomos Nederland B.V, Tomos USA Inc.

2 Contents CRANKCASE,CYLINDER,PISTON... 4 CRANKSHAFT, CLUTCH... 6 COUNTERSHAFT, MAINSHAFT... 8 STRARTER MECHANISM KICK STRARTER MECHANISM PEDAL MAGNETO ASSEMBLY, ELECTRIC STARTER CARBURATOR, INTAKE SILENCER EXAUST, SEAT, FUEL TANK SIDE COVER, FAIRING FRAME, REAR FORK, CENTRAL STAND DECALS FRONT FORK HANDELBAR, SPEEDOMETER, MIRROR FRONT WHEEL REAR WHEEL ELECTRIC PARTS... 34

3 TYPE-MODEL SPRINT-KICK SPRINT-PEDAL S32 87 SPRINT-KICK S32 88 SPRINT-PEDAL Vin-nr. is denominated from 4 to 11. nr. for EU directive MODELS A B C D 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 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 EXAMPLE FOR CHANGE 01/00 do - parts was built on vehicle till januar /01 od - parts we built on vehicle from november 2001

4 CRANKCASE,CYLINDER,PISTON

5 No. * Part No. Denomination A B C D ENGINE 45 km/h-black-kick ENGINE 45 km/h-black-pedal. 1, CRANKCASE-CPL (with parts 2-8,18,60,47 and bearings) CRANKCASE-CPL-PEDAL 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 CYLINDER STUD BOLT M6/M7 x CYLINDER WITH PISTON A56-B CPL STUD BOLT CYLINDER HEAD SPARK PLUG BR8ES, B.SUPER FE80R NUT M6-8 DIN 986 A2F WASHER PISTON A56-B (with parts 27-29) PISTON RING- UPPER PISTON RING- BUTTOM WRIST PIN 12 mm SPRING CIRCLIP 12 mm CYLINDER HEAD GASKET A56-0, ALLEN SCREW M6X ALLEN SCREW M6X INTAKE MANIFOLD INTAKE MANIFOLD GASKET SCREW M6X16 (ISO7380) WASHER BARRIER PIPE- UPPER BARRIER PIPE- BUTTOM RUBBER OIL PUMP COVER -PLASTIC SCREW PT*KA30X14* GASKET SET A

6 CRANKSHAFT, CLUTCH

7 No. * Part No. Denomination A 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 30 31

9 No. * Part No. Denomination A 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

10 STARTER MECHANISM KICK

11 No. * Part No. Denomination A 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

12 STARTER MECHANISM PEDAL

13 No. * Part No. Denomination B D STARTER SHAFT-pedal 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 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 1

14 MAGNETO ASSEMBLY, ELECTRIC STARTER

15 No. * Part No. Denomination A 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 GROUND WIRE ELECTRONIC SPARK PLUG CABLE (430mm) m m m m RUBBER PROTECTOR SPARK PLUG CAP SCREW M5x12 (ISO 7380) WASHER M

16 CARBURATOR, INTAKE SILENCER

17 No. * Part No. Denomination A B C D CARBURATOR DELL'ORTO PHVA 14 (with parts 1-38) THROTTLE VALVE NEEDLE A JET 209 GA MAIN JET Idle Jet Choke Jet FLOAT CPL (with parts 7,34,35) CABLE GUIDE TUBE CPL (with parts 10,11,12,13,15,16) THROTTLE VALVE SPRING NEEDLE HOLDER FLOAT CHAMBER CHOKE MECHANISM CPL (with parts 22,23,24,26) AIR CONTROL SCREW CPL (with parts 29,27) ADJUSTING SCREW CPL (with parts 31,32,33) FLOAT CHAMBER CPL (with parts 36,37) FLOAT CHAMBER SCREW GASKET SET INTAKE SILENCER (with parts 41-46) REAR SILENCER COVER FRONT SILENCER COVER SCREW ST 4,8X AIR FILTER FRONT FILTER SUPPORT REAR FILTER SUPPORT INTAKE PIPE CLAMP

18 EXHAUST, SEAT, FUEL TANK

19 No. * Part No. Denomination A B C D EXHAUST CPL S91 EXAUST COWER SCREW WASHER EXHAUST GASKET SPRING RING B CAP NUT M SCREW M8X20 (ISO 7380) WASHER NUT M8-SELFLOCKING SEAT Z51 HINGE RH-LH SCREW WASHER Z51 SEAT SLATE Z51 SUPPORT Z51 SEAT HOLDER SCREW WASHER NUT M6-SELFLOCKING RUBBER BUSH MOUNTING SLEEVE SCREW SPRING RING B NUT M TOOL TRAY SHEET SCREW 4,2X WASHER D5,2XD14,5X L LUGAGGE-BLACK SCREW M6X16 (ISO 7380) SPRING RING B WASHER FOOTTREST REAR- PAIR WITH PARTS 44,45 pair pair pair pair S91 EXHAUST COVER

20 SIDE COVER, FAIRING

21 No. * Part No. Denomination A B C D LAK RH SIDE COWER-LACK LAK RH SIDE COWER-LACK LAK LH SIDE COWER-LACK 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 PLAST SHEET SCREW 4,2X WASHER CHAIN GUARD (BLACK) SHEET SCREW 4,8X WASHER N STREAMER-HEADLAMP L FAIRING PAINTED WASHER D6XD CAP NUT M HEADLIGHT BRACKET RH HEADLIGHT BRACKET LH DISTANCE BUSH FOR HEADLIGHT SHEET SCREW 4,2X THRUST NUT 4, SELF-ADHESIVE PATCH LH SELF-ADHESIVE PATCH RH

22 FRAME, REAR FORK, CENTRAL STAND

23 No. * Part No. Denomination A B C D LAK Frame painted (with 1/1,50,51,52) Frame Bearing bush Gas cap without lock - black Fuel feed tap Spring clip Fuel line (per unit) m m m m oil filter Kickstand (black) - A Kickstand spring Spring carrier Screw M8x1x Washer Nut M8x1-selflocking L LAK Swing arm painted - A a Spacer d12 D26 L Distance tube Screw M12x1,25x Washer Nut Shock absorber (silver) - A Washer D10,5XD21X S91 supporttube Footpeg cpl Footrest rubber Screw M10x25 (ISO 7380) Spring ring B L LAK Front fender painted L LAK front mudguard holder Screw M5x Washer Washer Nut M5-selflocking screw Washer L Rear fender painted screw Washer Nut M Relay support Closed Nut M12x1 Fe/Zn 10A Sealing washers fi11x1,95 NBR

24 Seat holder-rear Seat holder-front Side cover holder-rear DECALS

25 No. * Part no. Denomination A B C D "DECAL ""ON-OFF-RES`"" " "DECAL ""OIL MIX 2%"" "DECAL ""SPRINT-CPL."" "DECAL ""TOMOS"" DECAL*WARNING-ONE RIDER DECAL*WARNING-KEY DECAL*WARNING-HELMET DECAL*WARNING-ACCESSORIES DECAL*WARNING-BATTERIES DECAL*WARNING-LOAD WEIGHT DECAL*WARNING-TIRE-2 1/4X

26 FRONT FORK

27 * Part No. Denomination A B C D FRONT FORK WITH PARTS FROM 1-21, L RH FORK -WITH BRAKE ACCESSORIES L LH FORK DUST COVER DUST COVER OIL CLAMP L LOWER YOKE PAINTED (REVIVA SCREW NUT M L UPPER YOKE PAINTED (PAINTE L HANDLEBAR CARRIER PAINTED SCREW M6X NUT M6-SELFLOCKING CROWN NUT HANDLEBAR BEARINGS CPL STEERING BEARING CONE STEERING BEARING CONE COVER (BRIGHT) GROOVED NUT P WASHER (S=2MM) CROWN NUT WASHER (CHROME) BALL BEARING STEERING BEARING CUP (TOP) STEERING BEARING CUP (BOTT LAMP HOLDER RH LAMP HOLDER LH O-RING FRONT REFLECTOR LOCK

28 HANDLEBAR, SPEEDOMETER, MIRROR

29 No. * Part No. Denomination A B C D LEVER RH WITH PARTS 1,3,4,5,6,7,13, SCREW BLACK BRAKE LEVER RH SPRING RH SCREW CPL 5,6, BOLT STOP SWITCH MOUNTING BRACKET LH 10,11,12,5,6,7,13, BRAKE LEVER LH SPRING RH MOUNTING BRACKET LH - A SCREW THROTTLE TWIST TUBE - A S91 HANDLEBAR MIRROR LH BLACK 8MM SPEEDOMETER (MPH) WHITE BULB 12V-2W BA7S BULB HOLDER SPEEDOMETER GASKET SPEEDOMETER HOLDER (L=52MM SPEEDOMETER CABLE L THROTTLE CABLE SPEEDOMETER HOUSING SCREW BULB 12V-2W BA9S FRONT BRAKE CABLE BULB HOLDER REAR BRAKE CABLE - A GRIP CPL 20,21, A LEVER RH CPL B LEVER LH CPL SET LEVERS WITH SWITCHES CPL

30 FRONT WHEEL

31 No. * Part No. Denomination A B C D WHEEL FRONT WHEEL FRONT (BLACK) FRONT BRAKE PLATE FRONT BRAKE PLATE (BLACK) BRAKE SHOE - PAIR SPRING RUBBER PLUG BRAKE CAM BRAKE LEVER WASHER NUT M BOLT DISTANCE BUSH BALL BEARING 12X32X10 ( FRONT AXLE DISTANCE BUSH (BLACK) WASHER NUT M12x1 SELFLOCKING TYRE (38J SAVA MC2) VENTIL TUBELESS INNER TUBE 2 1/4-16 VENTIL VG RH SPEEDOMETER DRIVE

32 REAR WHEEL

33 No. * Part No. Denomination A B C D REAR WHEEL REAR WHEEL (BLACK) REAR BRAKE PLATE REAR BRAKE PLATE (BLACK) BRAKE SHOE - PAIR SPRING RUBBER PLUG BRAKE CAM BRAKE LEVER WASHER NUT M BOLT ADJUSTING SCREW REAR AXLE DISTANCE BUSH BALL BEARING 12X32X10 ( DISTANCE BUSH (BLACK) DISTANCE BUSH WASHER D11.1XD20X NUT M11X REAR SPROCKET Z= PROTECTIVE PLATE SCREW M7X NUT M "TYRE' J-MC2-S INNER TUBE 2 1/4-16 VENTIL VG CHAIN TENSION ADJUSTER RH CHAIN TENSION ADJUSTER RH CHAIN (93 ROLLERS) CHAIN WASHER LINK CHAIN MASTER LINK

34 ELECTRIC PARTS

35 No. * Part No. Denomination A B C D HEADLAMP (with parts 2-6) BULB 12V 25/25W BA20D BULB HOLDER CLAMP BULB 12V 4W BA9s SCREW ST 3,9x WASHER NUT M6X16 (ISO 7380) 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 SCREW M6X12(IS0 7380) WASHER HORN REAR LAMP (with parts 31 and 32) BULB 12V 5W BULB 12V 10W SCREW ST 3,9x REAR LAMP HOLDER SCREW M6X16(ISO 7380) WASHER 6, DISTANCE BUSH L=7,5mm RUBBER INSERT PIECE WASHER d6,3xd SCREW M6X WASHER 6,4 D NUT M6 SELFLOCKING WOLTAGE REGULATOR

36 TOMOS D.O.O. TOMOS INC. TOMOS NEDERLAND B.V. MOTOINDUSTRIJA 202 BEECHTREE BLVD. KWEEKWEG PG EPE ŠMARSKA CESTA 4 GREENVILE, SC POSTBUS AD EPE SLOVENIJA USA NEDERLAND

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

SPARE PARTS MANUALS Tomos d.o.o., motoindustrija, Tomos Nederland B.V, Tomos USA Inc. LX SPARE PARTS MANUALS 2011 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-kick...