Page 1 Jamlirella OLDTIMERWORKSHOP.COM...
Page 2 150d-ld Jamlirella - � INSTRUCTIONS FOR REPAIR SHOPS ,·· INNOCENTI OLDTIMERWORKSHOP.COM...
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Page 4 rhis manual is mainly intended to provide the Service Stations with basic information regarding the. dismantling, overhauling, repairing and tuning-up of the « Lambretta 150 D » and « 150 LD ». The first section comprises the main features of the two models and the description of their most important elements .
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Page 6 UMMARY Main features pa g. Description pag . Dismantlin g pa g. Wear limits pag . Rei nsta I lation pag . 10 7 Troubles and repairs pa g. 11 3 Variations pa g. 16 5 Tool list pag . Index p ag.
Page 7 Light switch with ground and Gear indicator horn button Clutch lever ;; Throttle Gear control twistgrip Front brake lever Tank filler cap --:,____ --.._ Fuel tap Air cleaner Horn Shock absorber Tail light Number plate carrier Rear brake pedal Speed change connecting casing K, S.
Page 8 Light switch Gear indicator with ground and horn button Clutch Throttle Gear control Tank filler cap Headlight Fuel tap Tail light Number plate carrier Side brake pedal Silencer pedal Fig. 2 OLDTIMERWORKSHOP.COM...
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Page 10: Main Features
FEATURES MAIN OLDTIMERWORKSHOP.COM...
Page 11 FEATURES MAIN Mod. « D » Mod. « LD » TWO-STROKE SINGLE CYLINDER ENGINE Overall length 70" 70" 148 c.c. Capacity (l .770 m) (l.770 m) 2.244" Bore (57 mm) Stroke . 2.283" (58 mm) Overall height 38" 38" Compression ratio (0.960 m) (0.960 m) Hp output max...
Page 12 STARTING TANK Fuel capacity: By pedal. Mod. D 1,4 gals (6,3 It) including l, l /4 pt. (0,7 It) res. Mod. LD 1,55 gals ( 7, l It) including l, 1 /4 pt. (0,7 It) res. COOLING 3-way tap (for Model D see fig.
Page 13 supported torsion bar made of high-tensile steel. The socket is to be derived from terminal plate located into the head lamp. In such a case the tail lamp bulb must be swings of the engine group are transmitted to the torsion bar by means of return levers, which are properly pro...
Page 14 ELECTRICAL SYSTEM OPERATION DIAGRAM •II __ t1_ Engine stop (earthing) � __ ..Q_ Pilot light __ 1_ Dipped beam Main beam __ .1_ "' � l,IJ i; � � ... l,IJ l<JC:,, l,IJ,>c l,IJ '-' Q. c!! V) -0 ..�...
Page 15: Electrical System Diagram
ELECTRICAL SYSTEM DIAGRAM Fig. 4 OLDTIMERWORKSHOP.COM...
Page 16 LUBRICATION' OLDTIMERWORKSHOP.COM...
Page 17: Lubrication Table
LUBRICATION TABLE Parts to be lubricated Operation Interval ':tubrf cant �: miles Mix petrol with 8% For the first 900 , • Engine BP Energol Two Stroke Mix petrol with 6% After 900 miles (1500 km) Check level and refill to level BP Energol Motor Oil SAE 30 Every...
Page 18 LUBRICATION DIAGRAM BP Energ,-11 Al BP E111r9,- l3 BP Eneraol M.O. SAE30 BP Energreeae BP Energre- BP EM,gru" A1 Energ,-st BP Energol M.O. SAE Fig. For points marked with two typ· e s of lubricant, si,e table page 16.· · OLDTIMERWORKSHOP.COM...
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Page 20 DESCRIPTION OLDTIMERWORKSHOP.COM...
Page 21: Engine Operation
ENGINE OPERATION KICK STARTER The outline of the new « Lambretta D » and « LD » is si milar to the preceding models but the engine capacity has As shown in the diagram, the starting device consists of been increased to 150 cm•. Further innovations comprise a bevel pinion (12) engaging with the bevel engine gears, the improvement of the springing and gearbox.
Page 22: Gear Shifting
GEAR SHIFTING Top gear - The second gear pinion on the rriain shaft (2 4 ) sliding further backward in the splines (20) engages its dogs with the tooth spaces of the neutral gear on main Low gear - The main shaft (20), in constant mesh with shaft (22) so that the engine is put in direct drive, connect...
Page 23 GENERAL DIAGRAM REGARDING ENGINE GEAR SHIFTING AND TRANSMISSION OPERATION Fig. OLDTIMERWORKSHOP.COM...
Page 24 LEGEND Flywheel Magneto Clutch Splined Drum Cylinder Clutch Driven Discs 0· Cylinder Head 19) Clutch Driving Discs Piston Main Shaft Gudgeon Secondary Shaft 6) Connecting Rod Neutral Gear on Main Shaft Neutral Gear on Secondary Shaft 7) Connecting Rod Big-end Needle Rollers S3 ) Crankshaft 2 4) Second Gear on Main Shaft...
Page 25: Engine Components
ENGINE COMPONENTS incorporates the steel bush light-alloy rear wheel hub coupling with the transmission pin and the brake drum meshing on one side with neutral torsion bar (28) ring. gear inner teeth fitted on the main shaft (22) is construct ed of special steel to absorb shocks caused by sudden ac...
Page 26: Front Suspension
SPRING SUSPENSION FRONT SUSPENSION The suspension elements of the « Lambretta 150 D » and « LD » are placed within grease tight casings in order to ensure long life and perfect efficiency. The front suspension, as shown in figg. 7-8, is effected by means of two trailing links and two progressive type springs (l) located inside the fork tubes;...
Page 27 connect the engine group to the frame and the double extensions attaching the return lever to the torsion bar on the upper crankcase portion, flywheel side. The connection between engine and frame is obtained as follows: transversally to the frame (5) a tube with taper ed ends is welded on which the two clamping cones (l) of the engine centre axle (3) are seated, held in place by the nut (4).
Page 28 Fig. 9 • Engi ne connection to the frame. Fig. 11 • Rear suspension assembly. A cylindrical damper, which minimizes swing and vibration of the engine-wheel group when the machine runs and increases the static load of the entire rear suspension is fitted between the transmission case and the frame (fig.
Page 29: General Instructions
DELL'ORTO CARBURETTOR GENERAL INSTRUCTIONS The Dell'Orto carburettor, 19 B 4 type, is provided with starter, bowl filter, air filter with wire wool and special air inlet for reducing the intake noise. Starter device The starter device is a ready means to enrich the mixture for starting purpose when the engine is cold.
Page 30 To obtain an easy starting it is advisable to keep the throt foreign matter in petrol interferring between float nee tle closed and fully raise the starter lever. float chamber bottom with consequent leakage. Clean carburettor thoroughly and check for Once the engine is running and tends to accelerate, move efficiency of fuel filter and tightness of the gaskets.
Page 31 Needle Main jet Make sure it is in good condition and does not afford any Check for proper fitting of the jet into threaded seat distorsion or diameter reduction caused by wear. and for exact gauging. If necessary, replace with a new Check whether the clip is properly fitted and matched part, gauge «...
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Page 33: Spark Plug
SPARK PLUG Spark plug is one of the most important engine compo nents. In effect correct performance of engine depends in a great degree on the spark plug. The spark plug (fig. 15) is screwed to the cylinder head and is connected to the current-source by means of an in sulated cable;...
Page 34 The shape of the electrodes and the gap between the and oil sediment can be turned and eliminated with points are exactly designed so that, when the spark the exhaust gases. plug circuit is supplied with current, the spark can The upper limit is called spontaneous ignition tempe...
Page 35: Flywheel Magneto
FLYWHEEL MAGNETO Two different flywheel magneto types are fitted on similar but they have not interchangeable parts besides the two Lambretta models: FILSO and MARELLI. Both are H.T. and L.T. terminals. FLYWHEEL MAGNETO MARELLI « MVB4A » WHIT SEPARATE IGNITION COIL B 20 A Fig.
Page 36 The flywheel magneto « MVB 4 A », better described as an alternating current generator, provides the electric cur rent for the ignition and lighting. All components are assembled in two distinct groups: stator plate To flywheel rotor magneto The stator plate, made of light alloy, is fitted to the crank case and by means of screws allows a proper advance adjustment.
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Page 38 The pressure of breaker contacts must be 650+50 gr TEST DATA ( 1,44 ±0, 110 lbs.). Mechanical test Check the contact pressure by applying a dynamometer to the surface of the adjustable contact. Contact gap 0,4± 0,05 mm C0,0158"±0,l 10 lbs) For cleaning the ignition coil use petrol only and very Contact pressure 650 ±50 (1,44...
Page 39 FLYWHEEL MAGNETO FILSO A.V.S. » 30.6/140/F. 0176 C. The Filso flywheel magneto« A.V.S. » 30.6/140/F.0176.C. and the H. T. ignition coil are similar to the Marelli makes, previously described. However they are not reciprocally interchangeable. Fig. 20 - Stator Fig. 21 - Rotor OLDTIMERWORKSHOP.COM...
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Page 43 When removing or installing motor-scooter parts use the tor scooter in a case or separate place in order to avoid proper tools, and make sure that the parts are clean. mixing them up with other parts. Unsuitable tools can cause troubles or failure, which may Wash the removed parts with paraffin or petrol (gasoline);...
Page 44 E N G I N E D I S M A N T L I N ·,G To remove the engine from the frame it is necessary, in the case of the « LO » model, first to detach the side panels and the side boards.
Page 45: Flywheel Magneto Removal
stud bolt. Free the expansion chamber after loosening the screws locking it to the crankcase. To clean the silencer from carbon formations developed by exhaust gas, loosen the safety nut and the bushing fixing the bottom and drive out from the other end the bottom and the rod;...
Page 46 " Fig. 26 · Removal of the flywh,-el magneto rotor. Fig. 27 · Pulling out the nut of the flywheel flange. First take the Seeger ring off holding ,he gasket in place, and to avoid damaging the outer gasket diameter strike with the punch on the opposite side only, operating the outer bearing.
Page 47 R E M O VA L K. S. C A S E The K.S. unit of the motor scooters « D » and « LD » consists of two groups which have to be dismantled by following operations: Loosen the five exagonal bolts fixing the K.S. cover to the crankcase by using the spanner 37380;...
Page 48 CLUTCH REMOVAL ··------· The disconnected cover carries the two clutch control le vers (inner and outer); it is easy to dismantle them. Next dismantle the clutch· discs using the tool 49753 (fig. 31) and driving the clutch control rod into the tool center hole.
Page 49 Fig. 32 - Removing the clutch slotted drum. After ring removal, pul I out the fork, extracting discs, cups and springs fitted in the second group, still under compression. Fig. 33 - Clutch bell nut removal. If further dismantling of this group for repairing purpose is not necessary, do not remove the puller, as reinstalling Apply the wrench 37101 on the clutch drum notches (fig.
Page 50 Slide the clutch drum off; if necessary, help removal by forcing the screwdriver between the clutch slotted drum and the bell. Straighten the safety ring tabs: apply the hub lock ing wrench 49256 inserting it from the k.s. bevel gear hole;...
Page 51 ' • REMOVAL OF THE GEAR CHANGE SELECTOR CASING ?i�l� Remove � c�ing cover by loosening the three bolts. Loosen the two cable adjusters; remove e Seeger ring, and slide off the lever from the pin (fig. 36). Detach the casing from the crankcase by slackening the three sc �...
Page 52 WHEEL AND REAR MUDGUARD REMOVAL To remove the _rear wheel, unscrew the three cap nuts fixing the rims to the hub. Disassemble rims and take out the tyres; tighten the nuts previously loosened; apply washers. To do the same operation on Model « LO » first remove the left-hand side covering.
Page 53 REMOV .4 OF THE FRONT WHEEL AND TYRES < To remove the front wheel on both models, first discon nect the brake cable, then unscrew the side nuts fixing the wheel to the trailing links and slide off the washer located under the trailing link fixing nuts (fig.
Page 54 REMOVAL OF THE TRANSMISSION REAR SUSPENSION ASSEMBLY OPERATING FROM THE CRANKCASE SIDE r---- gree, . Pf ace a piece of wood between engine and frame in the manner shown in fig. 39 in order to hold the group lifted as otherwise it would rest on the torsion bar housing and prevent easy slackening of the transmission case fixing screws.
Page 55 DISMANTLING OF THE REAR BEVEL GEARS +--- - --- - - &J-- -------t After disconnecting the transmission case and rear wheel hub from the crankcase dismantle the entire group as follows: Slide the Seeger ring from the rear brake shoe pin off; operating with a screwdriver, detach the shoes from the Dwg.
Page 56 Wheel, axle, bearings, rear bevel gear, etc.; are fitted on the rear whee! supporting flange. To disconnect these �r----1 parts follow this sequence: Unscrew the four nuts fixing the bearing cover and deta,�h flange and packings take the cotter pin out from the castle nut locking the bevel gear loosen the nut which ho!ds the axle in place either by means of the wrench...
Page 57 Fig. 42 • Bevel pinion removal. Fit the washer at the transmission case end and operate Insert the tool from the transmission case rear hole; en the handle to remove the group from its seat. Drive the gage the tool clamps between pinion and bearing (see spacers out and dismantle the pinion assembly.
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Page 59 PISTON AND CRANKSHAFT REMOVAL Fig. 44 · Piston removal. Fig. 45 - How to remove the lock nut of the bevel pinion. To remove the piston, operate as fol lows: first free the Straighten the tabs of the washer placed under the bevel gudgeon pin from the Seeger ring and then using the tool pinion lock nut.
Page 60 �-- Fig. 46 Extracting the bevel pinion. i __ -- - Fig. 48 - How to pull out crankshaft and connecting rod from the crankcase. rod has reached the T.D.C. Insert the tool 49221 in the crankcase hole, cylinder side, to prevent any rotation of the crankshaft;...
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Page 63 The particular position for dismantling the torsion bar is Seeger rings and the washer located on the K.S. side, at the gearbox side. Slide the Seeger ring off placed at striking the torsion bar with a mallet until it is taken out. Insert, as shown in fig.
Page 64 STEERING DISMANTLING Fig. 52 · Handlebar removal. Fig. 53 • Removal of the steering upper bearing threaded ring. Loosen the locking nut fixing the handlebar support; re Apply the wrench 40482 to the steering adjusting bal I move bolt, nut and washer (fig. 52). Slide the handlebar cup, and the wrench 40490 to the adjusting threaded from the steering column and place it on the board.
Page 65 ---i Fig. 55 • Detailed drawing showing how to extract the bearing upper cup Fig. 54 - Front fork dismantling. using the tool 39982. • OLDTIMERWORKSHOP.COM...
Page 66 steering and front wheel group off. If repairs to column and fork are necessary, detach the control pin from the front brake shoe control lever, by loosening the locking pin and driving it out from the adiusting nut (fig. 54) and then from the holes drilled on the fork right arm.
Page 67 FRONT SUSPENSION DISMANTLING move the front wheel: loosen the three screws fixing the case covers and the nuts holding the trailing links and slide them off, using a screwdriver. Extract the inner levers and the case covers at the fork arm ends;...
Page 68: Wear Limits
WEAR LIMITS OLDTIMERWORKSHOP.COM...
Page 69 Preliminary instructions poor lubrication and maintenance or improper use of the machine and normal deterioration. We have reported in the following charts the data regar After dismantling the various engine components, before ding the different limits of the main engine elements. The reinstalling them, inspect accurately every part.
Page 70 INSTALLATION ALLOWANCE AND WEAR LIMITS FOR CYLINDER AND PISTON Inst allation allowa nce Pist o n Cylinder Wea r size Dimensions Dimensions limit s Opera t ion M. 201 Cast Dwg. max. 0.005866 -0.000393 95 A 0.000748 min. 0.004724 2.2393 1026 Normal max.
Page 71 INSTALLATION INTERFERENCE AND WEAR LIMITS BETWEEN PISTON AND GUDGEON PIN Interference Gudgeon Wear Piston Clearance limit </)A Operation Dwg. +0.000236 Normal -0.000433 -0.000472 M. 323 Installation 0.551181 0.551181 +0.000236 First -0.000472 M. 332 -0.000433 -0.000472 oversizing 0.555118 0.555118 -0.001181 +0.000236 Second -0.000472 M.
Page 72 PISTON RING AXIAL INSTALLATION ALLOWANCE AND WEAR LIMITS Piston Ring Axial Allowance Piston M. 324 Wear Limit ° = 0.003504-0.001968 ° =0.080709 +0.000551 -0.000984 ° = 0.003110-0.001653 ° 0.080393 0.003346 0.078748 =0.080118 \- o ° = 0.002913-0.001378 ° INSTALLATION ALLOWANCE AND WEAR LIMITS FOR RING END GAP AND RING DIAMETER Gap of the en�s with Outer...
Page 73 INSTALLATION ALLOWANCE AND WEAR LIMITS BETWEEN GUDGEON PIN AND CONNECTING ROD LITTLE END EYE little Piston pin bushing A llowance Wear limit Operation 1041 Dwg. Dimension +0.000629 Normal +0.001063 -0.000433 11 M. 323 installation 0.551181 0.551181 0.001496 +0.000629 0.002362 First M.
Page 74 INSTALLATION ALLOWANCE AND WEAR LIMITS BETWEEN CONNECTING ROD BIG END AND CRANKSHAFT THROW Connecting Crankshaft Needles throw Allowance Wear 2 M. 303 11 M. 304 1041 limit +0.000512 -0.000787 0.000787 0.003150 -0.001299 -0.000196 1.1378" 0.901574 0 0.118079 0.002205 OLDTIMERWORKSHOP.COM...
Page 75 INSTALLATION ALLOWANCE AND WEAR LIMITS BETWEEN CRANKSHAFT AND CONNECTING ROD BIG END Connecting rod Crankarm Side Crankshaft width clearance 1041 throw width +- '.) +0.005822 +0.001260 -0.002952 --0.004409 0.539370 0.551181 2.204724 OLDTIMERWORKSHOP.COM...
Page 76 REI NSTALLATION OLDTIMERWORKSHOP.COM...
Page 77 Preliminary instructions Before reinstalling, wash every part thoroughly. Lubricate all engine and suspension elements with oil or grease. Replace lockwashers and cotter pins which have been damaged during removal. Inspect every part carefully. Compare the size of the most impo r tant parts with the tabulated « Wear Limits». Che' c k wear conditions of bearings, gaskets and seals, and replace if necessary.
Page 78: Gas Ket I N S Tallati On
GENE R A L When replacing the piston rings, take care that the ends Under certain running conditions, a slapping of the piston do not press against the piston slot pins; furthermore it may be heard when the engine is cold. This noise does not affect engine performance.
Page 79 SILENTBLOCK INSTALLATION ON THE CRANKCASE Carry out the installation of the silentblocks on the crank case with considerable care. The seats on the crankcase should be examined to make sure they are free from marks and seizure. Press the silentblocks into the crankcase in such a manner that their final position results as shown in the fig.
Page 80 REINST ALLATION OF THE CRANKCASE ON THE FRAME facilitate installation of the bearings, bronze bushings abundantly coated with grease, into the crankcase hole (flywheel side); ascertain whether the bevel bushings align and gaskets it is advisable to operate the crankcase de correctly and lock by placing under the nut the safety tached from the frame.
Page 81 Backlash mm 0,12 0,16 (0,0047" ..:.. 0,0063") ',\\ Fig. 59 Coupling diagram f o r the crankshaft and clutch control bevel gears. The next step is to check the crankshaft for eccentricity. If a suitable clock indicator is not available use a scriber. For this purpose a clock indicator is required;...
Page 82 Insert the main shaft Should the eccentricity of the crankshaft be unsatisfactory from crankcase side and the hub with the clutch bevel gear already mounted from clutch first check the ground surface of the nut and next the drive and position the side;...
Page 83 REINST ALLATION OF THE PISTON Before reinstalling the piston, check the play between the reverse the operation described in the chapter regarding piston pin and the eye of the connecting rod little end, and «Dismantling». Fit the two circlips last; ascertain they the interference between gudgeon pin and piston.
Page 84 Ascertain if the rotor does not wobble. Allowance of 0, 1 is perfectly clean and that no deformation or burrs in the instal I the tapered flywheel end into mm (0,0039") on the larger diameter. key slot are present; Check wobbling using a comparator or a scriber point. the spindle, checking by rotating the flywheel whether it Should the flywheel rotation exceed this limit proceed as still wobbles.
Page 85 REAR BEVEL GEAR REINSTALLATION First prepare the various groups forming the rear trans Spring Washers mission, i.e. transmission case, wheel supporting flange, rear bevel pinion. Install in the transmission case the needle carrying bushing for the neutral gear on the main shaft and the bronze pinion bushing into the secondary shaft ;...
Page 86 ed; insert the spacers and springs washers and finally a plain washer. Positioning of these washers is very important (See fig. 60); ascertain whether their alignment and clamping with a Seeger ring are perfectly performed. Mount in the rear wheel supporting flange the first bear ing (rear wheel side), place the rubber ring and then install the bearing locking flange fixing it with four nuts and plain split washers.
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Page 88 During this operation check if the bevel pinion and the the rear wheel flange group and drive the bevel pinion crown teeth mesh exactly; tap with a leather mallet the retaining plate into the splined hole at transmission flange periphery fixing it to the transmission case by case end.
Page 89 Backlash mm 0,12-;- 0,16 (0,0047" 0,0063") Fig. 63 · Rear transmission bevel gear coupling diagram. mission case cover and the speedometer fitting cover; pla- Pour through the filler 100 gr ( ¼ lbs) MOBI LUBE GX 140 ce the gaskets and fix the covers with the proper screws. oil (See diagram page 11) and then fit plug and packing.
Page 90 GEARBOX REINSTALLATION AND CONNECTION OF TRANSMISSION GROUP TO CRANKCASE After installing the rear bevel and gearbox gears into rollers. Engage the torsion bar with the rear bevel pinion the transmission case, connect the latter to the crank on the transmission-rear suspension assembly. Engage also case, operating as follows: the neutral gear on the primary shaft, previously prepared;...
Page 91 the crankcase driving it from the latter and locking it been machined on the flange. Slacken the hexagon hedd with nut and washer from the transmission case side. screws and tighten them, after positioning the lever. After this operation check gearbox performance by ro During this operation care must be taken not to damage "' tating the clutch splined drum and shifting the gears by...
Page 92 REAR SUSPENSION REINST ALLATION To ensure correct installation of the rear suspension and Place the Seeger ring into the connecting pin. At the op efficient performance follow our instructions carefully. posite side locate safety washer and Seeger ring. Check accurately if the various parts do not show any Drive the rubber cap into housing (push it to the final posi...
Page 93 Installing and bolting of the bar must not cause friction or distortion; when the best position is selected, the bar must slide easily into the couplings. Use the device for torsion bar preloading 46604, as shown in fig. 64. Operate its screw with the proper wrench until the sha ckle hole aligns with the crankcase extension hole.
Page 94 · - -- i FRONT FORK REINST ALLATION ___ . _ _ J Fig. 65 - Preloading of front suspension springs. Fig. 66 - Reinstallation of the trailing links. their ends thoroughly; clean springs and other parts of bushings placed in the covers, coupling them with the op the suspension group.
Page 95 is necessary to mount them with the smaller pitch upwards. pin groove. Lock by tightening the screw interplacing the Install the preloading device 42621 as shown in fig. 65 split washer. and compress the push block and the springs. To get over possible difficulty when installing the rocker Insert the inner lever into the box in the manner that the arm, use a proper clamp (See fig.
Page 96 REINSTALLATION AND ADJUSTMENT OF GEARBOX Be sure the gear indicator on the left handgrip operates After correct engaging set the indicator in neutral position. correctly and smoothly, the control cables slide regularly Install the gear selecting casing; insert the lever in the in their covering and the handgrip play amount being not splined end of the control shaft and fix the casing to the excessive.
Page 97 CLUTCH REINST ALLATION When clutch assembling, check whether steel discs show disc retaining ring into the bell groove. Make sure the traces of overheating or rubbing. This should indicate installation is correct and remove the tool. Reinstall the clutch slipping and in such a case discs must be replaced. clutch control inner and outer levers into the cover.
Page 98 KICK STARTER REINSTALLATION Commence reinstalling the bevel pinion by inserting the Insert the entire group in the crankcase; ascertain the gear p. i nion into the aluminium support centre hole; f ix it with teeth mesh with the bevel pinion exactly and then lock plain washer and Seeger ring.
Page 99: Ignition Timing
IGNITION TIMING gap be ! ween sp rk plug electrodes: � 0,0/97 Timing adjustment is very important. Incor s0,0236 rect adjustment affects engine performan ce; therefore beside the description of the operation to be performed we have repor ted timing adjustment diagram for the two flywheel makes ( Marelli and Filso) fitted on our motor scooters.
Page 100 T.D.C. Dial gauge pointer « » (light on) by hand until T.D.C. is reached. The T.D.C. corresponds to the top of the pointer stroke, Dwg. 48059 before reversing the direction. Rotate the dial until the zero point corre sponds to the pointer position. Next connect the cable of the circuit tester to the earthing socket (I.
Page 101 GEAR AND THROTTLE CONTROL ON THE HANDLEBAR Wear increases the amount of play between the guiding as before, to avoid a new settlement which might cause slide of the gear and throttle twistgrip and the corre further wear. sponding grooves of the sleeves with a consequent increa To check controls, take the gear-cable from the outer ca...
Page 102 TROUBLES AND REPAIRS >· OLDTIMERWORKSHOP.COM...
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Page 104 FLYWHEEL MAGNETO If there is an indication that the magneto is causing trouble it is recommended before attempting to repair it, to check other elements such as the spark plug, carburettor, and connections; make sure the magneto timing is correct. INCORRECT IGNITION REMEDY CAUSE...
Page 105 INCORRECT IGNITION AT HIGH SPEED CAUSE REMEDY Magneto contact points out of adjustment Adjust in accordance with tabulated data Adjust or replace spring; check pressure reforring to ta Poor contact pressure bulated data Contact points imperfectly matching Adjust so that point surfaces match exactly Breaker arm does not turn freely on its pin Lubricate pin Poor connections (terminal, cables, etc.)
Page 106 LIGHT GENERATOR DOES NOT DEVELOP FULL POWER CAUSE REMEDY Light generator stator short-circuited or grounded Replace stator Inspect connections, terminals, clamping screws, etc. Poor connections LIGHT GENERATOR DOES NOT OPERATE CAUSE REMEDY Generator stator disconnected, short-circuited or grounded Replace stator OLDTIMERWORKSHOP.COM...
Page 107 SPARK PLUG Test spark plug for proper heat range; remove it and inspect condition. Symptoms noticed on the engine when using inadequate spark plug, and effects on the plug. Plug is too hot Plug test: Oil sediment and carbon on insulator end, shell and elec Engine missing, specially at high r.p.m., knocks, preigni...
Page 108 SPARK PLUG INSTALLING Before installing the spark plug on the engine, especially duction, with consequent burning of the gasket, and in if already used, make sure the insulator is in good con addition a deterioration of the general performance con ditions.
Page 109: Hard Starting
CARBURETTOR HARD STARTING Hard starting may depend on carburettor troubles, beside faulty ignition system, as previously described. CAUSE REMEDY Mixture does not reach carburettor correctly Inspect filter and if clogged clean with a brush or blow out all dirt with air. Atomizer hole partly clogged Clean hole by blowing with air Float is leaking and does not maintain proper level...
Page 110 CLUTCH The troubles which occur in the transmission system most frequently depend on badly adjusted or defective clutch. Adjust the clutch by unscrewing the ring of the clutch cable adjuster on the handlebar and loosening nut and counternut at the opposite cable end in the crankcase. Here are reported clutch troubles, their most likely causes and the remedies to be adopted.
Page 111 CLUTCH DOES NOT RELEASE COMPLETELY REMEDY CAUSE Clutch control cable too long with respect to the outer Regulate cable length, operating nut and counternut by cable. means of two 0.315" wrenches BEV EL GEARS UNUSUAL ENGINE NOISES AT HIGH SPEED R E M E D Y C A U S E Excessive play between bevel pinion and crown wheel of...
Page 112 couplings are correct. See fig. 63. If the trouble does - after locating the trouble, dismantle the flange and re not depend on the rear bevel gears, inspect and adjust place the shims placed under the bevel pinion group. Ex tract this group from the transmission case (See descrip...
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Page 114 150d-ld Jamlirella INSTRUCTIONS FOR REPAIR SHOPS MODIFICATIONS INNOCENTI OLDTIMERWORKSHOP.COM...
Page 115 MODIFICATION No. 1) - KICK STARTER GROUP In a series of 3000 machines the k. s. group has been improved as follows : The bevel pinion ( l ), into which the pin is forced (2), rotates on a ball bearing pair (3); a spacer (4) of proper thickness interposed between them carries some holes in order to facilitate adequate lubrication;...
Page 116 It will be realized that the solution adopted for the ma chines of later production is again that involving the sup porting sleeve and bronze bushing. However the position of the central p in has been retained to permit fitting the spring , which provides for constant engagement between the k.
Page 117 MODIFICATION No. 2) - PE RIODICAL L UBRICATION OF THE CRANKSHA FT BEA RING, FLYWHEEL M AGNETO SIDE As indicated in the Lubrication Diagram, after each 7000 Remove the hexagonal cap of the vent located near km (4300 miles), re-establish the prescribed quantity of the greaser and with engine running inject grease grease in the seat of the ball bearing, flywheel magneto at intervals until it will come out from the vent hole.
Page 118: Operation
MODIFICATION No. 4) - STARTING GROUP After the alterations, notif.ed in Modification l ) , the starting group has been further improved, as illustrated in fig. 72. 1 he last solution wi 11 remarkably improve the operation of the starting device, preventing the edge contact of the gears at the beginning of mesh through a new element, which allows engagement of the first tooth of quadrant ( 12) with the starter pinion ( 3) when the latter is in neutral on...
Page 119 causing them to mesh. Then the revolving motion is trans mitted to the crankshaft. After releasing the starter pedal, a torsion spring brings both pedal and quadrant back to the start position. iv\oving in the reverse direction, the tab ( l l) passes under the cup ( 4) and disengages the starting pinion momentarily from the bevel pinion ( l ), but engagement between the two gears will be re-established at once and they will fur...
Page 120 Dwg. 51258 Dwg. 51287 Fig. 74 - How to use the tool 51258 Fig. 75 • How to use the tool 51287 Bearing removal To extract the bearing from the cap, apply the tool 51528 ing the latter should be extracted, apply the puller 51287 ( See fig.
Page 121 REASSEMBLING The remaining parts ( see fig. 72) are similar to those of previous starting group; only the quadrant rotating on bron Install the bevel pinion ( 1), with the shaft ( 2) forced into ze bushing carries the plate ( 11 ). it, in the cover ( 15), where the bronze bushes have already The rubber ring, serving as a stop for the starter quadrant, been fated, ( Look at fig.
Page 122 MODIFICATION No. 5) - FLYWHEEL MAGNETO WITH AUTOMATIC ADVANCE MECHANISM Because of the desirability of having an easier starting, sties of which are different for the two makes ( MARELLI the Lambretta 150 cc, LO and D models, have been equip and FILSO);...
Page 123 Operation with the aid of its arm keeps the cam ( 3) in the position shown in fig. 76. The automatic mechanism permits to advance the timi·ng After having reached 1200 r.p.m., the expansion weight ° ° when starting the engine and to increase it up ( l ) starts moving c,utwards, due to the centrifugal force, °...
Page 124 l__---Hl+ll flywheel magneto. Fig. Showing Filso DISMANTLING AND REINSTALLATION OF FLYWHEEL MA TIMING GNETO WITH AUTOMATIC ADVANCE MECHANISM While the timing of the flywheel magneto previously mounted has been discussed and illustrated on page 98-99 The operations required for dismantling or reassembling of this Manual, the same general principle underlies the timing of the new flywheel magneto type ( MARELLI MVB purpose are similar to those concerning the old flywheel...
Page 125 crank axle crank axle 1-f-\ I · � � � key axle key axle Fig. 79 • Timing of the FILSO flywheel magneto. Fig. 78 - Timing of the MARELLI flywheel magneto. OLDTIMERWORKSHOP.COM...
Page 126 MODIFICATION No. 6) - LAMBRETTA 150 cc. WITH PARKING LIGHTS The new electrical equipment mounted on the Lambretta lights for parking purpose. Arrangement throughout the 150 cc. includes a cell battery, which permits to utilize machine is shown in a schematic manner in fig. 80. negative pole {·) connected to earth screw Mon the battery bracket cell battery...
Page 127 the terminal plate in the head lamp ( See Wiring Diagram). The electrical equipment is supplied by means of a fly wheel magneto, which induces low tension current to the ror the lighting circuit use only the following devices and twin-filament bulb ( 6V-25/25W), incorporated in the head...
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Page 129: Battery Maintenance
TEST AND MEASUREMENTS TEST EQUIPMENT cuit wires are perfecty tightened and coated with grease, to avoid corrosion. Hand-operated tachometer If the machine is to be left standing for a long time Voltmeter for direct current 0 + 1 0V it is desirable to dismantle the battery and store it Ammeter for direct current 0 + 3A where there is no danger of the water freezing ;...
Page 130 Lead-acid Battery quid should be 1.26 ( 30 Be). A hydrometer read ing of 1.21 indicates that the battery must be charg Refer to dry battery ed immediately to avoid deterioration. Once a month, and in any case after 1500 km ( 900 If the specific gravity (density) reading is less than miles) the level of the acid in each cell should be 1 .21 that means the deterioration process is being...
Page 131 • How th e ammeter is used. Fig. 83 . ;. OLDTIMERWORKSHOP.COM...
Page 132 Burnt fuse ( parking lights fail to operate): replace Failure of magneto owing to demagnetization ( head lamp light weak) : provide for re-magnetization or rep/ acement. ELECTRIC CIRCUIT TEST By checking reverse current from battery to circuit, it is possible to detect electrical leakage.
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Page 135 INSTALLATION ALLOWANCE AND WEAR LIMITS FOR CYLINDER AND PISTON Installation allowance Wear Piston Cylinder - � - � � size Limits Dimensions Dimensions ·;;; ·;;; "' Cast "ii M. 201 Dwg. 0.004961 2,239370 max. 2,244094 2,239606 min. 0.004488 max. 0.002598 2,241732 i;';- 2,244330...
Page 136 INSTALLATION ALLOWANCE AND WEAR LIMITS FOR CYLINDER AND PISTON Piston Installation allowance Cylinder Wear - � ·! size Dimensions � \i:l � Limits Dimensions M. 201 ·.; ·.; Cast Dwg. 0.004961 2.255118 2.259842 \i:l 0.004488 2.255354 min. ,:,, max. 0.002598 2.257480 ·;;...
Page 137 INSTALLATION ALLOWANCE AND WEAR LIMITS BETWEEN GUDGEON PIN AND CONNECTING ROD LITTLE END EYE Little end Piston Allowance Wear limit bushing Operation II M. 345 Dimension Dwg. 0.000629 Normal 0.001063 11 M. 346 - 0.000433 Installation 0.629921 0.629921 0.001496 0.000629 First 0.002362 11 M.
Page 138 INSTALLATION INTERFERENCE AND WEAR LIMITS BETWEEN PISTON AND GUDGEON PIN Interference p in Gudgeon Wear Piston O p eration Clearance Limit Dwg. Normal ± 0.00118 M. 346 - 0.000433 installation 0.629921 0.629921 - 0.000118 ± 0.00118 First 0.001181 M. 347 - 0.000433 Oversizing 0.629961...
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Page 140 Jamlirella 150ld VARIATION No. WITH ELECTRIC STARTER The electrical equipment has been designed so that the Holding the green wire ( breaker plate) in the M position entire set will be fed with 12 V direct current. A flywheel on the l.t. socket, connect the two remaining blue wires magneto supplies the batteries through a rectifier.
Page 141 DO�BLE- THROW SWITCH KEY SWITCH VOLT AGE REGULATOR HATTER/ES Fig 86 OLDTIMERWORKSHOP.COM...
Page 142 ELECTRICAL SET FEATURES Table No. 1 CATALOGUE No. FEA TU RES PART NAME 00811394 Of special type for 12 V electric starter. Flywheel magneto No. 2 I .t. coils, connected in series and insulated from earth; automatic advance with rotating weights; outer h.t. coil. Performance: 12,5 V at 3000 r.p.m.
Page 143 PART NAME CAT A LOGUE No. FEATURES Bulbs: standard socket of bayonet type. 12010152 V -25/25 bilux bulb; - Main-Dipped beam bulb, tubular shape, mm ( 1,53") length. 12010153 -Pilot light 12 V - shape, ( 1,53") length. 12010154 bulb, tubular - Tail lamp...
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Page 145 Batteries Before inserting the batteries into the cavity where they NOTE: TERMINALS SHOULD BE PROTECTED WITH SPECIAL RUBBER CAPS should be housed, assemble the group as illustrated in fig. 8 Motor Ascertain if the rubber protection for the cable attach ment on the motor is suitably fitted.
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Page 147: Maintenance Operations
MAINTENANCE OPERATIONS Table No. 2 SCHEME TESTING VALUES INSTRUMENTS TEST INSPECTION > r.p.m. Tachometer engine starting. rev. number Read > 1,26 gr/cm Hydrometer Inspect batteries. ,,,,. tachometer current. Ammeter Creek battery charging 11,5 13,3 Voltmeter regulation. Ammeter Check battery charge 14,4 15,4 Rheostat...
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Page 149 terminal (-) to the earth on the frame. Next idle the engine for 5-1 O", the holding the key in « 1 » position ( lamps off) speed up until ammeter reading is 4 A. Move the rheostat slider slowly to either direction: you will notice that the ammeter indicates values of 4 A and 1 + 1,5 A;...
Page 150 :-� --------J � �!�'------ --+- ---'�'----___:_J � � -- ----!------_, • ' - -----------------, �, 11.lt-ll.JV. fig. 91 1•.•••s.,v. the terminal ( of the battery and the terminal 6) Insulation and continuity tests (-) of the instrument to the cable al ready discon a) Motor circuit and battery charging circuit partially nected from the battery.
Page 151 ;fa/�_, . , - - - � __ .i � • �� -----+-----� ��-- - --+-----____, fig. 92 the earth. A value corresponding to > 5 M Q will the cable from battery terminal ( and the centre mean that insulation is all right. To check continuity red cable from the terminal plate located under the connect the megger to the cable leading to the saddle.
Page 152 / ' Y . . ? ..� ,------------, �5MO i \�1 :· � - � � �/ ! �r--------· t • + Mn -· .---+--i :,i.. ------- ,---� · --------1 fig. 93 between earth and bulb socket to which the feed:ng b) Police plate lamp circuit and a.c.
Page 153 r--- ;i,�Mn __ _ : rr:,- --- --., :+ '..'-·--. .,' - +�- - - M n __ 1 , ____ · ·' r---------, , �-�n .. . · . _ �- n · · , , -: :� ,/-r=�=-=- ...
Page 154 /J/ '"�"'" : - - � . ,. i�'-------+------� "'----- - - ---+----- - -� !n,ul hon ,,., ��Mn CoM,nu;,, •�•• 0 1-10 Ho•n ,;.,�;, <"1-<i,n 7 : ,.·,� o,..n ,.,,,,,,,, fig. 95 b«ol,,"'°'"'' with close contact-breaker points ( the horn circuit d) Headlamp circuit (fig.
Page 155 / ' Y - � · · · ,--;{@ ··' fig. 96 · Insulation rate should be > 5 MQ. nals connected red, yellow blue cables Continuity test should be carried out by connecting ( while checking red and blue cables, operate re the instrument (-) terminal to the switch A and peatedly the double-throw switch - main and dipped C terminals respectively.
Page 156 COMBINATION-TESTER FOR CHECKING ELECTRICAL Batteries: Refer to paragraph No. 2 - page 145. EQUIPMENT After the first 500 km ( 300 miles) and then Motor: When the combination-tester for checking Lambretta after 1000 km ( 600 miles) check if the engine oil does electrical equipment is available, the various operations not penetrate into the gear chamber.
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Page 158 TROUBLES AND REPAIRS SYMPTOM POSSIBLE CAUSE C HECK REM EDY A) STARTER MOTOR Ei t h e r the motor Discharged or partially dis- Voltage at the battery terminals and distilled water only; that does not turn or it charged batteries with shorted voltage of each cell.
Page 159 REMEDY CHECK POS SIBLE CAUSE SYMPTOM replace File smooth cable terminals batteries Continuity, Cable between Terminals. them. motor broken faulty connec- Replace cable. Terminal joint cable. batteries motor. smooth battery terminal. Cable attachment motor. File from cable Cable attachment rubber protection Remove corroded...
Page 160 R E M EDY SYMPTOM POSSIBLE CAUSE CHECK Drain through plug hole. Oil penetrates from engine Check gear chamber inconvenience occur frequently crankcase into motor plug placed bottom. Should this gear cham- removing plug been removed ber. although every 1.000 monthly, check sliding...
Page 161 CHECK REMEDY SYMPTOM POS SIBLE CAUSE revolves with- (mo- Remove motor from flange Wash joint with petrol; this does Motor Defective free-wheel joint tate pinion hand. correct trouble, replace joint. cranking side). transmission engine. bronze bush- Replace bronze bushings. Motor emits a buzz.
Page 162 REMEDY SYMPTOM POSSIBLE CAUSE CHECK 1) Broken resistance. Batteries gassing and 1) Check continuity between the two re- 1 ) Replace resistance. electrolyte leakage. sistance terminals. Resistance connection wires Eliminate circuit discontinuity. Replace Check voltage regulator rating ( Oper. broken or voltage regulator out No.
Page 163 CHECK REMEDY SYMPTOM POS SIBLE CAUSE VOLTAGE GULATOR FUSE GROUP 1 ) Inspect. Replace the fuse only after locating The voltage regula 1 ) Fuse either burnt or detach the failure source ( See Paragraph «Fuse tor chatters. ed from its support. burns »...
Page 164 REMEDY SYMPTOM POSSIBL E CAUSE CHECK '.\7�$, '>-<':'' SWITCH MAIN DOUBLE- THROW SWITCH Tighten terminal Defective contacts inside whether Unsteady brightness Check trouble gets when screws. worse switch. Replace lamps switch double-throw switch, both main switch double-throw switch main SO· Remove double-throw switch...
Page 165 SYMPTOM POSSIBL E CAUSE CHECK REMEDY Incorrect bulbs ( voltage hi- Check bulbs. Replace with proper bulbs. gher than prescribed). G) HORN l ) True contacts; replace earthing cable if With engine at rest Batteries are disconnected. Check both terminal clamping at bat perished.
Page 166: Tool List
TOOL LIST OLDTIMERWORKSHOP.COM...
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Page 168: Standard Tools
This list comprises the standard tools used at our works. They can be obtained from any accessory or tool stores. Reference is made to the ABC Catalogue (known all over the world) in order to facilitate the purchase of the tools. Innocenti NAME Ref.
Page 169 Innocenti NAME Ref. Standard ABC/3054 Wrench with bent handle, 24 mm ( 0. 945") 2032/24 ABC/3060 « T » wrench with sliding handle, l 0 mm ( 0.394") 2039/10 ABC/3264 Seeger ring pi iers with straight points, length 190 mm ( 7.480")
Page 170: Special Tools
2) SPECIAL TOOLS This list comprises special tools and devices used at our works. Their use will be found useful too by the Service Stations. NAME ° Dwg. N 35603 Wrench, wheel nut campling ( page 51) 37058 Puller, flywheel magneto cover ( page 44) 37061 Remover, rear wheel (page 51) 37101...
Page 171 NAME ° Dwg. N 38935 Replacer, clutch bearing ( page 81 ) 39127 Punch, needle bush installing 39146 Puller, clutch bell 39406 Puller, crankshaft bearings ( page 60) 39982 Puller, frame top ball cup dismantling ( page 64) 40295 Wrench, starter spring charging 40482 Wrench, steering adjuster cup ( page 63) 40490...
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Page 173 NAME ° Dwg. N 49123 Wrench, tank ring mounting (with saddle) 49131 Wrench, crankshaft rotation 49188 Puller, flywheel magneto flange ( page 44) 49189 Puller for crankshaft pinion ( page 60) Pliers, piston installing (11 M-322) 49194 Wrench, cylinder head locking nut 49195 49199 Puller, gudgeon pin ( page 58-82)
Page 174 INDEX OLDTIMERWORKSHOP.COM...
Page 175 OLDTIMERWORKSHOP.COM...
Page 176 Crankshaft and connecting rod big end . pag. Front fork reinstallation . pag. Steering and handlebar reinstallation pag. Connecting rod big end and crankshaft throw . pag. Reinstallation and adjustment qf gearbox pag. Clutch reinstallation pag. REINSTALLATION K.S. reinstallation pag. Preliminary instructions pag.
Page 177 ( INNOCENTI PRINTED IN ITALV STAB. POL, G, COLOMB: S.P.A, - MILANO OLDTIMERWORKSHOP.COM...
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