Innocenti Lambretta 150 d Instructions For Repair Shops Download Page 1

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Jamlirella

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Summary of Contents for Lambretta 150 d

Page 1: ...Jamlirella OLDTIMERWORKSHOP COM...

Page 2: ...Jamlirella 150d ld INSTRUCTIONS FOR REPAIR SHOPS IINNOCENTI OLDTIMERWORKSHOP COM...

Page 3: ...____ __ OLDTIMERWORKSHOP COM...

Page 4: ...f their most important elements The sections following ex plain how the vehicle is dismantled and then reassembled Wear limits of the various parts are outlined and the Service Stations helped through...

Page 5: ...OLDTIMERWORKSHOP COM...

Page 6: ...MARY Main features pag 9 Description pag 19 Dismantling pag 41 Wear limits pag 67 ReinstaIlation pag 75 Troubles and repairs pag 107 Variations pag 113 Tool list pag 165 Index pag 173 OLDTIMERWORKSHOP...

Page 7: ...absorber Tail light Number plate carrier Gear indicator Clutch lever Gear control twistgrip Speed change connecting casing Fig 1 IRear brake pedal K S pedal Light switch with ground and horn button Th...

Page 8: ...ail light Number plate carrier Side Fuel tap Gear indicator Clutch Gear control Silencer Fig 2 brake pedal pedal Light switch with ground and horn button Throttle Headlight 7 ____________________ OLDT...

Page 9: ...OLDTIMERWORKSHOP COM...

Page 10: ...MAIN FEATURES OLDTIMERWORKSHOP COM...

Page 11: ...DER ENGINE Capacity Bore Stroke Compression ratio Hp output max rpm 148 c c 2 244 2 283 6 5 6 4750 Cylinder of high quality wear resistant cast iron Cylinder head of light alloy die cast Cast piston o...

Page 12: ...32 fig 6 TANK Fuel capacity 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 3 way tap FRAME for Model D see fig 12 for Model LD see fig 13 C c...

Page 13: ...he right handlebar of lever type the lever serves to earth the engine as well Horn push button coupled with the switch If an illuminated speedometer is fitted the 6 V 1 5 W bulb 12 socket is to be der...

Page 14: ...LU 0 0 Ill X C Q 0 C l 3 Cl t CS ELECTRICAL SYSTEM OPERATION DIAGRAM __t1_ C __ Q_ __1_ Cl q Cl I __ 1_ l l_ I i l JC 1 1 Cl t Q I a J c i 0 J 0 f 0 O t l Fig 3 M 0 1 2 3 Engine stop earthing Off Pilo...

Page 15: ...ELECTRICAL SYSTEM DIAGRAM I Fig 4 14 OLDTIMERWORKSHOP COM...

Page 16: ...LUBRICATION OLDTIMERWORKSHOP COM...

Page 17: ...with 6 oil After 900 miles 1500 km Check level and refill to level Every 900 miles 1500 km BP Energol Motor Oil SAE 30 mark in Summer months and hot regions BP Energol Motor Oil After 300 miles then D...

Page 18: ...P E111r9 l3 Fig 5 For points marked with two typ es of lubricant si e table page 16 BP Energ 11 Al BP Eneraol M O SAE30 BP Energreeae L3 BP Energre L3 BP EM gru A1 BP Energ st A1 BP Energol M O SAE 17...

Page 19: ...F OLDTIMERWORKSHOP COM...

Page 20: ...DESCRIPTION OLDTIMERWORKSHOP COM...

Page 21: ...ngs 4 pressed or cast piston of light alloy cylinder 2 of special cast iron and die cast cylinder head 3 of light alloy 20 KICK STARTER As shown in the diagram the starting device consists of a bevel...

Page 22: ...p gear The second gear pinion on the rriain shaft 24 sliding further backward in the splines 20 engages its dogs with the tooth spaces of the neutral gear on main shaft 22 so that the engine is put in...

Page 23: ...22 GENERAL DIAGRAM REGARDING ENGINE GEAR SHIFTING AND TRANSMISSION OPERATION Fig 6 OLDTIMERWORKSHOP COM...

Page 24: ...end Needle Rollers 23 Neutral Gear on Secondary Shaft S3 Crankshaft 24 Second Gear on Main Shaft 9 Spark Plug 25 Second Gear on Secondary Shaft 10 Crankshaft Bevel Pinion 26 Keyed Gear on Main Shaft 1...

Page 25: ...e should be taken that the gears mesh exactly after dismantling and replacement of such gears always recheck interposition of the different washers and spacers fig 59 24 The light alloy rear wheel hub...

Page 26: ...pin of the former locking is ensured through one screw The levers and the push blocks are enclosed within grease tight casings 2 of malleable cast iron welded to the fork tubes and provided with bron...

Page 27: ...4 Swinging is ensured through the silentblocks 2 fitted in the crankcase extension holes The tie rod of the torsion bar 9 is fitted on the two extensions carrying a bore fig 10 The torsion bar is encl...

Page 28: ...h 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 l...

Page 29: ...old In the D mo Fig 12 D Model lever AV Position Starting M Position Running 28 Fig 13 LD Model Button AV Position Starting M Position Running del the starter is controlled by a lever fitted at the to...

Page 30: ...and running If carburettor is flooded look for following causes foreign matter in petrol interferring between float nee dle and float chamber bottom with consequent leakage Clean carburettor thorough...

Page 31: ...ottle valve Ascertain if throttle valve is in good condition and in ca se of lack of tightness which could determine incorrect idling replace with a new genuine part marked 75 30 Main jet Check for pr...

Page 32: ...OF DELL ORTO CARBURETTOR MA 19 B 4 TYPE N 75 D 3 at the second groove 255 B 11 30 i Main jet Needle jet Starter jet PETQOJL INLET TO CYLINDER Fig 14 A detailed drawing showing the carburettor operatio...

Page 33: ...lded which constitutes one of the electrodes earth electrode The spark jumps between the two electrodes The body is screwed to the cylinder the insulator b fitted to the sheI I a at the centre the sec...

Page 34: ...per formance has to remain within exactly specified li mits The lower limit is established by a temperature range of approx 500 C 930 F ensuring that carbon and oil sediment can be turned and elimina...

Page 35: ...d 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...

Page 36: ...m and the ignition after transforming the alternating current to direct current by means of the separate coil B 20 A the contact breaker consisting of the breaker arm 5 carrying the adjustable contact...

Page 37: ...l cam is clean and coated with grease so that the breaker arm does not become worn If necessary wipe the cam with a clean rag adding some oil to the lubricating felt The breaker arm must slide freely...

Page 38: ...voltage current which is transformed by the ignition coil B 20 A to high voltage current provides the desired spark once every revolution of the en gine at the points of the spark plug 2 the low volta...

Page 39: ...0 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 S...

Page 40: ...Contact pressure Electrical test H T 6000 0 4 0 05 mm 0 0158 0 00197 850 50 gr 1 90 0 110 lbs Min with standard 3 electrode spark meter opening 5 mm 0 197 170 200 revolutions lighting generator short...

Page 41: ...____ ___________ OLDTIMERWORKSHOP COM...

Page 42: ...1 DISMANTLING OLDTIMERWORKSHOP COM...

Page 43: ...to be sure to return them to their proper places assemble screws and their nuts and put all parts belonging to the same mo 42 tor scooter in a case or separate place in order to avoid mixing them up w...

Page 44: ...the cylinder is to re move the spark plug next detach the high voltage ca ble close the petrol tap and remove the carburettor after slackening the fixing screw finally take out the baffle plate To de...

Page 45: ...Next unscrew the lock nut Use the puller 37058 tc free the rotor from the crankpin Disconnect the cables from the terminal After dismantling care should be taken to reinsert each screw in its hole Re...

Page 46: ...he flywheel stator J 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 o...

Page 47: ...engine bevel gears and to drive out the clutch bearing but for partial overhauling of above groups first operate the pedal return spring fitted with three turns pre loading and fixed to the locking s...

Page 48: ...shing loosen the 5 s2rews fixing the cover to the crankcase using the spanner 37380 slacken the two locking screws and detach the outer cable control support from the cover vers inner and outer it is...

Page 49: ...the second group still under compression If further dismantling of this group for repairing purpose is not necessary do not remove the puller as reinstalling of the group will be easier 48 Fig 33 Clut...

Page 50: ...pply the bell puller by engaging its six teeth in the groo ves of the disc retaining ring then operate the puller screw sliding the bell off from the clutch control gear see fig 34 Loosen the three sc...

Page 51: ...the gear change selector casing Remove th_ c ing cover by loosening the three bolts Loosen the two cable adjusters remove th_e Seeger ring and slide off the lever from the pin fig 36 Detach the casing...

Page 52: ...the puller 3706l and pull the hub out of the shaft Remove the key located on the wheel axle to avoid dropping or losing it To remove the transmission and rear suspension assembly it is not necessary...

Page 53: ...he 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 38 To re move the tyres from the front and rea...

Page 54: ...screws Place a bowl under the crankcase connecting line to re collect oil Now we can start dismantling the transmission group first remove the bolt aligning the crankcase and the trans mission case T...

Page 55: ...control lever and the greaser and ex tract the pivot by striking with a suitable punch Remove the washer locking the cam bushing nut and unscrew the latter Insert into the bushing hole the threaded pu...

Page 56: ...eel hub momentarily Strike with punch the axle end to free the bearings Du ring this operation we recommend to place between the punch and the part a soft material spacer aluminium or lead to avoid da...

Page 57: ...tion and grip the part then lower the support again 56 Fit the washer at the transmission case end and operate the handle to remove the group from its seat Drive the spacers out and dismantle the pini...

Page 58: ...the pinion instead of the puller 42589 fig 42 Extract the needle carrying bushing on the main shaft ope rating from the transmission case engine side fig 43 Take care before starting this operation t...

Page 59: ...free the gudgeon pin from the Seeger ring and then using the tool 49199 pull the pin out 58 Fig 45 How to remove the lock nut of the bevel pinion Straighten the tabs of the washer placed under the be...

Page 60: ...Detail 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 c...

Page 61: ...emoval of the roller bearing To extract the bearing from the crankshaft apply the pul ler 39406 fig 49 Insert the threaded pin flywheel magneto side in the way that the tool supporting plate perfectly...

Page 62: ...BAR AND HOUSING LEVER BUSHING REMOVAL _J Fig 50 Showing how to dismantle the torsion bar Dwg 43303 Fig 51 Detailed drawing showing how to extract the bushing of the torsion bar lever 61 OLDTIMERWORKS...

Page 63: ...ends remove the Seeger rings and the washer located on the K S side striking the torsion bar with a mallet until it is taken out Insert as shown in fig 51 the tool 43303 driving it into the housing t...

Page 64: ...ng the gearbox control cable and the other cables on the handlebar Fig 53 Removal of the steering upper bearing threaded ring Apply the wrench 40482 to the steering adjusting balI cup and the wrench 4...

Page 65: ...l_ Fig 54 Front fork dismantling 64 i I _ Fig 55 Detailed drawing showing how to extract the bearing upper cup using the tool 39982 OLDTIMERWORKSHOP COM...

Page 66: ...ng lower bearing upper cup Apply the puller 39982 inserting it under the outer cup and operating the pressure screw lock the clip against the steering Rotate the puller lever until the cup is with dra...

Page 67: ...ocks and springs out If it is not possible to extract them by hand owing to seizing of the inner lever pins in the bronze bushing we recommend the use of the tool shown in the fig 55 oper ate as follo...

Page 68: ...WEAR LIMITS OLDTIMERWORKSHOP COM...

Page 69: ...us it will be easy to determine defects caused either by 68 poor lubrication and maintenance or improper use of the machine and normal deterioration We have reported in the following charts the data r...

Page 70: ...20 Grind to 0 000748 0 2 2600 Grind to 0 000748 0 2 2677 C i 0 c 95 A B JA P B 95 A 9 J B 95 A 9 J B Pist o n Inst allation allowa nce Dimensions C Dimensions i Cast in 0 Dwg in c o max 0 005866 0 000...

Page 71: ...tion A Clearance limit 0 B C in Dwg in in in Normal 0 000236 o 0 000472 11 M 323 0 000433 Installation 0 551181 0 551181 0 000236 o First 0 000472 11 M 332 0 000433 0 000472 Pin oversizing 0 555118 0...

Page 72: ...10 0 001653 0 003346 111 0 080118 o 0 078748 111 0 002913 0 001378 INSTALLATION ALLOWANCE AND WEAR LIMITS FOR RING END GAP AND RING DIAMETER Part N 11 M 324 11 M 334 11 M 335 11 M 336 Outer ring diame...

Page 73: ...e Wear limit Operation 11 M 1041 0 A Dwg Dimension C in in in in Normal 0 000629 o 0 001063 11 M 323 0 000433 installation 0 551181 0 551181 0 001496 First 0 000629 o 0 002362 0 001063 11 M 332 0 0004...

Page 74: ...G END AND CRANKSHAFT THROW Connecting Crankshaft Needles rod big end throw 2 M 303 Allowance Wear 11 M 1041 11 M 304 G limit E F in in in in in 0 000512 0 000787 o 0 000787 0 003150 0 0 001299 0 00019...

Page 75: ...ETWEEN CRANKSHAFT AND CONNECTING ROD BIG END Connecting rod Crankarm Side Crankshaft big end throw width 11 M 1041 width clearance in in in A B C 0 005822 0 001260 0 0 002952 0 004409 0 551181 0 53937...

Page 76: ...REINSTALLATION OLDTIMERWORKSHOP COM...

Page 77: ...ed during removal Inspect every part carefully Compare the size of the most important parts with the tabulated Wear Limits Che ck wear conditions of bearings gaskets and seals and replace if necessary...

Page 78: ...e crankcase are perfectly clean and not sized or badly marked by loose outer bea ring rings Press the bearings evenly in their seats and check for exact alignment Keep the bearings carefully free from...

Page 79: ...wn in the fig 58 For installing the silentblocks we recommend the use of a bench press do not forget to place a proper washer between the press and the silentblock in order to get the compression forc...

Page 80: ...wheel side with a proper wrench This operation must be performed accurately using stan dardized wrenches REINSTALLATION OF THE CRANKSHAFT AND CLUTCH BEVEL GEARS ADJUSTING Drive the crankshaft into the...

Page 81: ...ore than 5 100 mm 0 00 l 97 80 Backlash mm 0 12 0 16 0 0047 0 0063 I I Fig 59 Coupling diagram for the crankshaft and clutch control bevel gears If a suitable clock indicator is not available use a sc...

Page 82: ...seized Insert the main shaft from crankcase side and the hub with the clutch bevel gear already mounted from clutch side add a proper spacer and then drive and position the ball bearing using the pun...

Page 83: ...t main shaft end Insert the slotted drum on the main shaft cou pling and slightly tap with a leather mallet make sure it is exactly positioned Apply the clamping wrench 37101 engaging its two levers i...

Page 84: ...m Turn the crankshaft further until piston is a the bot tom and install the cylinder To make sure the piston rings are correctly fitted turn the engine if no installation defects or performance troubl...

Page 85: ...evious service Install the brake return pivot last The bevel pinion group must be prepared as follows Insert the retaining gasket into the sleeve so that its edge faces the gearbox To this p rpose use...

Page 86: ...bearing locking flange fixing it with four nuts and plain split washers Replace the rear wheel transmission axle and then mount the sleeve and the second bearing engage the bevel gear crown with the a...

Page 87: ...on case on the proper f1tting de vice 42507 see f1g 61 Fit the device so that transmission case end is up and insert in the pinion seat a suitable spacer The spacer thick ness has been selected at our...

Page 88: ...earings 42291 and one sleeve 43281 and then insert the washer and the rear wheel supporting flange See fig 63 After checking dismantle the rear wheel flange group and drive the bevel pinion retaining...

Page 89: ...gear coupling diagram mission case cover and the speedometer fitting cover pla ce the gaskets and fix the covers with the proper screws 88 Pour through the filler 100 gr lbs MOBI LUBE GX 140 oil See...

Page 90: ...on the countershaft Prepare the neutral gear on second ary shaft place and hold in with grease the 24 needle rollers Engage the torsion bar with the rear bevel pinion on the transmission rear suspensi...

Page 91: ...y engage operate the eccen tric pin of the selector lever To this end some holes have 90 been machined on the flange Slacken the hexagon hedd screws and tighten them after positioning the lever During...

Page 92: ...ver and shackle holes the greaser fitting must be on the bar outer side Place the Seeger ring into the connecting pin At the op posite side locate safety washer and Seeger ring Drive the rubber cap in...

Page 93: ...proper punch insert the shackle connecting pin slightly strike the punch pick up the spacer expelled by the pin and fix the safety ring and Seeger ring Locate the shim at the bar ends fixing it by me...

Page 94: ...e boxes and the inner lever pins Replace the bush ings if necessary Perform the same operation for the i ___ __J Fig 66 Reinstallation of the trailing links bushings placed in the covers coupling them...

Page 95: ...the rocker arm use a proper clamp See fig 66 Never try to press the lever with the aid of a punch which should damage the bronze bushing Insert the rubber block into the plug se _t locate the pack ing...

Page 96: ...screws and plain and split washers Next check if the gear indicator is still in neutral if any displacement is noticed try adjusting the cables to do this actuate the adjuster placed near the gear se...

Page 97: ...nut until the tool is compressed against the spring bearing disc and the springs therein contained are entirely compressed then force the 96 disc retaining ring into the bell groove Make sure the ins...

Page 98: ...nto the pinion cavity teeth side Reverse the group engage the starter clutch pinion and fasten it with washer and stopping ring to be forced into the pin cavity Insert the entire group in the crankcas...

Page 99: ...our motor scooters Inspect the contact breaker points Make sure the contact urface is smooth and clean If the points are pitted you can truing them with a special contact point file Check and adjust t...

Page 100: ...a corresponding advance angle of 24 and 26 respectively In the case that the readings are different timing must be corrected as follows slacken the screws fixing the stator plate care must be taken no...

Page 101: ...se in axial twistgrip play Eliminate this trouble by insert ing shims between the twistgrip end and the sleeves In refitting install the slides exactly in the same position 100 as before to avoid a ne...

Page 102: ...TROUBLES AND REPAIRS OLDTIMERWORKSHOP COM...

Page 103: ...t properly adjusted b Ignition Incorrect timing Improper heat range of the spark plug electrodes dirty Gap clearance wrong correct 0 0l 97 Poor insulation of H T coil Cable or wire earthed Breaker poi...

Page 104: ...ons terminal cables Defective condenser Magneto stator defective INCORRECT IGNITION REMEDY Clean Adjust according to given data Adjust so that point surfaces match exactly Adjust or replace spring che...

Page 105: ...arm locked on its pin Defective condenser Magneto stator discharged or shortcircuited Disconnected cables 104 REMEDY Adjust in accordance with tabulated data Adjust or replace spring check pressure re...

Page 106: ...tator short circuited or grounded Poor connections REMEDY Replace stator Inspect connections terminals clamping screws etc LIGHT GENERATOR DOES NOT OPERATE CAUSE REMEDY Generator stator disconnected s...

Page 107: ...cur because spark plug has be come loose in its seat incorrect spark timing mixture too lean and inner plug gasket burned Plug is too cold Engine does not fire as electrodes are short circuited 106 Pl...

Page 108: ...copper gasket between them and make sure the plug is drawn up tight Loose spark plug may cause poor compression of the engine defective heat con duction with consequent burning of the gasket and in a...

Page 109: ...rrectly Atomizer hole partly clogged Float is leaking and does not maintain proper level Float needle does not move freely Mixture too rich 108 REMEDY Inspect filter and if clogged clean with a brush...

Page 110: ...the crankcase Here are reported clutch troubles their most likely causes and the remedies to be adopted CLUTCH SLIPPING CAUSE Clutch control cable too long with respect to the outer cable and conseque...

Page 111: ...uated between the latter and the transmission case We recommend this operation sequence dismantle the rear wheel with the drum remove brake shoes and their pin and also the lock nut of the brake shoe...

Page 112: ...ng or withdrawing the pinion to or from the crown Reinstall following the equence indicated in Reinstallation and check if couplings are correct See fig 63 If the trouble does not depend on the rear b...

Page 113: ...OLDTIMERWORKSHOP COM...

Page 114: ...Jamlirella 150d ld INSTRUCTIONS FOR REPAIR SHOPS MODIFICATIONS IINNOCENTI I OLDTIMERWORKSHOP COM...

Page 115: ...ocked by means of two fixing screws prevents any axial movement of the group The k s gear 7 rotates on the central pin 2 and its engagement with the bevel pinion l provided with special dogs is ensure...

Page 116: ...mit fitting the spring which provides for constant engagement between the k s gear and the bevel pinion See fig 71 The cover carries the same curved surface portion like the design of Modification 1 F...

Page 117: ...th engine running inject grease at intervals until it will come out from the vent hole Use a common pressure gun Screw the vent cap in and inject further about 2 3 g grease MODIFICATION No 3 REMOVAL O...

Page 118: ...As the starting pedal is actuated the quadrant 12 starts rotating but before engaging the pinion 3 the tab of the plate 11 connected to the quadrant presses against the cup 4 and overcoming the press...

Page 119: ...starter pinion 3 over comes the pressure of the spring 5 and passes over shift ing the cup only In such a manner the reversal motion of the quadrant is ensured After the tab has passed over the cup r...

Page 120: ...he cap edge to facilitate the bearing to be freed In the case that the pin is forced into the bearing and assum Dwg 51287 Fig 75 How to use the tool 51287 ing the latter should be extracted apply the...

Page 121: ...screws 120 The remaining parts see fig 72 are similar to those of the previous starting group only the quadrant rotating on bron ze bushing carries the plate 11 The rubber ring serving as a stop for...

Page 122: ...he two makes MARELLI and FILSO therefore part are not interchangeable al though operation is quite similar MARELLI FLYWHEEL MAGNETO MVB 4 C The new model merely differs from the early design il lustra...

Page 123: ...ming the resistance of spring 2 causes the cam 3 to rotate rotation will be limited by the stop ping pin 4 on which rests the left side of the cavity of cam 3 The variation of the cam angle is 18 FILS...

Page 124: ...lywheel magneto and they have already been described on page 44 and 82 respectively TIMING While the timing of the flywheel magneto previously mounted has been discussed and illustrated on page 98 99...

Page 125: ...crank axle crank axle i key axle 1 f I key axle 124 Fig 78 Timing of the MARELLI flywheel magneto Fig 79 Timing of the FILSO flywheel magneto OLDTIMERWORKSHOP COM...

Page 126: ...king purpose Arrangement throughout the rectifier and fuse machine is shown in a schematic manner in fig 80 negative pole connected to earth screw Mon the battery bracket cell battery o 1 __ Fig 80 A...

Page 127: ...h handlebar the switch lever serves as well to earth the engine Position M on the switch The switch is coupled with the horn button still operated by alternating current If a speedometer of illuminate...

Page 128: ...Dipped beam Main beam Pilot or parking light lighting switch pilot or parking bulb r fD speedometer bulb headlamp Twin filament bulb horn H T coil spark plug I r _se 11 I r rectifier l tail lamp flyw...

Page 129: ...machine is to be left standing for a long time it is desirable to dismantle the battery and store it where there is no danger of the water freezing further the battery should be given a refreshing cha...

Page 130: ...Station When charging has been completed shacke the bat tery vigorously to facilitate escaping of the gas from the battery cells and finally get the level to the pre scribed height For the first batt...

Page 131: ...130 __ _j Fig 83 How the ammeter is used OLDTIMERWORKSHOP COM...

Page 132: ...more than 3 mA battery positive to milliammeter positive milliammeter negative to cir cuit cable Reading should be effected with the lighting switch lever in position O lights off If the reading is m...

Page 133: ...head light Should it occur for any cause that the battery does not deliver current the parking lights will fail to operate when the machine is at standstill but pilot bulb and tail lamp will function...

Page 134: ...VARIATION N 7 WEAR LIMITS OLDTIMERWORKSHOP COM...

Page 135: ...2 251882 0 B 2 242519 2 247244 2 251968 0 A 0 a I 2 247480 E i 2 249606 2 252200 0 B 2 249842 2 247520 0 2 252204 0 A u a 0 11 M 1022 2 247756 E II 2 249882 C 2 252480 0 B 2 250118 2 247795 0 0 2 2525...

Page 136: ...2 257755 max 0 002598 2 260354 i l B E 2 257991 min 0 002125 2 255668 max 0 004961 2 260394 D 0 i l A D 2 255904 min 0 004488 E 0 002598 2 258031 max 2 260630 i l B E 2 258267 min 0 002125 2 262992 ma...

Page 137: ...nce Wear limit Operation II M 345 Dimension C 0 A Dwg in in in Normal 0 000629 0 0 001063 11 M 346 0 000433 Installation 0 629921 0 629921 0 001496 First 0 000629 0 0 001063 11 M 347 0 000433 0 002362...

Page 138: ...Operation Piston 13 B Clearance Limit in Dwg in c in in Normal 0 00118 0 11 M 346 0 000433 installation 0 629921 0 629921 0 000118 First pin 0 00118 o 11 M 347 0 000433 0 001181 Oversizing 0 629961 0...

Page 139: ...OLDTIMERWORKSHOP COM...

Page 140: ...timing in the same way as it is being performed in the Lambretta scooter without electric starter that is the spark should occur at 25 1 before top dead center having the rotating weights fully open H...

Page 141: ...DO BLE THROW SWITCH KEY SWITCH VOLTAGE REGULATOR HATTER ES Fig 86 140 OLDTIMERWORKSHOP COM...

Page 142: ...full wave bridge connection Max operating voltage 20 V a c 5 A max current Output 63 approx Reverse current with 12 V d c voltage 5 mA Provided with current coil and voltage coil voltage coil input 0...

Page 143: ...lar shape 39 mm 1 53 length 12 V 3 w bulb tubular shape 39 mm 1 53 length 12 V 1 5 W bulb suitable to speedometer socket 12 V 5 w bulb tubular shape 39 mm 1 53 The same reference number tight chamber...

Page 144: ...ad famp n tado b 1h o h IV Pa hnq l 9h on l_ _______________6ROWN r L t d J B 1 Flywheel magneto 2 Rectifier 3 Voltage regulator 4 Fuse 5 Cell batteries 6 Starter motor 7 Main switch 8 Double throw sw...

Page 145: ...nd the stroke end stop 2 3 mm 0 039 0 078 Adjust by means of the knurled nut on the outer cable and lock the counternut after adjustment Ignition coil The coil maker states which terminal of the main...

Page 146: ...ting device for 5 this done take the reading which should be over 380 r p h 2 Checking batteries a Ascertain whether liquid level is 5 10 mm 0 19 0 39 above the plate tops Add distilled water if neces...

Page 147: ...ammeter Insulation and continuity tests a Starter motor circuit and partial battery charging circuit Megger or Insulation tester b Tail lamp circuit and a c supply to rectifier See above c High tensio...

Page 148: ...cuit and link nega tive pole to earth in the frame Faulty con nections will short batteries resulting in burnt fuse Make sure that ba ery terminals are properly tighte ned and coated with grease in or...

Page 149: ...e re gulator are as follows a change over from 4 A to the minimum current rate 14 4 15 4 V b change over from minimum current rate to 4 A 11 5 13 3 V This test requires a fully charged battery 5 Check...

Page 150: ...nt to the cable already discon nected from the battery Reading should indicate a max value of 5 mA r r 1 1 11 lt ll JV 1 s v 6 Insulation and continuity tests a Motor circuit and battery charging circ...

Page 151: ...er or the insulation tester between the cable to the battery terminal and fig 92 the earth A value corresponding to 5 M Q will mean that insulation is all right To check continuity connect the megger...

Page 152: ...the eventual speedometer bulb and holding the switch key in l position check insulation rate 5MO i 1 Mn r t1 l between earth and bulb socket to which the feed ng wire is connected and between earth an...

Page 153: ...oltage regulator terminal next with the key 152 r i Mn___ rr i Mn __1 ____J n r r _ n T q _ 1 1 I I J I I i fig 94 in 0 position measure insulation between grey cable and earth Insulation rate should...

Page 154: ...d by opening the contact breaker points and depressing the horn button Ho n 1 i n7 o n b ol n ulahon Mn CoM nu 0 1 10 d Headlamp circuit fig 96 Remove bulbs from their sockets in the headlamp and with...

Page 155: ...red and blue cables operate re peatedly the double throw switch main and dipped beam fig 96 Insulation rate should be 5 MQ Continuity test should be carried out by connecting the instrument terminal...

Page 156: ...PINION OND CLUTCH BELL TEETH Batteries Refer to paragraph No 2 page 145 Motor After the first 500 km 300 miles and then after 1000 km 600 miles check if the engine oil does not penetrate into the gear...

Page 157: ...I 1 l I I OLDTIMERWORKSHOP COM...

Page 158: ...rge if necessary Oper No 2 tainers indicates the exact level Test specific gravity in each cell In any case check if insufficient charge is caused by troubles in the machine electric circuit see parag...

Page 159: ...may be insufficient or 5 Adjust control cable stroke by operat close the circuit switch control cable jammed ing the knurled nut Oil the cable Check contacts for corrosion True contacts or replace the...

Page 160: ...to Ascertain if failure depends upon seized mechanical failure piston rotor rubbing on the stator etc Motor operates cor 1 Incorrect ignition 1 Check spark after removing spark 1 Replace damaged comp...

Page 161: ...ce the motor of either shocks or oxidation B BATTERIES Batteries do not 1 Parking of vehicle with main 1 With closed contact breaker points keep charge switch key in I II or Ill posi batteries supply...

Page 162: ...after elimina ting the cause of the inconvenience See Paragraph Fuse burns charge 2 Battery feeding circuit is 2 Check circuit continuity Oper No 2 Eliminate circuit discontinuity open 6 a 3 Poor eart...

Page 163: ...g discharge intensity exceeding 8 A 2 Short circuit when fitting the cover to the voltage regulator terminal plate Flashings occur into the fier recti 1 After disconnecting the batteries re place the...

Page 164: ...e is burnt 2 Examine 2 Replace the fuse only after eliminating of the bulbs varies according engine the trouble source to revolutions 3 Circuit is open 3 Check circuit continuity Oper No 6a 3 Eliminat...

Page 165: ...l True contacts replace earthing cable if perished 2 Replace fuse only after eliminating the trouble source 3 Eliminate circuit burnout l Eliminate circuit burnout 2 Check earthing of double throw sw...

Page 166: ...TOOL LIST OLDTIMERWORKSHOP COM...

Page 167: ...I L OLDTIMERWORKSHOP COM...

Page 168: ...74 Screwriver length 11 811 Screwdriver electrician length 7 874 Hexagon wrench 8 mm 0 315 Hexagon wrench 24 mm 0 945 Hexagon wrench 19 mm 0 748 Hexagon double wrench 20 22 mm Hexagon double wrench 14...

Page 169: ...with bent points length 190 mm 7 480 Seeger ring pliers with straight points length 190 mm 6 299 Universal pliers with knurled handles Steel hammer 0 66 lb Steel hammer 0 88 lb Aluminium hammer 0 66 I...

Page 170: ...37337 37380 38131 38489 NAME Wrench wheel nut campling page 51 Puller flywheel magneto cover page 44 Remover rear wheel page 51 Wrench clutch drum locking page 48 82 Wrench 19 mm 0 748 crankshaft nut...

Page 171: ...ing charging Wrench steering adjuster cup page 63 Wrench steering adjuster threaded ring page 63 Wrench clutch cover fixing screws Screwdriver screws 2F 157 Puller steering adjuster ball seat page 65...

Page 172: ...hing mounting page 84 Punch gasket and Seeger ring for rear wheel bearing installing Wrench crankcase and transmisston case screws Puller torsion bar lever bushing page 61 62 Punch bevel pinion gasket...

Page 173: ...2 Puller main shaft bearing removal from crankcase page 60 Lock wrench for slackening the pinion nut tightening page 44 82 Crankarm locking wrench for bevel pinion nut tightening page 59 79 Wrench exh...

Page 174: ...INDEX OLDTIMERWORKSHOP COM...

Page 175: ...22 pag 25 pag pag pag pag 28 32 34 38 DISMANTLING ngine dismantling pag 43 Flywheel magneto removal pag 44 Removal of K S case pag 46 Clutch removal pag 47 Removal of the gear change selector casing p...

Page 176: ...el magneto pag 82 Cylinder and cylinder head replacement pag 83 Rear bevel gear reinstallation Gearbox reinstallation and connection of trans mission group to crankase Rear suspension reinstallation p...

Page 177: ...INNOCENTI I PRINTED IN ITALV STAB POL G COLOMB S P A MILANO OLDTIMERWORKSHOP COM...

Page 178: ...1N 300N 11 OLDTIMERWORKSHOP COM...

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Innocenti Lambretta 150 d, Instructions For Repair Shops

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Summary of Contents for Lambretta 150 d

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