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" - " .-- • , BRITISH • OWNER ' S HANDBOOK • I CONTENTS Page ' Alphabetical index - 4-5 Introduction 6 Technical data 7-9 Instrumentation and Control layout 10-11 Registration for police and customs authorities, data for filling stations and workshops - 12 Controls and running-in instructions 12-16 Care of coachwork - 16-17 T echnicaJ. mainrt:enance - 18-28 M:inor inspecltiions and adjustments - 29-35 Maintenance survey 35-36 Maintenance chart - Pull out PRINTED IN GREAT BRITAIN 3 Figure Page Figure Page INDEX 22 ALPHAB~~[ICAL 19 36R Tool kit 16 Pedal shaft 19 35.,, Polishing 17 25/26 Torque arm '!-.¥$;, Track (tread) front 8 Rear wheels 8 Track (tread) rear 8 Reflectors 27 Transmission 7 Road performance 8/9 Transmission oil change 18 3t: 30 59 8 Page Figure Page Figure Rocker arm Tyres --;: 30 60 23 4,0'' Adjuster plate, chain 33 70 Feeler gauge 30 58 Rocker-box cover-gasket Tyre pressure 14 23 41 Adjuster bolt, brake 34 76 Fill-up data 9 Running-in Tyre wear Running-in speeds 14 Air cleaner ;24 42/43 Float chamber 32 69 Universal joint, steering 19 '~6L Axle construction 8 Folding hood front rail 15 16 Seat adjustment 13 13 Front wheel bearings 24 44 29 Valves 29/31 58/61 Battery maintenance ·22/23 38/39 Seat removal 17 Fuel consumption 8, 15/16 29 54/56 Valve adjustment 29/31 58/61 Blower wheel 30/31 Sparking plugs 59 Fuel line control tap 13 6 9, 14 Valve adjusting screw 29/31 Bore 7 Speed limits 59 Fuel tank 9, 12 4 7 Valve checking 29/30 Brakes 8, 33/34 74/76 Starter 58/59 Fuses 25/26 47 13 7 Valve clearance 29 Brake adjustment 34 75/76 Starter choke lever 59 13 7 Valve stem 30 Brake drum 33/34 Gear changing 13 8 Starter switch 14/15 13 7 Ventilation 14/15 Brake fluid 34 74 Gear lever 13 8 Starting 32 67 8 Volume control screw Brake master cylinder 34 74 Greasing 19 33/37 Steering 19 Brake pedal 34 Steering lubrication Washing 16/17 23/28 Headlamps 26 48/49 28 52 Brake shoes 34 75/76 Stop-tail lamps Weight 8 Height, overall 8 Stroke 7 8 Canvas hood 15 16 Wheelbase Horn 27 Suspension 8 15 17/21 Canvas hood maintenance 17 27 Wheel changing Swing arm 19 15 18 Capacity 7 Ignition 30/31 62/65 Wheel cover plate 15 17 Carburettor 31/32 66/69 Ignition capacitor 27 Tail lamp 28 52 Wheel spare 8 Carburettor adjustment 31/32 66/68 Ignition coil 27 50 Technical data 7/9 Width, overall 13, 28 12, 53 Care of coachwork 16/17 23/26 Ignition key 13 7 Technical maintenance 18/23 30/44 Windscreen wiper 29 56 Care of glass 17 28 Ignition switch 13 7 Terminal block 27 Wire brush 28 Pull out Carrying capacity 8 Ignition test lamp 31 65 Three-way fuel tap 13 6 Wiring diagram Chain 32/33 Ignition timing 31 Chain case 33 70/72 Ignition warning light 27 Cliiunois leathering 16 24 Instrumentation and control layout 10/11 Chassis frame 8 Intake valve 29 Choke lever 13 7 Cteaning, light metal parts 17 26 Jack 15 20/21 Climbing ability';..,;, , 8 Jets 31/32 Clutch ""'·'~" 7, 33 Kerb weight 8 Clutch adjustment 33 73 King pins 19 Clutch pedal clearance 33 73 Compression ratio 7 Lamps 25/28 45/52 Contact breaker gap 31 62/63 Length, overall 8 Contact gauge 31 62 Lighting switch 13 9 Contact plate 31 64/65 Locating pins 30 61 Contact point lock screw 31 64 Lubrication 7/9, 18/24 30/37 Control layout 1 Lucas electrics 21/23, 25/28 Cylinder head Dipper 13,25 10 Main dimensions 8 Directional signal switch 13, 25 11 Maximum speed 8 Door Hinge pins 19 37 Number plate lamp 27 51 Eccentric adjusting screw 31 63 Electrical equipment 7, 21/28 Oil capacity 9 Electrode gap 29 57 Oil change 18 30/32 Engine position 7 Oil dipstick 12 5 Engine power 7 Oil drain plug 18 ~0 Exhaust valve 29/30 Oil1evel, chain drive 18 32 4 5 SERVICING INTRODUCTION Isetta Service Stations art' organised in trained at the Isetta factory or by factory the form of a wide net of Isetta Agencies. representatives. Each' of these Service They are always at your service. Stations is equipped with proper tools At these Service Stations you will find and has a complete stock of genuine spare technicians wh9 have been specially parts. Technical data : Engine: J3MW single-cylinder, four stroke engine, blower cooled 300 c.c. engine In the following pages you will find The British-manufactured I~etta is a new Bore 72 mm (2.83 in.) described in non-technical language solution to motoring problems. Its Stroke 73 mm (2.87 in.) everything. the Isetta driver needs to manoeuvrability in dense traffic; the ab Capacity 295 c.c. (18.30 cu. in.) ·know about his vehicle. . solute weather-protection which at the Compression 6.8 to 1 Where technical details do occur, such as same time permits draught-free oren-alf on the succeeding two pages, they are driving by means of the folding sun roof; Power 13 bhp at 5,200 rpm included mainly for service stations and its comfortable interior dimensions; its Valves Overhead, in V -arrangement for the more technically-minded Isetta quick acceleration and considerable top· Valve timing measured at .08 in. in valve clearance : .. owner. speed given by a high performance air Intake opens 6° before T.D.C . cooled engine unit; and above all its Intake closes 34 o after B.D.C. tremendous mileage; these are advantages Exhaust opens 34 ° before B.D.C. that will certainly suit new trends in Exhaust closes 6° after T.D.C. motoring. "' Lubricating system Force feed lubrication You will find the J~S~J:~ .:;tri,.easy-to-handle runahout, suitablw;~~~B;~,:~:l.ity and toi.Intrry Single plate dry clutch driving, for field-tra2k ahd modern higp Right hand side, transverse .... 1tth~:iseat way alike. Furthermore, excellem road · 12 volt dynamo starter Noris, LA:'i~/BO;~: holding and a brake s)i;stem of r~f?arkable 12 volt/130 watt generator with voltage regulator efficiency ensure a maximum 6f driving equipment safety. >.4~~;·;~:;:~iJ~/n;~ ". ~~~¥-ucas 12 volt/32 amps battery and lighting equipment Sparking plug ./'Lodge CC14 - L 9' 0 ..- . . Carburettor Bing starter carburettor 1/22 Transmission : Gearbox four forward speeds and re-&erse Gear ratios : , . , Overall gear ratios : 1st 10.05 23.21 2nd 5.17 ;... 12.14 3rd 3.54 8.17 4th 2.70 6.1 6 Reverse 12.15 30.0 7 Transmission continued Fill-up data : Fuel tank 2.8 Imp. gal. = 3.4 U.S. gal. with reserve fuel supply Final drive Final drive 2.31 (13/30 teeth) through transverse of .65 Imp. gal. (.8 U.S. gal.) resilient mounted drive shaft and totally enclosed fully adjustable chain drive in oil bath. Oil capacity, engine 3.1 Imp. pints = 3.6 U.S. pints Oil capacity, gearbox 1 Imp. pint = 1.2 U.S. pints Chassis frame: Rigid tubular chassis frame constructed by Rubery Oil capacity, chain drive .44 Imp. pints = .55 U.S. pints Owen & Co. Limited. Tyre Pressure: Four Wheels 16 lbs. Front and Rear Axle layout and suspension : Three Wheels Front: 16 lbs. Rear: 28 lbs. Front wheels Independent front wheel suspension, swingmg arms, Fuels and lubricants: coil springs and shock absorbers. Fuel Regular or Premium grade Camber 1t deg. King pin inclination 5', in castor 12 o, toe-in Lubricant See lubrication chart 4 to 5 mm = 5/32 in. to 3/16 in., measured on the Recommended Speeds,: (m ph) rim borders, front and rear. 1st 2nd 3rd 4th Rear Wheels Suspension by quarter elliptic leaf springs and During running in 9 18 28 37 telescopic shock absorbers. (Permissible cruising speeds after running in period) 12 25 37 50 Wheels: St~el disc wheels by Dunlop. Rim size 3.50 in. X 10 in. Maximum speeds 15 28 40 52 Tyres: Four Wheels Tubeless tyres, size 4.80 in. X 10 in. and Three Wheels Fuel Consumption Curves Steering gear : Worm and nut, turning circle approx. 24 feet. 300 c.c. Brakes: HydTaulic braking to all four wheels. Brake diameter 7 in. Total brake lining area 50.25 sq. in. Dimensions : Track (tread), front 47.2 in. Track (tread), rear (four wheeled Isetta) 20.4 in. Wheelbase 58 in. Overall length 89.9 in. Overall ··width 54.3 in. Overall height (unladen) 52.6 in Weight: Four Wheels Kerb weight approx. 770 lbs. Three Wheels Kerb weight approx. 750 lbs. Carrying capacity 507 lbs. (N.B. Carrying Capacity refers to both) Maximum speed : 52 mph Climbing ability : First gear 1 in 3 Average fuel consumption : 76 miles/Imp. gal. Oil consumption : Approx. 3.5 Imp. pints per 1,000 miles 25 30 35 40 45 50 55 8 9 \ INSTRUMENTATION & CONTROL LAYOUT Left hand Drive Right hand Drive 1. Clutch pedal. 9. Directional signal switch. 1. Clutch pedal. 9. Directional signal switch. 2. Brake vedal. 10. Headlamp dipper switch. 2. Brake pedal. 10. Headlamp dipper switch. 3. Accelerator pedal. 11. Heater. 3. Accelerator pedal. 11. Heater. 4. Hand brake. 12. Ignition control light. 4. Hand brake. 12. Ignition control light. 5. Gear lever. 13. Headlamp main beam warning light. 5. Gear lever. 13. Headlamp main beam warning light. 6. Choke lever. 14. Speedometer. 6. Choke lever. 14. Speedometer. 7. Lighting switch. 15. Horn button. 7. Lighting switch. 15. Horn button. 8. Ignition and starter switch. 16. Windscreen wiper motor. 8. Ignition and starter switch. 16. Windscreen wiper motor. 10 11 2 For police and customs manufactur.ed lsetta these controls are 6 authorities accommodated in a convenient arrange ment that makes for easy handling. Serial plate : The lever for the three-way fuel line Inside ail: the r~ight in front of tt:he seat control tap, situated behind the seat (figure 2) squab, is easily reached with your right or left hand (figure 6). When starting Chassis number : from cold, pull choke lever full back On front cross member of frame, below (figure 7); at the same time turn the the right-hand door corner (figure 3, left, ignition key with the other hand (thereby number 1) switching on the ignition) and push same Engine number : in with a further short clockwise rotation On engine housing to the right of blower to- operate rthe starter motor. As soon as case (figure 3, right, number 2) possible after the engine 1fires, reset the choke lever into its foremost position. 3 The gear change mechanism works 7 For filling stations and smoothly especially if you get into the workshops habit of pulling the gear lever with the fingers and pushing it with the palm of Fuel tank: your hand (figure 8) instead of grasping In the rear end of vehicle, access from it with your whole hand. If first gear outside does not engage at once, release the clutch a little or clutch and declutch again Capacity 2.8 Imp. gal. = 3.4 U.S. gal. for an instant. with reserve fuel supply of .65 Imp. gal. The heating for the interior, which is an = .8 U.S. gal. (figure 4) optional extra, is hand-controlled by moving the larger lever situated just Engine oil filler : beneath the choke lever. The lighting Oil filler and dipstick on right-hand switch located below the ~teering wheel is bottom side of engine. Maintain oil level also within reach (figure 9.) The switch for up to the mark on dipstick (figure S). 4 dipping and raising the headlamp beams Oil capacity 3.1 Imp. pints=3.6 U.S. 8 is situated below the sliding windows and pints. Branded oil SAE 40 for summer just above the gear lever (figure 10). The use and SAE 20 for winter. Multigrade directional signal switch is mounted in lOW /30 for overseas. the centre of the door below the wind ~ screen (figur(\ 11). To bring the wind 1 screen wiper into operation, push the The new Isetta owner will probably have switch of the motor unit which is !fitted had experience as a driver or, at any to the door (figure 12). To adjust seating, rate, wiU have had tuition from a driving slacken the two screws underneath the school. It is, therefore, unnecessary to fI I seat and adapt the seat position to your include within the scope of this manual requirements (figure 13). details about how to use clutch, accelerator For the o1ther controls and instruments and other controls. With the British- see pages 10 and 11. 5 12 13 9 10 Your friends may have told you about to prevent opening from outside while 14 running in a new vehicle. On the other the vehicle is parked. To open a window, hand you may well already have had press the button of the locking device experience of it yourself. In any case, it and simultaneously push the window to is not a complicated operation. Do not be the desired position. All windows are afraid to give your Isetta plenty of work made of toughened safety glass (figures to do, even in the first weeks-continuous 14/15). development has made its engine a marvel The folding sun roof is opened by operat of precision and robustness. Correct use ing the lever situated on the middle of the of the gear box will avoid engine over front rail. After rain, do not open the loading during the first 600 miles and roof until it is completely dry. To close provided the recommended running i~ the canvas hood, draw the front rail speeds are strictly observed the engine forward and lock with the lever (figure will respond with long service and good 16). performance. In the case of wheel changes, removal of 11 For the first weeks of the running-in the spare wheel (an optional extra) is 15 period, that is for the first 600 miles, achieved by pulling the rear of the seat we recommend the following speed forward and lifting the spare wheel from limits:- behind (figure 17). Wheel-changing, which 1st gear : not over 10 mph should be carried out not only in the 2nd gear : not over 18.5 mph event of a damaged tyre, but in any case 3rd gear : not over 28 mph at regular intervals (see also page 23 and 4th gear : not over 37 mph 24, figures 40 and 41) does not involve These speed indications correspond with any trouble, though it should be done an engine rate of 4,000 to 4,500 rpm, with care. The jack is stowed beneath whereas the speeds mentioned under the seat. Figures 18, 19, 20 and 21 show 'Technical data' will be reached at a the method of wheel removal and jacking rate of about 5,200 rpm. positions front and rear. After the first 600 miles you may on The way in which you drive considerably occasions use your BMW engine's full influences the fuel consumption. You will profit by the economy of the BMW 12 power output. After 2,000 miles you may 16 consider the engine as being completely engine provided that you use accelerator run in. You may then use the cruising and brake-pedal in a careful manner. speeds indicated on page 9. Every vigorous movement of vour righit The red markings I, 11, Ill on the foot, every full depression. of the speedometer dial show the cruising speeds accelerator pedal or brake pedal, costs for first, second and third gear. In fourth, fuel. Therefore, try to adopt modern the speed range available within the red methods of changing gear. If, for instance, coloured section should only be used for 1 you drop from a higher speed to 25 mph .~ the purpose of passing other vehicles. in city traffic, and then want to accelerate The British-manufactured Isetta has you should shift from 4th into 3rd and many other advantageous features not so only change up again when you have far mentioned. For instance, the two regained the higher speed. If the traffic sliding windows have stop spring catches · speed is 25 mph stay in third gear a.t 13 14 15 17 18 half-throttle opening. ln this way you soap or shampoo too strong or the varnish 22 will spare your engine and you will save will become brittle. After soapy water fuel. BMW engine is designed for high or shampoo treatment wash the body revolutions and it will not suffer if you thoroughly with clear water and polish raise the revolution rate in the lower with a good quality wax (figure 25). Wax gears in traffic so as to get away polish should be applied with a soft quickly. With the remarkable acceleration polishing cloth or polishing cotton in and manoeuvrability of the British small quantities upon the completely dry Isetta you can easily wind through narrow finish, doing only a small area at a time. spaces and always keep up with the flow Remove the wax, using a clean polishing of traffic. cloth, until the original brilliance is restored. Light metal parts, such as bumpers, window frames, etc., which have Care of coachwork become opaque or spotted, should be The tool-kit (figure 22) contains all the coated with a chromium-nickel polish and 19 items you need for maintenance and then rubbed with a clean, soft linen cloth 23 minor repairs. Washing your Isetta or wad until the original brilliance is requires some care; the following pro restored (figure 26). cedure should be adopted. Maintenance of the canvas hood is easily First flush the chassis and lower part of carried out. Dust should be removed with the body with water from a low pressure a soft brush. From time to time clean open-end hose, to soak off dirt. After the canvas hood with a washing-brush, wards a brush should be used. Washing using plenty of water (figure 27). Never of the varnished areas to remove injurious try to remove spots with gasoline or other dirt-accumulations and dust should be chemical products, but rather use a good done when the body is cold; never wash textile cleaner as you would use it for or polish your Isetta in the direct rays of removing spots from clothes. the sun or while the body is still hot from Care should be taken in the maintenance having been exposed to sunshine. Apply of the window panels. In order to avoid an even spray of clear water on the scratches on the safety glass surface, the exterior finish until the dirt is removed. adherent dust should be removed with a 20 24 Do not allow a strong jet of water to hit duster, or, better, with plenty of flowing the varnished surface. water by means of a hose and sponge Using plenty of water, dirt should be (figure 28). It should never be rubbed removed with a clean sponge (figure 23). off with a linen cloth. Should you wish Clean the sponge at short intervals. to remove the seat of your vehicle in Next use the wrung-out sponge to wipe order to carry out interior maintenance, off all drops of water and then rub the first remove the spare wheel in the lacquer dry with a clean, soft chamois to manner already described and then fold avoid water spots (figure 24). If water the seat and turn it into the gap which alone does not do the job the varnished contained the spare wheel. Finally draw areas may be given a second wash with the seat on its left corner forward and lukewarm water, soapy water (1 to 2 per raise and remove in an upward direction cent) or shampoos. Do not, however, use (figure 28). 16 21 17 25 of this unit is about .5 Imp. pint= .6 U.S. Technical maintenance pint. 30 'Dhe following items can well be dealt The simplified design of 1Jhe British with by the owner:- [setta features only eight grease points, (a) Changes of oil in the engine should four on the front suspension (figures 33, be carried out after the first 300 34 and 35), two in the cabin on the miles, thereafter every 1,000 miles. steering and pedal controls (figure 36) To achieve this unscrew the drain one on the handbrake cable and one on plug at the bottom of the crankcase steering arm shaft. Each of the front (figure 30). After the last traces of suspension units features two grease old oil have drained, replace and nipples and one oil filler plug. The grease tighten the drain plug before filling nipples serve to lubricate top and bottom with the new oil up to the height of bearings of each steering knuckle king pin. the level mark on the dipstick. The The grease gun should be applied to them oil capacity is 3.1 Imp. pints = 3.6 every 1,000 miles at Service A. U.S. pints. The oil filler plug gives access to a small 27 Draining should :rake place with the oil reservoir that lubricates the fulcrum 31 oil still warm. On no account use bearings of the swing arm and the newly flushing oil to flush the engine. introduced torque arm (figure 35). (b) Similarly the oil while still warm Use engine oil SAE 40 for this lubrication should be drained from transmission point. Refill initially at 300 miles and and chain drive. The transmission subsequently every 2000 miles at Service drain plug is reached from the side B. Top up to about the middle of the opposite the engine, at the bottom filler hole thread. of the gearbox case (figure 31, left). The remaining two grease points are the The transmission 'filler plug is located universal joint at the lower end of the below the air filter in front of the steering column, accessible by opening the mudguard of the right-hand rear door (figure 36 left), and the shaft for the wheel (figure 31, right). Having foot pedals (figure 36 right). The old, drained the transmission oil and emerged grease should be properly thoroughly tightened the drain plug, removed on these two latter points as fill up with transmission oil througb they are located within the body and do 28 32 the filler orifice until it can be seen not get splashed by dirt and moisture. in the filler hole. The topping up Joints lacking grease nipples, such as the should be done in the same manner. door-hinge pins, the yoke pins on the. Oil capacity approx ..96 Imp. pint = linkage mechanism of the pedal shaft (see 1.1 U.S. pints. lubrication chart at the end of the book The oil level of the chain ca·se and let) and all other parts causing friction rear axle assembly is checked through should be given a few drops of oil from the filler orifice in the rear axle unit time to time (see lubrication chart) by (figure 32). The oil sheuld reach the means of an oil can (figure 37). For lower threads of the plug hole. The greasing use a lubricating-grease (all drain plug is situated just beneath makers' recommended lubricants) which the 'filler orifice and is marked by an should incidentally always be stored in arrow in figure 32. The oil capacity its securely closed container in order to prevent the ingress of dust and dirt. 18 19 29 33 HEADLAMPS for Three-Wheel Isetta for Plus model only Each headlamp contains a Lucas Light Unit secured by five W-shaped wire clips Wheel Change for Three-Wheel lsetta to the front rim. The Light Unit con sists of an aluminised reflector perman Jack up rear wheel placing jack under ently attached to the front glass which 1s the near, i.e., left-hand side, rear spring lensed to form an optical system of flutes i=IIM SE:CURIN~ SCREW and prisms. The bulb has two filaments, eye adjacent to axle. Headlamp Bulb Replacement. main and dip, and these are connected HEADLAMP SETTING With box spanner or brace (Fig. 1), through the dipper switch to provide The Headlamps should be set so that remove the four wheel nuts and backing double-dipping of the headlamps. The when the vehicle carries its normal load plate. Now remove wheel to the right filaments are fed through a Lucas adaptor the main beams are projected straight (554691). Lucas Bulb No. 355 12-volt ahead, parallel with each other and with (offside) until clear of bolts, and then 42/36 watt, B.P.F. cap. the road. The setting should be rechecked lower to ground (Fig. 2). after replacing a defective bulb. The HOW TO REPLACE BULB lamp bodies are secured to the vehicle by When replacing the wheel, it must be Slacken the screw at the bottom of the four set screws access to which is gained by removing the interior trim panels. pushed through the aperture between front rim and withdraw the rim and Light Unit assembly. Access to the bulb is These screws nius~t be slackened when it wheel studs and swing arm (Fig. 2), and will be found ·rhar,.the lamp bodies can be gained by releasing the bayonet-fixed adjusted to give the correct setting. the side of wheel on which the inflating adaptor with a press-in anti-clockwise valve is fixed should be next to the brake motion. It should be noted that a notch drum. Note that the distance pieces must in the flange of the bulb is arranged to locate with a ridge in the bulbholder to be replaced so that the tapered side is ensure that the bulb is non-reversible. nearest the wheel. The bulb is of a prefocus' pattern. 20 21 . :;~~~~- Lucas electrics hyd;~ineter readings fro' time to time, Battery but, to avoid low misleading r~adings, such measurements should nqt be made Model H07A/8; Type, 12 Lead-A~id; immediately after topp' p~3(figure 39). volt; 7 plates per cell. Capacity, 32 The readings shown be for ampere-hours at the 10-hour rate and 31 ambient temperatures ampere-hours at the 20-hour rate; first and above 90°F. charge current 2 amperes; recharge Climates bebw 90°F current 3 amperes. '(i) 1.270-1.290 1.200-1.220 Access to battery for topping up (see (ii) 1.190-1.210 1.120-1.140 figure 29 page 18). Every 1,000 miles or (iii) 1.110-1.130 1.040-1.060 monthly, whichever is the lesser, remove The indications ,givfrl by these readings the ·filler plugs from the battery and are as follows : ';;'~ inspect the electrolyte level with the top (i) Cell fully charged e:(f'~es of the inter-plate separators. This (ii) Cell about haif discharged 35' addition will replace water lost by (iii) Cell completely discharged evaporation. The readings for all cells should be approximately the same. If widely vary The use of a Lucas Battery Filler enables ing readings are obtained the battery the correct electrolyte level to be should be examined at a Lucas Service obtained automatically (figure 38). Depot or by an official Lucas Agent. Storage : Never leave the battery in a TAKE READING HOLD TUBE Use only distilled water. AT EYE LEVEL VERTICALLY discharged condition. If the vehicle is Never overfill the cells. to be out of use for an appreciable period, the battery should first be fully charged Never hold a naked light near the cell and, subsequently, should receive a short tops. refresher charge every fortnight. Keep the cell tops dry. 39 Run the vehicle immediately after topping Technical Maintenance (cont.) 36 up in cold weather. This will help to Tyre pressures should be checked (figure mix the distilled water and electrolyte 40) at frequent intervals and at least and so prevent freezing and possible once a week. If you use your own tyre damage to the battery. gauge, check it from time to time with a calibrated tyre gauge at a filiing station.. General care : Keep the cell tops clean. The tyre pressures should be adjusted to Keep the electrical connections and fixing 16 lbs.fsq. in. (front and rear) and 16 lbs. bolts tight. front and 28 lbs. rear on three wheelers. In order that tyre wear should be Hydrometer readings : Hydrometer read uniform with the spare wheel tyre, you ings indicate the condition and state of ~· should change the wheels round from charge of the' battery. Good cells wi11 time to time. The manner of rotating the yield clear electrolyte free of particles in wheels is shown by figure 41. suspension and will produce high specific Periodical maintenance should also in gravity readings. It is advisable to take clude care of the air cleaner. This filter 22 37 23 40 41 rt~zt'-~<,' is of the dry 'element type and should For the detailed indication of the pre ing the ;jlgle lens s~g{iring screw arid be cleaned every 2,000 miles. To do this scribed maintenance jobs and the corre withdrawing the lens. The bulb is Lucas unscrew the rubber hose-clip on the sponding service periods see mainte11ance ~No.'" 382, 1,2-volt 21 ·.~watt s.c.c. cap. carburettor with a, screwdriver. Push the chart. 'i' 25 44 24 45 motion. The fuse is a 25-ampere glass obligatory fitment intended to remind Ignition capacitor Part No. 425212 cartridge type and care must be taken drivers to dip their headlamps when The ignition capacitor is clipped to. the when inserting a replacement to see that SUPPLY CABLE LENS passing other vehicles. side of the ignition coil. It is of the the insulating sleeve is correctly fitted Access to the warning light bulb is metallised paper self-healing type and inside the carrier. ~PANEL gained by withdrawing the bulb-holder requires no attention in service beyond Before replacing a blown fuse, inspect from the rear of the instrument panel. an occasional check of the ignition coil the wiring of the affected circuits for ~'~"' 46 The bulb is Lucas No. 987 12...:volt 2.2 terminal "CB" to which it is con evidence of a short circuit. It is im watt M.E.S. cap. nected. portant to use only the correct replace ~lliii!lluJJJJ. Horn Model HF1849 Part No. 70141 ment fuse. Ignition warning light (Bracket 705179) ff \EZEL SUPPLY CABLE If the fuse blows repeatedly and the Model WL13 Part No. 38100 The horn is of the high frequency pat cause cannot be traced, the equipment The ignition warning light serves the tern deriving its note from the combined should be examined at a Lucas Service dual purpose of reminding the driver to vibrations of a diaphragm and tone disc. Depot or by an official Lucas Agent. switch off the ignition before leaving 47 These are coupled to an armature actu the vehicle and of acting as a no Headlamp setting ated electromagnetically as in an electric charge indicator. When the ignition is The headlamps (figure 48) should be set bell or buzzer. switched on, the warning light should be so that when the vehicle carries its normal Apart from an occasional inspection of illuminated only when the engine is load the main beams are projected the horn circuit cables and 'fixing bolts, stopped or turning over very slowly. As straight ahead, parallel with each other the horn requires no mainte~ance. Worn the engine accelerates, the light should and with the road. The setting should or chafed cables must be renewed and dim and go out at a fairly low engine always be checked after replacing a main the fixing bolts kept tight. speed. Failure of the light to behave bulb. Horn push Model CCS Part No. 33504 in this way will indicate a fault in the 48 Owners are strongly advised to have their The horn push is located in the hub of charging system. headlamps scientifically set with the aid the steering wheel and requires no Access to the warning light bulb is of a Lucas Beam Setter. When such attention in service. gained by withdrawing the bulb-holder facilities are not available, however, the from the rear of the instrument panel. lamps can be set by marking off a smooth Ignition coil Model LA12 Part No. 45053 The bulb is Lucas No. 987 12-volt 2.2 wall or screen and shining the lamps on . The ignition coil should be kept clean, watt M.E.S. cap. CENU.E LINE AHA OF CONCENTRATED it from a distance of at least twenty particular attention being paid to the OF VEHICLE LIGHT five feet. Details are shown in (figure 49). terminal moulding. From time to time Number plate lamp The lamps are secured to the car body check the terminals for loose connec Model 46712 Part No. 53650 by four set screws, access to which is tions and tighten as necessary. Renew Access to the bulb is gained by slacken gained by removing the interior trim the high tension cable if it shows signs ing the single cover securing screw and LAMP CENTRES 49 panels. These screws must be slackened FROM GROUND of perishing or cracking. To do this, withdrawing the cover. The bulb is when it will be found that the lamp remove the defective cable but do not Lucas No. 222 12-volt 4 watt M.C.C. (A) FRONT OF VEHICLE TO RE SQUARE WITH SCREEN bodies can be adjusted to give the correct lose the moulded terminal nut or split cap (figure 51). (B) VEHICLE TO BE LOADED AND STANDING ON LEVEL GROUND setting. washer. Thread the new cable through (C) RECOMMENDED DISTANCE FOR SETIJNG IS AT L~ST 25FT the terminal nut and bare the end of the Reflex reflectors (D) FOR EASE OF SETTING ONE HEADLAMP SHOULD BE COVERED Main beam warning light cable for about t in. Thread the exposed Model RERS Part No. 57075 Model WL13 Part No. 38145 strands through the split washer and bend The reflex reflectors are made of a termo The main beam warning light is con them back radially. Re~t the moulded plastic material, resistant to attack by H.T CABLE nected in parallel with the headlamp nut into the terminal rrtoulding (figure oil, petrol, paraffin, etc. They should main filaments and lights up when these 50). be kept clean. are in use. In some countries it is an 50 26 27 WASHER MOULDED CABLE TERM I~ STRANDS Stop-tail lamps Minor inspections and adjustments 54 Model 488 Part No. 53178 Many Isetta owners who have already Access to the bulb is gained by peeling possessed a motorcycle or a scooter will 51 back the outer rubber lip to release the have the technical knowledge to do rim and the inner lip to release the glass. minor repairs themselves. This hand The bulb contains two filaments of differ book, therefore, includes a number of re ing power and is, therefore, made non pair jobs which may be undertaken by reversible. The bulb is Lucas No. 380 those drivers who in addition to their 12-volt 21/6 watt S.B.C. (Indexed) cap technical knowledge possess the requisite (figure 52). tools and appliances, gauges, car lifts. suppont srtands, ertc. These insrtruotions are included so that the Isetta owner may Terminal block have the jobs performed at places which These screws must be kept tight. lack an authorised Isetta Service Station. Sparking plugs 55 Removal of the screw-plate on the body Windscreen wiper panel behind the seat-squab gives access Bosch Ltd. to the cylinder head of the engine for The windscreen wiper motor has its the sparking plug and valve treatment bearing, bearing surfaces and gears well (figure 54). Remove the sparking plug 52 lubricated during manufacture and, nor with the aid of a spark plug spanner mally, will require no further attention. (figure 55), clean it with a wire brush The blades are brought into play by (figure 56) and reset tJhe deotrode gap turning the switch lever located on the (.024) by means of a gauge (figure 57). motor cover. Valves Efficient wiping is dependent on having Valve checking and adjustment as. indi a clean windscreen and wiper blades in cated along the following lines should be good condition. Methylated spmts carried out every 2,000 miles. The valves (der.atured alcohol) should be used to are adjusted at T.D.C. compression when remove oil, tar spots and other stains the valves are closed at the moment of 56 from the windscreen. Silicone and wax igrntwn. The setting T.D.C. compres based polishes should not be used for sion is described in detail ~m page 30, this purpose. Worn or perished wiper under ignition timing. Make it a rule blades are readily removed for replace nort to adopt too small 'a clearance as this ment as shown in figure 53. mighlt caus,e the valves to burn and thus create major troubles. These adjustments to be carried out with the engine cold. Wiring diagram ·.~ Valve clearance should be .004-.006 in. BLADE A copy of the wiring diagram is in the for intake, .006-.008 in. fgr exhaust, 53 appendix of this qandbook, but additional with the engine cold. · The adjustment of the valves requires two spanners. First SLOT copies will be sent free on request to the Advertising Department, Joseph Lucas. slacken the locknut (figure 58), then turn ARM Great King Street, Birmingham 19. the adjusting screw as required until the 28 29 57 62 3. Check contact breaker gap with the cor'feot amou111t of play ~s felt with the contact gauge .016 in. (figure 62) feeler gauge ins,erted between rocker arm which must slip easily when being and valve stem end '(figm;e 59). When drawn fore and aft between the con this is obtained, hold adjuster with its tact points. If the gap is too big 01 spanner and retighten the locknut secure too small, slacken the stationary point ly. When this nut is properly tightened, locking screw 1 (figure 63), and turn check the play again, to make certain the eccentric adjusting screw 2 (figure that it has not been altered while tighten 63') until the correct gap is obtained. ing the nut. Then tighten lock screw 1 and re When adjusting the valves you should check the gap. inspect the rocker-box cover-gasket and 4. Slacken the two contact plate securing replace it, if necessary, in order to en screws (figures 64 and 65) and turn the sure the proper sealing of the rocker-box blower wheel until the colour-marked (figure 60). Place the gasket in such a blade meets the mark '· S " on the 63 way that the two locating pins fit in the blower housing. two holes of the gasket. Special care Now disconnect black coloured con should be taken in replacing the rocker tact breaker lead from terminal CB of covers to see that the locating pins engage ignition coil and connect the test lamp exa~tly in the corresponding drilled holes with one pole to terminal 1 of ignition provided in these units (figure 61). The coil and the other to the connector figures illustrating the servicing of the end of the disconnected black lead. valves in this booklet are shown with the 5. Push in ignition key to switch on engine in a completely accessible condi ignition and move the contact breaker tion after removal of the body. Nor plate contrary to rotation direction mally, these jobs are performed through (upwards) until the lamp lights up. the cover plate located behind the seat Then move contact breaker plate care- squab, as shown on figure 54. fully in direction of rotation (down Ignition the lamp just goes out. 64 The resetting of ignition timing requires tighten the contact a 12-V test lamp, a contact gauge 60 (> 6. (.016 in.) and a screwdriver. ignition key to switch off To perform the setting proceed as test lamp, reconnect follows:- er lead to "terminal 1 of igrutwn, detach test lamp, reconnect 1. Withdraw spark plug connector, unscrew sparking plug and remove wheel, replace spark plug and push high-tension lead connector over the cover from the blower wheel. sparking plug. 2. Rotate blower wheel in a clockwise direction until the colour-marked Carburettor blade meetiS the mark " S " on the The arrangement of jets and the car housing of the blower_ unit. burettor adjustment have been tested at Now continue turriing the blower the' factory in order to obtain the best wheel until the breaker contact points performance and a maximum of economy ai:e fully opened. 31 65 61 30 from time to tim6:·~~~Jhe striking of the in consumption. lt' pointless i~{'\herefore, chain against its case will tell you when to try and increase performance or to the chain has lengthened and needs lower fuel consumption by altering the adjustment. This is done by -means carburettor adjustment or by fitting jets of a perforated adjuster plate on the of other sizes. It is possible to lower chain case (figure 70), which is accessible the fuel consumption by using smaller from the si4e opposite the engine. j·ets, but this will immediately cause an Remove the adjuster pla;te locating-screw appreciable loss of power; there is the with an appropriate spanner (figure 70). risk of the engine overheating and of the Then raise it with a screwdriver from the valves burning. In short, major repairs bottom upwards until strong resistance will become necessary. Consequently this prevents further movement (figure 71). chapter includes only those jobs which This re-establishes the proper tension of can be done for the maintenance and chain. The next problem is to get the servicing of the carburettor. drill holes in the adjuster plate corre The carburettor is regulated by means sponding with one of the two screw holes of two screws (figure 67) and the idling in the chain case. This cannot be done adjusting screw (figure 66). The volume by forcibly lifting the plate until the holes control screw is best left with its original _meet one another (figure 72) because this adjustment as set at the factory. If this would result in excessive chain tension. adjustment has been altered by some If the hole in the chain case happens cause, slacken lock nut of the volume to stay between two adjuster plate holes, control screw, turn the screw fully in with slacken off in order to get the locating a screw driver, and then back it off by screw into its hole. 1t-2 turns. This is best done with a special tool and, therefore, you should Clutch leave the job to an expert (figure 68). The regulating and adjusting described The free movement of the clutch peda:l above is all that can be done on the car pad should be about .48 in. to .6 in. -burettor, by either layman or expert. To The readjustment of clutch pedal clear clean the carburettor, open the drain plug ance takes place on the clutch actuatino on the bottom of the float chamber lever at the transmission case and, lik~ (figure 69) having first set the fuel tap the cha:in adjustment, is achieved from (figure 6) into its " OFF " position. the side oppos•ite the engine. This can Should it become necessary to remove' be done with the vehicle supported at the top of the carburettor ensure th~t the rear, errtel'ing the spanner fr():m the gasket sealing is replaced correctly. behind. Turning the adjuster screw clock- wise increases clutch pedal clearance and contrary adjustment decreases it (figure Chain n~ . ' The power output of the engine is trans mitted to the rear wheels by means of Brakes a ch~in running in an oil bath. Since it The foot brake is hydraulic. It affects is completely protected this chain has a all four wheels, since the two rear wheels long life. It . 8hould, however, be adjusted 32 33 .. ~· 'I I 7 4 are mounted on a rigid scale. Maintenance car. Turn the square end of the adjuster 00 01 509, us,ing a 12 mm. flat of the brake includes checking the brake: on the outside of the rear brake ba~k ring spanner. fluid level. The brake-master cylinder plate in a clockwise direction until a (Note: Free Service, but oil is with the fluid reservoir is situated below resistance is felt, slacken two clicks, when chargeable.) the seat bench and is accessible simply the drum should rotate freely. (b) At 600 miles:- by unscrewing the filler plug. When Immediately after fitting replacement 1. Change oil in gearbox, rear removing it take care to avoid getting shoes it 1:> advisable to slacken one further drive and eng:ine. Oil and grease dirt into the brake fluid. Use only Girling click to allow for possible lining ex chassis points, oil all hinges and crimson fluid from the original can (figure pansion, reverting to normal adjustment joint. 74). If the brake pedal travels too freely, I afterwards. 2. Check front suspension mount it is an indication that air has entered tings. the hydraulic system; the fluid line must ~aintenance survey 3. Check and tighten all nuts and then be bled. This can best be done All jobs mentioned in the preceding bolts, including transmiss10n, by a service station as it requires special chapters for the proper maintenance and universal coupling bolts and devices and knowledge. I servicing of your vehicle are arranged in the following service groups and in the wheel nuts. 7 5 Running adjustments maintenance chart. The most frequent 4. Check electrolyte level of bat Girling brakes are adjusted for lining jobs form Service A, to be performed tery, add distilled water, give wear only at the brakes themselves and every 1,000 miles. The more complicated posts and terminals a grease on no account should any alteration be jobs to be done at longer intervals form coatJing. made to the handbrake cable for this Service B and Service C. 5. Remove valve rocker covers and purpose. The ex~perienced mechanic will on a " C " tighten the four cylinder head holding down bolts to a torque Front brakes (figures 75 and 76) Service check the entire chassis, brake and steering assemblies as well as all loading of 32 lbs. ft. This opera A separate snail cam adjuster is provided stationary and movable parts, and even tion should, of course, be carried for each shoe. Jack up the vehicle until tually provide them with the necessary out diagonally. Re-adjust tappets the front wheel to be adjusted is clear paint /and anti-corrosion coatings. with engine cold (see "Valves," of the ground, then fully release both In addition to Services A, B and C the page 29) and refit rocker covers. adjuster bolts on outside of the back following jobs should be done: 6. Che'ck and· re-tighten if neces plate by Fuming anti-clockwise. (a) After the first 300 miles:~ sary cylinder base nuts, Part No. Turn one' of the adjuster bolts clockwise 1. Drain engine oil, remove oil 00 01 509, using a 12 mm. flat 7 6 until the brake shoe concerned touches sump, clean it and wash the oil ring spanner. , the brake drum then release the adjuster screen, refit sump and refill with 7. Clean sparking. plug and adjust until the shoe is just free of the drum. fresh oil. gap. Repeat the process for the second adjuster 2. Remove valve rocker covers and 8. Check ignition po~nts, read)ust and shoe. tighten the four cylinder head if necessary. Spin the wheel to ensure that the brake holding down bolts to a torque 9. Remove carburettor, clean out shoes are quite free of the drum. Repeat loading of 32 lbs. ft. This opera jets and . petrol filter, clean the whole procedure for the second front tion should, of course, be carried throttle slide and ensure needle wheel. out diagonally. Re-adjust tappets is in correct slot, ensure correct Rear brake (figure 77) wirh engine cold (see "Valves", clearance; on throttle and choke cables. One common adjuster is provided for page 29) and refit rocker covers. 10. Adjust slow running, clean out both shoes. 3. Check and re-tighten if necessary air intake filter. Release the handbrake and jack up the cylinder base nuts, Part No. 77 34 35 This document was downloaded free from www.iw1axr.eu/carmanual.htm Questo documento è stato scaricato gratuitamente da www.iw1axr.eu/auto.htm