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Gilera 150 Autostrada.....also needs lots of work

Posted: Fri Jan 05, 2018 4:22 am
by lambs
In a similar way to my 202 thread, this thread will be about the 150 Autostrada discussed in this thread:

This is the beast itself:
engine # 104-7639
frame # 104-7639

These numbers perhaps suggest quite late production - 1970/1971 ??

Seat, muffler, carb are obviously 'wrong'. Original RH footpeg is just a cobbled up affair possibly to support the muffler. The carb will be an easy fix, since the carb fitted to the 202 is a UBF24BS (should be UBF22BS) a stroke of luck, an Australian ebay seller recently had a bare, new UB24BS2 carb body for sale very cheap (50AUD), which is the correct type for the 150, so I grabbed it and will transfer all the the needed parts over from the UBF24 carb. Some jets will need changing but not a big deal.

Other 'problems' I've found with the 150:

- rear mudguard is cracked in a couple of places. Repair should be possible.
- virtually all the original wiring is gone and been replaced by someone's very poor attempt at a rewire...this will be completely tossed and I'll make a new loom from scratch of need be
- ignition advance mechanism in the flywheel is very badly worn. This could present difficulties as I suspect new replacements will be hard to find.
- all cables (throttle, clutch, brake, tacho+speedo) need to be replaced.
- front headlamp shell has been modified to accept a Japanese lens, etc...12V !?!?
- tail light assembly appears to be Lucas brand...

The front wheel is also 'wrong'....if you look closely at the attached picture you can see that there is a speedo cable 'hole' in the RHS of the hub....but the speedo drive mechanism is actually in the rear wheel (same for the 202) and the cable is still there. The front rim is chrome steel and has these markings:

1.4 x 17
14 16
--17 07--

While the rear wheel also has a chrome steel rim, which has these markings:

Made in Italy
WM1 1.6 x 17

Looks like the rear wheel is 'original', but not so for the front.

[sigh] Such is the restoration game......

Re: Gilera 150 Autostrada.....also needs lots of work

Posted: Thu Jan 18, 2018 11:44 pm
by Nozem
Hi Lambs,

Here's a good start to get your Gilera 150 Autostrada right.
Unfortunately it is in Italian but I hope it will be of any help.

Nozem rulez

Re: Gilera 150 Autostrada.....also needs lots of work

Posted: Thu Jan 18, 2018 11:55 pm
by Nozem
And here's the wiring diagram. This is part of the complete workshop manual that can be found here: ... 05v_MO.pdf

Nozem rulez

Re: Gilera 150 Autostrada.....also needs lots of work

Posted: Tue Jan 23, 2018 10:49 pm
by Gilera 150 5v Trial

I have parts for the autostrada.


Re: Gilera 150 Autostrada.....also needs lots of work

Posted: Sun Feb 04, 2018 10:30 am
by lambs
Thanks (again) Nozem for your comments and the very useful information. The photo of the 150 is interesting as it shows what appears to be an air filter assembly, but other photos of 150 Autostrada's I've seen show the carb with just a velocity stack or air filter. Perhaps different model years had one or the other....or maybe the air filter was an optional extra (??).

Gilera 150 5v Trial - I'm interested to see what parts you have. Probably best to discuss separately so I'll send you a message.

My goal is get this bike on the road as quickly as I can - the 202 will have to wait. I've managed to track down a few things that I need, but a new spring for the ignition advance mechanism is proving elusive. Due to a piece of pure luck I've manage to track down a suitable seat, so the main parts I'm going to need is a complete front headlamp assembly, ditto for the tail light and number plate holder (portatarga ??)....and maybe a complete front wheel.....

I've discovered that part of the frame bracket used to support the rear mudguard has broken away from the frame proper. A fairly simple fix but probably requires some disassembly to allow access to re-weld the bracket.

Re: Gilera 150 Autostrada.....also needs lots of work

Posted: Thu Jun 21, 2018 1:28 pm
by lambs
An update on progress.....things got a little more complex than expected.

The Good

- as well as the seat, I've managed to track down a front wheel, taillamp, headlamp, wiring loom, RH footpeg and some other minor parts.

- I now have a usable spring for the advance mechanism + new points and condensor.

- worked out that a Guzzi V35III tacho cable will do the job. I also have a new speedo cable from a supplier in Italy.

The Bad

- removed the rear wheel to find that the RHS (sprocket side) wheel bearing had 'walked' about 5mm out of the hub. I was a bit puzzled at how this could have happened, but soon realised that something must be missing. A quick check of the parts manual showed that there should be a spacer between the bearing and the swinging arm :roll: The bike would have been totally unsafe, even dangerous to ride in that condition. I have managed to track down a replacement spacer reasonably cheaply.

- the cush drive rubber is a bit worn and could do with replacing, but so far haven't been able to find one. I will still be able to use the old one for the time being.

- all the engine seals appear to be original and completely beyond their use-by date (hardened). They are all standard sizes so a local bearing supplier has sourced replacements quite cheaply.

The Ugly

- the cylinder base gasket was obviously hand cut from a bit of cardboard. It also appeared that the clutch cover gasket had been re-used with gasket cement applied to try to keep everything oil-tight.....unsuccessfully. An ATHENA full gasket set only cost me $60 delivered, so I decided to pull off the cylinder head and barrel to check things more closely and replace the head/base gaskets......

- ...removed the clutch cover to find everything in mostly OK (usable) condition BUT a very important part missing from the oil feed to the crank. There should be a spring, steel sleeve and bronze 'mushroom' connecting oil feed to the crank, however the sleeve is completely missing so oil pressure to the crank would have been almost non-existant. Oil supply to the valve gear would also have been reduced.

- tappets found to be in reasonable condition although valve contact tips a bit worn....I've been able to re-profile.

- disassembled valves (was going to relap valves) to find valve stems badly worn.....need to be replaced. I've sourced a genuine exhaust valve but not been able find a new inlet valve. Fortunately, the motorcycle head repair specialist I've used for years will be able to modify a suitable from another motorcycle to fit. Valve guides will be k-lined to new spec.

- head is cracked between inlet and exhaust valve seats. The crack is also a bit eroded meaning that it has been present for a long time and that's a good thing as it's less likely the valve seats have been affected (moved). There are some modern methods that can be used to 'repair' so we're going to try that as finding a good replacement head is likely to be difficult ad probably costly.

- While replacing the drive sprocket oil seal I discovered that the output shaft has about 2-3mm of sideways play.....stuffed support bearing. Replacing the bearing means splitting the cases......

All of the above problems discovered with the engine means that I am now doing almost a complete rebuild with new gaskets and bearings + the required head repairs. The barrel and piston+rings are actually in good condition (thankfully...). Marks on the head of the piston indicate the barrel has been bored to 60.4mm (imagine the extra power.....) I'll hone the bore and re-assemble using the existing rings.

More work than I hoped, but I'm getting there.....

Re: Gilera 150 Autostrada.....also needs lots of work

Posted: Thu Jun 21, 2018 8:55 pm
by Joachim

ciao Joachim