Lambretta gear changing cable routing & trunnions

Lambretta Cable Routing

How to get the Lambretta gear changing work perfectly and smoothly?

We take a close look at the controls and what can be done down from the headset through the cables to the gear swivel and gear selector arm on the engine casings.

Let's face it the last Lambrettas have left the Innocenti factory half a century ago. And not everyone has been maintained and serviced regular and as it should be done. One of the many beauties on the Lambrettas is that they are very simple to work on, especially with the right tools, right parts and the right hints (Sticky). There are three areas to look at:

  • Handle bar / headset
  • Cables
  • Engine casing


Lambretta handlebar/headset

Thru the Li family there had been different changes on the internals of the headset. On well-maintained bikes most of the time taking everything apart, cleaning and put it properly greased and lubricated can do the job. When you are up the job, it won't do no harm to renew all the bushings in the headset. These are the guides for the gear and throttle rods. Available as handy sets from Casa Lambretta:

* also dl / GP range

Anti-vibration kit handlebar -Lambretta-

If you need additional spares a nice way to find them are our exploded views, which are online for all Lambretta scooters. Here you see the dl / GP headset:

Once everything is properly rebuild and any slack is taken out - especially of the gear change housing and the gearchange rod - you are done with the headset and can have a look at the cables.


Lambretta cables and routing

Essential are Teflon / PTFE lined cables. These run super smooth and are maintenance free. The bgm cable sets are especially made for the Li family Lambretta and have some unique features. The right inner and outer cable lengths are granted. Here you will find additional info about how good these are: Back to the plot: Once you have routed the outer cables in the right way as can be seen on the bgm's fitting instructions:

  • Cable set bgm PTFE inner liner- Lambretta DL, GP | BGM6401N
  • Cable set bgm PTFE inner liner - Lambretta LI, LIS, SX, TV (Series 2-3) | BGM6400N

Lambretta Cable Routing


It's time to fit the inner cables. On the brake and clutch levers use a good blob of grease to keep everything well lubricated. Especially the lever screw, the trunnion of the inner cable and all operating and moving parts.

Brake lever screw - clutch lever screw -LAMBRETTA- LI (series 1-3), LIS, SX, TV (series 2-3), GP, DL

Anti-vibration spring cap brake clutch lever -LAMBRETTA- LI, LIS, SX, TV, DL, GP, J, Lui

Anti-vibration spring brake clutch lever -LAMBRETTA- LI, LIS, SX, TV, DL, GP, J, Lui


A run-down of the inner cables with Teflon spray does no harm and especially the operating of the clutch is much more easy:

PTFE spray -MOTIP- 400ml


Top tip: If the bolts of the clutch and brake lever are not properly greased they can wear off the holes in the light switch housing and gear change housing. These can easily be repaired with the oversize bolt:

Brake lever screw - clutch lever screw -MB DEVELOPMENTS- Lambretta LI (series 1-3), LIS, SX, TV (series 2-3), GP, DL - stainless steel / oversize


Lambretta engine casing

The most important thing is to avoid any unwanted slop in the gear swivel, tie rodgear change and the selector arm. Luckily there are many different choices for everyone's tasting available.

Selector sets

Like the made to original specs Casa Lambretta gear selector set:

Shift scale set -LAMBRETTA- Lambretta LI, SX, LI S, TV


Or the high grade CNC machined set from bgm Made by JPP tuning for us:

Shift scales set including adjusting block -BGM Pro made by JPP, aluminum CNC- Lambretta LI, LIS, SX, TV (series 2-3), SX, DL, GP - black anodized

Shift scales set including adjusting block -BGM Pro made by JPP, aluminum CNC- Lambretta LI, LIS, SX, TV (series 2-3), SX, DL, GP - silver anodized


Trunnion sets

Paired with the bgm trunnions you really have a perfect and long lasting set:

Clamp nipple / screw nipple set -BGM ORIGINAL- Lambretta LI, LIS, SX, TV (series 2-3), DL, GPbgm Original item no .: BGM6466

This is the full bgm trunnion set:

Adjusting screws and clamping nipple / screw nipple set -BGM ORIGINAL- Lambretta LI, LIS, SX, TV (series 2-3), DL, GPbgm original Ø customer rating (1 ratings) Item no .: BGM6465

Lambretta Tool & Tool bags

To ensure the bgm trunnions have the original 3.5 mm allen key size as found on original machines as well as on original toolbags supplied with your brand new scooter:

Tool kit -CASA LAMBRETTA- Lambretta LI (series 1-3) Casa Lambretta Item no .: 3331475

Tool bag including tools -CASA LAMBRETTA- Lambretta universal - GrauCasa Lambretta Item no .: 8050083KT


Something we went not original is the key for adjusting these. The bgm one comes with a ball end. This makes adjusting the gear change trunnions a cakewalk as you come across the clutch cable easily:

Allen key -BGM PRO- 3.5mm-bgm Pro Article no .: BGM6466TL


Top tip: For all the rusteration freaks out there that want to keep their Lambrettas as original as possible we have oversize trunnions made for preserving worn out gear swivels:

Clamp nipple / screw nipple set -BGM PRO Oversize- Lambretta LI, LIS, SX, TV (series 2-3), DL, GP

The oversize makes the trunnions fit perfectly in used gear swivels. If necessary, grind out new shifting paddles minimally.

These perfectly compliment the inner cable sets: |