SERVICE STATION MANUAL
633734 ÷ 633741
MSS ZIP 100 4T
SERVICE STATION
MANUAL
MSS ZIP 100 4T
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this manual remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of single
models should be checked at the official Piaggio sales network.
"© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
SERVICE STATION MANUAL
MSS ZIP 100 4T
This service station manual has been drawn up by Piaggio & C. Spa to be used by the workshops of
Piaggio-Gilera dealers. It is assumed that the user of this manual for maintaining and repairing Piaggio
vehicles has a basic knowledge of mechanical principles and vehicle repair technique procedures. Any
significant changes to vehicle characteristics or to specific repair operations will be communicated by
updates to this manual. Nevertheless, completely satisfactory work cannot be carried out without the
necessary equipment and tools. It is therefore advisable to read the sections of this manual relating to
appropriate tools, along with the appropriate tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
TIME TIME
INDEX OF TOPICS
CHARACTERISTICS CHAR
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are wellventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid naked flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spare parts may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces, except tapered couplings, before refitting these parts.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. Using unsuitable
coupling members and tools may damage the scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.
MSS ZIP 100 4T Characteristics
CHAR - 7
Vehicle identification
VEHICLE IDENTIFICATION
Specification Desc./Quantity
Engine prefix M252M ÷ 1001
Chassis prefix LEMM25200 ÷ 1001
Dimensions and mass
WEIGHTS AND DIMENSIONS
Specification
Desc./Quantity
Total and dry weight 89 ± 3 kg
Width 680 mm
Length 1700 mm
Wheelbase 1200 mm
Height 1060 mm
Engine
ENGINE
Specification
Desc./Quantity
Type single-cylinder, four-stroke
Bore 50 mm
Stroke 49 mm
Cubic capacity 96.21 cc
Compression ratio 10.5 ÷ 11.5 : 1
Timing system single overhead camshaft, two valves, driven by a chain to the
left side.
Depression carburettor KEIHIN CVK
CO adjustment 3.2% ± 0.5
Engine idle speed (100 cc) ~ 1500 ± 150 rpm
Air filter sponge impregnated with a mixture 50% oil (Selenia Air Filter
Oil) and 50% unleaded petrol.
Starting system electric starter/kick-starter
Lubrication engine lubrication with lobe pump (inside the crankcase),
chain-driven, and double filter: mesh and centrifugal.
Fuel supply Gravity feed, with unleaded petrol (with a minimum octane rat-
ing of 95) with carburettor.
Max power (to the crankshaft) 4.2 kW (5.7 CV) at 6750 rpm
Maximum torque (to the crankshaft) 6.92 Nm 6000 rpm.
Cooling system with forced air.
Valve clearance (cold engine) intake 0.10 mm
discharge 0.15 mm
Characteristics MSS ZIP 100 4T
CHAR - 8
Transmission
TRANSMISSIONS
Specification Desc./Quantity
TRANSMISSION With automatic expandable pulley variator, torque server, V-
belt, automatic clutch, gear reduction unit.
Capacities
CAPACITY
Specification Desc./Quantity
Main and supplementary fuel tank (including ~ 1.2 l reserve)
(100 cc)
~ 7 l
Rear hub (100 cc) approx. 80 cm³
Engine oil approx. 850 cm³ (recommended oil: SELENIA HI SCOOTER 4
Tech)
Electrical system
ELECTRICAL COMPONENTS
Specification
Desc./Quantity
Type of ignition Capacitive discharge type electronic ignition, with incorporated
high voltage coil
Variable ignition advance by microprocessor (before TDC) 15° at 1500 rpm.
22° at 5000 ÷ 6000 rpm.
spark plug Champion RG 4 HC
CHAMPION RG 4 PHP
NGK CR9EB
Fuse (100 cc) 10 A
Generator single-phase alternating current
Frame and suspensions
FRAME
Specification
Desc./Quantity
Type of chassis Welded tubular steel chassis with stamped sheet reinforce-
ments.
Front suspension Mechanical telescopic fork with 30-mm stems.
Front suspension stroke 77 mm
Rear suspension travel 70 mm
Front brake Disc brake (220 mm in diameter) with hydraulic control (lever
on the right side of the handlebar).
Rear brake Drum brake (140 mm in diameter) with expanding shoes, me-
chanically operated
Front tyre size 100/80-10''
Rear tyre size 120/70-10''
Tyre pressure (100 cc) Front wheel: 1.3 bar
Rear wheel: 1.6 ÷ 1.8 bar
Rims made of light alloy:
2.50x10'' (front)
3.00x10'' (rear)
N.B.
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. REGULATE PRESSURE ACCORDING TO THE WEIGHT OF BOTH RIDER AND ACCESSORIES
MSS ZIP 100 4T Characteristics
CHAR - 9
Brakes
BRAKES
Specification Desc./Quantity
Front brake Disc brake (Ø 175 mm) with hydraulic control (lever on the
handlebar right end).
Rear brake Ø 110 mm drum brake with mechanically controlled expansion
shoes (lever on the handlebar left end)
Secondary air
•
The SAS (Secondary air housing) operating principle for 50 4T engines is
similar to that for 50 2T engines; the
only difference lies in how air is sucked
in the external and the external side of
the transmission compartment.
•
Air is taken in along tube «A» (to the
cylinder side) and, after been cleaned
through the filter «B», gets into the reed
valve «C» to be directed towards the
head through a flexible pipe and then a
rigid one «D» flanged to the head. In
this way, the air reaches the discharge
pipe to increase the amount of oxygen
in the unburned gases before the catalytic converter, thus helping a better
reaction of this device.
Carburettor
KEHIN CARBURETTOR
Specification
Desc./Quantity
Code CVK 20
Throttle valve diameter Ø 20.5 mm
Diffuser diameter Ø 19 mm
Body stamping ADA
Maximum jet 75
Tapered pin stamping 4REEG
Minimum jet 35
Starter nozzle 45
Type vacuum
Starter nozzle code 6ZC
Notches from the top the rod has no notches
Gasoline inlet hole Ø 1.6 mm
Starter piston protrusion 11 mm at 24°C
Characteristics MSS ZIP 100 4T
CHAR - 10
50cc Version
Tightening Torques
STEERING ASSEMBLY
Name Torque in Nm
Upper steering ring nut 35 ÷ 40
Lower steering ring nut 12 ÷ 14
Handlebar clamping screw 20 - 25 Nm
FRAME ASSEMBLY
Name Torque in Nm
Engine-swinging arm bolt 33 ÷ 41
Frame-swinging arm bolt 64 - 72
Bolt fixing shock absorber to the chassis 20 ÷ 25 Nm
Bolt fixing shock absorber to the engine 33 ÷ 41
Rear wheel axle 104 ÷ 126
Stand bolt 25 ÷ 30 Nm
Front mudguard fixing screw 4 ÷ 6
FRONT SUSPENSION
Name Torque in Nm
Fork bottom screw 20 ÷ 25
Front wheel axle 45 ÷ 50
Odometer drive screw 6 ÷ 7
FRONT BRAKE
Name
Torque in Nm
Brake fluid pump-hose fitting 20 ÷ 25
Brake fluid pipe-calliper fitting 20 ÷ 22
Calliper tightening screw 20 ÷ 25
Oil bleeding valve 8 ÷ 12
Disc tightening screw (°) 5 ÷ 6.5
N.B.
IN ORDER TO ENSURE AN ADEQUATE LOCKING TORQUE, LUBRICATE THE NUTS BEFORE
ASSEMBLING THEM.
ENGINE ASSEMBLY
Name
Torque in Nm
Ignition spark plug 10 ÷ 15 Nm
Head cover screws 8 ÷ 10
Head-cylinder stud bolt nuts 6 ÷ 7 + 90° + 90° *
Screws fixing head and cylinder to crankcase 8 ÷ 10
Chain tensioner pad screw 5 ÷ 7
Timing chain tensioner screws 8 ÷ 10 Nm
Timing chain tensioner central screw 5 ÷ 6
Camshaft pulley screw 12 ÷ 14
Rocking lever axle and camshaft bearing screw 3 ÷ 4 Nm
Valve clearance adjustment lock nuts 7 ÷ 9 Nm
Engine oil pre-filter cover 25 ÷ 28 Nm
Engine oil drainage cap 25 ÷ 28
Alternator flywheel nut 40 ÷ 44 Nm
Stator screws 3 ÷ 4
Pick-up screws 3 ÷ 4
Oil pump bulkhead screw 4 ÷ 5
Timing chain/oil pump compartment cover screws 4 ÷ 5
Oil decantation labyrinth sheet screws 7 ÷ 8
Oil pump crown screw 8 ÷ 10
Screws fixing oil pump to the crankcase 5 ÷ 6
Oil pump coupling screws 7 ÷ 9 Nm
MSS ZIP 100 4T Characteristics
CHAR - 11
Name Torque in Nm
Oil sump screws 8 ÷ 10
Inlet manifold screw 7 ÷ 9
Carburettor/manifold clamp screw 1.2 ÷ 1.5 Nm
Screws fixing cables to starter motor 1.5 ÷ 2.5
Starter screws 11 ÷ 13
Transmission cover screws 11 ÷ 13 Nm
Start-up lever screw 11 ÷ 13
Rear brake lever screw 11 ÷ 13
Crankcase cooling cover screw 2 ÷ 2.5
Nut locking clutch unit on pulley 55 ÷ 60 Nm
Crankshaft pulley nut 18 ÷ 20 + 90° ± 10°
Driven pulley shaft nut 40 ÷ 44 Nm
Hub oil drainage screw 3 ÷ 5 Nm
Rear hub cap screws 24 ÷ 26 Nm
Crankcase half union screw 8 ÷ 10
Overhaul data
Assembly clearances
Cylinder - piston assy.
COUPLING BETWEEN PISTON AND CYLINDER
Name
Initials Cylinder Piston Play on fitting
Cylinder Ø C 50
+0.021-0.007
A 49.993 ÷ 50.000 49.948 ÷ 49.955 0.038 ÷ 0.052
Cylinder Ø C 50
+0.021-0.007
B 50.000 ÷ 50.007 49.955 ÷ 49.962 0.038 ÷ 0.052
Piston Ø P 49.962
±0.014
C 50.007 ÷ 50.014 49.962 ÷ 49.969 0.038 ÷ 0.052
Piston Ø P 49.962
±0.014
D 50.014 ÷ 50.021 49.969 ÷ 49.976 0.038 ÷ 0.052
Cylinder 1st Oversize Ø
C 50.2+0.021-0.007
A1 50.193 ÷ 50.200 50.148 ÷ 50.155 0.038 ÷ 0.052
Cylinder 1st Oversize Ø
C 50.2+0.021-0.007
B1 50.200 ÷ 50.207 50.155 ÷ 50.162 0.038 ÷ 0.052
Piston 1st Oversize Ø P
50.162±0.014
C1 50.207 ÷ 50.214 50.162 ÷ 50.169 0.038 ÷ 0.052
Characteristics MSS ZIP 100 4T
CHAR - 12
Name Initials Cylinder Piston Play on fitting
Piston 1st Oversize Ø P
50.162±0.014
D1 50.214 ÷ 50.221 50.169 ÷ 50.176 0.038 ÷ 0.052
Cylinder 2nd Oversize
Ø C 50.4+0.021-0.007
A2 50.393 ÷ 50.400 50.348 ÷ 50.355 0.038 ÷ 0.052
Cylinder 2nd Oversize
Ø C 50.4+0.021-0.007
B2 50.400 ÷ 50.407 50.355 ÷ 50.362 0.038 ÷ 0.052
Piston 2nd Oversize Ø
P 50.362±0.014
C2 50.407 ÷ 50.414 50.362 ÷ 50.369 0.038 ÷ 0.052
Piston 2nd Oversize Ø
P 50.362±0.014
D2 50.414 ÷ 50.421 50.369 ÷ 50.376 0.038 ÷ 0.052
Cylinder 3rd Oversize Ø
C 50.6+0.021-0.007
A3 50.593 ÷ 50.600 50.548 ÷ 50.555 0.038 ÷ 0.052
Cylinder 3rd Oversize Ø
C 50.6+0.021-0.007
B3 50.600 ÷ 50.607 50.555 ÷ 50.562 0.038 ÷ 0.052
Piston 3rd Oversize Ø P
50.562±0.014
C3 50.607 ÷ 50.614 50.562 ÷ 50.569 0.038 ÷ 0.052
Piston 3rd Oversize Ø P
50.562±0.014
D3 50.614 ÷ 50.621 50.569 ÷ 50.576 0.038 ÷ 0.052
Piston rings
SEALING RINGS
Name
Description Dimensions Initials Quantity
1st Compression ring 50 x 1 A 0.10 ÷ 0.25 (0.40)
2nd Compression ring 50 x 1 A 0.10 ÷ 0.25 (0.35)
Scraper ring 50 x 2 A 0.20 ÷ 0.70 (0.80)
1st Compression ring 1st Oversize 50.2 x 1 A 0.10 ÷ 0.25 (0.40)
2nd Compression ring 1st Oversize 50.2 x 1 A 0.10 ÷ 0.25 (0.35)
Scraper ring 1st Oversize 50.2 x 2 A 0.20 ÷ 0.70 (0.80)
1st Compression ring 2nd Oversize 50.4 x 1 A 0.10 ÷ 0.25 (0.40)
2nd Compression ring 2nd Oversize 50.4 x 1 A 0.10 ÷ 0.25 (0.35)
Scraper ring 2nd Oversize 50.4 x 2 A 0.20 ÷ 0.70 (0.80)
1st Compression ring 3rd Oversize 50.6 x 1 A 0.10 ÷ 0.25 (0.40)
2nd Compression ring 3rd Oversize 50.6 x 1 A 0.10 ÷ 0.25 (0.35)
Scraper ring 3rd Oversize 50.6 x 2 A 0.20 ÷ 0.70 (0.80)
MSS ZIP 100 4T Characteristics
CHAR - 13
Crankcase - crankshaft - connecting rod
AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD
Name
Description Dimensions Initials Quantity
Half-shaft, transmission
side
14 +0 -0.005 A
Flywheel-side half-shaft 16 +0 -0.005 B
Connecting rod 14.8 +0.05 -0 C
Built-up camshaft 45.00 / Fits and clearan-
ces D = 0.15 ÷ 0.30
E
Characteristics MSS ZIP 100 4T
CHAR - 14
Slot packing system
THE VALUE OF MEASUREMENT «A» TO BE TAKEN CAN REFER TO EITHER THE PROTRUSION
OR RE-ENTRY OF THE PISTON. VALUES «A» INDICATED BY «-» CORRESPOND TO RE-ENTRY
AND THOSE INDICATED BY «+» CORRESPOND TO PROTRUSION. THEREFORE, THE MORE
THE PISTON PROTRUDES BEYOND THE PLANE FORMED AT THE CYLINDER UPPER END, THE
THICKER THE GASKET TO BE USED AT THE CYLINDER BASE «B» SHOULD BE.
Characteristic
Shimming system to control the compression ratio
CR: 10.5 ÷ 11.5 : 1
CYLINDER HEIGHT
54.95 ± 0.05
HEAD GASKET THICKNESS (steel)
0.3 ± 0.05
BASE GASKET THICKNESS
Specification
Desc./Quantity
Size measured «A» -0.25 ÷ -0.05 0.4
Size measured «A» -0.05 ÷ -0.15 0.5
Products
TABLE OF RECOMMENDED PRODUCTS
Product
Description Specifications
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-
quirements of API GL3 specifications
AGIP CITY HI TEC 4T Oil to lubricate flexible transmissions
(brakes, throttle control and odometer)
Oil for 4-stroke engines
MSS ZIP 100 4T Characteristics
CHAR - 15
Product Description Specifications
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP GP 330 Grease (brake control levers, throttle
grip)
Calcium complex soap-based grease
with NLGI 2; ISO-L-XBCIB2
AGIP CITY HI TEC 4T Engine oil SAE 5W-40, API SL, ACEA A3, JASO MA
Synthetic oil
AGIP BRAKE 4 Brake fluid FMVSS DOT 4 Synthetic fluid
MONTBLANC MOLYBDENUM
GREASE
Grease for driven pulley shaft adjusting
ring and movable driven pulley housing
Grease with Molybdenum disulphide
AGIP GREASE PV2 Grease for steering bearings, bolt seat-
ings for swinging arms and faying surface
of driven pulley spring (only pulley side)
Soap-based lithium and zinc oxide
grease containing NLGI 2; ISO-L-
XBCIB2
Characteristics MSS ZIP 100 4T
CHAR - 16
INDEX OF TOPICS
TOOLING TOOL
RECOMMENDED TOOLS
Stores code Description
001330Y Tool for fitting steering seats
001467Y008 Pliers to extract 17 mm ø bearings
001467Y029 Bell for bearings, O.D. 38 mm
005095Y Engine support
008119Y009 Tube to assemble shafts and axles
020004Y Punch for removing fifth wheels from
headstock
020074Y Tool to align crankshaft
020150Y Air heater support
Tooling MSS ZIP 100 4T
TOOL - 18
Stores code Description
020151Y Air heater
020392Y Fork to assemble piston and cylinder
020329Y Mity-Vac vacuum-operated pump
020330Y Stroboscopic light to check timing
020331Y Digital multimeter
MSS ZIP 100 4T Tooling
TOOL - 19
Stores code Description
020332Y Digital rpm indicator
020333Y Single battery charger
020334Y Multiple battery charger
020335Y Magnetic support for dial gauge
494929Y Exhaust fumes analyser
Tooling MSS ZIP 100 4T
TOOL - 20
BASIC TOOLS
Stores code Description
004499Y Bearing extractor. Fitted with: 1 Bell, 2
Sleeve, 3 Screw, 6 Ring, 27 Half rings, 34
Half rings
020055Y Wrench for steering tube ring nut
020162Y Flywheel extractor
020171Y Punch for driven pulley roller bearing
020265Y Bearing fitting base
020306Y Punch for assembling valve seal rings
MSS ZIP 100 4T Tooling
TOOL - 21
Stores code Description
020340Y Flywheel and transmission oil seals fitting
punch
020358Y 37x40-mm Adaptor
020359Y 42 x 47 mm Adaptor - For main bearings
and wheel axle
020360Y 52x55-mm Adaptor
020362Y 12 mm guide
020363Y 20-mm guide
020364Y 25-mm guide
020376Y Adaptor handle
Tooling MSS ZIP 100 4T
TOOL - 22
Stores code Description
020382Y Valve fitting/ removal tool
020382Y011 adapter for valve removal tool
020431Y Valve oil seal extractor
020432Y Tool to fit the start-up sector spring
020439Y 17-mm guide
020444Y Tool for fitting/ removing the driven pulley
clutch
MSS ZIP 100 4T Tooling
TOOL - 23
Stores code Description
020449Y Piston position check support
020450Y Camshaft fitting/removal tool
020451Y Driving pulley lock wrench
020452Y Tube for removing and refitting the driven
pulley shaft
020456Y Ø 24 mm adaptor
020565Y Flywheel lock calliper spanner
020498Y Pin lock fitting tool
Tooling MSS ZIP 100 4T
TOOL - 24
INDEX OF TOPICS
MAINTENANCE MAIN
Maintenance chart
AFTER 1000 KM
Action
Engine oil - level check/ top-up
Hub oil level - replacement
Valve clearance - Check
Idle speed (*) - adjustment
Throttle lever - adjustment
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Safety locks - check
Electrical System and Battery - Check
Tyre pressure - check
Vehicle and brake test - road test
AT 6000; AT 18,000; AT 30,000; AT 42,000; AT 54,000; AT 66,000 KM
Action
Engine oil - change
Hub oil level - check
Oil filter - Replacement
Variable speed rollers - check or replacement
Driving belt - Check
Brake pads - check condition and wear
Brake fluid level - check
Electrical System and Battery - Check
Tyre condition and wear - Check
Tyre pressure - check
Vehicle and brake test - road test
AT 12000; AT 36,000; AT 60,000 KM
Action
Engine oil - change
Hub oil level - check
Spark plug - replacement
Oil filter - Replacement
Idle speed (*) - adjustment
Throttle lever - adjustment
Variable speed rollers - check or replacement
Driving Belt - replacement
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - Check
Electrical System and Battery - Check
Headlight - adjustment check
Tyre condition and wear - Check
Tyre pressure - check
Vehicle and brake test - road test
AT 24000 AND AT 48000 KM
Action
Engine oil - change
Hub oil level - replacement
Spark plug - replacement
Oil filter - Replacement
Maintenance MSS ZIP 100 4T
MAIN - 26
Action
Valve clearance - Check
Idle speed (*) - adjustment
Throttle lever - adjustment
Variable speed rollers - check or replacement
Driving Belt - replacement
Cylinder ventilation system - check
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - Check
Electrical System and Battery - Check
Headlight - adjustment check
Tyre condition and wear - Check
Tyre pressure - check
Vehicle and brake test - road test
AFTER 72000 KM
Action
Engine oil - change
Hub oil level - replacement
Spark plug - replacement
Oil filter - Replacement
Valve clearance - Check
Idle speed (*) - adjustment
Throttle lever - adjustment
Variable speed rollers - check or replacement
Driving Belt - replacement
Cylinder ventilation system - check
Odometer gear - greasing
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid hoses - replacement
Brake fluid level - check
Transmission elements - lubrication
Safety locks - check
Suspensions - Check
Electrical System and Battery - Check
Headlight - adjustment check
Tyre condition and wear - Check
Tyre pressure - check
Vehicle and brake test - road test
EVERY 3000 KM
Action
Air filter - cleaning
Engine oil - Check level /Top-up
EVERY 24 MONTHS
Action
Brake fluid - change
MSS ZIP 100 4T Maintenance
MAIN - 27
Carburettor
- Disassemble the carburettor in its parts, wash all
of them with solvent, dry all body grooves with
compressed air to ensure adequate cleaning.
- Check carefully that the parts are in good condition.
-The throttle valve should move freely in the
chamber. Replace valve in case of wear due to
excessive clearance.
- If there are wear marks in the chamber causing
inadequate tightness or a free valve slide (even if
it is new), replace the carburettor.
- It is advisable to replace the gaskets at every refit.
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE
GASKETS TO AVOID PETROL LEAKS
1. Needle valve - 2. Idle speed adjustment screw - 3. Max jet - 4. Accelerating pump - 5. Tapered pin -
6. Jet holder - 7. Float - 8. Chamber - 9. Starter device - 10. Vacuum valve - 11. Cover - 12. Minimum
jet.
Specifications
Brand and Code: KEIHIN CVK 20
Adjustment code: AD8A
Type: vacuum
Diffuser diameter Ø 20.5 mm
Max. jet: 75
Min. jet: 35
Starter nozzle: 45
Starter nozzle code: 6ZC
Diffuser: Ø 2.1 mm
Tapered pin Type: 4 REEG
Notches from the top: the rod has no notches
Gasoline inlet hole: Ø 1.6 mm
Starter piston protrusion: 11 mm at 24ºC
Maintenance MSS ZIP 100 4T
MAIN - 28
Checking the spark advance
The vehicle is fitted with a variable advance electronic device. There are two timing references on the
flywheel cover in order to ensure a better precision when detecting the reference on the fan. Use a
Tecnotest 130/P stroboscopic gun or a similar device to check. Start the engine and rev it to 1800 rpm
(engine idle speed), operate the phase shifter and align the reference on the flywheel fan in between
the two references done on the cover; at the same time read the advance value shown in the stroboscopic gun display; the value must be 10°. Repeat the operation with the engine at 5000 ÷ 6000 rpm;
the advance read must be 17°.
CAUTION
SHOULD THE FLASH INDICATIONS BE UNSTABLE AND THE RPM INDICATION DOES NOT
CORRESPOND WITH THE TRUE ENGINE SPEED VARIATION (FOR EXAMPLE, VALUES SHOWN
ARE HALVED), INSTALL A 10 ÷ 15 KΩ RESISTIVE CABLE CONNECTED IN SERIES TO AN HV
CABLE. IF THE IRREGULAR READING CONTINUES AFTER THIS OPERATION, CHECK THE
COMPONENTS OF THE IGNITION SYSTEM.
N.B.
WHEN THE INDUCTION CLAMP READS THE SIGNAL CORRECTLY, A READING CAN BE CARRIED OUT AT OVER 6000 RPM.
REVOLUTION LIMITER
Specification
Desc./Quantity
1 spark on 7 10300 Rpm
1 spark on 3 10400 Rpm
all sparks are suppressed 10500 Rpm
MSS ZIP 100 4T Maintenance
MAIN - 29
Spark plug
- Disconnect and remove the spark plug pipe.
- Remove the spark plug; if necessary, use the
spanner supplied with the vehicle.
- Examine it carefully and replace it if the insulator
is chipped or cracked.
- Measure the electrode gap with a thickness
gauge and, if necessary, adjust the gap by carefully bending the outer electrode.
- Make sure the sealing washer is in good condition.
- Assemble the spark plug, screw it manually and
lock it to the prescribed torque with a spark plug
spanner.
Characteristic
Electrode gap
0.7 ÷ 0.8 mm
Recommended spark plug:
Champion RG 4 HC
CHAMPION RG 4 PHP
NGK CR9EB
Locking torques (N*m)
Spark plug 10 ÷ 15 Nm
Hub oil
Maintenance MSS ZIP 100 4T
MAIN - 30
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