PIAGGIO MSS ZIP 100 4T, ZIP 4T Service Manual

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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.

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

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

Check

- Park the scooter on level ground and rest it on the centre stand.

- Unscrew the dipstick «A», dry it with a clean rag and then reinsert it, screwing it tightly into place.

- Take out the dipstick checking oil level is between the second and third notch from the bottom (MAX and MIN shown in figure).

- If the level is under the MIN notch, refill the hub with the right amount of oil.

- Screw up the oil dipstick again and make sure it is locked properly into place.

Recommended products

AGIP ROTRA 80W-90 Rear hub oil

SAE 80W/90 Oil that exceeds the requirements of API GL3 specifications

Replacement

- Remove the oil filling cap/dipstick «A»

- Unscrew the oil drainage cap «B» shown in the figure and drain out all the oil.

- Screw the drainage cap back and fill up the hub with the required oil (about 80 cc)

MSS ZIP 100 4T Maintenance

MAIN - 31

Air filter

Remove the air cleaner cap after undoing the 6 fixing screws, then extract the filter.

Cleaning:

- Wash with water and soap.

- Dry with a clean cloth without wringing.

- Soak with a mixture of 50% petrol and 50% SELENIA AIR FILTER OIL.

-Drip dry the filter and then squeeze it between the hands without wringing.

N.B. NEVER RUN THE ENGINE WITHOUT THE AIR FILTER,

THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER.

Engine oil

Engine oil is used in 4T engines to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can cause serious damage to the engine. In all 4T engines, a loss of efficiency in oil performance and a certain level of consumption should be considered normal. Consumption is specially affected by use conditions (e.g.: oil consumption increases when driving at "full throttle". The replacement frequencies provided for by the maintenance programme are defined, depending on the total contents of oil in the engine and average consumption measured following standardised methods. In order to avoid problems, it is advisable to control oil level every

time the vehicle is used.

Replacement

Replace oil and clean the mesh filter every 6,000 km. The engine must be drained by running off the oil from drainage cap «B» with hot engine. To facilitate oil drainage, loosen the cap «C» and take out the mesh filter. After cleaning and refitting the mesh filter, tighten cap «C», refill with about 650 cc oil through cap «A». Then start up the scooter, leave it running for a few minutes and switch it off: 5 minutes later check oil level and, if necessary, add oil without exceeding the MAX level. Only use new oil of the recommend type for oil top-ups and change.

Maintenance MSS ZIP 100 4T

MAIN - 32

CAUTION USING THE ENGINE WITH INSUFFICIENT LUBRICATION

OR WITH THE WRONG LUBRICANTS MAY INCREASE WEAR AND TEAR ON THE MOVING PARTS AND MAY RESULT IN SERIOUS DAMAGE.

WARNING USED OIL CONTAINS ENVIRONMENTALLY HARMFUL

SUBSTANCES

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40, API SL, ACEA A3, JASO MA Synthetic oil

Check

Every time the scooter is used, a visual check should be made on the engine oil level when the engine is cold. The oil level should be somewhere between the MAX and MIN oil marks; during the oil check, the vehicle must be resting on its centre stand on an even, horizontal surface. The MAX level mark indicates a quantity of around 850 cc of oil in the engine. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry out a correct check it is necessary to wait at least 10 minutes after the engine has been stopped, so as to get the correct level.

Oil top-up

Always check oil level before a top-up and add oil without exceeding the MAX level. After every 3000 km check level and, if necessary, refill with engine oil.

MSS ZIP 100 4T Maintenance

MAIN - 33

Engine oil filter

- Change oil when the engine is hot.

- Place a container under the oil sump and remove the oil drainage cap.

- After draining the oil, clean the mesh filter with a specific solvent and then blow it with compressed air.

- The filter can be reached after removing cap "A" (see figure).

- After this operation, refit the filter and screw the oil cap at the prescribed torque using a new ORing

- Refill the engine with oil through the oil filling hole located in the oil sump.

- Engine oil capacity: ~ 850 cc.

- Lock the cap manually.

N.B. MAKE THE ENGINE TURN FOR A COUPLE OF MINUTES

AND THEN CONTROL OIL LEVEL WHEN THE ENGINE IS COLD. THE LEVEL SHOULD ALWAYS BE BELOW THE MAX. NOTCH.

N.B. IF IT IS THE 1ST TIME IT IS FILLED OR CHECKED, ADD 850

CC OF ENGINE OIL. IN ANY OTHER CIRCUMSTANCE OR FOR TOP-UPS, ADD 650 CC.

Recommended products

AGIP CITY HI TEC 4T Engine oil

SAE 5W-40 Synthetic oil that exceed the requirements of API SL, ACEA A3, JASO MA specifications

Locking torques (N*m)

Engine oil pre-filter cover 25 ÷ 28 Nm

Maintenance MSS ZIP 100 4T

MAIN - 34

Checking the ignition timing

- Turn the flywheel clockwise until its 2nd notch coincides with the Pick-up reference mark as shown in the figure. Make sure that the reference point on the camshaft command crown is aligned with the reference point on the head as shown in the second figure. If the reference is opposite the indicator on the head, turn the crankshaft once more as the piston must be at the TDC of the bursting phase.

N.B. TIME THE TIMING SYSTEM UNIT AS DESCRIBED IN CHAP-

TER 6 IF IT IS NOT IN PHASE

Checking the valve clearance

- Remove the spark plug access cover, undo the 4 fixing screws indicated in the figure and remove the tappet cover.

- To check valve clearance, centre the reference marks of the timing system point as described above.

- Use an adequate thickness gauge to check that the clearance between the valve and the register corresponds with the indicated values. Should the valve clearance values, intake and drainage respectively, be different from the ones indicated below, adjust them by loosening the lock nut and operate on the register with a screwdriver as shown in the figure.

Characteristic

Inlet (with cold engine)

0.10 mm

Outlet (with cold engine)

MSS ZIP 100 4T Maintenance

MAIN - 35

0.15 mm

Headlight adjustment

Proceed as follows:

1. Place the vehicle, in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10-m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen;

2. Turn on the headlight and check that the borderline of the projected light beam on the screen is not higher than 9/10 or lower than 7/10 of the distance from the ground to the centre of vehicle headlamp;

3. If otherwise, adjust the right headlight with screw «A».

N.B. THE ABOVE PROCEDURE COMPLIES WITH THE EURO-

PEAN STANDARDS REGARDING MAXIMUM AND MINIMUM HEIGHT OF LIGHT BEAMS. REFER TO THE STATUTORY REGULATIONS IN FORCE IN EVERY COUNTRY WHERE THE VEHICLE IS USED.

CO check

- CO checking may be necessary when an engine operation failure is detected or during engine idle speed adjustment operations.

- This test must be carried out after washing all carburettor parts carefully, the air filter must be clean and the ignition spark plug in good conditions.

1) warm up the vehicle travelling on the streets at about 50 km/h for ~5 minutes; time enough for the automatic starter to exclude the circuit.

2) Shut off the vehicle only for the time required to carry out steps 3) and 4).

3) Connect a - 50 cm extension pipe to the exhaust fumes intake in the muffler.

4) Make sure the muffler and the pipe are adequately connected and tight. Insert the exhaust fumes analyser probe into the pipe.

5) Connect the tester thermometer to the sump, using a cover with oil expressly prepared for probes.

6) Start the engine and before adjusting the idle speed, make sure that the oil temperature is between 70÷80 °C.

7) Wait until the idle speed stabilises for one minute.

8) Without operating the accelerator again and using the flow screw rev the engine at 1500±150 rpm.

Maintenance MSS ZIP 100 4T

MAIN - 36

9) Adjust the flow screw so that the "CO" value is equal to 3.2 % :t 0.5 %.

10) Slowly operate the throttle accelerating the engine until it reaches 4000 rpm and then set throttle back to close position; check that the idle speed remains at the above set value; if not, repeat the procedure starting from step (3).

Specific tooling

020332Y Digital rpm indicator 494929Y Exhaust fumes analyser 020331Y Digital multimeter

MSS ZIP 100 4T Maintenance

MAIN - 37

INDEX OF TOPICS

TROUBLESHOOTING TROUBL

EXCESSIVE FUEL CONSUMPTION

Possible Cause Operation

Air filter obstructed or dirty. Dismantle the sponge, wash with water and shampoo, then

soak it in a mixture of 50% petrol and 50% Selenia Air Filter Oil,

then allow to drip dry. Wring out water manually without

squeezing and reassemble

The starter remains on Check that the starter runs correctly and it is properly powered

Loose nozzles Check the maximum and minimum nozzles are adequately

fixed in their fittings

Incorrect float level Restore the correct level in the chamber (the float must be par-

allel to the upper cover contact plane, that is the throttle valve

membrane cover)

FAULTY CLUTCH

Possible Cause Operation

Tear or irregular functioning Check that there is no grease on the masses. Check that the

clutch masses' contact surface with the clutch bell is mainly in the middle with equivalent specifications on the three masses.

Check that the clutch bell is not scored or worn abnormally

This section makes it possible to find the solutions to use in troubleshooting. For each breakdown, a list of the possible causes and respective interventions is given.

Engine

Poor performance

LOW COMPRESSION

Possible Cause

Operation

Wrong valve adjustment Adjust the valve clearance properly

incorrect valve sealing Remove the head and the valves, grind the seats, descale the

valve heads and, if necessary, replace any faulty part.

Valve seat distorted Replace the head assembly

Worn or broken cylinder or piston rings Replace the piston cylinder assembly or the piston rings

POOR PERFORMANCE

Possible Cause

Operation

The carburettor is dirty; vacuum operated cock failure Dismantle, wash with solvent and dry with compressed air or

replace

Excess of scales in the combustion chamber Descale the cylinder, the piston, the head and the valves

Incorrect timing or worn timing system elements Time the system again or replace the worn parts

Muffler obstructed Replace

Automatic starter failure Check: mechanical movement, electric connection and fuel

supply, replace if required.

Oil level exceeds maximum Check for causes and fill to reach the correct level

Lack of compression: parts, cylinder and valves worn Replace the worn parts

Driving belt worn Replace

Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-

aged parts and lubricate the driven pulley moveable guide with

Montblanc Molybdenum Grease

Clutch slipping Check the clutch system and/or the bell and replace if neces-

sary

Overheated valves Remove the head and the valves, grind or replace the valves

Wrong valve adjustment Adjust the valve clearance properly

Valve seat distorted Replace the head unit

MSS ZIP 100 4T Troubleshooting

TROUBL - 39

Possible Cause Operation

Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then

soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to

drip dry and then reassemble.

Defective floating valve Check the proper sliding of the float and the functioning of the

valve

Rear wheel spins at idle

REAR WHEEL

Possible Cause Operation

Idling rpm too high Check the idling speed and, if necessary, adjust the C.O.

Clutch fault Check the spring/friction mass and the clutch bell

Air filter housing not sealed Correctly refit the filter housing and replace it if it is damaged

Purifier-carburettor fitting damaged Replace

Starting difficulties

DIFFICULTY STARTING UP

Possible Cause Operation

Defective spark plug or with incorrect electrode gap Check and if necessary replace the spark plug and the elec-

trode gap

Battery flat Check the state of the battery. If it shows signs of sulphation

replace it and bring the new battery into service charging it for

eight hours at a current of 1/10 of the capacity of the battery

itself

- Engine flooded. Start the vehicle keeping the throttle fully open alternately making the engine run for approx. five seconds and stopping for

other five seconds. If however it does not start, remove the

spark plug, the engine over with the throttle open being careful

to keep the cap in contact with the spark plug and the spark plug grounded but away from its hole. Refit a dry spark plug

and start the vehicle.

Vacuum operated cock failure Check that fuel is adequately supplied through the pipe by ap-

plying a vacuum on the suction pipe

Failing automatic starter on the carburettor Check the electrical wiring and mechanical movement, replace

if necessary.

Wrong ignition advance Check flywheel keying on the crankshaft, replace control unit if

necessary

Incorrect valve sealing or valve adjustment Remove the head and the valves, grind the seats, descale the

valve heads and, if necessary, replace any faulty part. check

and restore the correct valve clearance.

Start-up rpm too low or starter motor failure Check starter motor

Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill

Carburettor nozzles clogged or dirty Dismantle, wash with solvent and dry with compressed air

Excessive oil consumption/Exhaust smoke

RICH OR GREASY MIX

Possible Cause

Operation

Air calibrated holes in carburettor blocked Dismantle, wash with solvent and dry with compressed air

Defective floating valve Check the proper sliding of the float and the functioning of the

valve

Level in chamber too high Restore the correct level in the chamber (the float must be par-

allel to the upper cover contact plane, that is the throttle valve

membrane cover)

The starter remains on Check that the automatic starter works and moves correctly

and it is properly powered.

Troubleshooting MSS ZIP 100 4T

TROUBL - 40

Possible Cause Operation

Air filter dirty Dismantle the sponge, wash with water and shampoo, then

soak it in a mixture of 50% petrol and 50% Selenia Air Filter Oil,

then allow to drip dry. Wring out water manually without

squeezing and reassemble.

EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Possible Cause Operation

Worn or broken cylinder or piston rings Replace the piston cylinder assembly or the piston rings

Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal

Worn valve oil guard Replace the valve oil guard

Worn valve guides Check and replace the head unit if required

Insufficient lubrication pressure

POOR OR LEAN MIX

Possible Cause Operation

Carburettor nozzles clogged Dismantle, wash with solvent and dry with compressed air

Defective floating valve Check the proper sliding of the float and the functioning of the

valve

Level in chamber too low Restore the correct level in the chamber (the float must be par-

allel to the upper cover contact plane, that is the throttle valve

membrane cover)

Tank breather hole obstructed Restore the proper reservoir aeration

Fuel filter on vacuum operated cock blocked Clean the cock filter

Fuel supply pipes choked or clogged Restore the adequate fuel supply

Intake joint cracked or with a bad seal Replace intake joint and check for correct sealing on the head

Air filter housing not sealed Correctly refit the filter housing and replace it if it is damaged

Purifier-carburettor fitting damaged Replace

POOR LUBRICATION PRESSURE

Possible Cause

Operation

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the

By-Pass area.

Oil pump with excessive clearance Perform the dimensional checks on the oil pump components

Oil filter too dirty Replace the cartridge filter Oil level too low Restore the level using the recommended oil type (Selenia HI

Scooter 4 Tech)

Engine tends to cut-off at full throttle

THE MOTOR TENDS TO STOP AT MAXIMUM THROTTLE

Possible Cause

Operation

Maximum jet clogged Remove the carburettor, wash with solvent and dry with com-

pressed air

Incorrect ignition advance Use a stroboscopic light to check ignition advance and the fly-

wheel correct keying

Water or condensation in the carburettor chamber Remove the chamber, wash with solvent and dry with com-

pressed air or empty the tank through the appropriate bleed

screw

Air filter obstructed or dirty. Dismantle the sponge, wash with water and shampoo, then

soak it in a mixture of 50% petrol and 50% Selenia Air Filter Oil,

then allow to drip dry. Wring out water manually without

squeezing and reassemble

Incorrect float level Check and restore the correct fuel level in the chamber

MSS ZIP 100 4T Troubleshooting

TROUBL - 41

Engine tends to cut-off at idle

THE ENGINE TENDS TO STOP AT IDLE SPEED

Possible Cause Operation

Wrong idling adjustment Correctly adjust the engine idling and check the level of the

C.O.

Spark plug defective or faulty Replace the spark plug with one with the specified degree and

check the plug gap

The starter remains activated Check that the automatic starter works and moves correctly

and it is properly powered.

Minimum jet dirty Remove the carburettor, wash with solvent and dry with com-

pressed air

Electronic ignition circuit failure Use a stroboscopic light and an rpm indicator to check for cor-

rect ignition advance and make sure the flywheel is correctly

keyed

Pressure too low at the end of compression Check the thermal group seals and replace worn components;

check and restore the correct valve clearance.

Incorrect timing Time the system and check the timing system components

Excessive exhaust noise

EXCESSIVE EXHAUST NOISE

Possible Cause

Operation

Depression intake pipe of the secondary air device disconnec-

ted or dented

Replace the pipe

Reed valve of the secondary air device does not close correctly and wears out the rubber coupling between the device and the

head pipe

Replace the device and the coupling

High fuel consumption

HIGH FUEL CONSUMPTION

Possible Cause

Operation

Float level Restore the level in the tank by bending on the float the thrust-

ing reed of the petrol inlet rod so as to have the float parallel to

the tank level with the carburettor inverted.

Loose nozzles Check the maximum and minimum nozzles are adequately

fixed in their fittings

Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and

power supply

Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then

soak it in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then hand dry without squeezing, allow to

drip dry and then reassemble.

SAS malfunctions

ANOMALIES IN THE SECONDARY AIR DEVICE

Possible Cause

Operation

Depression intake pipe of the secondary air device disconnec-

ted or dented

Replace the pipe

Reed valve of the secondary air device does not close correctly and wears out the rubber coupling between the device and the

head pipe

Replace the device and the coupling

Troubleshooting MSS ZIP 100 4T

TROUBL - 42

Transmission and brakes

REAR BRAKE LEVER FAIL TO RETURN

Possible Cause Operation

Return spring broken Replace spring.

Shoe control bolt not lubricated Lubricate with Z2 grease.

Clutch grabbing or performing inadequately

IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

Possible Cause Operation

Faulty clutch Check that there is no grease on the masses. Check that the

clutch mass faying surface with the bell is mainly in the centre with equivalent characteristics on the three masses. Check that

the clutch casing is not scored or worn in an anomalous way

Insufficient braking

INEFFICIENT OR NOISY BRAKING

Possible Cause

Operation

Brake pads or shoes worn Replace the brake pads or shoes and check for brake disk or

drum wear conditions. If the front calliper is removed to facilitate replacement, remember to replace the copper gaskets located

on the tube joint when refitting; failure to do so may result in

inadequate tightness; it is necessary to bleed the brakes after

this operation.

Air bubbles inside the hydraulic braking system Carefully bleed the hydraulic braking system, (there must be

no flexible movement of the brake lever).

Brake disc or drum deformed Use a dial gauge to check the levelness of the disk with the

wheel correctly fitted and the concentricity of the rear drum;

check the brake disc screws are locked

Fluid leakage in hydraulic braking system Elastic fittings, piston seals or brake pump breakdown, replace

Excessive backlash in the rear brake control cable Adjust backlash with the appropriate adjuster on the shoe con-

trol lever

The brake fluid has lost its properties Replace the front brake fluid and top up to the correct level in

the pump

INSUFFICIENT BRAKING

Possible Cause

Operation

Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are

not worn, scored or warped. Check the correct level of fluid in the pumps and change brake fluid if necessary. Check there is no air in the circuits; if necessary, bleed the air. Check that the

front brake calliper moves in axis with the disc.

Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace

Brakes overheating

BRAKES OVERHEATING

Possible Cause

Operation

Defective plunger sliding Check calliper and replace any damaged part.

Brake disc or drum deformed Use a dial gauge to check the levelness of the disk with the

wheel correctly fitted and the concentricity of the rear drum;

check the brake disc screws are locked

MSS ZIP 100 4T Troubleshooting

TROUBL - 43

Electrical system

Battery

BATTERY

Possible Cause Operation

The battery is the electrical device in the system that requires

the most frequent inspections and thorough maintenance.

The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance. If the vehicle is not used for some time (1 month or more) the battery

needs to be recharged periodically. The battery runs down completely in the course of 5 ÷ 6 months. If the battery is fitted on a motorcycle, be careful not to invert the connections, keeping in mind that the black earth wire is connected to the negative terminal while the red wire is connected to the terminal marked

Turn signal lights malfunction

ELECTRICAL SYSTEM MALFUNCTION

Possible Cause

Operation

Turn indicators do not turn on Check turn indicators device and/or wiring as described in the

«Electrical system» chapter.

TURN INDICATOR NOT WORKING

Possible Cause

Operation

Electronic ignition device failure With the key switch set to "ON" jump the contacts 1 (Blue -

Black) and 3 (White) on the voltage regulator connector. If by

operating the turn indicator control the lights are not steadily

on, replace the control unit; otherwise, check the cable harness

and the switch.

Steering and suspensions

Rear wheel

REAR WHEEL ROTATES WITH ENGINE AT IDLE

Possible Cause

Operation

Idling rpms too high Adjust the engine idle speed and the CO%, if necessary.

Clutch fault Check the springs / clutch masses

Controls

STEERING AND SUSPENSIONS CONTROLS

Possible Cause

Operation

Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-

larities continue in turning the steering even after making the above adjustments, check the seats in which the ball bearings rotate: replace them if they are recessed or if the balls are flat-

tened.

Troubleshooting MSS ZIP 100 4T

TROUBL - 44

Possible Cause Operation

Excessive steering clearance Check the tightening of the top ring nut. If irregularities continue

in turning the steering even after making the above adjust-

ments, check the seats in which the ball bearings rotate: re-

place if they are recessed.

Noisy suspension If the front suspension is noisy, check: that the front shock ab-

sorber works properly and the ball bearings are good condition. In conclusion, check the tightening torque of the wheel hub, the brake calliper, the shock absorber disk in the attachment to the

hub and the steering tube.

Check that the swinging arm connecting the engine to the

chassis and the rear shock absorber work properly

Oil leakage from suspension Replace the shock absorber

MSS ZIP 100 4T Troubleshooting

TROUBL - 45

INDEX OF TOPICS

ELECTRICAL SYSTEM ELE SYS

KEY

1. Electronic ignition device

2. Spark plug

3. Magneto flywheel

4. Voltage regulator

5. Main fuse

6. Key switch

7. Battery

8. Starter motor

9. Starter remote control

10. Starter button

11. Rear brake STOP button

12. Front brake STOP button

13. Horn button

14. Horn

15. Left rear turn indicator bulbs

16. Tail lights/stop light bulbs

17. Turn indicator switch

18. Right rear turn indicator bulbs

19. Left side headlight assembly

MSS ZIP 100 4T Electrical system

ELE SYS - 47

A. Left front turn indicator bulb B. Front position light bulb

20. Headlight assembly with high-/low-beam bulb

21. Right side headlight assembly A. Left front turn indicator bulb B. Front position light bulb

22. Light switch

23. Instrument panel A. Turn indicator warning light B. High-beam warning light C. Low fuel warning light D. Instrument panel bulb E. Instrument panel bulb

24. Fuel level warning light control

25. Automatic starter

26. Resistance Ar = Orange, Az = Sky Blue, Bi = White, Bl = Blue, Gi = Yellow, Gr = Grey, Ma = Brown, Ne = Black,

Ro = Pink, Rs = Red, Ve = Green, Vi = Purple

Conceptual diagrams

Electrical system MSS ZIP 100 4T

ELE SYS - 48

Ignition

KEY

1. Electronic ignition device

2. Spark plug

3. Magneto flywheel

6. Key switch

MSS ZIP 100 4T Electrical system

ELE SYS - 49

Headlights and automatic starter section

KEY

3. Magneto flywheel

4. Voltage regulator

16. Tail lights/stop light bulbs

19. Left side headlight assembly A. Left front turn indicator bulb B. Front tail light bulb

20. Headlight assembly with high-/low-beam bulb

21. Right side headlight assembly A. Left front turn indicator bulb B. Front position light bulb

22. Light switch

23. Instrument panel

25. Automatic starter

26. Resistance

Electrical system MSS ZIP 100 4T

ELE SYS - 50

Battery recharge and starting

KEY

3. Magneto flywheel

4. Voltage regulator

5. Main fuse

6. Key switch

7. Battery

8. Starter motor

9. Starter remote control

10. Starter button

11. STOP button on rear brake

12. Front brake STOP button

16. Tail lights/stop light bulbs

MSS ZIP 100 4T Electrical system

ELE SYS - 51

Level indicators and enable signals section

KEY:

5. Main fuse

6. Key switch

7. Battery

23. Instrument panel A. Flashing warning light B. High-beam warning light C. Low fuel warning light D. Instrument panel bulb E. Instrument panel bulb

24. Fuel level warning light control

Electrical system MSS ZIP 100 4T

ELE SYS - 52

Turn signal lights

KEY:

3. Magneto flywheel

4. Voltage regulator

5. Main fuse

6. Key switch

7. Battery

13. Horn button

14. Horn

15. Left rear turn indicator bulbs

17. Turn indicator switch

18. Right rear turn indicator bulbs

19. Left side headlight assembly A. Left front turn indicator bulb B. Front tail light bulb

21. Right side headlight assembly A. Left front turn indicator bulb B. Front tail light bulb

23. Instrument panel

MSS ZIP 100 4T Electrical system

ELE SYS - 53

A. Flashing warning light B. High-beam warning light C. Low fuel warning light D. Instrument panel bulb E. Instrument panel bulb

Checks and inspections

In case the cause of ignition failure or malfunction cannot be easily identified at sight, first of all replace the control unit by another one in operating conditions. Remember that the engine must be off to disconnect and replace the control unit. If after replacement the vehicle starts properly, the control unit is failing and must be replaced.

If the failure persists, check the generator and the stator components as follows: After a sight control of the electrical connections, use a specific tester to measure the stator winding and the pick-up. If checks on the loading coil, pick-up detect irregularities, replace the stator and the failing com- ponents. Disconnect the connector on the flywheel cover and measure the resistance between either contact and the earthing.

Specific tooling

020331Y Digital multimeter

PICK-UP CHECK

Specification

Desc./Quantity

1 1) Brown cable and earth ~ 170 Ω

STATOR WINDING CHECK

Specification

Desc./Quantity

1 1) Black cable and earth ~ 1 Ω

Electrical system MSS ZIP 100 4T

ELE SYS - 54

KEY: Br= brown Bl= black A= Pick-up B= Stator

Ignition circuit

All the control operations of the system that require the disconnection of cables (checks of the connections and the devices making up the ignition circuit) must be done with the engine off: if this is not done, the controls might be irretrievably damaged.

Stator check

- Using a tester, check the resistance between the brown-earth and black-earth terminal.

N.B. VALUES ARE STATED AT AMBIENT TEMPERATURE. A

CHECK WITH THE STATOR AT OPERATING TEMPERATURE LEADS TO VALUES HIGHER THAN THOSE STATED.

Electric characteristic

Stator : Brown-earth

approx. 170 Ω (Pick-Up)

Stator : Black-earth

~ 1 Ω (Stator)

MSS ZIP 100 4T Electrical system

ELE SYS - 55

Voltage regulator check

A malfunction in the voltage regulator might cause the following problems depending on the type of fault:

Alternating current section

1) Bulbs burned out (regulator in short circuit).

2) Malfunctioning of the lighting system and the

electric starter (regulator interrupted).

Direct current section

3) Battery not recharging.

4) Turn indicators not working.

The regulator is earthed through the electrical system, so the regulator body does not earth the circuits inside the regulator. There must be insulation between each regulator terminal and the regulator body (use the tester to check electric resistance).

Measures

1) Bulbs burn out

Replace the regulator because it is certainly inefficient.

2) Lights and starter not working

Gain access to the voltage regulator, start the engine and keep it at idle speed; keep the vehicle lighting system off. Connect the tester positive end (select it to detect alternating voltage) to terminal No 1 (grey cable) and the negative end to terminal No 2 (black cable); check there is voltage (see figure). If there is voltage, check the wiring connecting lights switch and the regulator and make sure the switch works properly. If no voltage is detected, try connecting the negative end directly to earth; if voltage is detected with this operation, check the earth wiring of the regulator; otherwise, replace the regulator because it is damaged.

Electrical system MSS ZIP 100 4T

ELE SYS - 56

As a last check, the voltage supplied by the stator can be measured:

- Disconnect the regulator connector and place a tester between the Grey-Blue cable (4) and the earth in order to detect alternating voltages (see figure).

- Voltage supplied at 2000 rpm must be about 25 ÷ 35V. If no values are detected with this test, replace the regulator because it is obviously broken.

N.B. TO MEASURE THE ABOVE VOLTAGE USE AN ANALOGUE

TESTER THAT CAN MEASURE ALTERNATING VOLTAGES AND KEEP THE ENGINE AT IDLE TO HAVE AN ALTERNATING VOLTAGE OF A FREQUENCY AS CLOSE AS POSSIBLE TO 50HZ SO AS TO DETECT THE EFFICIENT VOLTAGE VALUE SUPPLIED BY THE REGULATOR (ABOUT 12V).

Recharge system voltage check

3) Battery fails to recharge

a failure in the direct current section of the voltage regulator may cause the following problems depending on the type of fault:

a) Protection fuse blows due to overvoltage (regulator in short circuit) and consequently the battery fails to recharge. b) Battery fails to recharge (regulator interrupted). Measures a) Protection fuse blows (regulator in short circuit).

Check that the wiring connecting the protection fuse and the key switch is not damaged and causing a short circuit to the earth (thus excluding the possibility that the regulator is damaged); if the protection fuse blows only after the key switch is set to "ON" and with the regulator connector disconnected, check that the upstream wiring and devices of the key switch are not in short circuit to the earth. Now measure the resistance between contact 3 (White) and contact 2 (Black) of the volt-

MSS ZIP 100 4T Electrical system

ELE SYS - 57

age regulator (with connector disconnected); the measurement must be ~8 M/Ohm. If the value measured is far from that indicated, replace the regulator because it is in short circuit. b) Battery fails to recharge (regulator interrupted). To check if there is any failure in the voltage regulator recharge section, first connect 2 testers to the battery (one to detect voltage and the other to detect current) as indicated in the second figure and follow the procedure below: Start the engine (temporarily connect the red cable to the battery positive terminal in order to avoid damaging the device that measures current). Check there is at least 13V (charged battery) and a recharge current of 1.5 ÷ 2A with the vehicle lights off. As the engine rpm increases, so do the current and the recharge voltage; with rpm over 4000 there must be a recharge current of about 4.5A; when the vehicle lights and the stop light are switched on and the horn is powered, current values below or equal to 5A and a voltage value of 14 ÷ 14.5V ( regulator threshold voltage) can be registered. If values other than those above are detected, replace the regulator; contrariwise, check the cable harness and the connections.

Starter motor

Test to be carried out to check the electrical starter motor

1) Check the battery charging conditions.

2) - Check the remote control and the system. The check can be carried out by replacing a 12V-35W

bulb of the starter.

- If the bulb turns on, replace the starter motor.

- If the bulb does not turn on, check the system and the remote control.

Starter motor Specifications:

- Nominal voltage 12V.

Electrical system MSS ZIP 100 4T

ELE SYS - 58

- Nominal power 0.25 kW.

- Leftward rotation seen from the pinion side.

- Connection to the engine by means of pinion and crown gear on the crankshaft, transmission side.

- Control with switch.

- Battery used for the test: 12V-7Ah.

Turn signals system check

4) Turn indicators not working

If the turn indicators do not work, do the following:

- Disconnect the regulator connection and insert the tester end between the white cable (3) and the black one (2).

- Turn the key switch to ON and check that the battery is getting voltage. If no voltage is detected, repeat the test now between the white cable and the earth; if there is no voltage even after this operation, check the wiring and the contacts of the key switch and the battery. If voltage in the battery is detected (black cable), check the regulator earth wiring.

- If the above tests have positive results, jump the contacts 5 (blue/black) and 3 (white) on the connector, set the key switch to ON and turn the turn indicator switch left and right to see when the lights are steadily on (as they are powered directly from the battery). If even after this operation the turn indicators fail to turn on, check the wiring is not damaged and switch works properly; If these last two tests have a positive result, replace the regulator because it is certainly not functioning properly.

Specific tooling

020331Y Digital multimeter

MSS ZIP 100 4T Electrical system

ELE SYS - 59

Fuses

The electrical system is protected by a 10 A fuse «A» located to the left of the battery support. The ignition system, the automatic starter, front headlight and the tail light are not fuse-protected. Before replacing a blown fuse, find and solve the problem that caused it to blow. Do not substitute the fuse with any alternative form of conductor

BATTERIES CONTAIN VERY ENVIRONMENTAL DANGEROUS SUBSTANCES. FOR BATTERY REPLACEMENT, CONTACT AN AUTHORISED PIAGGIO-GILERA SERVICE CENTRE, AS THEY ARE EQUIPPED FOR THE DISPOSAL IN AN ENVIRONMENTALLY FRIENDLY AND LEGAL WAY.

Sealed battery

Using the sealed battery for the first time

If the vehicle is provided with an airtight battery, the only maintenance required is the check of its charge and recharging, if needed. These operations should be carried out before delivering the scooter, and on a six-month basis while the vehicle is stored in open circuit. Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, before storing the scooter and afterwards every six months.

Instructions for the renewal recharge after open-circuit storage

1) Voltage check

Before installing the battery on the vehicle, check the open circuit voltage with a normal tester.

- If the voltage exceeds 12.60 V, the battery may be installed without any renewal recharge.

- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).

2) Constant voltage battery charge mode

-Constant voltage equal to 14.40 to 14.70V

-Initial charge voltage equal to 0.3 to 0.5 x nominal capacity

-Duration of the charge: 10 to 12 h recommended Minimum 6 h

Electrical system MSS ZIP 100 4T

ELE SYS - 60

Maximum 24 h

3) Constant current battery charge mode

-Charge current equal to 1/10 of the nominal capacity of the battery

-Duration of the charge: 5 h

WARNING

-WHEN THE BATTERY IS REALLY FLAT (WELL BELOW

12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE. IN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED EIGHT HOURS OF CONTINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.

1 Hold the vertical tube 2 Look at the level 3 The float must be freed

Dry-charge battery

Battery maintenance

The battery is an electrical device which requires careful monitoring and diligent maintenance. The maintenance rules are:

1) Check the level of the electrolyte

The electrolyte level must be checked frequently and must reach the upper level. Only use distilled water, to restore this level. If it is necessary to add water too frequently, check the vehicle's electrical system: the battery that is working in overloaded mode gets ruined quickly.

2)Load status check

After restoring the electrolyte level, check its density using an appropriate densitometer (see the figure). When the battery is charged, you should detect a density of 30÷32 Bé corresponding to a specific weight of 1.26÷1.28 at a temperature not lower than 15ºC. If the density has fallen below 20 Bé, the battery is completely flat and therefore it is necessary to recharge it. After charging the battery, check each element electrolyte level and density. If the vehicle is not used for some time (1 month or more) the battery needs to be recharged periodically. The battery runs down completely in the course of three months. If it is necessary to refit the battery in the vehicle, be careful not to reverse the connections, remembering that the ground wire (black) marked (-) must be connected to the -negative clamp while the other two

red wires marked (+) must be connected to the clamp marked with the +positive sign.

3) Recharging the battery

The normal bench charging must be carried out with the specific battery charger 020333Y (single) or 020334 (multiple), placing the battery charger selector on the type of battery to be recharged. The connections to the power supply must be made by connecting to the corresponding poles (+ with+ and

-with -).

WARNING

BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.

MSS ZIP 100 4T Electrical system

ELE SYS - 61

KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED. FIRST DETACH THE NEGATIVE LEAD BEFORE REMOVING THE BATTERY FROM THE VEHICLE.

4) Cleaning the battery

You are advised to keep the battery clean,especially in the upper part, and to protect the terminals with Vaseline.

CAUTION

NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE.

CAUTION

ORDINARY AND DRINKING WATER CONTAINS MINERAL SALTS THAT ARE HARMFUL FOR THE BATTERY. FOR THIS REASON, YOU MUST ONLY USE DISTILLED WATER.

CAUTION

TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY.

Use of dry-cell batteries :

1) Having removed the short, closed tube and removed the caps, put into the elements sulphuric acid

of the type for specific weight 1.26 accumulators corresponding to 30 Bé at a temperature of no less than 15°C, until the upper level is reached.

2)Leave to rest for at least 2 hours; then, restore the level with sulphuric acid.

3) Within the following 24 hours, recharge with the specific battery charger 020333Y (single) or 020334Y

(multiple) at a density of about 1/10 of the battery nominal capacity and until the acid density is about

1.27, corresponding to 31Bé, and these values are stabilised.

4) Once the charge is over, level the acid (by adding distilled water). Replace the caps and clean carefully.

5)Once the above operations have been performed, install the battery in the vehicle ensuring the connections between the wiring and the battery terminals are correct.

WARNING

- ONCE THE BATTERY HAS BEEN INSTALLED IN THE VEHICLE IT IS NECESSARY TO REPLACE THE SHORT TUBE (WITH CLOSED END) NEAR THE + POSITIVE TERMINAL WITH THE CORRESPONDING LONG TUBE (WITH OPEN END), THAT YOU FIND FITTED TO THE VEHICLE, TO ENSURE THAT THE GASES THAT FORM CAN ESCAPE PROPERLY.

WARNING

THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH THE EYES, THE SKIN AND CLOTHING. IF COMING INTO CONTACT WITH EYES OR SKIN, WASH ABUNDANTLY WITH WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IN THE EVENT OF ACCIDENTAL INGESTION OF THE LIQUID, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR MILK, MAGNESIUM MILK, BATTERED EGG OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. THE BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIGARETTES; VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF REACH OF CHILDREN

Electrical system MSS ZIP 100 4T

ELE SYS - 62

INDEX OF TOPICS

ENGINE FROM VEHICLE ENG VE

Exhaust assy. Removal

- Remove the 2 fixing nuts from the manifold to the head

- Undo the 2 screws fixing the muffler to the housing; then remove the whole muffler paying attention to the interference between its supporting bracket and the cooling cover.

Removal of the engine from the vehicle

Removing the engine from the chassis

-Disconnect the battery.

-Remove the muffler assembly.

- Remove the rear wheel.

- Remove the rear brake mechanical transmission.

-Disconnect the electric terminals.

-Remove the throttle grip transmission.

- Disconnect the tubing (petrol-vacuum operated cock control).

- Disconnect the swinging arm on the engine side

- Disconnect the rear shock absorber lower clamping

WARNING

Be very careful when handling fuel.

CAUTION

When installing the battery, first attach the positive cable and then the negative cable.

WARNING

Wear safety goggles when using hitting tools.

Engine from vehicle MSS ZIP 100 4T

ENG VE - 64

INDEX OF TOPICS

ENGINE ENG

Automatic transmission

Transmission cover

- Remove the 12 fixing screws.

- Remove the oil filling cap and then slide out the cover. If this operation is carried out directly on the vehicle, it is necessary to remove the transmission cooling coupling and the air filter housing retainers.

N.B. USE A MALLET ON THE APPROPRIATE COUPLINGS TO

REMOVE THE COVER.

Kickstart

-To remove the start up pinion push the starter lever to facilitate extracting the pinion.

-Remove the kick-start screw and lever.

-Remove the Seeger ring and the washer indicated in the figure.

-Pull out the toothed sector.

WARNING THE SECTOR KEEPS THE SPRING SET, BE CAREFUL SO

AS NOT TO CAUSE ANY ACCIDENTS

Air duct

- To remove the intake throat on the transmission cover, just remove the three fixing screws indicated in the figure.

Engine MSS ZIP 100 4T

ENG - 66

Removing the driven pulley shaft bearing

- Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing.

N.B. IN CASE OF DIFFICULTY A STANDARD 8MM-INSIDE DI-

AMETER EXTRACTOR CAN BE USED.

Refitting the driven pulley shaft bearing

Refit the bearing with the aid of a bushing with the same diameter as the external plate of the bearing after slightly heating the crankcase from the inside.

N.B.

WHEN REFITTING, ALWAYS REPLACE THE BEARING WITH A NEW ONE.

CAUTION

WHEN REMOVING/REFITTING THE BEARING, TAKE CARE NOT TO DAMAGE THE COVER PAINTED SURFACE.

Removing the driven pulley

- Lock the clutch bell housing with the specific tool.

- Remove the nut, the clutch bell housing and the whole of the driven pulley assembly.

N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING

PULLEY MOUNTED.

Specific tooling

020565Y Flywheel lock calliper spanner

MSS ZIP 100 4T Engine

ENG - 67

Inspecting the clutch drum

- Check that the clutch bell is not worn or damaged.

- Measure the inner diameter of the clutch bell.

Characteristic

Clutch bell diameter/standard value

Ø 107+0.2 +0 mm

Clutch bell diameter/max. value allowed after use

Ø 107.5 mm

Eccentricity measured /max.

0.20 mm

Removing the clutch

- Equip the tool with long pins screwed into position «A» from the outside, insert the entire driven pulley in the tool and have the central screw make contact.

CAUTION THE TOOL WILL BE DEFORMED IF THE CENTRAL SCREW

IS TIGHTENED UP TOO FAR.

- Using a 34 mm socket wrench remove the clutch locking nut.

- Loosen the central screw by undoing spring of the driven pulley unit

- Separate the components.

Specific tooling

020444Y Tool for fitting/ removing the driven pulley clutch

Engine MSS ZIP 100 4T

ENG - 68

Inspecting the clutch

- Check the thickness of the clutch mass friction material.

- The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals.

N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-

TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR.

CAUTION DO NOT OPEN THE MASSES USING TOOLS TO PREVENT

A VARIATION IN THE RETURN SPRING LOAD.

Characteristic

Check minimum thickness

1 mm

Pin retaining collar

- Remove the collar with the aid of 2 screwdrivers.

- Remove the three guide pins and the mobile half pulley.

MSS ZIP 100 4T Engine

ENG - 69

Removing the driven half-pulley bearing

- Remove the roller bearing with the special extractor inserted from the bottom of the fixed halfpulley.

CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI-

ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING.

Specific tooling

001467Y029 Bell for bearings, O.D. 38 mm

- Remove the ball bearing retention snap ring.

- Expel the ball bearing from the side of the clutch housing by means of the special tool.

N.B. PROPERLY SUPPORT THE HALF-PULLEY SO AS NOT TO

DEFORM THE SLIDING SURFACE OF THE DRIVING BELT

Specific tooling

020376Y Adaptor handle 020363Y 20-mm guide

Inspecting the driven fixed half-pulley

- Check that there are no signs of wear on the work surface of the belt. If there are, replace the halfpulley..

- Make sure the bearings do not show signs of unusual wear.

- Measure the external diameter of the pulley bushing.

Characteristic

Stationary driven half-pulley/Standard diameter

Ø 33.965 to 33.985 mm

Stationary driven half-pulley / Minimum diameter admitted after use

Ø 33.96 mm

Engine MSS ZIP 100 4T

ENG - 70

Inspecting the driven sliding half-pulley

- Remove the 2 inner sealing rings and the two Orings.

- Measure the inside diameter of the mobile halfpulley bushing.

Characteristic

Mobile driven half-pulley/ Maximum diameter allowed

Ø 34.08 mm

- Check the belt contact surfaces.

- Insert the new oil seal and O-rings on the mobile half-pulley.

- Fitting the half-pulley on the bushing.

Recommended products

AGIP GREASE SM 2 Grease for the C-ring of the tone wheel

Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

- Make sure the pins and collar are not worn, reassemble the pins and collar.

- Use a greaser with a curved spout to lubricate the driven pulley unit with around 6 g of grease. This operation must be done through one of the holes inside the bushing until grease comes out of the opposite hole. This procedure is necessary to prevent the presence of grease beyond the O-ring.

Recommended products

AGIP GREASE SM 2 Grease for the C-ring of the tone wheel

Soap-based lithium grease containing NLGI 2 Molybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20

Refitting the driven half-pulley bearing

- Fit a new ball bearing with the specific tool.

- Fit the ball bearing retention snap ring.

- Fit the new roller bearing with the wording visible from the outside.

CAUTION PROPERLY SUPPORT THE HALF-PULLEY TO PREVENT

DAMAGE TO THE THREADED END WHILE THE BEARINGS ARE BEING FITTED.

Specific tooling

020376Y Adaptor handle

MSS ZIP 100 4T Engine

ENG - 71

020456Y Ø 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case

Inspecting the clutch spring

- Check that the contrast spring of the driven pulley does not show signs of deformation

- Measure the free length of the spring

Characteristic

Standard length

118 mm

Minimum length allowed after use

XXXX

- Check the thickness of the clutch mass friction material.

-The masses must not show traces of lubricants; otherwise, check the driven pulley unit.

N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-

TRAL CONTACT SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR.

CAUTION DO NOT OPEN THE MASSES USING TOOLS SO AS TO

PREVENT A VARIATION IN THE RETURN SPRING LOAD.

Characteristic

Minimum thickness permitted:

1 mm

Refitting the clutch

- Preassemble the driven pulley group with spring, sheath and clutch.

- Position the spring with the sheath

- Insert the components in the tool and preload the spring being careful not to damage the plastic sheath and the end of the threaded bar.

Engine MSS ZIP 100 4T

ENG - 72

- Reassemble the nut securing the clutch and tighten to the prescribed torque.

CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK-

ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE

NUT IN CONTACT WITH THE CLUTCH

Locking torques (N*m)

Nut locking clutch unit on pulley 55 ÷ 60 Nm

Refitting the driven pulley

-Refit the driven pulley assembly, the clutch bell and the nut, using the specific tool.

Specific tooling

020565Y Flywheel lock calliper spanner

Locking torques (N*m)

Driven pulley shaft nut 40 to 44 Nm

Drive-belt

- Make sure the driving belt is not damaged and does not have cracks in the toothed grooves.

- Check the width of the belt.

Characteristic

Transmission belt/Minimum width

17.5 mm

MSS ZIP 100 4T Engine

ENG - 73

Removing the driving pulley

- Lock the driving pulley using the appropriate tool.

- Remove the central nut with the related washer, then remove the drive and the plastic fan.

- Remove the stationary half-pulley.

- Remove the belt, washer and remove the mobile half-pulley with its bushing, being careful that the rollers and contrast plate fitted loosely on it do not come off.

Specific tooling

020451Y Starting ring gear lock

Inspecting the rollers case

1) Check that the bushing and the sliding rings of the mobile pulley do not show signs of scoring or deformation.

2) Check the roller running tracks on the contact pulley; there must not be signs of wear and check the condition of the contact surface of the belt on the half-pulleys (mobile and stationary).

3) Check that the rollers do not show signs of marked facetting on the sliding surface and that the metallic insert does not come out of the plastic shell borders.

4) Check the integrity of the sliding blocks of the contact plate.

- Check that the internal bushing shown in the figure is not abnormally worn and measure inside diameter «A».

- Measure outside diameter «B» of the pulley sliding bushing shown in the figure.

CAUTION DO NOT LUBRICATE OR CLEAN THE BUSHING.

Characteristic

Driving pulley / Maximum diameter:

Engine MSS ZIP 100 4T

ENG - 74

20.12 mm

Driving pulley/ Standard diameter:

20.021 mm

Driving pulley bushing/ Diameter maximum:

XXX mm

Driving pulley bushing/ Standard diameter:

20 -0.020/-0.041mm

Refitting the driving pulley

- Manually move the movable driven half-pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting.

N.B. IT IS GOOD PRACTICE ALWAYS TO FIT THE BELT SO

THAT THE WORDS CAN BE READ IN CASE IT DOES NOT SHOW A FITTING SIDE.

- Refit the components of the assembly (roller container assembly with bushing, limiting washer, stationary half-pulley, cooling fan belt with drive, washer and nut).

- With the specific tool, tighten the lock nut to 20 Nm and then perform a final 90° locking in order to prevent the rotation of the driving pulley.

N.B. REPLACE THE NUT WITH A NEW ONE AT EVERY REFIT CAUTION UPON FITTING THE DRIVING PULLEY UNIT IT IS OF UT-

MOST IMPORTANCE THAT THE BELT IS FREE INSIDE IN ORDER TO AVOID WRONG TIGHTENING AND CONSEQUENTLY DAMAGING THE CRANKSHAFT KNURLING.

Specific tooling

020451Y Starting ring gear lock

Locking torques (N*m)

Crankshaft pulley nut 18 to 20 + 90° Nm

MSS ZIP 100 4T Engine

ENG - 75

Refitting the transmission cover

- Check the following for wear: toothed section, toothed section shaft, cover seat bushing, pinion shaft and its seating in the crankcase and the return spring.

- Remove the damaged components.

- Grease the spring.

- Remove the toothed sector and load the spring with an appropriate tool.

- Refit the washer, the Seeger and the Kick-start lever.

Recommended products

AGIP GREASE MU3 Grease for odometer transmission gear case

Soap-based lithium grease with NLGI 3; ISO-LXBCHA3, DIN K3K-20

- Insert the pinion in its seating by pushing the starter lever.

- Fit the intake throat and tighten the 3 screws.

-Make sure the oil sump presents centring dowels and sealing gaskets.

- Replace the cover tightening the 12 screws to the prescribed torque.

-Refit the oil filling cap.

Locking torques (N*m)

Transmission cover screws 11 ÷ 13 Nm

End gear

Engine MSS ZIP 100 4T

ENG - 76

Removing the hub cover

- Drain the rear hub oil

- Remove driven pulley

- Remove the rear brake shoes

- Remove the 5 screws fixing the cover to the crankcase

- Remove the cover with the wheel axle and pull it out

- Remove the intermediate gear with the appropriate shim washers

Removing the wheel axle bearings

- Remove the oil seal and the seeger ring.

- Fix the hub cover properly to avoid damaging the sealing surface with the housing

- Remove the wheel axle bearing using the specific tool

Specific tooling

020363Y 20-mm guide 020376Y Adaptor handle 020477Y 37 mm adaptor

MSS ZIP 100 4T Engine

ENG - 77

Removing the driven pulley shaft bearing

- Remove the seeger ring

- Heat the engine crankcase but do not direct the hot air towards the bearing

- Extract the driven pulley shaft together with the bearing with a few mallet blows

- Remove the bearing off the driven pulley shaft using the specific tool and a press

N.B. USE THE SPECIFIC TOOL ON THE SIDE WITH THE SMALL-

ER INTERNAL DIAMETER

Specific tooling

020452Y Tube for removing and refitting the driven pulley shaft

Engine MSS ZIP 100 4T

ENG - 78

Inspecting the hub shaft

- Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings.

- In case of anomalies, replace the damaged components.

- Check capacity ( A ) of the transmission gear (wear, deformations, etc.)

- Check the pulley shaft seating: Superficial wear ( B ) may indicate irregularities in the crankcase seatings or in the pulley shaft capacities

Inspecting the hub cover

- Check that the fitting surface is not dented or distorted.

- If faults are found, replace the hub cover.

Refitting the wheel axle bearing

- Support the hub cover on a wooden surface

- Heat up the hub cover using the thermal gun.

- Preassemble the bearing on the specific punch using grease and then insert the bearing in its seating

- Refit the seeger ring and the oil seal using the 42 x 47 mm adaptor

N.B. POSITION THE OIL SEAL WITH THE SEALING LIP FACING

THE HUB INTERNAL SIDE

Specific tooling

020150Y Air heater support 020151Y Air heater 020376Y Adaptor handle

MSS ZIP 100 4T Engine

ENG - 79

020363Y 20-mm guide 020359Y 42x47-mm Adaptor

Refitting the hub bearings

- Remove the wheel axle on the cover and pay attention not to damage the sealing lip of the oil seal

- Apply a thin layer of grease on the two shim washers of the intermediate gear and fit one on the cap so that it does not interfere with the wheel axle gear when placing the transmission shaft

Refitting the ub cover

- Apply product recommended for surfaces on the hub cap and refit cap on the crankcase

- Fit the 5 screws and tighten them to the specified torque.

N.B. CLEAN THE CONTACT SURFACES OF THE HUB COVER

AND THE HALF CRANKCASE OF RESIDUE FROM PREVIOUS GASKETS BEFORE APPLYING A NEW ONE.

Recommended products

Loctite 510 Liquid sealant

Engine MSS ZIP 100 4T

ENG - 80

Gasket

Locking torques (N*m)

hub cap screws 24 - 26

Flywheel cover

Cooling hood

- Remove the manifold and the carburettor undoing the 2 fixing screws on the head

- Remove the fastening clamp of the secondary air pipe and disconnect it

- Remove the 4 front coupling screws (1 of them is a knob) and the side fixing screw at the crankcase base.

- Remove the 4 side screws

- Extract the 3 covers - Remove the cover sealing gaskets on the head

- For refitting, repeat the removal steps but in reverse order

CAUTION TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL

CONNECTOR. N.B. WHEN REFITTING THE COVER, TAKE CARE NOT TO DAM-

AGE THE STATOR WIRING.

MSS ZIP 100 4T Engine

ENG - 81

Cooling fan

- Remove the cooling fan by undoing the 3 screws fixing it to the rotor

- When refitting the fan, pay attention that the screw holes in the fan and the rotor coincide, then tighten screws at the specified torque.

Removing the stator

- Remove the 2 Pick-Up screws and the 2 stator fixing screws indicated in the figure.

- Remove the stator and its wiring.

Refitting the stator

- Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque.

N.B. THE PICK-UP CABLE MUST BE POSITIONED ADHERING

TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEMBLY.

Locking torques (N*m)

Pick-up screws 3 ÷ 4 Stator screws 3 ÷ 4

Flywheel and starting

Engine MSS ZIP 100 4T

ENG - 82

Removing the starter motor

- Undo the screw on the power positive contact and disconnect the cable

- Undo the 2 screws fixing the starter motor to the crankcase and recover the power wiring.

Removing the flywheel magneto

- Lock the rotation of the flywheel using the calliper spanner.

- Remove the nut.

CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE

ONE SUPPLIED COULD DAMAGE THE STATOR COILS

- Extract the flywheel with the extractor.

Specific tooling

020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor

MSS ZIP 100 4T Engine

ENG - 83

Inspecting the flywheel components

- Check that the flywheel internal magnets are in good conditions.

- Check that the flywheel splines exhibit no loosening.

- Check there are no deformations that may cause rubbing on the stator and the Pick-Up.

- Check that the stator winding, its ferromagnetic support and the pick-up are in good conditions.

Starter gear rim

- Check the toothing is level and in good conditions

Intermediate gear

- Check that the keying toothing on the crown and the starter motor are in good conditions.

- Check that the Bendix opens and returns adequately.

Engine MSS ZIP 100 4T

ENG - 84

Refitting the flywheel magneto

- Refit the stator and the pick-up being careful to pass the wiring through the appropriate crankcase couplings.

- Refit the flywheel to the crankshaft being careful to respect the keying, then lock rotation with the specific tool and tighten the nut to the prescribed torque.

N.B. A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO

A VARIATION IN THE IGNITION ADVANCE SUCH AS TO CAUSE PINGING, KNOCKING ETC.

Specific tooling

020565Y Flywheel lock calliper spanner

Locking torques (N*m)

Flywheel nut 52 ÷ 58

Refitting the starter motor

- Install the starter motor in its seating in the crankcase.

- Tighten the screw on the head side but do not lock it, screw the second screw inserting the earth cable (black), then tighten the 2 screws at the prescribed torque.

- Tighten the locking screw of the positive cable (red) on the side contact.

N.B. REFIT THE REMAINING PARTS AS DESCRIBED IN THE

CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL AND TRANSMISSION CHAPTERS.

Locking torques (N*m)

Starter screws 11 ÷ 13

Cylinder assy. and timing system

MSS ZIP 100 4T Engine

ENG - 85

Removing the rocker-arms cover

- Remove the cooling covers

- Remove the 4 retainers of the tappet cover

- Remove the cover and the O-ring

- Remove the 4 screws and then remove the Blowby cover

- Clean the nozzle labyrinth and the membrane (replace it, if necessary), then remove the cover unit.

PIAGGIO MSS ZIP 100 4T, ZIP 4T Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual