PIAGGIO ZIP 50 4T, ZIP 100 4T User Manual
PIAGGIO WOULD LIKE TO THANK YOU
for choosing one of its products. We have prepared this manual to help you to get the very best from your vehicle. Please read it carefully before riding
the vehicle for the first time. It contains information, tips and precautions for using your vehicle. It also describes features, details and devices to assure
you that you have made the right choice. We believe that if you follow our suggestions, you will soon get to know your new scooter and it will serve you
well for a long time to come. This booklet forms an integral part of the vehicle; should the vehicle be sold, it must be transferred to the new owner.
ZIP 50 - 100 4T
Ed. 03_10/2012
The instructions given in this booklet are intended to provide a clear, simple guide to using your scooter; details are also given of routine maintenance
procedures and regular checks that should be carried out on the vehicle at and Authorized PIAGGIO Dealer or Service Centre. The booklet also
contains instructions for simple repairs. Any operations not specifically described in this booklet require the use of special tools and/or particular technical
knowledge: to carry out these operations refer to any authorized PIAGGIO Dealer of Service Centre.
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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 dam-
aging 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.
The signs that you see on this page are very important. They are used to highlight parts
of the booklet that should be read with particular care. The different symbols are used
to make each topic in the manual simple and quick to locate.
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4
INDEX
VEHICLE...................................................................................... 7
Dashboard................................................................................ 8
Keyswitch.................................................................................. 8
Lockingthesteeringwheel....................................................... 9
Switchdirectionindicators.......................................................... 9
Hornbutton................................................................................ 10
Lightswitch................................................................................ 10
Start-upbutton........................................................................... 11
Openingthesaddle................................................................. 11
Keys.......................................................................................... 13
Identification.............................................................................. 14
USE.............................................................................................. 15
Checks...................................................................................... 16
Refuelling.................................................................................. 16
Tyrepressure............................................................................. 17
Runningin.................................................................................. 18
Startinguptheengine.................................................................. 19
Difficultstartup........................................................................... 20
Stoppingtheengine.................................................................... 21
Automatictransmission.............................................................. 21
Safedriving................................................................................ 22
MAINTENANCE........................................................................... 25
Engineoillevel............................................................................ 26
Engineoillevelcheck............................................................... 26
Engineoiltop-up..................................................................... 27
Engineoilchange.................................................................... 27
Huboillevel................................................................................ 28
Tyres......................................................................................... 29
Sparkplugdismantlement.......................................................... 30
Removingtheairfilter.................................................................. 31
Secondaryairsystem................................................................. 32
Checkingthebrakeoillevel.......................................................... 33
Battery....................................................................................... 34
Long periods of inactivity.......................................................... 35
Fuses........................................................................................ 36
Frontlightgroup.......................................................................... 37
Headlightadjustment.............................................................. 38
Frontdirectionindicators............................................................. 38
Rearopticalunit.......................................................................... 39
Rearturnindicators..................................................................... 40
Rear-viewmirrors....................................................................... 41
Idleadjustment........................................................................... 41
Frontandreardiscbrake.............................................................. 42
Reardrumbrake......................................................................... 43
Puncture.................................................................................... 44
delveicolo.................................................................................. 45
Cleaningthevehicle.................................................................... 45
TECHNICALDATA....................................................................... 51
Toolkit....................................................................................... 58
SPAREPARTSANDACCESSORIES........................................... 59
Warnings................................................................................... 60
SCHEDULEDMAINTENANCE..................................................... 63
Scheduledservicingtable........................................................... 64
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6
ZIP 50 - 100 4T
Chap. 01
Vehicle
7
01_01
Dashboard (01_01)
A = Speedometer
B = Low fuel warning light
C = Turn indicator warning light
D = Preset warning light
F = Starter button
G = Odometer
H = High-beam headlight warning light
I = Horn button
L = Turn indicator switch
M = Headlight switch
01_02
Keyswitch (01_02)
LOCK = Ignition to earth, extractable key, steering lock engaged.
OFF = Ignition to earth, extractable key, steering lock disengaged.
ON = Ready to start, steering lock disengaged, key cannot be extracted.
In the position«ON» and «OFF» it is possible to open the front glove-box pushing the
key switch, in position LOCK the glove-box is closed.
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01_03
Lockingthesteeringwheel (01_03)
Turn the handlebar to the left (as far as it will go), turn the key to «LOCK» and remove
the key.
CAUTION
DO NOT TURN THE KEY TO «LOCK» OR «KEY OFF» WHILE RIDING.
01_04
Switchdirectionindicators (01_04)
0 = Turn indicators off.
D = Turn indicators on (right side)
S = Turn indicators on (left side)
The positions «D» and «S» are unstable. The switch lever «B» always returns to
«0». Push the lever to switch off the turn indicators.
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1 Vehicle
01_05
Hornbutton (01_05)
Horn button «F»
01_06
Lightswitch (01_06)
0 = Low-beam and tail light
1 = High-beam and tail light
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01_07
Start-upbutton (01_07)
Starter button "G"
Openingthesaddle (01_08, 01_09, 01_10)
Insert the key into the saddle lock «A», turn it counterclockwise and tip the saddle
forward.
In this scooter, the saddle height can be adjusted to three positions thanks to a rack
«C» assembled on the saddle hinge and to the stroke buffers «B».
Adjustments:
rack low position-buffer position 1
rack medium height-buffer position 2
rack high position- buffer position 3
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1 Vehicle
01_08
01_09
Insert the key in lock «A», turn it anticlockwise and tip the saddle forward.
After having tipped the saddle, place the helmet as shown in the figure.
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01_10
01_11
Keys (01_11)
The vehicle is supplied with two keys (one spare) which serve to start the engine and
unlock the saddle compartment. The keys are accompanied by a tag marked with the
identification code to be quoted when ordering duplicates.
WARNING
WE RECOMMEND KEEPING THE DUPLICATE KEY TOGETHER WITH ITS CODE
IN A SAFE PLACE AND NOT ON THE VEHICLE
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1 Vehicle
01_12
01_13
Identification (01_12, 01_13)
The identification numbers consist of a prefix stamped on the chassis and on the engine, followed by a number. They must be quoted when ordering spare parts. We
recommend that you check that the prefix and chassis number stamped on the vehicle
correspond with those in the vehicle documents.
CAUTION
PLEASE REMIND THAT ALTERING IDENTIFICATION REGISTRATION NUMBERS CAN LEAD TO SERIOUS PENAL SANCTIONS (IMPOUNDING OF THE
VEHICLE, ETC.).
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ZIP 50 - 100 4T
Chap. 02
Use
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Checks
Before using the vehicle, check:
1. that the fuel tank is full.
2. The oil level in the rear hub.
3. engine oil level (see section «Engine oil level»).
4. That tyres are properly inflated.
5. correct functioning of headlights, rear taillight and turn indicators.
6. The correct functioning of the front and rear brakes.
7. The fluid level in the front brake pump tank.
02_01
Refuelling (02_01, 02_02)
Fill fuel tank«A» with unleaded petrol (minimum octane rating = 95).
When the fuel reaches the reserve level, the warning light fitted on the instrument
panel lights up.
CAUTION
SHUT OFF THE ENGINE BEFORE REFUELLING WITH PETROL. PETROL IS
HIGHLY FLAMMABLE. DO NOT LET PETROL SPILL FROM THE TANK OR WHILE
REFUELLING
CAUTION
DO NOT BRING NAKED FLAMES OR CIGARETTES NEAR THE MOUTH OF THE
FUEL TANK: FIRE HAZARD. ALSO AVOID INHALING HARMFUL VAPOURS.
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02_02
CAUTION
USING OILS OTHER THAN THOSE RECOMMENDED CAN SHORTEN THE LIFE
OF THE ENGINE.
Characteristic
Fuel tank
In plastic, with a capacity of ~ 7.5 l (approximate value, including ~ 1.2 l reserve)
Main and supplementary fuel tank (including ~ 1.2 l reserve) (100 cc)
~ 7 l
Tyrepressure
CAUTION
TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD.INCORRECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND MAKES RIDING DANGEROUS.
TYRES MUST BE REPLACED WHEN THE TREAD REACHES THE WEAR LIMITS
SET FORTH BY LAW.
Characteristic
Front tyre pressure
Front wheel: 1.3 bar
Rear tyre pressure
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2 Use
Rear wheel: 1.6 bar
Rear tyre pressure (rider and luggage)
Rear wheel (rider and luggage): 1.8 bar
Tyre pressure (100 cc)
Front wheel: 1.3 bar
Rear wheel: 1.6 ÷ 1.8 bar
02_03
Runningin (02_03)
WARNING
DURING THE FIRST 1000 KM DO NOT RIDE THE VEHICLE OVER 80% OF ITS
MAXIMUM SPEED. AVOID TWISTING THE THROTTLE GRIP FULLY OR KEEPING A CONSTANT SPEED ALONG LONG SECTIONS OF ROAD. AFTER THE
FIRST 1000 KM, GRADUALLY INCREASE SPEED UNTIL REACHING THE MAXIMUM PERFORMANCE.
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02_04
Startinguptheengine (02_04)
The vehicle is fitted with direct drive automatic transmission. Therefore, always start
the engine with the throttle grip slightly twisted; to start-off from stationary position,
progressively twist the throttle grip.
The vehicle is equipped with a fuel valve and a starter which switch on automatically
as soon as the engine is started.
To start it up, it is necessary to:
1: Put the scooter on its stand "E"; check that the rear wheel is off the ground.
2: Keep the throttle grip slightly twisted.
3: Insert the key in ignition switch «D» and turn it to «ON»; when turning the key to
«ON», the fuel reserve warning light turns on for a few seconds indicating the correct
functioning of the bulb.
4: Push the starter button «A» after pulling the rear brake lever «B» or the front brake
lever «C».
CAUTION
DO NOT CARRY OUT THESE OPERATIONS IN CLOSED AREAS SINCE EXHAUST GASES ARE TOXIC.
CAUTION
ALWAYS PLACE THE VEHICLE ON ITS STAND BEFORE KICK STARTING.
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2 Use
02_05
Difficultstartup (02_05)
If there is a problem you can follow the instructions below:
1. Engine flooded. Place the vehicle on its centre stand and check that the rear wheel
is off the ground. Open the throttle fully and press the starter button for five seconds
and then stop for five seconds. If the engine does not start after a few attempts, let
the engine sit for a few minutes and then repeat the above operations. In any case do
not operate the starter motor longer than 20" in an attempt to start the engine.
2. In the case of battery inefficiency. Place the vehicle on stand «E»; make sure
that the rear wheel is off the ground, turn the key switch «D» to «ON».
3. Empty fuel tank. After refuelling the scooter, start the engine by pressing the starter
button «A» with the throttle at a minimum to provide maximum aspiration for the tap.
If the scooter fails to start even after taking the steps described above, contact an
Authorised Piaggio Service Centre.
CAUTION
ALWAYS PLACE THE VEHICLE ON ITS STAND BEFORE KICK STARTING.
WARNING
TAMPERING MAY CAUSE SERIOUS ENGINE MALFUNCTION.
AS THE CARBURETTOR IS FITTED WITH AN ACCELERATOR PUMP DO NOT
ENGAGE THE ACCELERATOR WITH THE ENGINE OFF IN ORDER TO AVOID
FLOODING SPECIALLY IN HOT WEATHER.
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02_06
Stoppingtheengine (02_06)
Stop acceleration, then turn the key switch «D» to «OFF » to stop the engine (extractable key).
02_07
Automatictransmission (02_07)
To ensure simple, pleasurable riding, the vehicle is equipped with automatic transmission with regulator and centrifugal clutch. The system is designed to give the best
possible performance in terms of both acceleration and consumption, on level ground
and uphill, thanks to the adjustments made to engine speed and transmitted torque.
If you have to stop on an uphill slope (traffic lights, traffic jam, etc.) only use the brake
to keep the vehicle still, leaving the motor running at idling speed. Using the motor to
keep the vehicle still can cause the clutch to overheat. This problem is due to the
friction of the clutch parts on the clutch bell. It is therefore recommended to avoid
conditions of prolonged clutch slippage leading to clutch overheating (for example, as
well as the situation described above, riding uphill fully laden on steep slopes or starting off on slopes greater than 25%, etc.):
1. Do not continue riding in such conditions.
2. Let the clutch cool down with the motor at idling speed for a few minutes
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2 Use
Safedriving (02_08)
WARNING
SOME SIMPLE TIPS ARE PROVIDED BELOW WHICH WILL ENABLE YOU TO
USE YOUR VEHICLE ON A DAILY BASIS MORE EASILY AND SAFELY.
<
02_08
Your ability and your knowledge of the vehicle form the basis of safe riding. We recommend trying out the vehicle in traffic-free zones to get to know your vehicle
completely.
ALWAYS DRIVE WITHIN YOUR LIMITS
1. Before riding off, remember to put on your helmet and fasten it correctly.
2. Reduce speed and ride cautiously on uneven roads.
3. Remember that after riding on a long stretch of wet road without using the brakes,
the braking effect is initially lower. Under these conditions, it is a good idea to operate
the brakes from time to time.
4. Do not brake hard on a wet surface, on dirt tracks or on any slippery road surface.
5. If you have to brake, use both brakes in order to divide the braking action between
both wheels.
6. Avoid starting off by mounting the vehicle while it is still resting on its stand. In any
case, the rear wheel should not be turning when it comes into contact with the ground,
in order to avoid abrupt departures.
7. If the vehicle is used on roads covered with sand, mud, snow mixed with salt, etc.,
clean the brake disc frequently with mild detergent in order to prevent abrasive substances from building up within the holes, which can result in early wear of the brake
pads.
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8. Any elaboration that modifies the vehicle's performances, such as tampering with
original structural parts is strictly forbidden by law, and renders the vehicle not conforming to the approved type and therefor dangerous to ride.
CAUTION
RIDING UNDER THE INFLUENCE OF ALCOHOL, DRUGS OR CERTAIN MEDICINES CAN BE EXTREMELY DANGEROUS FOR ONESELF AND FOR OTHERS.
CAUTION
ANY ELABORATION THAT MODIFIES THE VEHICLE'S PERFORMANCES, SUCH
AS TAMPERING WITH ORIGINAL STRUCTURAL PARTS IS STRICTLY FORBIDDEN BY LAW, AND RENDERS THE VEHICLE NO LONGER CONFORMING TO
THE APPROVED TYPE AND DANGEROUS FOR RIDING.
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2 Use
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