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PIAGGIO
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ZIP 4T
PIAGGIO ZIP 4T User Manual
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Starter motor
STARTER MOTOR - START UP LEVER
Code
Action
Duration
1
001020
Starter motor - change
2
001017
Starter sprocket wheel - replace
3
005045
Starter motor with cables unit - Re-
plac.
4
001084
Starter lever - Replacement
5
008008
Starter spring pack - Replacement
6
001021
Kick starter - Inspection
Time
MSS ZIP 100 4T
TIME - 164
163
165
Table of Contents
Index of Topics
5
Characteristics
6
Safety Rules
7
Maintenance Rules
7
Vehicle Identification
8
Dimensions and Mass
8
Engine
8
Transmission
9
Capacities
9
Electrical System
9
Frame and Suspensions
9
Brakes
10
Secondary Air
10
Carburettor
10
50Cc Version
11
Tightening Torques
11
Front Suspension
11
Front Brake
11
Overhaul Data
12
Assembly Clearances
12
Cylinder - Piston Assy
12
Piston Rings
13
Crankcase - Crankshaft - Connecting Rod
14
Slot Packing System
15
Products
15
Tooling
17
Recommended Tools
18
Basic Tools
21
Maintenance
25
Maintenance Chart
26
Checking the Spark Advance
29
Spark Plug
30
Hub Oil
30
Check
31
Replacement
31
Air Filter
32
Engine Oil
32
Engine Oil Filter
34
Checking the Ignition Timing
35
Checking the Valve Clearance
35
Headlight Adjustment
36
CO Check
36
Troubleshooting
38
Rear Wheel Spins at Idle
40
Insufficient Lubrication Pressure
41
Engine Tends to Cut-Off at Full Throttle
41
Engine Tends to Cut-Off at Idle
42
Excessive Exhaust Noise
42
High Fuel Consumption
42
SAS Malfunctions
42
Transmission and Brakes
43
Clutch Grabbing or Performing Inadequately
43
Insufficient Braking
43
Brakes Overheating
43
Battery
44
Turn Signal Lights Malfunction
44
Steering and Suspensions
44
Rear Wheel
44
Electrycal System
46
Ignition
49
Headlights and Automatic Starter Section
50
Battery Recharge and Starting
51
Level Indicators and Enable Signals Section
52
Turn Signal Lights
53
Checks and Inspections
54
Ignition Circuit
55
Stator Check
55
Voltage Regulator Check
56
Recharge System Voltage Check
57
Starter Motor
58
Turn Signals System Check
59
Fuses
60
Sealed Battery
60
Dry-Charge Battery
61
Engine from Vehicle
63
Exhaust Assy. Removal
64
Removal of the Engine from the Vehicle
64
Engine
65
Automatic Transmission
66
Transmission Cover
66
Kickstart
66
Air Duct
66
Removing the Driven Pulley Shaft Bearing
67
Refitting the Driven Pulley Shaft Bearing
67
Removing the Driven Pulley
67
Inspecting the Clutch Drum
68
Removing the Clutch
68
Inspecting the Clutch
69
Pin Retaining Collar
69
Removing the Driven Half-Pulley Bearing
70
Inspecting the Driven Fixed Half-Pulley
70
Inspecting the Driven Sliding Half-Pulley
71
Refitting the Driven Half-Pulley Bearing
71
Inspecting the Clutch Spring
72
Refitting the Clutch
72
Refitting the Driven Pulley
73
Drive-Belt
73
Removing the Driving Pulley
74
Inspecting the Rollers Case
74
Refitting the Driving Pulley
75
Refitting the Transmission Cover
76
End Gear
76
Removing the Hub Cover
77
Removing the Wheel Axle Bearings
77
Inspecting the Hub Shaft
79
Inspecting the Hub Cover
79
Refitting the Wheel Axle Bearing
79
Refitting the Hub Bearings
80
Refitting the Ub Cover
80
Flywheel Cover
81
Cooling Hood
81
Cooling Fan
82
Removing the Stator
82
Refitting the Stator
82
Flywheel and Starting
82
Removing the Starter Motor
83
Removing the Flywheel Magneto
83
Inspecting the Flywheel Components
84
Starter Gear Rim
84
Intermediate Gear
84
Refitting the Flywheel Magneto
85
Refitting the Starter Motor
85
Cylinder Assy. and Timing System
85
Removing the Rocker-Arms Cover
86
Removing the Timing System Drive
86
Removing the Cam Shaft
87
Removing the Cylinder Head
88
Removing the Valves
89
Removing the Cylinder - Piston Assy
89
Inspecting the Small End
90
Inspecting the Wrist Pin
90
Inspecting the Piston
90
Inspecting the Cylinder
91
Inspecting the Piston Rings
92
Removing the Piston
93
Choosing the Gasket
93
Refitting the Piston Rings
96
Refitting the Cylinder
97
Inspecting the Cylinder Head
97
Inspecting the Timing System Components
98
Inspecting the Valve Sealings
99
Inspecting the Valve Housings
99
Inspecting the Valves
100
Inspecting the Springs and Half-Cones
101
Refitting the Valves
101
Inspecting the Cam Shaft
101
Refitting the Head and Timing System Components
103
Refitting the Timing Chain
104
Refitting the Rocker-Arms Cover
106
Refitting the Intake Manifold
106
Crankcase - Crankshaft
106
Splitting the Crankcase Halves
107
Removing the Crankshaft Bearings
108
Refitting the Crankshaft Bearings
108
Refitting the Crankcase Halves
110
Lubrication
110
Crankshaft Oil Seals
111
Removal
111
Refitting
111
Oil Pump
112
Removing the Oil Sump
115
Refitting the Oil Sump
115
Fuel Supply
115
Removing the Carburettor
116
Refitting the Carburettor
120
Level Check
122
Inspecting the Automatic Choke Device
123
Adjusting the Idle
125
Suspensions
128
Removing the Front Wheel
129
Front Wheel Hub Overhaul
129
Refitting the Front Wheel
130
Handlebar
131
Front Fork
131
Overhaul
131
Steering Column
133
Removing the Rear Wheel
134
Refitting the Rear Wheel
134
Shock Absorbers
134
Centre-Stand
135
Braking System
136
Front Brake Calliper
137
Front Brake Disc
139
Disc Inspection
140
Front Brake Pads
140
Fill
141
Front Brake Pump
142
Rear Drum Brake
143
Chassis
145
Removing the Ignition Key-Switch When on *Off*
146
Removing the Ignition Key-Switch When on *Lock*
146
Footrest
146
Rear Mudguard
147
Helmet Bay
148
Fuel Tank
148
Pre-Delivery
149
Aesthetic Inspection
150
Tightening Torques Inspection
150
Levels Check
151
Road Test
151
Static Test
151
Functional Inspection
152
Time
153
Crankcase
155
Crankshaft
155
Cylinder Assy
156
Cylinder Head Assy
157
Rocker Arms Support Assy
158
Cylinder Head Cover
159
Driven Pulley
160
Driving Pulley
162
Flywheel Magneto
165
Exhaust Pipe
166
Air Cleaner
167
Frame
168
Legshield Spoiler
169
Rear Cover
170
Central Cover
171
Mudguard
172
Rear Shock-Absorber
174
Steering Column Bearings
175
Handlebar Covers
176
Handlebar Components
177
Swing-Arm
178
Seat
179
Front Wheel
181
Electric Devices
183
Electronic Controls
185
Transmissions
186
Brake Callipers
187
Rear Wheel Axle
190
Secondary Air Box
191
5
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PIAGGIO ZIP 4T Specifications
General
Brand
PIAGGIO
Model
ZIP 4T
Category
Scooter
Language
English
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