PIAGGIO ZIP 100 4T Manual Download

Page: 72 / 76

FTER

72000

Engine oil - change

Hub oil - change

Spark plug / electrode gap - replacement

oil filter - cleaning

Valve clearance - check

idle rpm (*) - adjustment

Throttle lever - adjustment

CVT rollers - check or replacement

Drive belt - replacement

Cylinder ventilation system - check

Odometer gear - greasing

Steering - adjustment

Brake levers - greasing

Brake pads - check for condition and wear

Brake fluid hoses - replacement

Brake fluid level - check

Transmission - lubrication

Safety fasteners - check

Suspension - check

Electrical system and battery - check

Headlight - adjustment

6 Scheduledmaintenance

Summary of Contents for ZIP 100 4T

Page 1: ...ation 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 wil...

Page 2: ...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...

Page 3: ...ing 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 s...

Page 4: ...4...

Page 5: ...eoillevelcheck 26 Engineoiltop up 27 Engineoilchange 27 Huboillevel 28 Tyres 29 Sparkplugdismantlement 30 Removingtheairfilter 31 Secondaryairsystem 32 Checkingthebrakeoillevel 33 Battery 34 Long peri...

Page 6: ...6...

Page 7: ...ZIP 50 100 4T Chap 01 Vehicle 7...

Page 8: ...rn 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 sta...

Page 9: ...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 position...

Page 10: ...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 10 1 Vehicle...

Page 11: ...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 Adjustment...

Page 12: ...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 12 1 Vehicle...

Page 13: ...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 DUPLI...

Page 14: ...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 PLEA...

Page 15: ...ZIP 50 100 4T Chap 02 Use 15...

Page 16: ...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 o...

Page 17: ...erve 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 INCOR RECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEAR AND...

Page 18: ...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 KEEP ING A CONSTANT SP...

Page 19: ...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 tur...

Page 20: ...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 engi...

Page 21: ...f 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 ca...

Page 22: ...raking 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...

Page 23: ...d therefor dangerous to ride CAUTION RIDING UNDER THE INFLUENCE OF ALCOHOL DRUGS OR CERTAIN MEDI CINES CAN BE EXTREMELY DANGEROUS FOR ONESELF AND FOR OTHERS CAUTION ANY ELABORATION THAT MODIFIES THE V...

Page 24: ...24 2 Use...

Page 25: ...ZIP 50 100 4T Chap 03 Maintenance 25...

Page 26: ...heck oil level every time the vehicle is used with the engine cold The level should be between the MAX and MIN marks on the oil level dipstick A shown in the figure the stand should be firm on an even...

Page 27: ...cleaning and mounting again the mesh filter screw cap C and fill with oil the hole of the cap dipstick used to check engine oil level Then start the vehicle leave it running for a few minutes and swi...

Page 28: ...NING THE ENGINE WITH INSUFFICIENT LUBRICATION OR WITH THE IN ADEQUATE LUBRICANTS ACCELERATES WEAR AND TEAR OF THE MOVING PARTS AND CAN CAUSE IRRETRIEVABLE DAMAGE CAUTION USED OILS CONTAIN SUBSTANCES H...

Page 29: ...d this occur go to an authorised workshop or to a workshop properly equipped for refitting CAUTION TYRE PRESSURE SHOULD BE CHECKED WHEN TYRES ARE COLD INCOR RECT TYRE PRESSURE CAUSES ABNORMAL TYRE WEA...

Page 30: ...ocedure in the re verse order taking care that the teeth are introduced into the corresponding places on the upper cover WARNING THE SPARK PLUG MUST BE REMOVED WHEN THE ENGINE IS COLD THE USE OF A SPA...

Page 31: ...in a mix of oil and petrol at a ratio of 50 Then gently squeeze the filter element between your hands leave it to dry and mount it again CAUTION IN CASE OF RIDING ON DUSTY ROADS IT IS ADVISABLE TO CL...

Page 32: ...hort blasts of compressed air While cleaning the filter check the good condition of the reed valve C and mount it back in place on the housing Before closing the cover of the SAS housing check the goo...

Page 33: ...level follow the instructions below Unscrew the screw B and remove the plastic cover unscrew the 2 screws C lift the brake fluid reservoir cover D and add as much fluid as necessary the fluid level m...

Page 34: ...and the access hatch to the battery compartment unscrewing the star head screws A shown in the figure CAUTION IN ORDER TO AVOID DAMAGING THE ELECTRICAL SYSTEM NEVER DISCON NECT THE WIRING WHILE THE E...

Page 35: ...e to the battery follow any of these steps At least once a month start the engine and run it slightly above idle speed for 10 15 minutes This keeps all the engine components as well as the battery in...

Page 36: ...ted by a plug fuse B located to the left of the battery compartment The ignition system headlight and the rear light are not fuse protected Before replacing a blown fuse find and solve the problem tha...

Page 37: ...ll Position the screwdriver between the front and rear handlebar cover and levering gently release the right and left attachments After removing the bulb holder joints move the bulb holder countercloc...

Page 38: ...izontal borderline between the dark and the light area is not higher than the horizontal line drawn on the screen To remove the headlight unscrew the screw A located below it Before adjusting the head...

Page 39: ..._20 03_21 Remove both screws E and take out the light then remove the tail light bulbs fol lowing the same instructions as for the rear turn indicators for the stop light push and rotate the bulb coun...

Page 40: ...03_22 03_23 Rearturnindicators 03_22 03_23 To replace the rear turn indicator lamp unscrew the 4 fixing screws D of the glass to remove it pull the cable harness and then the bulb 40 3 Maintenance...

Page 41: ...the clearance of the throttle control transmission Adjust the idle speed with the rear wheel off the ground vehicle on stand and with a warm engine screw and unscrew the knob type head screw until re...

Page 42: ...brake lever stroke may indicate the presence of air in the braking circuit or an irregular brake operation In this case particularly considering the importance of the brakes in terms of safety it is s...

Page 43: ...OKE TO ITS CORRECT POSITION CAUTION BRAKING SHOULD BEGIN AFTER ABOUT 1 3 OF THE BRAKE LEVER STROKE 03_27 Reardrumbrake 03_27 Actuate on the set screw A indicated on the figure bearing in mind that the...

Page 44: ...final repair take your vehicle to an Authorised Service Centre or Dealer The replacement of a tyre involves re moving the wheel in question Take your vehicle to an Authorised Service Centre or Dealer...

Page 45: ...procedures described in the Battery section 5 Drain the petrol from the carburettor float chamber through the bleed cap Recommended products eni i Ride PG 5W 40 Synthetic based lubricant for high perf...

Page 46: ...rine areas hot and wet weather WARNING Prevent deposits from remaining on the bodywork industrial and pollutant residual dust tar spots dead insects bird droppings etc Do not park the vehicle under th...

Page 47: ...ND MECHANICAL CHARACTERISTICS WARNING WHEN WASHING THE ENGINE WITH A HIGH PRESSURE WATER JET ONLY USE FAN SPRAY JETS DO NOT PLACE THE NOZZLE CLOSER THAN 60 CM DO NOT USE WATER AT TEMPERATURES OVER 40...

Page 48: ...plug insulator Replace the spark plug if the insulator is cracked or broken If the spark plug is in good conditions contact an Authorised Service Centre LACK OF COMPRESSION Spark plug loose Loose cyl...

Page 49: ...gio Service Centre INEFFICIENT SUSPENSION Oil leak worn limit switch bumpers worn shock absorber attachment points Contact an Authorised Service Centre AUTOMATIC TRANSMISSION PROBLEMS Deteriorated rol...

Page 50: ...50 3 Maintenance...

Page 51: ...ZIP 50 100 4T Chap 04 Technicaldata 51...

Page 52: ...e TDC 8 at 1800 to 2000 rpm 24 at 5000 to 6000 rpm Spark plug NGK CR8EB Alternative spark plug DENSO U24ESR NB Depression carburettor KEIHIN CVK 18 mm valve clearance intake 0 10 mm exhaust 0 10 mm Ma...

Page 53: ...r reduction unit Fuel tank In plastic with a capacity of 7 5 l approximate value including 1 2 l reserve Front suspension with telescopic fork Rear suspension fitted with spring and coaxial hydraulic...

Page 54: ...d Driver only Engine oil Capacity approx 850 cm Engine oil change 850 cm Rear hub oil Quantity approx 80 cm TECHNICAL DATA 100 ENGINE Single cylinder four stroke Bore 50 mm Compression ratio 10 5 11 5...

Page 55: ...ication with lobe pump inside the crankcase controlled by chain and double filter mesh and centrifugal Cooling Forced circulation air cooling TRANSMISSION With continuously variable transmission torqu...

Page 56: ...type Welded tubular steel chassis with stamped sheet reinforcements Front brake Disc 220 mm diameter with hydraulic control lever on the right side of the handlebar Rear brake Drum brake 140 mm diamet...

Page 57: ...04_01 57 4 Technicaldata...

Page 58: ...Toolkit Wrenches one box spanner one twin screwdriver The tools are located under the saddle In order to take out the tools from the case release the lever and remove the clamp 58 4 Technicaldata...

Page 59: ...ZIP 50 100 4T Chap 05 Sparepartsanda ccessories 59...

Page 60: ...PARE PARTS CAUSES YOUR WARRANTY RIGHTS TO EXPIRE WARNING PIAGGIO MARKETS ITS OWN LINE OF ACCESSORIES THAT ARE RECOG NISED AND GUARANTEED FOR USE IT IS THEREFORE ESSENTIAL TO CON TACT AN AUTHORISED DEA...

Page 61: ...05_02 61 5 Sparepartsandaccessories...

Page 62: ...62 5 Sparepartsandaccessories...

Page 63: ...ZIP 50 100 4T Chap 06 Scheduledmaint enance 63...

Page 64: ...hicle serviced to the prescribed intervals of time even if you have not reached the predicted mileage Punctual vehicle servicing is necessary for the correct use of the guarantee For any further infor...

Page 65: ...I R I R I R I R I R I R I R I R I R I R Brake Pads Shoes I I I I I I I I I I I Tyre pressure I I I I I I I I I I I Headlight A A A A A Vehicle road test I I I I I I I I I I I Idle speed A A A A A A Od...

Page 66: ...e Centre or Dealer without waiting until the next scheduled service to solve it It is indispensable to have your vehicle serviced to the prescribed intervals of time even if you have not reached the p...

Page 67: ...heck Electrical system and battery check Tyre pressure check Vehicle test and brake test Road test See instructions in Idle speed adjustment section AT 6000 KM OR 12 MONTHS 18000 30000 42000 54000 AND...

Page 68: ...b oil level control Spark plug electrode gap replacement oil filter cleaning idle rpm adjustment Throttle lever adjustment CVT rollers check or replacement Drive belt replacement Odometer gear greasin...

Page 69: ...uctions in Idle speed adjustment section See regulations in the Secondary air system section AFTER 24000 KM AND 48000 KM Engine oil change Hub oil change Spark plug electrode gap replacement oil filte...

Page 70: ...ck Electrical system and battery check Headlight adjustment Tyre pressure and wear check Tyre pressure check SAS box sponge cleaning Vehicle test and brake test Road test See instructions in Idle spee...

Page 71: ...wear Brake fluid hoses replacement Brake fluid level check Transmission lubrication Safety fasteners check Suspension check Electrical system and battery check Headlight adjustment Tyre pressure and...

Page 72: ...check or replacement Drive belt replacement Cylinder ventilation system check Odometer gear greasing Steering adjustment Brake levers greasing Brake pads check for condition and wear Brake fluid hoses...

Page 73: ...P BRAKE 4 Brake fluid Synthetic fluid SAE J 1703 FMVSS 116 DOT 3 4 ISO 4925 CUNA NC 956 DOT 4 eni i Ride PG 5W 40 Synthetic based lubricant for high performance four stroke engines JASO MA MA2 API SL...

Page 74: ...74 6 Scheduledmaintenance...

Page 75: ...TABLE OF CONTENTS B Battery 34 C Checks 16 F Fuses 36 I Identification 14 K Keys 13 M Maintenance 25 P Puncture 44 R Refuelling 16 T Toolkit 58 Tyres 29 V Vehicle 7 75...

Page 76: ...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 pub...

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Summary of Contents for ZIP 100 4T

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