PIAGGIO MSS ZIP 100 4T Bedienungsanleitung

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 Sectionsmarked with this symbol indicatethe correct use of thevehicle

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 well-

ventilated, 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

suretheelectricconnectionshavebeenmadeproperly,particularlythegroundandbatteryconnections.

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. REGU-

LATE 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) op-

erating 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

throughthefilter«B»,getsintothereed

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 cat-

alytic 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

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