PIAGGIO ZIP 4T - Page 22

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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

Main Page

Index of Topics5
Characteristics6
Safety Rules7
Maintenance Rules7
Vehicle Identification8
Dimensions and Mass8
Engine8
Transmission9
Capacities9
Electrical System9
Frame and Suspensions9
Brakes10
Secondary Air10
Carburettor10
50Cc Version11
Tightening Torques11
Front Suspension11
Front Brake11
Overhaul Data12
Assembly Clearances12
Cylinder - Piston Assy12
Piston Rings13
Crankcase - Crankshaft - Connecting Rod14
Slot Packing System15
Products15
Tooling17
Recommended Tools18
Basic Tools21
Maintenance25
Maintenance Chart26
Checking the Spark Advance29
Spark Plug30
Hub Oil30
Check31
Replacement31
Air Filter32
Engine Oil32
Engine Oil Filter34
Checking the Ignition Timing35
Checking the Valve Clearance35
Headlight Adjustment36
CO Check36
Troubleshooting38
Rear Wheel Spins at Idle40
Insufficient Lubrication Pressure41
Engine Tends to Cut-Off at Full Throttle41
Engine Tends to Cut-Off at Idle42
Excessive Exhaust Noise42
High Fuel Consumption42
SAS Malfunctions42
Transmission and Brakes43
Clutch Grabbing or Performing Inadequately43
Insufficient Braking43
Brakes Overheating43
Battery44
Turn Signal Lights Malfunction44
Steering and Suspensions44
Rear Wheel44
Electrycal System46
Ignition49
Headlights and Automatic Starter Section50
Battery Recharge and Starting51
Level Indicators and Enable Signals Section52
Turn Signal Lights53
Checks and Inspections54
Ignition Circuit55
Stator Check55
Voltage Regulator Check56
Recharge System Voltage Check57
Starter Motor58
Turn Signals System Check59
Fuses60
Sealed Battery60
Dry-Charge Battery61
Engine from Vehicle63
Exhaust Assy. Removal64
Removal of the Engine from the Vehicle64
Engine65
Automatic Transmission66
Transmission Cover66
Kickstart66
Air Duct66
Removing the Driven Pulley Shaft Bearing67
Refitting the Driven Pulley Shaft Bearing67
Removing the Driven Pulley67
Inspecting the Clutch Drum68
Removing the Clutch68
Inspecting the Clutch69
Pin Retaining Collar69
Removing the Driven Half-Pulley Bearing70
Inspecting the Driven Fixed Half-Pulley70
Inspecting the Driven Sliding Half-Pulley71
Refitting the Driven Half-Pulley Bearing71
Inspecting the Clutch Spring72
Refitting the Clutch72
Refitting the Driven Pulley73
Drive-Belt73
Removing the Driving Pulley74
Inspecting the Rollers Case74
Refitting the Driving Pulley75
Refitting the Transmission Cover76
End Gear76
Removing the Hub Cover77
Removing the Wheel Axle Bearings77
Inspecting the Hub Shaft79
Inspecting the Hub Cover79
Refitting the Wheel Axle Bearing79
Refitting the Hub Bearings80
Refitting the Ub Cover80
Flywheel Cover81
Cooling Hood81
Cooling Fan82
Removing the Stator82
Refitting the Stator82
Flywheel and Starting82
Removing the Starter Motor83
Removing the Flywheel Magneto83
Inspecting the Flywheel Components84
Starter Gear Rim84
Intermediate Gear84
Refitting the Flywheel Magneto85
Refitting the Starter Motor85
Cylinder Assy. and Timing System85
Removing the Rocker-Arms Cover86
Removing the Timing System Drive86
Removing the Cam Shaft87
Removing the Cylinder Head88
Removing the Valves89
Removing the Cylinder - Piston Assy89
Inspecting the Small End90
Inspecting the Wrist Pin90
Inspecting the Piston90
Inspecting the Cylinder91
Inspecting the Piston Rings92
Removing the Piston93
Choosing the Gasket93
Refitting the Piston Rings96
Refitting the Cylinder97
Inspecting the Cylinder Head97
Inspecting the Timing System Components98
Inspecting the Valve Sealings99
Inspecting the Valve Housings99
Inspecting the Valves100
Inspecting the Springs and Half-Cones101
Refitting the Valves101
Inspecting the Cam Shaft101
Refitting the Head and Timing System Components103
Refitting the Timing Chain104
Refitting the Rocker-Arms Cover106
Refitting the Intake Manifold106
Crankcase - Crankshaft106
Splitting the Crankcase Halves107
Removing the Crankshaft Bearings108
Refitting the Crankshaft Bearings108
Refitting the Crankcase Halves110
Lubrication110
Crankshaft Oil Seals111
Removal111
Refitting111
Oil Pump112
Removing the Oil Sump115
Refitting the Oil Sump115
Fuel Supply115
Removing the Carburettor116
Refitting the Carburettor120
Level Check122
Inspecting the Automatic Choke Device123
Adjusting the Idle125
Suspensions128
Removing the Front Wheel129
Front Wheel Hub Overhaul129
Refitting the Front Wheel130
Handlebar131
Front Fork131
Overhaul131
Steering Column133
Removing the Rear Wheel134
Refitting the Rear Wheel134
Shock Absorbers134
Centre-Stand135
Braking System136
Front Brake Calliper137
Front Brake Disc139
Disc Inspection140
Front Brake Pads140
Fill141
Front Brake Pump142
Rear Drum Brake143
Chassis145
Removing the Ignition Key-Switch When on *Off*146
Removing the Ignition Key-Switch When on *Lock*146
Footrest146
Rear Mudguard147
Helmet Bay148
Fuel Tank148
Pre-Delivery149
Aesthetic Inspection150
Tightening Torques Inspection150
Levels Check151
Road Test151
Static Test151
Functional Inspection152
Time153
Crankcase155
Crankshaft155
Cylinder Assy156
Cylinder Head Assy157
Rocker Arms Support Assy158
Cylinder Head Cover159
Driven Pulley160
Driving Pulley162
Flywheel Magneto165
Exhaust Pipe166
Air Cleaner167
Frame168
Legshield Spoiler169
Rear Cover170
Central Cover171
Mudguard172
Rear Shock-Absorber174
Steering Column Bearings175
Handlebar Covers176
Handlebar Components177
Swing-Arm178
Seat179
Front Wheel181
Electric Devices183
Electronic Controls185
Transmissions186
Brake Callipers187
Rear Wheel Axle190
Secondary Air Box191

PIAGGIO ZIP 4T - Page 22

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