PIAGGIO MSS ZIP 100 4T Service Manual
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PIAGGIO MSS ZIP 100 4T Service Manual

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SERVICE STATION MANUAL
633734 ÷ 633741
MSS ZIP 100 4T

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Summary of Contents for PIAGGIO MSS ZIP 100 4T

  • Page 1 SERVICE STATION MANUAL 633734 ÷ 633741 MSS ZIP 100 4T...
  • Page 2 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. "© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
  • Page 3 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.
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM CHAS HASSIS PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    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.
  • Page 8 MSS ZIP 100 4T Characteristics 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...
  • Page 9 MSS ZIP 100 4T Characteristics 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) ~ 7 l...
  • Page 10 MSS ZIP 100 4T Characteristics 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 •...

  • Page 11: Tightening Torques

    MSS ZIP 100 4T Characteristics 50cc Version Tightening Torques STEERING ASSEMBLY Name Torque in Nm Upper steering ring nut 35 ÷ 40 Lower steering ring nut 12 ÷ 14 Handlebar clamping screw 20 - 25 Nm FRAME ASSEMBLY Name Torque in Nm Engine-swinging arm bolt 33 ÷...

  • Page 12: Assembly Clearances

    MSS ZIP 100 4T Characteristics Name Torque in Nm Oil sump screws 8 ÷ 10 Inlet manifold screw 7 ÷ 9 Carburettor/manifold clamp screw 1.2 ÷ 1.5 Nm Screws fixing cables to starter motor 1.5 ÷ 2.5 Starter screws 11 ÷ 13 Transmission cover screws 11 ÷...
  • Page 13 MSS ZIP 100 4T Characteristics Name Initials Cylinder Piston Play on fitting Piston 1st Oversize Ø P 50.214 ÷ 50.221 50.169 ÷ 50.176 0.038 ÷ 0.052 50.162±0.014 Cylinder 2nd Oversize 50.393 ÷ 50.400 50.348 ÷ 50.355 0.038 ÷ 0.052 Ø C 50.4+0.021-0.007 Cylinder 2nd Oversize 50.400 ÷...
  • Page 14 MSS ZIP 100 4T Characteristics Crankcase - crankshaft - connecting rod AXIAL CLEARANCE BETWEEN CRANKSHAFT AND CONNECTING ROD Name Description Dimensions Initials Quantity Half-shaft, transmission 14 +0 -0.005 side Flywheel-side half-shaft 16 +0 -0.005 Connecting rod 14.8 +0.05 -0 Built-up camshaft 45.00 / Fits and clearan-...
  • Page 15 MSS ZIP 100 4T Characteristics Slot packing system THE VALUE OF MEASUREMENT «A» TO BE TAKEN CAN REFER TO EITHER THE PROTRUSION OR RE-ENTRY OF THE PISTON. VALUES «A» INDICATED BY «-» CORRESPOND TO RE-ENTRY AND THOSE INDICATED BY «+» CORRESPOND TO PROTRUSION. THEREFORE, THE MORE THE PISTON PROTRUDES BEYOND THE PLANE FORMED AT THE CYLINDER UPPER END, THE THICKER THE GASKET TO BE USED AT THE CYLINDER BASE «B»...
  • Page 16 MSS ZIP 100 4T Characteristics Product Description Specifications AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in- creased adhesiveness AGIP GP 330 Grease (brake control levers, throttle Calcium complex soap-based grease grip) with NLGI 2; ISO-L-XBCIB2...
  • Page 17 INDEX OF TOPICS TOOL OOLING...

  • Page 18: Recommended Tools

    MSS ZIP 100 4T Tooling RECOMMENDED TOOLS Stores code Description 001330Y Tool for fitting steering seats 001467Y008 Pliers to extract 17 mm ø bearings 001467Y029 Bell for bearings, O.D. 38 mm 005095Y Engine support 008119Y009 Tube to assemble shafts and axles...
  • Page 19 MSS ZIP 100 4T Tooling Stores code Description 020151Y Air heater 020392Y Fork to assemble piston and cylinder 020329Y Mity-Vac vacuum-operated pump 020330Y Stroboscopic light to check timing 020331Y Digital multimeter TOOL - 19...
  • Page 20 MSS ZIP 100 4T Tooling Stores code Description 020332Y Digital rpm indicator 020333Y Single battery charger 020334Y Multiple battery charger 020335Y Magnetic support for dial gauge 494929Y Exhaust fumes analyser TOOL - 20...
  • Page 21 MSS ZIP 100 4T Tooling BASIC TOOLS Stores code Description 004499Y Bearing extractor. Fitted with: 1 Bell, 2 Sleeve, 3 Screw, 6 Ring, 27 Half rings, 34 Half rings 020055Y Wrench for steering tube ring nut 020162Y Flywheel extractor 020171Y...
  • Page 22 MSS ZIP 100 4T Tooling 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...
  • Page 23 MSS ZIP 100 4T Tooling Stores code Description 020382Y Valve fitting/ removal tool 020382Y011 adapter for valve removal tool 020431Y Valve oil seal extractor 020432Y Tool to fit the start-up sector spring 020439Y 17-mm guide 020444Y Tool for fitting/ removing the driven pulley...
  • Page 24 MSS ZIP 100 4T Tooling Stores code Description 020449Y Piston position check support 020450Y Camshaft fitting/removal tool 020451Y Driving pulley lock wrench 020452Y Tube for removing and refitting the driven pulley shaft 020456Y Ø 24 mm adaptor 020565Y Flywheel lock calliper spanner...
  • Page 25 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 26: Maintenance Chart

    MSS ZIP 100 4T Maintenance Maintenance chart 1000 K FTER Action Engine oil - level check/ top-up Hub oil level - replacement Valve clearance - Check Idle speed (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake control levers - greasing...
  • Page 27 MSS ZIP 100 4T Maintenance Action Valve clearance - Check Idle speed (*) - adjustment Throttle lever - adjustment Variable speed rollers - check or replacement Driving Belt - replacement Cylinder ventilation system - check Odometer gear - greasing Steering - adjustment...
  • Page 28 MSS ZIP 100 4T Maintenance Carburettor - Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning. - Check carefully that the parts are in good condi- tion.

  • Page 29: Checking The Spark Advance

    MSS ZIP 100 4T Maintenance Checking the spark advance The vehicle is fitted with a variable advance electronic device. There are two timing references on the flywheel cover in order to ensure a better precision when detecting the reference on the fan. Use a Tecnotest 130/P stroboscopic gun or a similar device to check.

  • Page 30: Spark Plug

    MSS ZIP 100 4T Maintenance Spark plug - Disconnect and remove the spark plug pipe. - Remove the spark plug; if necessary, use the spanner supplied with the vehicle. - Examine it carefully and replace it if the insulator is chipped or cracked.
  • Page 31 MSS ZIP 100 4T Maintenance Check - Park the scooter on level ground and rest it on the centre stand. - Unscrew the dipstick «A», dry it with a clean rag and then reinsert it, screwing it tightly into place.
  • Page 32 MSS ZIP 100 4T Maintenance Air filter Remove the air cleaner cap after undoing the 6 fixing screws, then extract the filter. Cleaning: - Wash with water and soap. - Dry with a clean cloth without wringing. - Soak with a mixture of 50% petrol and 50% SE- LENIA AIR FILTER OIL.
  • Page 33 MSS ZIP 100 4T Maintenance CAUTION USING THE ENGINE WITH INSUFFICIENT LUBRICATION OR WITH THE WRONG LUBRICANTS MAY INCREASE WEAR AND TEAR ON THE MOVING PARTS AND MAY RE- SULT IN SERIOUS DAMAGE. WARNING USED OIL CONTAINS ENVIRONMENTALLY HARMFUL SUBSTANCES...

  • Page 34: Engine Oil Filter

    MSS ZIP 100 4T Maintenance Engine oil filter - Change oil when the engine is hot. - Place a container under the oil sump and remove the oil drainage cap. - After draining the oil, clean the mesh filter with a specific solvent and then blow it with compressed air.

  • Page 35: Checking The Ignition Timing

    MSS ZIP 100 4T Maintenance Checking the ignition timing - Turn the flywheel clockwise until its 2nd notch coincides with the Pick-up reference mark as shown in the figure. Make sure that the reference point on the camshaft command crown is aligned with the reference point on the head as shown in the second figure.

  • Page 36: Headlight Adjustment

    MSS ZIP 100 4T Maintenance 0.15 mm Headlight adjustment Proceed as follows: 1. Place the vehicle, in running order and with the tyres inflated to the prescribed pressure, on a flat surface 10-m away from a white screen situated in a shaded area, making sure that the longitudinal axis of the scooter is perpendicular to the screen;...
  • Page 37 MSS ZIP 100 4T Maintenance 9) Adjust the flow screw so that the "CO" value is equal to 3.2 % :t 0.5 %. 10) Slowly operate the throttle accelerating the engine until it reaches 4000 rpm and then set throttle back to close position;...
  • Page 38 INDEX OF TOPICS TROUBL ROUBLESHOOTING...
  • Page 39 MSS ZIP 100 4T Troubleshooting EXCESSIVE FUEL CONSUMPTION Possible Cause Operation Air filter obstructed or dirty. Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% Selenia Air Filter Oil, then allow to drip dry. Wring out water manually without...

  • Page 40: Rear Wheel Spins At Idle

    MSS ZIP 100 4T Troubleshooting Possible Cause Operation Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% of specific oil (Se- lenia Air Filter Oil), then hand dry without squeezing, allow to drip dry and then reassemble.
  • Page 41 MSS ZIP 100 4T Troubleshooting Possible Cause Operation Air filter dirty Dismantle the sponge, wash with water and shampoo, then soak it in a mixture of 50% petrol and 50% Selenia Air Filter Oil, then allow to drip dry. Wring out water manually without squeezing and reassemble.
  • Page 42 MSS ZIP 100 4T Troubleshooting Engine tends to cut-off at idle THE ENGINE TENDS TO STOP AT IDLE SPEED Possible Cause Operation Wrong idling adjustment Correctly adjust the engine idling and check the level of the C.O. Spark plug defective or faulty...
  • Page 43 MSS ZIP 100 4T Troubleshooting Transmission and brakes REAR BRAKE LEVER FAIL TO RETURN Possible Cause Operation Return spring broken Replace spring. Shoe control bolt not lubricated Lubricate with Z2 grease. Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE...
  • Page 44 MSS ZIP 100 4T Troubleshooting Electrical system Battery BATTERY Possible Cause Operation The battery is the electrical device in the system that requires The battery is the electrical device in the system that requires the most frequent inspections and thorough maintenance.
  • Page 45 MSS ZIP 100 4T Troubleshooting Possible Cause Operation Excessive steering clearance Check the tightening of the top ring nut. If irregularities continue in turning the steering even after making the above adjust- ments, check the seats in which the ball bearings rotate: re- place if they are recessed.
  • Page 46 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 47 MSS ZIP 100 4T Electrical system 1. Electronic ignition device 2. Spark plug 3. Magneto flywheel 4. Voltage regulator 5. Main fuse 6. Key switch 7. Battery 8. Starter motor 9. Starter remote control 10. Starter button 11. Rear brake STOP button 12.
  • Page 48 MSS ZIP 100 4T Electrical system A. Left front turn indicator bulb B. Front position light bulb 20. Headlight assembly with high-/low-beam bulb 21. Right side headlight assembly A. Left front turn indicator bulb B. Front position light bulb 22. Light switch 23.
  • Page 49 MSS ZIP 100 4T Electrical system Ignition 1. Electronic ignition device 2. Spark plug 3. Magneto flywheel 6. Key switch ELE SYS - 49...
  • Page 50 MSS ZIP 100 4T Electrical system Headlights and automatic starter section 3. Magneto flywheel 4. Voltage regulator 16. Tail lights/stop light bulbs 19. Left side headlight assembly A. Left front turn indicator bulb B. Front tail light bulb 20. Headlight assembly with high-/low-beam bulb 21.
  • Page 51 MSS ZIP 100 4T Electrical system Battery recharge and starting 3. Magneto flywheel 4. Voltage regulator 5. Main fuse 6. Key switch 7. Battery 8. Starter motor 9. Starter remote control 10. Starter button 11. STOP button on rear brake 12.
  • Page 52 MSS ZIP 100 4T Electrical system Level indicators and enable signals section KEY: 5. Main fuse 6. Key switch 7. Battery 23. Instrument panel A. Flashing warning light B. High-beam warning light C. Low fuel warning light D. Instrument panel bulb E.
  • Page 53 MSS ZIP 100 4T Electrical system Turn signal lights KEY: 3. Magneto flywheel 4. Voltage regulator 5. Main fuse 6. Key switch 7. Battery 13. Horn button 14. Horn 15. Left rear turn indicator bulbs 17. Turn indicator switch 18. Right rear turn indicator bulbs 19.
  • Page 54 MSS ZIP 100 4T Electrical system A. Flashing warning light B. High-beam warning light C. Low fuel warning light D. Instrument panel bulb E. Instrument panel bulb Checks and inspections In case the cause of ignition failure or malfunction cannot be easily identified at sight, first of all re- place the control unit by another one in operating conditions.
  • Page 55 MSS ZIP 100 4T Electrical system KEY: Br= brown Bl= black A= Pick-up B= Stator Ignition circuit All the control operations of the system that require the disconnection of cables (checks of the con- nections and the devices making up the ignition...
  • Page 56 MSS ZIP 100 4T Electrical system Voltage regulator check A malfunction in the voltage regulator might cause the following problems depending on the type of fault: Alternating current section 1) Bulbs burned out (regulator in short circuit). 2) Malfunctioning of the lighting system and the electric starter (regulator interrupted).
  • Page 57 MSS ZIP 100 4T Electrical system As a last check, the voltage supplied by the stator can be measured: - Disconnect the regulator connector and place a tester between the Grey-Blue cable (4) and the earth in order to detect alternating voltages (see figure).
  • Page 58 MSS ZIP 100 4T Electrical system age regulator (with connector disconnected); the measurement must be ~8 M/Ohm. If the value measured is far from that indicated, replace the regulator because it is in short circuit. b) Battery fails to recharge (regulator interrupted).
  • Page 59 MSS ZIP 100 4T Electrical system - Nominal power 0.25 kW. - Leftward rotation seen from the pinion side. - Connection to the engine by means of pinion and crown gear on the crankshaft, transmission side. - Control with switch.
  • Page 60 MSS ZIP 100 4T Electrical system Fuses The electrical system is protected by a 10 A fuse «A» located to the left of the battery support. The ignition system, the automatic starter, front head- light and the tail light are not fuse-protected. Be- fore replacing a blown fuse, find and solve the problem that caused it to blow.
  • Page 61 MSS ZIP 100 4T Electrical system Maximum 24 h 3) Constant current battery charge mode -Charge current equal to 1/10 of the nominal ca- pacity of the battery -Duration of the charge: 5 h WARNING -WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT BE THAT 5 HOURS OF RECHARGING ARE...
  • Page 62 MSS ZIP 100 4T Electrical system KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED. FIRST DETACH THE NEGATIVE LEAD BEFORE REMOVING THE BATTERY FROM THE VEHICLE. 4) Cleaning the battery You are advised to keep the battery clean,especially in the upper part, and to protect the terminals with Vaseline.
  • Page 63 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 64 MSS ZIP 100 4T Engine from vehicle Exhaust assy. Removal - Remove the 2 fixing nuts from the manifold to the head - Undo the 2 screws fixing the muffler to the hous- ing; then remove the whole muffler paying atten- tion to the interference between its supporting bracket and the cooling cover.
  • Page 65 INDEX OF TOPICS NGINE...

  • Page 66: Automatic Transmission

    MSS ZIP 100 4T Engine Automatic transmission Transmission cover - Remove the 12 fixing screws. - Remove the oil filling cap and then slide out the cover. If this operation is carried out directly on the vehi- cle, it is necessary to remove the transmission cooling coupling and the air filter housing retain- ers.

  • Page 67: Removing The Driven Pulley

    MSS ZIP 100 4T Engine Removing the driven pulley shaft bearing - Slightly heat the crankshaft from the inside side to avoid damaging the coated surface and use the driven pulley shaft or a pin of the same diameter to remove the bearing.

  • Page 68: Inspecting The Clutch Drum

    MSS ZIP 100 4T Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the inner diameter of the clutch bell. Characteristic Clutch bell diameter/standard value Ø 107+0.2 +0 mm Clutch bell diameter/max. value allowed after Ø...
  • Page 69 MSS ZIP 100 4T Engine Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must not show traces of lubricants; otherwise, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL FAYING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER.
  • Page 70 MSS ZIP 100 4T Engine Removing the driven half-pulley bearing - Remove the roller bearing with the special ex- tractor inserted from the bottom of the fixed half- pulley. CAUTION POSITION THE HOLDING EDGE OF THE EXTRACTION PLI- ERS BETWEEN THE END OF THE BEARING AND THE BUILT IN SEALING RING.
  • Page 71 MSS ZIP 100 4T Engine Inspecting the driven sliding half-pulley - Remove the 2 inner sealing rings and the two O- rings. - Measure the inside diameter of the mobile half- pulley bushing. Characteristic Mobile driven half-pulley/ Maximum diameter allowed Ø...
  • Page 72 MSS ZIP 100 4T Engine 020456Y Ø 24 mm adaptor 020362Y 12 mm guide 020171Y Punch for Ø 17 mm roller case Inspecting the clutch spring - Check that the contrast spring of the driven pulley does not show signs of deformation...

  • Page 73: Refitting The Driven Pulley

    MSS ZIP 100 4T Engine - Reassemble the nut securing the clutch and tight- en to the prescribed torque. CAUTION SO AS NOT TO DAMAGE THE CLUTCH NUT USE A SOCK- ET WRENCH WITH SMALL CHAMFER. CAUTION POSITION THE NON-CHAMFERED SURFACES OF THE...

  • Page 74: Removing The Driving Pulley

    MSS ZIP 100 4T Engine Removing the driving pulley - Lock the driving pulley using the appropriate tool. - Remove the central nut with the related washer, then remove the drive and the plastic fan. - Remove the stationary half-pulley.
  • Page 75 MSS ZIP 100 4T Engine 20.12 mm Driving pulley/ Standard diameter: 20.021 mm Driving pulley bushing/ Diameter maximum: XXX mm Driving pulley bushing/ Standard diameter: 20 -0.020/-0.041mm Refitting the driving pulley - Manually move the movable driven half-pulley away by pulling it towards the clutch unit and insert the belt observing the direction of rotation of the first fitting.
  • Page 76 MSS ZIP 100 4T Engine Refitting the transmission cover - Check the following for wear: toothed section, toothed section shaft, cover seat bushing, pinion shaft and its seating in the crankcase and the re- turn spring. - Remove the damaged components.
  • Page 77 MSS ZIP 100 4T Engine Removing the hub cover - Drain the rear hub oil - Remove driven pulley - Remove the rear brake shoes - Remove the 5 screws fixing the cover to the crankcase - Remove the cover with the wheel axle and pull it...
  • Page 78 MSS ZIP 100 4T Engine Removing the driven pulley shaft bearing - Remove the seeger ring - Heat the engine crankcase but do not direct the hot air towards the bearing - Extract the driven pulley shaft together with the...
  • Page 79 MSS ZIP 100 4T Engine Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - In case of anomalies, replace the damaged com- ponents.
  • Page 80 MSS ZIP 100 4T Engine 020363Y 20-mm guide 020359Y 42x47-mm Adaptor Refitting the hub bearings - Remove the wheel axle on the cover and pay at- tention not to damage the sealing lip of the oil seal - Apply a thin layer of grease on the two shim...
  • Page 81 MSS ZIP 100 4T Engine Gasket Locking torques (N*m) hub cap screws 24 - 26 Flywheel cover Cooling hood - Remove the manifold and the carburettor undo- ing the 2 fixing screws on the head - Remove the fastening clamp of the secondary air...

  • Page 82: Removing The Stator

    MSS ZIP 100 4T Engine Cooling fan - Remove the cooling fan by undoing the 3 screws fixing it to the rotor - When refitting the fan, pay attention that the screw holes in the fan and the rotor coincide, then tighten screws at the specified torque.
  • Page 83 MSS ZIP 100 4T Engine Removing the starter motor - Undo the screw on the power positive contact and disconnect the cable - Undo the 2 screws fixing the starter motor to the crankcase and recover the power wiring. Removing the flywheel magneto - Lock the rotation of the flywheel using the calliper spanner.
  • Page 84 MSS ZIP 100 4T Engine Inspecting the flywheel components - Check that the flywheel internal magnets are in good conditions. - Check that the flywheel splines exhibit no loos- ening. - Check there are no deformations that may cause rubbing on the stator and the Pick-Up.
  • Page 85 MSS ZIP 100 4T Engine Refitting the flywheel magneto - Refit the stator and the pick-up being careful to pass the wiring through the appropriate crankcase couplings. - Refit the flywheel to the crankshaft being careful to respect the keying, then lock rotation with the specific tool and tighten the nut to the prescribed torque.
  • Page 86 MSS ZIP 100 4T Engine Removing the rocker-arms cover - Remove the cooling covers - Remove the 4 retainers of the tappet cover - Remove the cover and the O-ring - Remove the 4 screws and then remove the Blow-...
  • Page 87 MSS ZIP 100 4T Engine - Remove the driving pulley - Remove the oil pump chain - Remove the tappet cover - Remove the central screw and the belleville washer indicated in the figure and lock the cam- shaft crown with the specific tool.

  • Page 88: Removing The Cylinder Head

    MSS ZIP 100 4T Engine 020450Y Camshaft fitting/removal tool 004499Y Camshaft bearing extractor 004499Y001 Bearing extractor bell 004499Y002 Bearing extractor screw 004499Y006 Bearing extractor ring 004499Y027 Bearing extractor part - Pull out the rocking lever bolt operating on the flywheel hole and remove the rocking levers at the same time.

  • Page 89: Removing The Valves

    MSS ZIP 100 4T Engine Removing the valves - Using the specific tool fitted with the element shown in the figure, remove the cotters, the plates and the spring between the valves. - Remove the oil seals with the appropriate tool.

  • Page 90: Inspecting The Small End

    MSS ZIP 100 4T Engine Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N.B. IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE MAXIMUM DIAMETER ALLOWED, SHOWS SIGNS OF WEAR OR OVERHEATING REPLACE THE CRANKSHAFT AS DESCRIBED IN THE "CRANKCASE AND CRANK-...
  • Page 91 MSS ZIP 100 4T Engine - Calculate the piston pin coupling clearance. Fitting clearance Pin coupling clearance 13 +0.010+0.005mm 0.005 ÷ 0.014 mm - Measure the outside diameter of the piston, perpendicular to the gudgeon pin axis. - Carry out the measurement at 27 from the piston crown as shown in the figure.
  • Page 92 MSS ZIP 100 4T Engine - The cylinder rectifying operation should be car- ried out with a surfacing that respects the original angle. at 120° crossed. - The cylinder surface roughness should be of R.A.= 0.30 ÷ 0.50. - This is indispensable for a good seating of the sealing rings, which in turn minimises oil consump- tion and guarantees optimum performance.

  • Page 93: Removing The Piston

    MSS ZIP 100 4T Engine Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust. - Fit the pin stop ring onto the appropriate tool. Specific tooling...
  • Page 94 MSS ZIP 100 4T Engine Specification Desc./Quantity Measure detected 1 ± 0.05 Base gasket thickness CYLINDER BASE GASKET THICKNESS Specification Desc./Quantity Cylinder height 57.15 ± 0.05 Head gasket thickness (steel) 0.3 ± 0.05 Measure detected 0.20 ± 0.05 Base gasket thickness Measure detected 0.30 ±...
  • Page 95 MSS ZIP 100 4T Engine ENG - 95...
  • Page 96 MSS ZIP 100 4T Engine Refitting the piston rings - Fit the oil scraper ring starting from the spring, taking care that the spring ends do not superim- pose. Fit the two piston rings so that their gaps and that of the oil scraper ring are never aligned.

  • Page 97: Inspecting The Cylinder Head

    MSS ZIP 100 4T Engine NATION WITH A USED CYLINDER MAY HAVE DIFFERENT BEDDING CONDITIONS THAN THE STANDARD. SEALING RINGS Name Descripti Dimensio Initials Quantity Top piston 0.08 ÷ 0.35 mm ring 0.20 mm Middle pis- 0.05 ÷ 0.30 mm ton ring 0.20 mm...
  • Page 98 MSS ZIP 100 4T Engine 0.05 mm HEAD CHECK Specification Desc./Quantity Standard diameter (mm) A Ø 32.015 ÷ 32.025 mm Standard diameter (mm) B Ø 16.0 ÷ 16.018 Standard diameter (mm) C Ø 11.0 ÷ 11.018 Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out.
  • Page 99 MSS ZIP 100 4T Engine Inspecting the valve sealings - Insert the valves into the cylinder head. - Test the 2 valves alternatively. - The test is carried out by filling the manifold with petrol and checking that the head does not ooze through the valves when these are just pressed with the fingers.
  • Page 100 MSS ZIP 100 4T Engine Wear limits: Max. 1.6 mm. Inspecting the valves - Measure the diameter of the valve stems in the three positions indicated in the diagram. - Calculate the clearance between the valve and the valve guide.
  • Page 101 MSS ZIP 100 4T Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. Refitting the valves - Lubricate the valve guides with graphite grease. - Place the lower plates of the valve spring on the head.
  • Page 102 MSS ZIP 100 4T Engine Ø 11.98 mm Minimum diameter allowed - Bearing B: Ø 15.96 mm - If any of the above dimensions are outside the specified limits, or there are signs of excessive wear, replace the defective components with new ones.
  • Page 103 MSS ZIP 100 4T Engine Refitting the head and timing system components - Fix the head on a workbench. - Screw the tool to fit the camshaft fully down on the bearing's inner track. - Fit the camshaft fully into its seating together with the bearing with the aid of a mallet.
  • Page 104 MSS ZIP 100 4T Engine - Finish the head tightening following the proce- dure below: screw the four head nuts to an initial torque at two crossed passes. Afterwards tighten the nuts with 2 turns of 90° each to be done at two crossed passes.
  • Page 105 MSS ZIP 100 4T Engine - Bring the screw closer but without reaching its final locking point. - Push the tensioner pad lightly so as to check the correct timing. - Use the specific tool to lock the camshaft crown gear and tighten the screw.
  • Page 106 MSS ZIP 100 4T Engine Refitting the rocker-arms cover - Carry out the removal procedure but in reverse order and tighten the four fixing screws to the specified torque. N.B. FIT A NEW O-RING ON THE TAPPET COVER. Locking torques (N*m) Timing chain tensioner screws 8 ÷...
  • Page 107 MSS ZIP 100 4T Engine Splitting the crankcase halves - Remove the ten crankshaft coupling screws. -Separate the crankcase halves keeping the half casing driving shaft engaged on the transmission side. - Remove the crankshaft. CAUTION IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT AC- CIDENTALLY FALL.
  • Page 108 MSS ZIP 100 4T Engine - Check that the half shaft surfaces are not scored and with the aid of a gauge check the driving shaft width as indicated in the figure. Characteristic Standard measure 45 mm Removing the crankshaft bearings - Remove the flywheel bearing fitted on the driving shaft using the specific tool.
  • Page 109 MSS ZIP 100 4T Engine - Support the crankcase on a surface and place it with the driving shaft axle in a vertical position. - Warm the crankcase at ~ 120° C with a thermal gun (and support). - Fit the punch with guide and adaptor, place the bearing on the punch using grease (to keep it from falling).
  • Page 110 MSS ZIP 100 4T Engine 020074Y Support base for checking crankshaft alignment Refitting the crankcase halves -Be careful to place the two centring dowels pref- erably on the flywheel side half casing. -Insert the crankshaft on the half casing on the transmission side.
  • Page 111 MSS ZIP 100 4T Engine Crankshaft oil seals Removal - Check that the chain contrast pad is not worn. -Otherwise, replace the pad or fit it inverted to make it work on the other side. - Any operation on the chain cover oil seal should be carried out placing the cover on the workbench on the covering plate side of the oil pump chain.
  • Page 112 MSS ZIP 100 4T Engine - Fit a new oil seal on the outer rim with the help of the specific tools below. - Fit a new O-ring and lubricate it with grease. - Install the cover on the engine crankcase, insert the three screws and place the cover in its position.
  • Page 113 MSS ZIP 100 4T Engine - Remove the central screw and the belleville washer - Remove the chain with the crown gear. - Remove the crankshaft control pinion. - Remove the oil pump by undoing the 2 screws indicated in the figure.
  • Page 114 MSS ZIP 100 4T Engine - Check the axial clearance of the rotors using a trued bar as reference as shown in the figure. N.B. MAKE SURE THE TRUED BAR IS POSITIONED PROPERLY ON THE TWO POINTS ON THE PUMP BODY.

  • Page 115: Fuel Supply

    MSS ZIP 100 4T Engine Removing the oil sump - Remove the oil filling cap, the transmission cover, the complete driving pulley assembly with belt and pinion. - Unscrew the oil drainage plug «A» shown in the figure and drain out all the oil from the sump.

  • Page 116: Removing The Carburettor

    MSS ZIP 100 4T Engine - Disconnect the fuel supply and the suction taking pipe from the carburettor. - Check that there are no fuel leaks between the two tubes. - Close the fuel outlet pipe. - By means of the MITYVAC pump apply 0.1 bar of suction to the tap.
  • Page 117 MSS ZIP 100 4T Engine - Remove the protection, the bracket and the start- er undoing the screw shown in the figure. CAUTION THE CARBURETTOR FEATURES AN ANTI-VIBRATION RUBBER BUFFER FITTED ON THE LOWER SUPPLEMENT OF THE ACCELERATING PUMP BODY. UPON REFITTING...
  • Page 118 MSS ZIP 100 4T Engine - Remove the cover being careful with the spring below, then remove the spring, take out the rubber protection and the diaphragm together with the pipe O-Ring. -Remove the accelerating pump jet together with the ball spring.
  • Page 119 MSS ZIP 100 4T Engine - Remove the sprayer tilting the carburettor body. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM- AGE IT.
  • Page 120 MSS ZIP 100 4T Engine Refitting the carburettor - Before refitting, wash the carburettor body accu- rately with a degreasing solvent and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For the minimum circuit, make sure the following...
  • Page 121 MSS ZIP 100 4T Engine - Wash and blow the minimum nozzle properly and reassemble it. - Accurately wash and blow the components of the maximum circuit, the sprayer, the diffuser and the nozzle. - Introduce the sprayer in the carburettor body with the bigger cylindric part directed to the diffuser.
  • Page 122 MSS ZIP 100 4T Engine - Check the diaphragm is in good conditions and remove the remaining components of the acceler- ating pump following these steps: - Insert the O-Ring in the pipe. - Insert the diaphragm together with the pin and its spring.
  • Page 123 MSS ZIP 100 4T Engine - Insert the diaphragm into the throttle valve. - Insert the tapered pin together with the plastic support and the contrast spring into the throttle valve. N.B. PLACE THE SPRING PLASTIC SUPPORT WITH ITS TEETH...
  • Page 124 MSS ZIP 100 4T Engine - The starter should disconnect progressively by means of electrical heating. - Check the starter resistance when adjusted to the ambient temperature. Characteristic ambient temperature 24° C Electric characteristic Automatic starter resistance 6 Ω ± 5 % - Use battery to power the automatic starter and check that piston protrudes as much as possible.
  • Page 125 MSS ZIP 100 4T Engine - Insert rubber pipes for chamber ventilation. - Insert the O-Ring, the washer, the spring and the idle flow screw in their seatings. - Refit the carburettor on the engine and connect again the accelerator cable with the sheath and the support plate and the electrical connection of the starter.
  • Page 126 MSS ZIP 100 4T Engine 40 ÷ 50 cm - Connect the tester thermometer to the sump, us- ing a cover with oil expressly prepared for probes. - Start the engine and before adjusting the idle speed, make sure that the oil temperature is be- tween 70÷80 °C.
  • Page 127 MSS ZIP 100 4T Engine loss of engine blows as the mixture is too lean (low CO), ignition failure or, incorrect timing or a clogged or unsealed exhaust valve. If it is difficult to adjust CO values, check accurately: - That the automatic starter is efficient.
  • Page 128 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 129: Removing The Front Wheel

    MSS ZIP 100 4T Suspensions This section is devoted to operations that can be carried out on the suspensions. Front Removing the front wheel - Remove the wheel axle lock nut. - Remove the wheel axle and the wheel. - Upon removal take care not to damage the sen- sor that detects movement in the odometer.
  • Page 130 MSS ZIP 100 4T Suspensions - Check that the bearings do not show flaws or jamming. Otherwise, replace them. - Check that the internal spacer does not show ab- normal wear. Otherwise, replace it. - With a hot air gun heat the seat of the bearing on...

  • Page 131: Front Fork

    MSS ZIP 100 4T Suspensions Handlebar Removal Handlebar removal Remove the handlebar cover before carrying out this operation,. - After removing the transmissions and discon- necting the electrical terminals, remove the termi- nal fixing the handlebar to the steering. - Check all components and replace faulty parts.
  • Page 132 MSS ZIP 100 4T Suspensions - Remove the upper screw (2). - Add 30 cc ±1 "Fork PG" oil (SAE 20W oil for forks). - Refit all components. Locking torques (N*m) Upper screw tightening torque Lower 20 to 25 Nm...
  • Page 133 MSS ZIP 100 4T Suspensions Steering column Refitting Lower and upper seating on the chassis Lower and upper seating on the chassis Removal Washer and upper seating of upper bearing After removing the upper seating, tilt the vehicle to a side and take out the steering tube making sure mudflaps have been removed and the calliper dis- connected.

  • Page 134: Removing The Rear Wheel

    MSS ZIP 100 4T Suspensions Removing the rear wheel - Use a screwdriver as a lever between the drum and the cover. -Straighten the split pin and remove the cap. -Remove the wheel acting on the central fixing point. WARNING -ALWAYS USE NEW SPLIT PINS FOR REFITTING.
  • Page 135 MSS ZIP 100 4T Suspensions - To replace the shock absorber remove the rear cover and battery access flap to get and remove the shock absorber/ chassis anchoring nut. Then remove the shock absorber/engine anchorage nut. Refitting - When refitting, tighten the shock absorber/chassis anchoring nut and the shock absorber/engine pin to the prescribed torque.
  • Page 136 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 137 MSS ZIP 100 4T Braking system Front brake calliper Removal - Inspect the condition of the hoses, packing and joint. In the event of fluid leaks from the calliper, this must be replaced. - Detach the oil brake pipe from the calliper; pour the fluid inside a container.
  • Page 138 MSS ZIP 100 4T Braking system 2) place the guide rubbers (8) and refit the fixed plate (4); 3) assemble the reaction plate (3) tightening the screws (2), insert the brake pad check spring (9) and then the pads, fixing them with the corre- sponding screws (1);...

  • Page 139: Front Brake Disc

    MSS ZIP 100 4T Braking system Refitting - When refitting, tighten the nuts to the prescribed torque. - Bleed the system. N.B. WHILE REFITTING, REPLACE THE COPPER GASKETS ON THEIR FITTINGS. Locking torques (N*m) Oil bleed screw 7 ÷ 10 Calliper tightening screw 24 ÷ 27 Brake fluid pipe-calliper fitting 19 ÷ 24...

  • Page 140: Front Brake Pads

    MSS ZIP 100 4T Braking system Disc Inspection - Remove the wheel and check for unevenness of the disc. Maximum permissible out of true is 0.1 mm. If the value measured is greater, fit a new disc and re- peat the check.
  • Page 141 MSS ZIP 100 4T Braking system Medium Loctite 243 threadlock Locking torques (N*m) Screw tightening calliper to support 20 ÷ 25 Pad fixing pin 19.6 ÷ 24.5 Fill Front -Once the bleed valve is closed, fill the system with brake liquid to the maximum level.
  • Page 142 MSS ZIP 100 4T Braking system WHEN CARRYING OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM BETWEEN THE BLEED SCREW AND ITS SEAT ON THE CALLIPER. CAREFULLY DRY THE CALLIPER AND DEGREASE THE DISC SHOULD THERE BE OIL ON IT.

  • Page 143: Rear Drum Brake

    MSS ZIP 100 4T Braking system 8 - Spring CAUTION - THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES THE BRAKING EFFICIENCY. IN THIS CASE, REPLACE THE PADS AND CLEAN THE DISC WITH A HIGH-QUALITY SOLVENT.
  • Page 144 MSS ZIP 100 4T Braking system Specific tooling 020325Y Pliers for brake-shoe springs BRAK SYS - 144...
  • Page 145 INDEX OF TOPICS CHAS HASSIS...
  • Page 146 MSS ZIP 100 4T Chassis Removing the ignition key-switch when on *off* • Remove the shield back plate • Push the lock body until the stop spring does not show grooves. • Keep the lock body blocked with a screwdriver and remove the spring with a pair of pliers.

  • Page 147: Rear Mudguard

    MSS ZIP 100 4T Chassis Air filter • Unscrew the 7 cover screws and remove the cover to reach the filter sponge. • To disassemble the filter housing, unscrew the 2 bottom screws and disconnect the manifold con- nections, the carburettor and the external air in- take.
  • Page 148 MSS ZIP 100 4T Chassis Helmet bay - Remove the side fairings - Remove the helmet compartment by undoing the 4 screws indicated in the figure Fuel tank - Remove the side fairings - Remove the rear mudguard - Remove the crews shown in the photograph...
  • Page 149 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 150 MSS ZIP 100 4T Pre-delivery Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check - Safety locks - clamping screws Safety locks Rear shock absorber upper fixing Rear shock absorber lower fixing...
  • Page 151 MSS ZIP 100 4T Pre-delivery CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE. INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. WARNING BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
  • Page 152 MSS ZIP 100 4T Pre-delivery - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE. CAUTION NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
  • Page 153 INDEX OF TOPICS TIME...
  • Page 154 MSS ZIP 100 4T Time This section is devoted to the time necessary to carry out repairs. The description and code for each operation is in- dicated. Engine ENGINE Code Action Duration 001001 Engine from frame - Removal and re- fit.
  • Page 155 MSS ZIP 100 4T Time Crankcase CRANKCASE Code Action Duration 001133 Engine crankcase - Replacement Crankshaft TIME - 155...
  • Page 156 MSS ZIP 100 4T Time CRANKSHAFT Code Action Duration 001117 Crankshaft - Replacement 001099 Oil seal, flywheel side - Replacement 001100 Oil seal, clutch side - Replacement 001118 Main bearings - Replacement Cylinder assy. CYLINDER- PISTON Code Action Duration 001002...
  • Page 157 MSS ZIP 100 4T Time Cylinder head assy. HEAD Code Action Duration 001056 Head gasket - Replacement 001045 Valves - Replacement 001126 Head - Replacement TIME - 157...
  • Page 158 MSS ZIP 100 4T Time Rocker arms support assy. CAMSHAFT SUPPORT Code Action Duration 001049 Valve clearance - Adjustment 001148 Valve rocking levers - Replacement 001044 Camshaft - Replacement TIME - 158...

  • Page 159: Cylinder Head Cover

    MSS ZIP 100 4T Time Cylinder head cover HEAD COVER Code Action Duration 001093 Spark plug - Replacement 001088 Head cover gasket - Replacement 001097 Cooling hood - Replacement 001089 Head cover - Replacement TIME - 159...

  • Page 160: Driven Pulley

    MSS ZIP 100 4T Time Driven pulley DRIVEN PULLEY - CLUTCH Code Action Duration 001110 Driven pulley - Replacement 001012 Driven pulley - Overhaul 001022 Clutch - Replacement 001155 Clutch bell housing - Replacement TIME - 160...
  • Page 161 MSS ZIP 100 4T Time Oil pump IL PUMP Code Action Duration 001051 Belt/Timing chain - Change 001112 Oil pump - change 001042 Oil pump - Service 001121 Chain cover oil seal - Replacement 001122 Oil pump chain - Replacement...
  • Page 162 MSS ZIP 100 4T Time Driving pulley PULLEY REAR VIEW Code Action Duration 001177 Variator rollers / shoes - Replace- ment 001086 rear-view half-pulley - Replacement 001066 Driving pulley - Removal and refitting 001011 Driving belt - Replacement TIME - 162...
  • Page 163 MSS ZIP 100 4T Time Transmission cover TRANSMISSION COVER Code Action Duration 001096 Transmission crankcase cover - re- place 001132 Transmission air inlet pipe - Replace- ment 001131 Transmission air intake - Replace- ment 001135 Transmission cover bearing - Re-...
  • Page 164 MSS ZIP 100 4T Time Starter motor STARTER MOTOR - START UP LEVER Code Action Duration 001020 Starter motor - change 001017 Starter sprocket wheel - replace 005045 Starter motor with cables unit - Re- plac. 001084 Starter lever - Replacement...

  • Page 165: Flywheel Magneto

    MSS ZIP 100 4T Time Flywheel magneto FLYWHEEL FAN Code Action Duration 001067 Stator - Fitting and Refitting 001058 Flywheel - Replacement 001102 Net oil filter - Replacement / Cleaning 001109 Cooling fan - Replacement 001087 Flywheel cover - Replacement...
  • Page 166 MSS ZIP 100 4T Time Exhaust pipe MUFFLER Code Action Duration 001009 Muffler - Replacement 001095 Muffler guard - Replacement 001136 Exhaust emissions - Adjustment TIME - 166...

  • Page 167: Air Cleaner

    MSS ZIP 100 4T Time Air cleaner AIR FILTER Code Action Duration 001014 Air filter - Replacement /Cleaning 001015 Air filter box - Replacement TIME - 167...
  • Page 168 MSS ZIP 100 4T Time Frame FRAME Code Action Duration 004004 Stand - Replacement 001053 Stand bolt - Replacement 004001 Frame - replace TIME - 168...
  • Page 169 MSS ZIP 100 4T Time Legshield spoiler FRONT SHIELD SPOILER Code Action Duration 004159 Plates / Stickers - Replacement 004149 Shield central cover - Replacement 004064 Front shield, front part - Removal and refitting 004015 Footrest - Removal and Refitting...
  • Page 170 MSS ZIP 100 4T Time Rear cover REAR SHIELD Code Action Duration 004174 Trunk levers - Replacement 004065 Legshield, rear part - Removal and refitting 004081 Glove box door - Replacement TIME - 170...
  • Page 171 MSS ZIP 100 4T Time Central cover CENTRAL COVER Code Action Duration 004059 Spark plug inspection flap - Replace- ment 004106 Under-saddle band - Replacement 004085 Fairing (1) - Replacement 004105 Right side clamp - Replacement 004131 Luggage rack support - Replacement...
  • Page 172 MSS ZIP 100 4T Time Mudguard MUDGUARDS Code Action Duration 004002 Front mudguard - Replacement 004009 Rear mudguard - Replacement TIME - 172...
  • Page 173 MSS ZIP 100 4T Time Fuel tank FUEL TANK Code Action Duration 004168 Fuel tank cap - Replacement 005010 Tank float - Replacement 004112 Cock-carburettor hose - Replace- ment 004005 Fuel tank - Replacement 004007 Fuel valve - Replacement 004109...
  • Page 174 MSS ZIP 100 4T Time Rear shock-absorber REAR SHOCK ABSORBER Code Action Duration 003007 Rear shock absorber - Removal and Refitting TIME - 174...
  • Page 175 MSS ZIP 100 4T Time Steering column bearings STEERING FIFTH WHEELS Code Action Duration 003051 Complete fork - Replacement 003002 Steering fifth wheels - Replacement 003073 Steering clearance - Adjustment TIME - 175...
  • Page 176 MSS ZIP 100 4T Time Handlebar covers HANDLEBAR COVERS Code Action Duration 004019 Handlebar rear section - Replace- ment 004018 Handlebar front section - Replace- ment 005078 Odometer glass - Replacement 005076 Clock / Cell - Replacement 005014 Odometer - Replacement...
  • Page 177 MSS ZIP 100 4T Time Handlebar components HANDLEBAR COMPONENTS Code Action Duration 004066 Driving mirror - Replacement 002037 Brake or clutch lever - Replacement 002071 Left hand grip - Replacement 003001 Handlebar - Replacement 005017 Stop switch - Replacement 002024...
  • Page 178 MSS ZIP 100 4T Time Swing-arm SWINGING ARM Code Action Duration 001072 Engine / frame swinging arm fitting - Replacement 003080 Swinging arm on frame - Replace- ment TIME - 178...
  • Page 179 MSS ZIP 100 4T Time Seat SADDLE Code Action Duration 004003 Saddle - Replacement 004068 Passenger handgrip - Replacement TIME - 179...
  • Page 180 MSS ZIP 100 4T Time Turn signal lights TURN INDICATOR LIGHTS Code Action Duration 005002 Front headlamp - change 005012 Front turn indicator - Replacement 005067 Front turn indicator bulb - Replace- ment 005008 Headlight bulbs - Replacement 005005 Taillight - change...

  • Page 181: Front Wheel

    MSS ZIP 100 4T Time Front wheel FRONT WHEEL Code Action Duration 003038 Front wheel axle - Remov. and refitt. 002011 Odometer movement sensor - Re- placement 003040 Front wheel bearings - Replacement 003047 Front tyre - Replacement 003037 Front wheel rim - Removal and Re-...
  • Page 182 MSS ZIP 100 4T Time Rear wheel REAR WHEEL Code Action Duration 004126 Rear wheel tyre - Replacement 001071 Rear wheel rim - Removal and Refit- ting 001016 Rear wheel - Replacement 002002 Rear brake pads/shoes - Repl. TIME - 182...

  • Page 183: Electrical Devices

    MSS ZIP 100 4T Time Electric devices ELECTRICAL DEVICES Code Action Duration 005001 Electrical system - Replacement 005009 Voltage regulator - Replacement 001094 Spark plug cap - Replacement 001023 Control unit - Replacement 005114 Electrical system - Service TIME - 183...
  • Page 184 MSS ZIP 100 4T Time ELECTRICAL DEVICES Code Action Duration 005011 Start-up remote control switch - Re- placement 005007 Battery - change 005052 Fuse (1) - Replacement TIME - 184...
  • Page 185 MSS ZIP 100 4T Time Electronic controls ELECTRIC CONTROLS Code Action Duration 005039 Lights switch - Replacement 005006 Light or turning indicator switch - Re- placement 005040 Horn button - Replacement 005003 Horn - Replacement 005041 Starter button - Replacement...
  • Page 186 MSS ZIP 100 4T Time Transmissions TRANSMISSIONS Code Action Duration 002051 Odometer transmission assembly - Replacement 002049 Odometer cable - Replacement 002053 Rear brake transmission complete - replacement TIME - 186...

  • Page 187: Brake Callipers

    MSS ZIP 100 4T Time Brake callipers CALLIPER Code Action Duration 002021 Front brake hose - Remov. and Re- fitt. 002007 Front brake shoes/pads - Remov. and Refitt 002039 Front brake calliper - Removal and Refitting 002047 Front brake fluid and air bleed sys-...
  • Page 188 MSS ZIP 100 4T Time Steering column STEERING Code Action Duration 003048 Fork oil seal - Replacement 003076 Fork sheath - Replacement 003079 Fork stem - Replacement 003010 Front suspension - Service TIME - 188...
  • Page 189 MSS ZIP 100 4T Time Helmet bay HELMET COMPARTMENT Code Action Duration 004016 Helmet compartment - Removal and Refitting 005046 Battery cover - change TIME - 189...

  • Page 190: Rear Wheel Axle

    MSS ZIP 100 4T Time Rear wheel axle REAR WHEEL AXLE Code Action Duration 001156 Gear reduction unit cover - Replace- ment 004125 Rear wheel axle - Replacement 001010 Geared reduction unit - Service 003065 Gear box oil - Replacement...
  • Page 191 MSS ZIP 100 4T Time Secondary air box SECONDARY AIR HOUSING Code Action Duration 001164 Crankcase secondary air connection - Replacement 001161 Secondary air filter - Replacement / Cleaning 001162 Secondary air housing - Replace- ment 001163 Muffler secondary air connection -...
  • Page 192 Air filter: 32, 147 Battery: 44, 51, 60, 61 Brake: 137, 139, 140, 142, 143, 187 Carburettor: 10, 28, 116, 120, 165 Engine oil: 32 Fuel: 42, 115, 148, 173 Fuses: 60 Headlight: 36 Hub oil: 30 Identification: 8 Maintenance: 7, 26 Oil filter: 34 Saddle: Shock absorbers: 134...

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