Table of Contents
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PIAGGIO WOULD LIKE TO THANK YOU
for choosing one of its products. We have prepared this manual to help you to get the very best from your vehicle. Please read it carefully before riding
the vehicle for the first time. It contains information, 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 will soon get to know your new scooter and it will serve you
well for a long time to come. This booklet forms an integral part of the vehicle; should the vehicle be sold, it must be transferred to the new owner.
ZIP 50 - 100 4T
Ed. 03_10/2012
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Table of Contents
Related Manuals for PIAGGIO ZIP 50 4T
Summary of Contents for PIAGGIO ZIP 50 4T
- Page 1 PIAGGIO WOULD LIKE TO THANK YOU for choosing one of its products. We have prepared this manual to help you to get the very best from your vehicle. Please read it carefully before riding the vehicle for the first time. It contains information, tips and precautions for using your vehicle. It also describes features, details and devices to assure you that you have made the right choice.
- Page 2 The instructions given in this booklet are intended to provide a clear, simple guide to using your scooter; details are also given of routine maintenance procedures and regular 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.
- Page 3 Personal safety Failure to completely observe these instructions will result in serious risk of personal injury. Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent dam- aging 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.
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Page 5: Table Of Contents
INDEX VEHICLE..................Long periods of inactivity............35 Dashboard................Fuses..................36 Keyswitch.................. Frontlightgroup................37 Lockingthesteeringwheel............Headlightadjustment.............. 38 Switchdirectionindicators............Frontdirectionindicators............. 38 Hornbutton................10 Rearopticalunit................39 Lightswitch................10 Rearturnindicators..............40 Start-upbutton................11 Rear-viewmirrors............... 41 Openingthesaddle..............11 Idleadjustment................41 Keys..................13 Frontandreardiscbrake.............. 42 Identification................14 Reardrumbrake................. -
Page 7: Vehicle
ZIP 50 - 100 4T Chap. 01 Vehicle... -
Page 8: Dashboard
Dashboard (01_01) A = Speedometer B = Low fuel warning light C = Turn indicator warning light D = Preset warning light F = Starter button G = Odometer 01_01 H = High-beam headlight warning light I = Horn button L = Turn indicator switch M = Headlight switch Keyswitch (01_02) -
Page 9: Lockingthesteeringwheel
Lockingthesteeringwheel (01_03) Turn the handlebar to the left (as far as it will go), turn the key to «LOCK» and remove the key. CAUTION DO NOT TURN THE KEY TO «LOCK» OR «KEY OFF» WHILE RIDING. 01_03 Switchdirectionindicators (01_04) 0 = Turn indicators off. D = Turn indicators on (right side) S = Turn indicators on (left side) The positions «D»... -
Page 10: Hornbutton
Hornbutton (01_05) Horn button «F» 01_05 Lightswitch (01_06) 0 = Low-beam and tail light 1 = High-beam and tail light 01_06... -
Page 11: Start-Upbutton
Start-upbutton (01_07) Starter button "G" 01_07 Openingthesaddle (01_08, 01_09, 01_10) Insert the key into the saddle lock «A», turn it counterclockwise and tip the saddle forward. In this scooter, the saddle height can be adjusted to three positions thanks to a rack «C»... - Page 12 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. 01_08 01_09...
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Page 13: Keys
01_10 Keys (01_11) The vehicle is supplied with two keys (one spare) which serve 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 DUPLICATE KEY TOGETHER WITH ITS CODE IN A SAFE PLACE AND NOT ON THE VEHICLE... -
Page 14: Identification
Identification (01_12, 01_13) The identification numbers consist of a prefix stamped on the chassis and on the en- gine, followed by 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. -
Page 15: Use
ZIP 50 - 100 4T Chap. 02... -
Page 16: Checks
Checks Before using the vehicle, check: 1. that the fuel tank is full. 2. The oil level in the rear hub. 3. engine oil level (see section «Engine oil level»). 4. That tyres are properly inflated. 5. correct functioning of headlights, rear taillight and turn indicators. 6. -
Page 17: Tyrepressure
CAUTION USING OILS OTHER THAN THOSE RECOMMENDED CAN SHORTEN THE LIFE OF THE ENGINE. Characteristic Fuel tank In plastic, with a capacity of ~ 7.5 l (approximate value, including ~ 1.2 l reserve) 02_02 Main and supplementary fuel tank (including ~ 1.2 l reserve) (100 cc) ~ 7 l Tyrepressure CAUTION... -
Page 18: Runningin
Rear wheel: 1.6 bar Rear tyre pressure (rider and luggage) Rear wheel (rider and luggage): 1.8 bar Tyre pressure (100 cc) Front wheel: 1.3 bar Rear wheel: 1.6 ÷ 1.8 bar Runningin (02_03) WARNING DURING THE FIRST 1000 KM DO NOT RIDE THE VEHICLE OVER 80% OF ITS MAXIMUM SPEED. -
Page 19: Startinguptheengine
Startinguptheengine (02_04) The vehicle is fitted with direct drive automatic transmission. Therefore, always start the engine with the throttle grip slightly twisted; to start-off from stationary position, progressively twist the throttle grip. The vehicle is equipped with a fuel valve and a starter which switch on automatically as soon as the engine is started. -
Page 20: Difficultstartup
3. Empty fuel tank. After refuelling the scooter, start the engine by pressing the starter button «A» with the throttle at a minimum to provide maximum aspiration for the tap. If the scooter fails to start even after taking the steps described above, contact an Authorised Piaggio Service Centre. CAUTION 02_05 ALWAYS PLACE THE VEHICLE ON ITS STAND BEFORE KICK STARTING. -
Page 21: Stoppingtheengine
Stoppingtheengine (02_06) Stop acceleration, then turn the key switch «D» to «OFF » to stop the engine (ex- tractable key). 02_06 Automatictransmission (02_07) To ensure simple, pleasurable riding, the vehicle is equipped with automatic trans- mission with regulator and centrifugal clutch. The system is designed to give the best possible performance in terms of both acceleration and consumption, on level ground and uphill, thanks to the adjustments made to engine speed and transmitted torque. -
Page 22: Safedriving
Safedriving (02_08) WARNING SOME SIMPLE TIPS ARE PROVIDED BELOW WHICH WILL ENABLE YOU TO USE YOUR VEHICLE ON A DAILY BASIS MORE EASILY AND SAFELY. < Your ability and your knowledge of the vehicle form the basis of safe riding. We rec- ommend trying out the vehicle in traffic-free zones to get to know your vehicle completely. - Page 23 8. Any elaboration that modifies the vehicle's performances, such as tampering with original structural parts is strictly forbidden by law, and renders the vehicle not con- forming to the approved type and 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.
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Page 25: Maintenance
ZIP 50 - 100 4T Chap. 03 Maintenance... -
Page 26: Engineoillevel
Engineoillevel In 4T engines, the engine oil is used to lubricate the distribution elements, the bench bearings and the thermal group. An insufficient quantity of oil can seriously dam- age the engine. In all 4T engines the decay of oil characteristics as well as some consumption is normal. -
Page 27: Engineoiltop-Up
Always check oil level before carrying out top-ups and add oil without exceeding the MAX level. An engine oil check-up and top-up should be carried out every 3,000 km at an Authorised Piaggio Service Centre. Engineoilchange (03_03) Change oil and clean the filter after every 6,000 km at an Authorised Service Cen- tre. -
Page 28: Huboillevel
Huboillevel (03_04, 03_05, 03_06) To check the hub oil level, proceed as follows: 1. Park the scooter on level ground and rest it on its stand. 2. Unscrew the oil dipstick «A», dry it with a clean cloth and then reinsert it, screwing it fully into place;... -
Page 29: Tyres
API GL-4 Characteristic Rear hub oil Quantity: approx. 85 cc Tyres (03_07) Periodically check the inflation pressure of each tyre. Tyres have tread wear indicators and must be replaced as soon as these indicators are visible on the tread; should this occur, go to an authorised workshop or to a workshop properly equipped for refitting. -
Page 30: Sparkplugdismantlement
Sparkplugdismantlement (03_08) Remove the 3 screws «A», and the hatch too «B» sliding it upwards. Loosen the spark plug HV wire and remove the spark plugs with the box-spanners. When refitting the plug, tighten it by hand, being sure to insert it at the right angle; Use the wrench only to fasten it. -
Page 31: Removingtheairfilter
Removingtheairfilter (03_09) Take out the air cleaner cover «D» after having unscrewed the 6 fixing screws, then take out the filter. Clean with water and shampoo, then dry with compressed air and immerse 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. -
Page 32: Secondaryairsystem
Before closing the cover of the SAS housing, check the good condition of the sealing O-ring; replace it if damaged or deformed. N.B. The reed valve can be inserted in only one direction on the SAS housing CAUTION 03_10 CONTACT AN AUTHORISED PIAGGIO SERVICE CENTRE TO CARRY OUT THESE OPERATIONS. -
Page 33: Checkingthebrakeoillevel
The brake fluid level may fall due to wear on the brake pads. Should the level be below the minimum, the customer is advised to contact an Authorised Piaggio Service Centre for a thorough check of the braking system. To adjust the level follow the instructions below. -
Page 34: Battery
WARNING IN NORMAL CLIMATIC CONDITIONS IT IS ADVISABLE TO REPLACE THE ABOVE-MENTIONED FLUID EVERY 2 YEAR. NEVER USE BRAKE FLUID CON- TAINED IN CONTAINERS WHICH ARE ALREADY OPEN OR PARTIALLY USED. Battery (03_13) To have access to the battery it is necessary to remove the saddle («Keys» section) and the access hatch to the battery compartment unscrewing the star-head screws «A»... -
Page 35: Long Periods Of Inactivity
WARNING USED BATTERIES ARE HARMFUL FOR THE ENVIRONMENT. COLLECTION AND DISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITH REGULA- TIONS IN FORCE. Long periods of inactivity Battery performance will be poor if the vehicle is not used for a long time. This is the result of the natural phenomenon of battery discharging, and may be due to residual absorption by vehicle components with constant power consumption. -
Page 36: Fuses
WARNING DO NOT DISCONNECT THE BATTERY CABLES WITH THE ENGINE RUNNING, THIS CAN CAUSE IRREPARABLE DAMAGE TO THE VEHICLE'S ELECTRONIC CONTROL UNIT. WARNING USED BATTERIES ARE HARMFUL FOR THE ENVIRONMENT. COLLECTION AND DISPOSAL SHOULD BE CARRIED OUT IN COMPLIANCE WITH REGULA- TIONS IN FORCE. -
Page 37: Frontlightgroup
Frontlightgroup (03_15, 03_16) To have access to the headlight bulbs, it is necessary to remove the rear part of the handlebar cover as follows: Unscrew the rear-view mirror after loosening the screw «A» located under the corre- sponding rubber protection. Unscrew the 3 screws «B»... -
Page 38: Headlightadjustment
Headlightadjustment (03_17, 03_18) Position the unloaded vehicle a flat surface and at 10 m away from a white screen located in the dark. Make sure that the vehicle is perpendicular to the screen. Draw a horizontal line on the screen at a height of 83 ÷ 85 cm from the ground. Start the engine, turn on the headlight, turn on the low-beam light and orientate it so that the horizontal borderline between the dark and the light area is not higher than the horizontal line drawn on the screen. -
Page 39: Rearopticalunit
Rearopticalunit (03_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 counterclockwise. 03_20 03_21... -
Page 40: Rearturnindicators
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. 03_22 03_23... -
Page 41: Rear-Viewmirrors
(vehicle on stand) and with a warm engine: screw and unscrew the knob-type head screw until reaching a regular rpm: i.e, without letting the engine move the rear wheel. This operation should be carried out at an Authorised PIAGGIO Service Centre. 03_25 SHOULD THERE BE PROBLEMS DURING THE IDLE SPEED ADJUSTMENT OP- ERATION, IT MAY BE NECESSARY TO ADJUST THE LEVEL OF EXHAUST EMISSIONS (CO). -
Page 42: Frontandreardiscbrake
CAUTION WHEN ADJUSTING IDLE SPEED, PAY SPECIAL ATTENTION NOT TO TOUCH THE CATALYTIC MUFFLER TO AVOID BURNS. Characteristic Idle speed 1900÷2100 rpm Engine idle speed (100 cc) ~ 1500 ± 150 rpm Frontandreardiscbrake (03_26) The brake disc and pad wear is automatically compensated, therefore it has no effect on the functioning of the front and rear brakes. -
Page 43: Reardrumbrake
AFTER FITTING NEW BRAKE PADS DO NOT USE THE VEHICLE UNTIL YOU HAVE ACTIVATED THE BRAKE LEVER REPEATEDLY TO POSITION THE PADS AND RESTORE THE LEVER STROKE TO ITS CORRECT POSITION. CAUTION BRAKING SHOULD BEGIN AFTER ABOUT 1/3 OF THE BRAKE LEVER STROKE. Reardrumbrake (03_27) Actuate on the set screw «A»... -
Page 44: Puncture
Puncture (03_28) The vehicle is equipped with Tubeless tyres (without inner tube). In the event of a puncture, Tubeless tyres - unlike tyres with inner tubes - go flat very slowly, resulting in a greater steering safety. In the event of a puncture, an emergency repair can be carried out using an "inflate and repair"... -
Page 45: Delveicolo
delveicolo (03_29) We recommend carrying out the following operations: 1. General cleaning of the vehicle. 2. With the engine off and the piston at the bottom dead centre position, remove the spark plug, and pour 1÷ 2 cm³ of recommended oil through its opening. Press the engine start pedal 3 or 4 times letting the engine perform a few revolutions slowly, then replace the spark plug. - Page 46 WARNING To avoid the appearance of oxidations, wash the vehicle every time it is used in certain areas or in special conditions of: · Environmental / seasonal conditions: use of salt, de-icer chemical products on the road in winter. · Air pollution: city and/or industrial areas. ·...
- Page 47 WARNING NEVER WASH THE VEHICLE UNDER DIRECT SUNLIGHT, ESPECIALLY IN SUM- MER WHEN THE BODYWORK IS STILL HOT, AS THE CAR SHAMPOO MAY DRY BEFORE BEING RINSED OFF, AND COULD DAMAGE THE PAINTWORK. NEVER USE RAGS SOAKED IN PETROL OR DIESEL OIL TO CLEAN THE PAINTED OR PLASTIC SURFACES, IN ORDER TO PREVENT THEM LOSING THEIR SHINE AND MECHANICAL CHARACTERISTICS.
- Page 48 If the spark plug is in good conditions, contact an Authorised Service Centre. ACK OF COMPRESSION Spark plug loose. Loose cylinder Contact an Authorised Piaggio head, worn piston retaining rings. Service Centre Incorrect valve clearance HIGH CONSUMPTION AND LOW PERFORMANCE Air filter blocked or dirty.
- Page 49 Oil on drum or disc. Worn Pads/ Contact an Authorised Service Shoes Centre Rear brake incorrectly adjusted. Turn to an Authorised Piaggio Air in the front brakes circuit Service Centre INEFFICIENT SUSPENSION Oil leak; worn limit switch bumpers; Contact an Authorised Service...
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Page 51: Technicaldata
ZIP 50 - 100 4T Chap. 04 Technicaldata... - Page 52 ECHNICAL Engine Single-cylinder, four-stroke Bore x stroke 39 X 41.8 mm Engine capacity 49.93 cm³ Compression ratio 11.5 :1 Ignition advance (before 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 Ø...
- Page 53 Fuel supply Gravity feed, unleaded petrol, through carburettor. Lubrication Engine lubrication with lobe pump (inside the crankcase) controlled by chain and double filter: mesh and centrifugal. Cooling Forced-circulation air cooling. Transmission With automatic expandable pulley variator, torque server, V-belt, automatic clutch, gear reduction unit.
- Page 54 Front brake disc brake with hydraulic control (lever on the right side of the handlebar). Rear brake Drum brake with expanding shoes, controlled mechanically (lever on the left side of the handlebar ). Kerb weight in running order 84 kg Maximum load Driver only.
- Page 55 Max. speed According to current legislation TECHNICAL DATA 100 Width 735 mm Length 1880 mm Maximum height 1150 mm Wheelbase 1340 mm Fuel system Gravity feed, with unleaded petrol (with a minimum octane rating of 95) with carburettor. Lubrication engine lubrication with lobe pump (inside the crankcase) controlled by chain and double filter: mesh and centrifugal.
- Page 56 Tyre pressure (100 cc) Front wheel: 1.3 bar Rear wheel: 1.6 ÷ 1.8 bar Ignition type Capacitive discharge electronic ignition, with incorporated HV coil Chassis 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).
- Page 57 04_01...
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Page 58: Toolkit
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. -
Page 59: Sparepartsandaccessories
ZIP 50 - 100 4T Chap. 05 Sparepartsanda ccessories... -
Page 60: Warnings
Warnings (05_01, 05_02) WARNING IT IS RECOMMENDED THAT "ORIGINAL PIAGGIO SPARE PARTS" BE USED, AS THESE ARE THE ONLY ONES OFFERING YOU THE SAME QUALITY AS- SURANCE AS THOSE INITIALLY FITTED ON THE VEHICLE. IT SHOULD BE REMEMBERED THAT USING NON-ORIGINAL SPARE PARTS CAUSES YOUR WARRANTY RIGHTS TO EXPIRE. - Page 61 05_02...
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Page 63: Scheduledmaintenance
ZIP 50 - 100 4T Chap. 06 Scheduledmaint enance... -
Page 64: Scheduledservicingtable
Scheduledservicingtable (06_01) Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, a series of checks and maintenance operations (at the owner's expense) have been suggested, which are included in the summary table on the following page. Any minor faults should be reported without delay to an Authorised Service Centre or Dealer without waiting until the next scheduled service to solve it. - Page 65 Km x 1000 Electrical system and battery Cylinder ventilation system Brake levers Brake oil level (*) Hub oil level Engine oil Brake Pads/Shoes Tyre pressure Headlight Vehicle road test Idle speed Odometer gear CVT rollers Suspension Steering Transmission I: CHECK AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY. C: CLEAN, R:REPLACE, A: ADJUST, L:LUBRICATE * Replace every 2 years...
- Page 66 Scheduledservicingtable (06_01) Adequate maintenance is fundamental to ensuring long-lasting, optimum operation and performance of your vehicle. To this end, a series of checks and maintenance operations (at the owner's expense) have been suggested, which are included in the summary table on the following page. Any minor faults should be reported without delay to an Authorised Service Centre or Dealer without waiting until the next scheduled service to solve it.
- Page 67 Valve clearance - check idle rpm (*) - adjustment Throttle lever - adjustment Steering - adjustment Brake levers - greasing Brake pads - check for condition and wear Brake fluid level - check Safety fasteners - check Electrical system and battery - check Tyre pressure - check Vehicle test and brake test - Road test (*) See instructions in «Idle speed adjustment»...
- Page 68 Electrical system and battery - check Tyre pressure and wear - check Tyre pressure - check Vehicle test and brake test - Road test 12000 60000 KM OR MONTHS AND Engine oil - change Hub oil level - control Spark plug / electrode gap - replacement oil filter - cleaning idle rpm (*) - adjustment Throttle lever - adjustment...
- Page 69 Suspension - check 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 speed adjustment» section (**) See regulations in the «Secondary air system»...
- Page 70 Odometer gear - greasing Steering - adjustment Brake levers - greasing Brake pads - check for condition and wear Brake fluid level - check Transmission - lubrication Safety fasteners - check Suspension - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Tyre pressure - check...
- Page 71 oil filter - cleaning idle rpm (*) - adjustment Throttle lever - adjustment CVT rollers - check or replacement Drive belt - replacement 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...
- Page 72 72000 FTER 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...
- Page 73 Tyre pressure and wear - check Tyre pressure - check SAS box (sponge) (**) - cleaning Vehicle test and brake test - Road test (*) See instructions in «Idle speed adjustment» section (**) See regulations in the «Secondary air system» section RECOMMENDED PRODUCTS TABLE Product Description...
- Page 75 TABLE OF CONTENTS Battery: 34 Puncture: 44 Checks: 16 Refuelling: 16 Fuses: 36 Toolkit: 58 Tyres: 29 Identification: 14 Vehicle: 7 Keys: 13 Maintenance: 25...
- Page 76 The descriptions and images in this publication are given for illustrative purposes only and are not binding. While the basic characteristics as described and illustrated in this booklet remain unchanged, Piaggio & C. S.p.A. 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.