Mode d'emploi PIAGGIO ZIP

[. . . ] SERVICE STATION MANUAL 633734 ÷ 633741 MSS ZIP 100 4T Downloaded from www. Manualslib. com manuals search engine 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. [. . . ] - Remove the stator and its wiring. Refitting the stator - Refit the stator and flywheel carrying out the removal procedure in reverse, tightening the retainers to the specified torque. N. B. THE PICK-UP CABLE MUST BE POSITIONED ADHERING TO THE FUSION TONGUE ON THE CRANKSHAFT IN SUCH A WAY AS TO AVOID BEING CRUSHED BY THE FAN COVER ASSEMBLY. Locking torques (N*m) Pick-up screws 3 ÷ 4 Stator screws 3 ÷ 4 Flywheel and starting ENG - 82 Downloaded from www. Manualslib. com manuals search engine 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. - Remove the nut. CAUTION THE USE OF A CALLIPER SPANNER OTHER THAN THE ONE SUPPLIED COULD DAMAGE THE STATOR COILS - Extract the flywheel with the extractor. Specific tooling 020565Y Flywheel lock calliper spanner 020162Y Flywheel extractor ENG - 83 Downloaded from www. Manualslib. com manuals search engine Engine MSS ZIP 100 4T Inspecting the flywheel components - Check that the flywheel internal magnets are in good conditions. - Check that the flywheel splines exhibit no loosening. - Check there are no deformations that may cause rubbing on the stator and the Pick-Up. - Check that the stator winding, its ferromagnetic support and the pick-up are in good conditions. Starter gear rim - Check the toothing is level and in good conditions Intermediate gear - Check that the keying toothing on the crown and the starter motor are in good conditions. - Check that the Bendix opens and returns adequately. ENG - 84 Downloaded from www. Manualslib. com manuals search engine 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. N. B. A VARIATION OF THE AIR GAP DISTANCE CAN LEAD TO A VARIATION IN THE IGNITION ADVANCE SUCH AS TO CAUSE PINGING, KNOCKING ETC. Specific tooling 020565Y Flywheel lock calliper spanner Locking torques (N*m) Flywheel nut 52 ÷ 58 Refitting the starter motor - Install the starter motor in its seating in the crankcase. - Tighten the screw on the head side but do not lock it, screw the second screw inserting the earth cable (black), then tighten the 2 screws at the prescribed torque. - Tighten the locking screw of the positive cable (red) on the side contact. N. B. REFIT THE REMAINING PARTS AS DESCRIBED IN THE CYLINDER HEAD, TIMING, LUBRICATION, FLYWHEEL AND TRANSMISSION CHAPTERS. Locking torques (N*m) Starter screws 11 ÷ 13 Cylinder assy. and timing system ENG - 85 Downloaded from www. Manualslib. com manuals search engine Engine MSS ZIP 100 4T 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 Blowby cover - Clean the nozzle labyrinth and the membrane (replace it, if necessary), then remove the cover unit. See also Cooling hood Removing the timing system drive - Temporarily loosen the tensioner central screw and remove it together with the spring. - Unscrew the 2 retainers indicated in the figure and remove the chain tightener support being careful to recover the sealing gasket. N. B. SHOULD THE GASKET NOT BE IN GOOD CONDITIONS, REPLACE IT AFTER CAREFULLY CLEANING THE FAYING SURFACE IN ORDER TO AVOID ENGINE OIL LEAKS ENG - 86 Downloaded from www. Manualslib. com manuals search engine 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 camshaft crown with the specific tool. N. B. TO FACILITATE REMOVING THE HEAD COMPONENTS, SET THE CRANKSHAFT TO THE TIMING POINT (TDC OF THE COMPRESSION END). Specific tooling 020565Y Flywheel lock calliper spanner - Remove the camshaft control pulley and the washer below. - Remove the pinion of the crankshaft timing control - To remove the chain lower guiding pad, remove the head by pulling it upwards N. B. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE DIRECTION OF ROTATION IS MAINTAINED. See also Removing the rocker-arms cover Removal Removing the driving pulley Removing the cam shaft - Remove the bearing clamping screw indicated in the figure. - Remove the entire camshaft with bearing using the specific tool shown in the figure. - Take out the camshaft bearing with the aid of the specific tool, being careful to mount a screw on the camshaft in order to protect its thread. N. B. IF A BEARING SEPARATES FROM THE CAMSHAFT, IT IS ESSENTIAL TO FIT A NEW BEAR. Specific tooling ENG - 87 Downloaded from www. Manualslib. com manuals search engine Engine MSS ZIP 100 4T 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. N. B. MARK THE ASSEMBLY POSITION OF THE ROCKING LEVERS IN ORDER TO AVOID MISPLACING THE INTAKE AND DISCHARGE ENDS. Removing the cylinder head - Remove the cooling covers, the timing control, the camshaft and the rocking levers. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. [. . . ] - Make a hole on the block using a drill as shown in the figure. - Insert the wheel cylinder with the key and with the anchoring tab facing down halfway on the lock body taking care that the insertion phase of the key is oriented matching "ON" (the only position that enables the cylinder to get into the lock body); now turn the key leftwards to "OFF" and at the same time press until the cylinder is completely in. Footrest - Remove the side fairings - Remove the shield back plate - Remove the 6 screws shown in the photograph CHAS - 146 Downloaded from www. Manualslib. com manuals search engine 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 connections, the carburettor and the external air intake. Rear mudguard - Remove the side fairings - Remove the 4 screws shown in the photograph CHAS - 147 Downloaded from www. Manualslib. com manuals search engine Chassis MSS ZIP 100 4T 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 - Remove the shock absorber upper clamping in order to create the necessary space to take out the tank. CHAS - 148 Downloaded from www. Manualslib. com manuals search engine INDEX OF TOPICS PRE-DELIVERY PRE DE Downloaded from www. Manualslib. com manuals search engine Pre-delivery MSS ZIP 100 4T 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 Front wheel axle nut Wheel hub nut Frame - swinging arm bolt * Swinging arm bolt - Engine Engine arm pin - Frame arm Handlebar lock nut Steering lower ring nut Upper steering ring nut Electrical system Electrical system: - Main switch - Headlamps: high-beam lights, low-beam lights, tail and parking lights and their warning lights - Adjusting the headlights according to the regulations currently in force - Rear light, parking light, stop light - Front and rear stop light switches - Turn indicators and their warning lights - Instrument panel lights - Instrument panel: fuel gauge - Instrument panel warning lights - Horn - Starter PRE DE - 150 Downloaded from www. Manualslib. com manuals search engine 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. [. . . ]