PIAGGIO MSS X9 EVOLUTION 250 Workshop Manual Download

Page: 104 / 262

- Line up the two holes in the flywheel as shown in

the photo

- Screw in the guide bushing that is part of the

special flywheel stop tool on the flywheel as shown

in the photo.

- Insert the special flywheel stop tool on the fly-

wheel as shown in the photo

Specific tooling

020627Y

Flywheel lock wrench

- Remove the flywheel nut with its washer

- Do up the flywheel nut by three or four threads

so that the flywheel does not fall accidentally on

extraction

- Screw the extractor onto the flywheel and extract

it as shown in the photograph

Specific tooling

020467Y

Flywheel extractor

Refitting the free wheel

- Make sure the freewheel faying surfaces are in good condition.

- Thoroughly clean the free wheel to remove LOCTITE residue.

- Degrease the threading of the holes in the free wheel and the clamping screws.

Engine

MSS X9 Evolution 250

ENG - 104

Summary of Contents for MSS X9 EVOLUTION 250

Page 1: ...WORKSHOP MANUAL 618153 MSS X9 Evolution 250 ...

Page 2: ...y 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 Copyright 2007 PIAGGIO C S p A Pontedera All rights reserved Reprodu...

Page 3: ...the sections of this manual relating to specific tools along with the specific 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 observ...

Page 4: ......

Page 5: ...S CHAR TOOLING TOOL MAINTENANCE MAIN TROUBLESHOOTING TROUBL ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG SUSPENSIONS SUSP BRAKING SYSTEM BRAK SYS COOLING SYSTEM COOL SYS CHASSIS CHAS PRE DELIVERY PRE DE TIME TIME ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...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 spares may damage the vehicle Use only the appropriate tools designed for this vehicle Always use new gaskets sealing rings and s...

Page 8: ...gine prefix M23XM Dimensions and mass DIMENSIONS AND WEIGHT Specification Desc Quantity Empty weight 173 Kg Wheelbase 1500 mm Overall height 1450 mm Saddle height 790 mm Overall length 2130 mm Overall width 910 mm Characteristics MSS X9 Evolution 250 CHAR 8 ...

Page 9: ...rburettor CVK 30 Air filter Sponge impregnated with mixture 50 Selenia Air Filter Oil and 50 lead free fuel Start up system electric starter Lubrication with twin screw pump inside the crank case controlled by chain and dual filter net and paper filter Power supply Petrol with minimum octane level 95 lead free with vacuum pump and through carburettor Max speed xxx Km h Spark plug CHAMPION RG4HC Tr...

Page 10: ...Three phase alternating current Variable spark advance 10 1 at 2000 Rpm 28 1 at 6500 Rpm Frame and suspensions CHASSIS AND SUSPENSIONS Specification Desc Quantity Rear wheel max travel 90 mm Rear suspension Engine with oscillating fork articulated to the chassis by means of a double swinging arm Double acting hydraulic shock ab sorbers coaxial helicoidal spring with variable step adjustable at pre...

Page 11: ...TYRES Specification Desc Quantity Tyre pressure when cold Front 2 1 bar Rear 2 3 bar 2 5 bar with driver and luggage Tyres Front 120 70 14 55P Rear 140 60 14 64P Light alloy rims Front rim 3 50x14 Rear rim 3 50x14 Secondary air General notes The SAS for Quasar 250 Euro 2 engines operates in a similar manner to the SAS for 2T engines The differences are the following instead of entering through the...

Page 12: ... pipe E connec ted to the air head and reaches a discharge joint in order to supply oxygen to the unburned gases before the catalytic converter thus favouring an improved reaction of the catalytic converter Carburettor 250cc Version Keihin KEHIN CARBURETTOR Specification Desc Quantity Depression carburettor CVEK 30 Body stamping CVEK Stamping 303A Tapered pin notches position from top Fixed positi...

Page 13: ...Vacuum type WVF 7H Diffuser Ø 29 30 3x27 0 Starter jet 50 Starter diffuser jet 130 Starter air jet 200 Diffuser nozzle Ø 2 7 Stamping N B THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE Tightening Torques REAR BRAKE Product Description Specifications Loctite 243 Medium strength threadlock Apply LOCTITE 243 medium strength threadlock FRONT BRAKE Name Torque in Nm Oil bleed screw 8 1...

Page 14: ...ews 11 13 Crankcase timing system cover screws 3 5 4 5 ENGINE FLYWHEEL Name Torque in Nm Pick Up clamping screws 3 4 Stator assembly screws 3 4 Flywheel cover fixing screws 5 6 Flywheel nut 250 94 102 Screw fixing freewheel to flywheel 13 15 ENGINE TRANSMISSION Name Torque in Nm Rear hub cover screws 24 27 Driven pulley shaft nut 54 60 Transmission cover screws 11 13 Drive pulley nut 75 83 Clutch ...

Page 15: ...ssure sensor 12 14 N B Before fitting the nuts lubricate them with engine oil N B Use new nuts NOTE DI ASSISTENZA TECNICA For correct tightening the expansion tank cap locking torque has been standardised to 2 5 Nm Overhaul data Assembly clearances Cylinder piston assy COUPLING CATEGORIES ENGINE 250 Name Initials Cylinder Piston Play on fitting Cylinder piston A 71 990 71 997 71 953 71 960 0 030 0...

Page 16: ...EALING RINGS Name Description Dimensions Initials Quantity Compression ring 72 x 1 5 A 0 15 0 30 Oil scraper ring 72 x 1 A 0 20 0 40 Oil scraper ring 72 x 2 5 A 0 20 0 40 Characteristics MSS X9 Evolution 250 CHAR 16 ...

Page 17: ...ft Crankshaft to crankcase axial clearance Crankshaft to crankcase axial clearance CRANKSHAFT CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Half shaft transmission side 16 6 0 0 05 A D 0 20 0 50 Flywheel side half shaft 16 6 0 0 05 B D 0 20 0 50 Connecting rod 18 0 10 0 15 C D 0 20 0 50 Spacer tool 51 4 0 05 E D 0 20 0 50 MSS X9 Evolution 250 Characteristics CHAR 17 ...

Page 18: ...ease for driven pulley shaft adjusting ring and movable driven pulley housing Grease with Molybdenum disulphide AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in creased adhesiveness AGIP GREASE MU3 Grease for odometer transmission gear case Soap based lithium grease with NLGI 3 ISO L XBCHA3 DIN K3K 20 AGIP CITY HI TEC 4T Engine oil SAE 5W 40 Synthetic oil that e...

Page 19: ...INDEX OF TOPICS TOOLING TOOL ...

Page 20: ...ICA Stores code Description 020151Y Air heater 020331Y Digital multimeter 020333Y Single battery charger 020334Y Multiple battery charger 001467Y014 Pliers to extract ø 15 mm bearings Tooling MSS X9 Evolution 250 TOOL 20 ...

Page 21: ...tores code Description 020412Y 15 mm guide 020335Y Magnetic support for dial gauge 020565Y Flywheel lock calliper spanner 020439Y 17 mm guide 020359Y 42x47 mm adaptor MSS X9 Evolution 250 Tooling TOOL 21 ...

Page 22: ...0 mm guide 020459Y Punch for fitting bearing on steering tube 020458Y Puller for lower bearing on steering tube 005095Y Engine support 008564Y Flywheel extractor 020434Y Oil pressure control fitting Tooling MSS X9 Evolution 250 TOOL 22 ...

Page 23: ... for valve removal tool 020424Y Driven pulley roller casing fitting punch 020431Y Valve oil seal extractor 020193Y Oil pressure gauge 020306Y Punch for assembling valve seal rings 020360Y Adaptor 52 x 55 mm MSS X9 Evolution 250 Tooling TOOL 23 ...

Page 24: ...mm guide 020375Y Adaptor 28 x 30 mm 020376Y Adaptor handle 020444Y Tool for fitting removing the driven pulley clutch 020330Y Stroboscopic light to check timing 001467Y035 Belle for OD 47 mm bearings Tooling MSS X9 Evolution 250 TOOL 24 ...

Page 25: ...g pulley lock wrench 020319Y Immobilizer check tester 020287Y Clamp to assemble piston on cylinder 020263Y Sheath for driven pulley fitting 020262Y Crankcase splitting strip 020430Y Pin lock fitting tool MSS X9 Evolution 250 Tooling TOOL 25 ...

Page 26: ...020428Y Piston position check support 020426Y Piston fitting fork 020425Y Punch for flywheel side oil seal 020423Y driven pulley lock wrench 020414Y 28 mm guide 020393Y Piston fitting band Tooling MSS X9 Evolution 250 TOOL 26 ...

Page 27: ...tters equipped with part 012 re moval tool 020455Y 10 mm guide 020442Y Pulley lock wrench 020329Y MityVac vacuum operated pump 020357Y Adaptor 32 x 35 mm 020409Y Multimeter adaptor Peak voltage detec tion MSS X9 Evolution 250 Tooling TOOL 27 ...

Page 28: ...m adaptor 020332Y Digital rev counter 020074Y Support base for checking crankshaft alignment 020055Y Wrench for steering tube ring nut 002465Y Pliers for circlips 001330Y Tool for fitting steering seats Tooling MSS X9 Evolution 250 TOOL 28 ...

Page 29: ...tting piston pin stops 200 250 020622Y Transmission side oil guard punch 020444Y011 adapter ring 020444Y009 46x55 Wrench 001467Y Extractor for bearings for holes 001467Y013 Pliers to extract ø 15 mm bearings MSS X9 Evolution 250 Tooling TOOL 29 ...

Page 30: ...Stores code Description 020444Y010 adapter ring 020628Y Water pump service kit Tooling MSS X9 Evolution 250 TOOL 30 ...

Page 31: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 32: ...lers check Driving belt checking Coolant level check Brake pads check condition and wear Brake fluid level check Electrical system and battery check Tyre pressure and wear check Vehicle and brake test road test AT 12000 KM OR 24 MONTHS AND AT 60000 KM Action Engine oil replacement Hub oil level check Spark plug electrode gap check replacement Air filter clean Engine oil change Idle speed adjustmen...

Page 33: ...speed adjustment Sliding block variable speed rollers change Throttle lever adjustment Coolant level check Steering adjustment Brake control levers greasing Brake pads check condition and wear Brake fluid level check Transmission elements lubrication Safety locks check Suspensions check Electrical system and battery check Headlight adjustment Tyre pressure and wear check Vehicle and brake test roa...

Page 34: ...test See rules in the Adjusting the engine idle section AT 72000 KM Action Engine oil replacement Hub oil change Spark plug electrode gap check replacement Air filter clean Engine oil change valve clearance 125 check 250 cc Valve Play Check Idle speed adjustment Sliding block variable speed rollers change Throttle lever adjustment Driving belt replacement Coolant level check Radiator external clea...

Page 35: ...ETROL LEAKS Checking the spark advance To check the ignition advance use the strobo scopic lamp with induction collet connected to the spark plug power supply cable Connect the induction collet according to the right polarity the arrow on the collet must be facing the spark plug Set the lamp selector to the central position 1 spark 1 driving shaft revolution as in 2 stroke engines Start the engine...

Page 36: ...r 2 000 rpm The programmed control unit allows the engine revolution within the prescribed limits Specific tooling 020330Y Stroboscopic light to check timing Characteristic 250 spark advance check 10 1 at 2000 Rpm 32 1 at 6000 Rpm Spark advance variation Characteristic Operation threshold First threshold 9600 50 Second threshold 9800 50 Reactivation threshold First threshold 9500 50 Second thresho...

Page 37: ...r provided with retain rubber cap remove the spark plug Disconnect the spark plug lug and remove it Inspect it carefully if the insulator is damaged or chipped replace it Measure the distance between the electrodes using a thickness gauge if required adjust it by carefully bending the external electrode Make sure that the sealing washer is in good working order MSS X9 Evolution 250 Maintenance MAI...

Page 38: ...ctrode distance 0 7 mm 0 8 mm Electric characteristic Recommended spark plug CHAMPION RG4HC Locking torques N m Spark plug 12 14 Hub oil Check Level check Move the vehicle to a flat ground and rest it on the stand Unscrew the oil bar dry it with a clean cloth and reinsert it screwing it in thoroughly Extract the bar and check that the oil level reaches the second notch of the bar from the bottom S...

Page 39: ... and neutral soap Dry with a clean cloth and short blasts of com pressed air Soak with a mixture of 50 petrol and 50 SE LENIA AIR FILTER OIL Drip dry the filter and then squeeze it between the hands without wringing CAUTION NEVER RUN THE ENGINE WITHOUT THE AIR FILTER THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE PISTON AND CYLINDER CAUTION WHEN TRAVELLING ON DUSTY ROADS THE AIR FILTER MUST BE CLEA...

Page 40: ... below 1 Place the vehicle on its centre stand and on flat ground 2 Undo cap dipstick A dry it off with a clean cloth and replace it screwing down completely 3 Remove the cap dipstick again and check that the level is between the min and max marks top up if necessary The MAX level mark indicates a quantity of around 1300 cc of engine oil If the check is carried out after the vehicle has been used ...

Page 41: ... turn the engine in the direction that is the reverse of the normal direction using a cal liper spanner applied to the camshaft command pulley casing Checking the valve clearance To check valve clearance centre the reference marks of the timing system Use a thickness gauge to check that the clear ance between the valve and the register corre sponds with the indicated values When the valve clearanc...

Page 42: ...rm the cooling system checks The coolant level should be checked every 6 000 km with the engine cold following the instruction given below a Put the vehicle in an upright position on the kickstand b Remove the expansion tank cap A by turning it anti clockwise c Look inside the expansion tank the minimum and maximum levels are marked on the plastic in side the expansion tank d Top up if the level o...

Page 43: ...Y TO KEEP THE RADIATOR GRILLE CLEAN Recommended products AGIP PERMANENT SPEZIAL coolant Monoethylene glycol based antifreeze fluid CU NA NC 956 16 Braking system Level check The front and rear brake fluid tanks are placed on the pumps under the handlebar covers Proceed as follows 1 Put the vehicle up on the central kickstand and with the handlebar centred 2 Remove cover A by unscrewing the fixing ...

Page 44: ...eding pipe from the SAS control valve Insert a conical plug into the vacuum feeding pump Connect the MITIVAC vacuum pump to the SAS control valve using a suitable pipe having the same size as the original fitted on the vehicle Start the vacuum up to 0 6 0 8 Bar so as to close the valve and cut off the SAS system Remove the exhaust gas collection Kit closing cap and connect the analyser properly pr...

Page 45: ...crews of the secondary air filter cover indicated in the figure remove the cover and then take out the filtering element Wash with water and mild soap Dry with a clean cloth and short blasts of com pressed air Remove the flywheel cover by operating on its clamps and remove the primary filtering element Wash with water and neutral soap Dry with a clean cloth and short blasts of com pressed air Chec...

Page 46: ...INDEX OF TOPICS TROUBLESHOOTING TROUBL ...

Page 47: ...le guide with Montblanc Molybdenum Grease Clutch slipping Check the clutch system and or the bell and replace if neces sary Overheated valves Remove the head and the valves grind or replace the valves Wrong valve adjustment Adjust the valve clearance properly Valve seat distorted Replace the head assembly Air filter dirty Dismantle the sponge wash with water and shampoo then soak it in a mixture o...

Page 48: ...ON SMOKEY EXHAUST Possible Cause Operation Worn valve guides Check and replace the head unit if required Worn valve oil guard Replace the valve oil guard Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal Worn or broken piston rings or piston rings that have not been fitted properly Replace the piston cylinder unit or just the piston rings I...

Page 49: ...s out the rubber coupling between the device and the head pipe Replace the device and the coupling High fuel consumption HIGH FUEL CONSUMPTION Possible Cause Operation Float level Restore the level in the tank by bending on the float the thrust ing reed of the petrol inlet rod so as to have the float parallel to the tank level with the carburettor inverted Loose nozzles Check the maximum and minim...

Page 50: ...pump seals replace Brakes overheating BRAKES OVERHEATING Possible Cause Operation Rubber gaskets swollen or stuck Replace gaskets Compensation holes on the pump clogged Clean carefully and blast with compressed air Brake disc slack or distorted Check the brake disc screws are locked use a dial gauge and a wheel mounted on the vehicle to measure the axial shift of the disc Defective piston sliding ...

Page 51: ...tinue even after making the above adjustments check the seats on which the ball bearings rotate replace them if they are recessed or if the balls are flat tened Steering hardening Check the tightening of the top and bottom ring nuts If irregu larities continue in turning the steering even after making the above adjustments check the seats in which the ball bearings rotate replace them if they are ...

Page 52: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 53: ... Emergency flashing button 8 Reset button 9 Front fuse holder box 10 Output for immobilizer diagnostic instrument 11 Fuse 7 5 A 12 Fuses 10A 13 Engine stop remote control switch 14 Headlight remote control switch 15 Connector fitting for PICS control unit 16 Diode 17 Connector fitting for PICS control unit 18 Analogue instrument unit 19 PICS display fitting MSS X9 Evolution 250 Electrical system E...

Page 54: ...5 Remote starter switch 46 Diodo 47 Battery 12V 12Ah 48 Fuse 15A 49 Fuse Rear position light protection number plate light front position light 7 5A 50 Fuse 10 A 51 Rear fuse holder box 52 Helmet compartment lamp bulb 12V 5W 53 Helmet compartment lighting button 54 Socket for users 12V 180W max 55 Starter motor 56 Rear left headlight N 1 bulb 12V 55W for position light N 1 bulb 12V 10W for flashin...

Page 55: ...eto flywheel 3 Key switch contacts 4 Electronic controller 5 Spark plug 6 HV coil 7 Immobilizer aerial 8 Voltage regulator 9 Voltage regulator 10 Diagnostic tester outlet 11 Fuse 15A 12 Immobilizer LED 13 Battery 12V 12Ah MSS X9 Evolution 250 Electrical system ELE SYS 55 ...

Page 56: ...adlight remote control protection 10 A 10 Helmet compartment lamp bulb 12V 5W 11 Fuse upper beam protection 10 A 12 Bulb for upper beams 12V 55W 13 Bulb for dipped beams 12V 55W 14 Fuse Rear position light protection number plate light front position light 7 5A 15 Bulbs N 2 12v 3w front pos Lights n 2 12v 5w rear pos Lights n 1 12v 5w number plate light 16 Fuse 15A 17 Socket for users 12V 180W max...

Page 57: ...tor 6 Starter motor 7 Battery 12V 12Ah 8 Start up enable and front stop button 9 Start up enable and rear stop button 10 Digital instrument 11 Start up button 12 Fuse 15 A 13 Diode 1 A 14 Stop light N 5 bulbs 12V 2 3W 15 Electronic ignition 16 Engine stop relay 17 Engine stop switch 18 Stand switch 19 Engine not enable indicator MSS X9 Evolution 250 Electrical system ELE SYS 57 ...

Page 58: ...nt unit 3 Thermistor 4 Outside temperature sensor 5 Wheel RPM sensor 6 Fuel level sender 7 Oil pressure sensor 8 Reset button 9 Emergency button 10 Fuse 10 A 11 Key switch contacts 12 Radiatore electric fan motor 13 Thermal switch for electric fan 14 Magneto flywheel 15 Voltage regulator 16 Fuse 15A Electrical system MSS X9 Evolution 250 ELE SYS 58 ...

Page 59: ...0001025 Beverly in order to prevent possible malfunctioning of the thermal switch Turn signal lights FLASHING LIGHTS HORN AND ACCESSORY FITTINGS Specification Desc Quantity 1 Digital instrument unit 2 Direction indicators N 2 2 bulbs 12V 10W 3 Indicators switch 4 Fitting for accessories 5 Horn button 6 Horn 7 Fuse 10 A 8 Key switch contacts 9 Fuses 10A MSS X9 Evolution 250 Electrical system ELE SY...

Page 60: ...charging process When the key switch is turned to ON this blinking function is deactivated A flash then confirms the system has switched to ON The duration of the flash depends on the electronic control unit program see figure If the led turns off and remains so when switching to ON it is necessary to check if there is battery voltage in the electric control unit Connect the immobilizer tester to ...

Page 61: ...ency cut off switch Side stand contacts Key switch contacts Virgin circuit If the ignition system has not been programmed the engine can be started but it will run limited to 2000 rpm When trying to accelerate some evi dent loss of power may be felt Program the system with the MASTER Brown and SERVICE Black keys as follows Insert the MASTER key turn it to ON and keep it in that position for 2 seco...

Page 62: ... it is advisable to use resistive spark plugs Diagnostic codes The flash indicating the switching to ON can be followed by a phase of programmed failure warnings That is the led is off for 2 seconds and then diagnosis codes are transmitted with 0 5 second flashes After the failure code indication a steadily on LED signals that ignition is disabled see the table 2 FLASH CODE Example with programmed...

Page 63: ...witch If the failure disappears when the MASTER key is used proceed to encode the service keys Black If the failure persists it means that the MASTER key and the control unit are not linked in this case replace the control unit and then encode the keys The immobilizer system is efficient when after switching over to ON only a 0 7 second flash is detected see diagram In this case the engine can be ...

Page 64: ...forming values are detected replace the Pick Up otherwise check the cable har ness and the connections In case conforming values are measured and the wiring and connections check is OK try replacing the control unit without programming and make sure the failure has been solved by checking sparks are produced in the spark plug only then program the control unit If no sparks are produced with the ne...

Page 65: ...e terminal to connector No 8 see fig ure Use the start up system to run the engine and measure the voltage produced by the Pick Up Replace Pick Up if non conforming values are measured Electric characteristic Pick Up voltage value Pick Up voltage value 2 Volt HV coil With the control unit and HV coil connected meas ure the voltage of the coil primary during the start up test with the voltage peak ...

Page 66: ...e detected repeat the checks directly to the stator In case of further rep etitions of incorrect values replace the stator or repair the wiring Using a tester check the continuity between con nection 4 3 4 1 and 3 1 Check the earth insulation on the three stator phases 4 earth 3 earth and 1 earth Indicative resistance of each phase 0 7 0 9 Ω Pick Up Check Check that there is a resistance of about ...

Page 67: ...for the voltage to set at about 12 V Start the engine and measure the current gen erated by the system with lights on and a high running engine In case the generated current value is lower than 10A repeat the test using a new regulator and stator alternatively The recharge system is provided with a three phase generator with permanent magneto flywheel The generator is directly connected to the vol...

Page 68: ...f there is no volt age check the wiring connections to the key switch and that the 15A fuse works properly If there is voltage check again the ignition control unit connector After disconnecting the starter start the engine and keep it at idle speed Check if there is voltage when the multimeter positive probe is connected to the terminal No 5 Sky blue and the negative one to the terminal No 7 Blac...

Page 69: ...shows the features of the fuses on the vehicle CAUTION BEFORE REPLACING A BLOWN FUSE FIND AND SOLVE THE FAILURE THAT CAUSED IT TO BLOW NEVER TRY TO REPLACE THE FUSE USING ANY OTHER MATERIAL A PIECE OF ELECTRICAL WIRE FOR EXAMPLE OR A FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED Electric characteristic Light indicator on digital instrument panel front and rear side taillights 7 5 A Digital instru...

Page 70: ...olled by the signal sent by the H V coil Fuel level indicator controlled by a resistive sensor into the tank Cooling fluid temperature indicator controlled by a resistive sensor on the head These instruments are electrical and managed by stepping motors The instrument panel digital section is completed by a liquid crystal display and 4 control buttons The display has 3 icons Oil Service Belt The O...

Page 71: ...nt panel is on To ensure safety while riding the direction indicators control function is connected to the odometer If the indicator is left on it automatically stops after 1 kilometre travelled The engine disabled indicator is activated by the side stand switch and by the emergency switch on the right side of the handlebar The LCD display gives a 5 digit indication for the total kilometres covere...

Page 72: ...een previously activated reset the Oil Service and Belt functions The calendar is programmed from 2000 to 2050 For date and time adjustment act on the Clock and Set buttons To guarantee vehicle safety each time the key switch is set to ON there is an automatic checking of all the indicators on the digital section The digital section provides also a functional checking of the 4 analogue instruments...

Page 73: ...E BATTERY IF THE VEHICLE IS NOT USED FOR SOME TIME 1 MONTH OR MORE THE BATTERY NEEDS TO BE RECHARGED PERIODICALLY THE BATTERY RUNS DOWN COMPLETELY IN THE COURSE OF THREE MONTHS IF IT IS NECESSARY TO REFIT THE BATTERY IN THE VEHICLE BE CAREFUL NOT TO REVERSE THE CONNECTIONS TAKING INTO ACCOUNT THAT THE GROUND WIRE BLACK MARKED MUST BE CONNECTED TO THE NEGATIVE TERMINAL WHILE THE OTHER TWO RED WIRES...

Page 74: ...battery to eliminate any air bubbles formed while recharging Check the electrolyte level again restore if required up to the tol reference using distilled water tighten the caps of the single elements and install it on the vehicle If lower voltages are detected recharge the battery for 4 6 hours more as described above N B BATTERIES STORED FOR A LONG TIME CAN REQUIRE LONGER TIMES BATTERY CHARGERS ...

Page 75: ... SERIAL CLOCK OUTPUT 4 ANTITHEFT DEVICE LED OUTPUT ANTITHEFT DEVICE LED OUTPUT 5 ANALOGUE CARD SERIAL DATE OUTPUT ANALOGUE CARD SERIAL DATE OUTPUT 6 LIGHTS ON OUTPUT LIGHTS ON OUTPUT 7 Not connected 8 Not connected 16 WAY INSTRUMENT CONNECTOR Specification Desc Quantity 1 GENERAL USE WARNING LIGHT INPUT GENERAL USE WARNING LIGHT INPUT 2 ABS WARNING LIGHT INPUT NOT CONNECTED ABS WARNING LIGHT INPUT...

Page 76: ...NDICATOR OFF SWITCH INPUT 14 RESET SERVICE MANAGEMENT BUTTON INPUT RESET SERVICE MANAGEMENT BUTTON INPUT 15 WATER TEMPERATURE SENSOR INPUT WATER TEMPERATURE SENSOR INPUT 16 FUEL LEVEL SENSOR INPUT FUEL LEVEL SENSOR INPUT Electrical system MSS X9 Evolution 250 ELE SYS 76 ...

Page 77: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 78: ...Wear safety goggles when using hitting tools WARNING BE VERY CAREFUL WHEN HANDLING FUEL CAUTION WHEN INSTALLING THE BATTERY ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG ATIVE LEAD Silencer fixing Please take note that starting from chassis serial number ZAPM2300004503144 the three M8 x 50 silencer bracket fixing screws have been replaced by three M8 x 60 flanged head screws in order to strength...

Page 79: ...n The engine is now free Carry out the removal operations but in reverse order observing the prescribed tightening torques Locking torques N m Lower shock absorber clamp 33 41 Engine swinging arm bolt 33 41 MSS X9 Evolution 250 Engine from vehicle ENG VE 79 ...

Page 80: ...INDEX OF TOPICS ENGINE ENG ...

Page 81: ...ven pulley shaft locking nut and washer Specific tooling 020423Y driven pulley lock wrench Remove the cap dipstick from the engine oil filling hole Remove the ten screws Remove the transmission cover If this operation is carried out directly on the vehi cle remove the cooling air supply coupling of the transmission housing Air duct Remove the five screws on two different levels as well as the smal...

Page 82: ...75Y Adaptor 28 x 30 mm 020412Y 15 mm guide Refitting the driven pulley shaft bearing Slightly heat the crankcase from the inside so as not to damage the painted surface Insert the bearing in its seat Refit the seeger ring CAUTION USE AN APPROPRIATE REST SURFACE TO AVOID DAM AGING THE COVER PAINT N B ALWAYS REPLACE THE BEARING WITH A NEW ONE UPON REFITTING Specific tooling 020376Y Adaptor handle 02...

Page 83: ...ts that could jeopardise belt functioning For refitting place the roller with the belt contain ment edge on the engine crankcase side Tighten the wrench to the prescribed torque Locking torques N m Anti flapping roller 12 16 Removing the driven pulley Remove the spacer the clutch bell and the whole driven pulley unit N B THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED MSS X9 Evolution...

Page 84: ...er 15 and 17 mm Lock with the original spacer and nut Place the bell shaft assembly on the support to check the crankshaft alignment Using a feeler pin gauge and the magnetic base measure the bell eccentricity Repeat the measurement in 3 positions Central internal external If faults are found replace the bell Specific tooling 020074Y Support base for checking crankshaft alignment 020335Y Magnetic ...

Page 85: ...tch and spring with its plastic holder CAUTION THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND THE CENTRAL SCREW MUST BE BROUGHT INTO CON TACT WITH THE TOOL EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TOOL TO BUCKLE Specific tooling 020444Y011 adapter ring 020444Y009 46x55 Wrench 020444Y Tool for fitting removing the driven pulley clutch Inspecting the clutch Check the thickness of the clutch mass fric...

Page 86: ...O RING SEAL Remove the four torque server pins and pull the pulley halves apart Removing the driven half pulley bearing Check there are no signs of wear and or noisi ness Replace with a new one if there are Remove the retaining ring using two flat blade screwdrivers Support the pulley bushing adequately from the threaded side using a wooden surface Using a hammer and pin knock the ball bearing out...

Page 87: ...Inspecting the driven fixed half pulley Version 250 Measure the outside diameter of the pulley bush ing Check the contact surface with the belt to make sure there are no flaws Check the riveted joints are functional Check the evenness of the belt contact surface Characteristic Half pulley minimum diameter Minimum admissible diameter Ø 40 96 mm Half pulley standard diameter Standard diameter Ø 40 9...

Page 88: ... 000 41 035 mm maximum allowable diameter Ø 41 08 mm Remove the belt and slide the movable half pulley with the relevant bush taking care of the falling free assembled rollers Remove the return rollers plate with the relative guide pads Refitting the driven half pulley bearing Support the pulley bushing adequately from the threaded side using a wooden surface Fit a new roller sleeve as in the figu...

Page 89: ...curved spout grease gun lubricate the driven pulley unit with approximately 6 gr of grease Apply the grease through one of the holes in the bushing until it comes out through the hole on the opposite side This operation is necessary to avoid the presence of grease beyond the O rings N B THE TORQUE SERVER CAN BE GREASED WHETHER WITH BEARINGS FITTED OR WHEN THEY ARE BEING RE PLACED UNDERTAKING THE O...

Page 90: ...Introduce the adapter ring 11 with the chamfering facing upwards Insert the clutch on the adapter ring Lubricate the end of the spring that abuts against the servo system closing collar Insert the spring with its plastic holder in contact with the clutch Insert the driving belt into the pulley unit accord ing to their direction of rotation Insert the pulley unit with the belt into the tool Slightl...

Page 91: ...emove the driven pulley belt unit from the tool N B DURING THE SPRING PRELOADING PHASE BE CARE FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND THE BUSHING THREADING N B FOR DESIGN REASONS THE NUT IS SLIGHTLY ASYM METRIC THE FLATTEST SURFACE SHOULD BE MOUN TED IN CONTACT WITH THE CLUTCH Specific tooling 020444Y Tool for fitting removing the driven pulley clutch 020444Y011 adapter ring 020444Y009 46x5...

Page 92: ...e services at 6 000 km 18 000 km etc check that the rim bottom of the toothing does not show signs of incisions or cracking see figure The rim bottom of the tooth must not have incisions or cracking if it does change the belt Removing the driving pulley Turn the crankshaft until the ropes of the pulley are on a horizontal axis Insert the adaptor sleeve of the appropriate tool in the hole shown in ...

Page 93: ...ameter B of the pulley sliding bushing shown in the figure Check that the rollers are not damaged or worn Check the guide shoes for the variator back plate are not worn Check the wear of the roller housings and of the belt contact surfaces on both pulley halves Check that stationary driving pulley does not show signs of abnormal wear on the grooved edge and on the surface in contact with the belt ...

Page 94: ...ter 20 5 20 7 mm Roller Minimum diameter permitted Ø 20 mm Refitting the driving pulley Fit the steel shim in contact with the bushing and the stationary drive pulley Install the appropriate tool as described in the re moval phase Tighten the nut with washer to the prescribed tor que Specific tooling 020626Y Driving pulley lock wrench Locking torques N m Drive pulley nut 75 83 Engine MSS X9 Evolut...

Page 95: ...asher and the driven pulley nut Tighten the nut to the prescribed torque using the lock wrench and the torque wrench tools Replace the plastic cover Specific tooling 020423Y driven pulley lock wrench Locking torques N m Transmission cover screws 11 13 Driven pul ley shaft nut 54 60 End gear Removing the hub cover Empty the rear hub through the oil drainage plug Remove the 7 flanged screws indicate...

Page 96: ...eck the state of the bearings being examined wear clearance and noisiness If faults are de tected do the following Use the specific bearing extractor to remove the three 15 mm bearings 2 in the crankcase and 1 in the hub cover Specific tooling 001467Y013 Pliers to extract ø 15 mm bearings Engine MSS X9 Evolution 250 ENG 96 ...

Page 97: ... shaft bearing As you need to remove the driven pulley shaft its bearing and oil guard remove the transmission cover as described above Extract the driven pulley shaft from its bearing Remove the oil guard using a screwdriver work ing from inside the bearing and being careful not to damage the housing make it come out of the belt transmission side Remove the seeger ring shown in the figure Remove ...

Page 98: ...ng the wheel axle bearing Support the hub cover on a wooden surface Heat the crankcase cover with the specific heat gun Fit the wheel shaft bearing with a modular punch as shown in the figure Fit the seeger ring Fit the oil guard with seal lip towards the inside of the hub and place it flush with the internal sur face by means of the appropriate tool used from the 52 mm side The 52 mm side of the ...

Page 99: ...ing facing the bearing and the new oil guard flush with the crank case on the pulley side N B TO FIT THE BEARING ON THE COVER SUPPORT THE COVER WITH THE STUD BOLT SET N B IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN ER PLACE IT SO THAT THE BALLS ARE VISIBLE FROM THE HUB INNER SIDE N B WHEN FITTING THE BEARINGS ON THE ENGINE CRANK CASE SUPPORT THE CRANKCASE PREFERABLY ON A SURFACE TO ALLOW THE BE...

Page 100: ... using black silicone sealant Fit the gearbox cover making sure the breather pipe is in the correct position Place the 3 shortest screws identifiable by their different colour as shown in the figure Fasten the breather pipe support bracket with the lower short screw Assemble the remaining 4 screws and tighten the 7 screws to the prescribed torque Locking torques N m Rear hub cover screws 24 27 Eng...

Page 101: ...Flywheel cover Removing the hub cover Remove the clip fixing the hose to the cylinder Remove the 10 fixings Remove the flywheel cover MSS X9 Evolution 250 Engine ENG 101 ...

Page 102: ...or and its wiring Refitting the stator Refit the stator and flywheel carrying out the re moval procedure in reverse tightening the retain ers to the specified torque Locking torques N m Stator assembly screws 3 4 Refitting the flywheel cover Position the spline clip on the crankshaft and ori ent the end as shown in the figure Engine MSS X9 Evolution 250 ENG 102 ...

Page 103: ...ismantling procedure CAUTION TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR MAKE SURE THE CEN TRING DOWELS ARE PRESENT Locking torques N m Flywheel cover screws 11 13 Flywheel and starting Removing the starter motor Remove the two screws indicated in the figure Take the starter motor out of its seat Removing the flywheel magneto Remove the water pump shaft and crankshaft spline clip MSS X9...

Page 104: ...el nut with its washer Do up the flywheel nut by three or four threads so that the flywheel does not fall accidentally on extraction Screw the extractor onto the flywheel and extract it as shown in the photograph Specific tooling 020467Y Flywheel extractor Refitting the free wheel Make sure the freewheel faying surfaces are in good condition Thoroughly clean the free wheel to remove LOCTITE residu...

Page 105: ... side is in contact with the fly wheel itself i e with wheel seeger ring visible Lock the six clamping screws in criss cross fash ion to the prescribed torque Locking torques N m Screw fixing freewheel to flywheel 13 15 Oil the free wheel rollers Refitting the flywheel magneto Remove the freewheel retaining plate indicated in the photograph Remove the transmission gear and the freewheel MSS X9 Evo...

Page 106: ...e Specific tooling 020627Y Flywheel lock wrench Locking torques N m Flywheel nut 94 102 Refitting the starter motor Fit a new O ring on the starter motor and lubricate it Fit the starter on the crankcase locking the two screws to the prescribed torque Locking torques N m Starter motor screws 11 13 Cylinder assy and timing system Removing the intake manifold Loosen the 3 crews and remove the intake...

Page 107: ...pring and by pass piston oil pump pulley cover O ring on the crankshaft and the sprocket wheel separa tion washer Remove the tappet cover Remove the central screw fastener and the au tomatic valve lifter retaining cover as shown in the figure Remove the return spring of the automatic valve lifter unit and the automatic valve lifter unit and its end of stroke washer MSS X9 Evolution 250 Engine ENG ...

Page 108: ...asher Remove the command sprocket wheel and the timing chain Remove the screws indicated in the figure the spacer bar and the tensioner slider The chain tensioning pad must be removed from the transmission side As regards the lower chain guide pad it may only be removed after the head has been removed N B IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN SURE THAT THE INITIAL DIRECTION OF ROTATION ...

Page 109: ...cam shaft Remove the pins and the rocker arms from the flywheel side holes N B IN CASE OF NEED THE HEAD MAY BE REMOVED WITH THE CAMSHAFT PINS ROCKING LEVERS AND FIXING BRACKET THE HEAD CAN ALSO BE REMOVED WITH OUT REMOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER MSS X9 Evolution 250 Engine ENG 109 ...

Page 110: ...g the appropriate tool fitted with an adaptor remove the cotters caps springs and valves Remove the oil guards with the appropriate tool Remove the lower spring supports CAUTION REPLACE THE VALVES IN SUCH A WAY AS TO RECOG NISE THEIR ORIGINAL POSITION ON THE HEAD Specific tooling 020382Y011 adapter for valve removal tool 020382Y Valve cotters equipped with part 012 removal tool 020306Y Punch for a...

Page 111: ... the internal diameter of the small end using an internal micrometer N B REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE ROD SMALL END EXCEEDS THE STANDARD DIAMETER OR IT SHOWS SIGNS OF WEAR OR OVERHEATING Characteristic Rod small end check up Maximum diameter 15 030 mm Rod small end check up Standard diameter 15 0 015 0 025 mm MSS X9 Evolution 250 Engine ENG 111 ...

Page 112: ...sition shown in the figure Carefully clean the seal housings Measure the coupling clearance between the sealing rings and the grooves using suitable sen sors as shown in the diagram If the clearance is greater than that indicated in the table replace the piston N B MEASURE THE CLEARANCE BY INSERTING THE BLADE OF THE FEELER THICKNESS GAUGE FROM THE SECOND SEAL SIDE N B THE PIN HOUSINGS HAVE 2 LUBRI...

Page 113: ...ing maximum clearance allowed after use 0 07 mm Inspecting the cylinder Using a bore gauge measure the internal diam eter of the cylinder following the directions given in the figure and at three different heights Check that the plane of coupling with the head does not show wear or deformations The pistons and cylinders are classified with cat egories depending on the diameters The coupling is car...

Page 114: ...e tool With opening in the position indicated on the tool S left D right Place the wrist pin stop ring into position using a punch Fit the wrist pin stop using the plug as shown in the figure N B THE TOOL FOR INSTALLING THE STOP RINGS MUST BE USED MANUALLY CAUTION USING A HAMMER MIGHT DAMAGE THE STOPS HOUS ING Specific tooling 020454Y Tool for fitting piston pin stops 200 250 Engine MSS X9 Evoluti...

Page 115: ...ylinder base gasket to be used for reassembly by the table below Cor rectly identify the cylinder base gasket thickness to keep the correct compression ratio Remove the special tool and the cylinder N B MEASUREMENT A TO BE TAKEN IS A VALUE OF PISTON RE ENTRY IT INDICATES BY HOW MUCH THE PLANE FORMED BY THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY THE TOP OF THE CYLINDER THE FURTHER THE PISTON ...

Page 116: ...Engine MSS X9 Evolution 250 ENG 116 ...

Page 117: ...cing the crown of the piston Offset the piston ring gaps on the three rings by 120 to each other as shown in the figure Lubricate the components with engine oil The top piston ring on the 250 engine has an L cross section N B THE TWO PISTON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSS SECTION THIS IS TO ACHIEVE A BETTER BEDDING Refitting the cylinder Insert the cylinder base gasket with...

Page 118: ...allowable run out 0 05 mm Check that the camshaft and the rocker pin ca pacities exhibit no wear Check that the cylinder head cover surface the intake manifold and the exhaust manifold are not worn Characteristic bearing A Ø 12 000 12 018 mm bearing B Ø 20 000 20 021 mm bearing C Ø 37 000 37 025 mm Engine MSS X9 Evolution 250 ENG 118 ...

Page 119: ...the centre screw with the washer and the tensioner spring Check that the one way mechanism is not worn Check the condition of the tensioner spring If examples of wear are found replace the whole assembly Inspecting the valve sealings Insert the valves into the cylinder head Alternatively check the intake and exhaust valves The test is carried out by filling the manifold with petrol and checking th...

Page 120: ...d diameter 5 000 5 012 mm Valve seat wear Exhaust guide Accepted limit 5 022 Valve seat wear Exhaust guide Standard diameter 5 000 5 012 mm Inspecting the valves Measure the width of the sealing surface on the valve seats and on the valves Sealing surface width After use Intake and ex haust 1 6 mm If any of the sealing surfaces on the valves is wider than the specified limit or is damaged in one o...

Page 121: ...T KEEP ROTATING THE VALVE WHEN NO LAPPING COMPOUND IS LEFT CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED N B DO NOT CHANGE THE POSITIONS THE VALVES ARE FITTED IN Characteristic Valve check standard length Outlet 94 4 mm Valve check standard length Inlet 94 6 mm Valve check Maximum admissible clearance Outlet 0 072 mm Valve check...

Page 122: ...Inspecting the springs and half cones Check that the upper spring caps and the cotter halves show no signs of abnormal wear Engine MSS X9 Evolution 250 ENG 122 ...

Page 123: ...ol 020382Y011 adapter for valve removal tool Inspecting the cam shaft Inspect the cam shaft for signs of abnormal wear on the cams Check the cam height Check there is no wear on the cam shaft retaining plate and its associated groove on the cam shaft 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 C...

Page 124: ... Cam shaft check Maximum admissible axial clearance 0 42 mm Cam shaft check Standard axial clearance 0 11 0 41 mm Cam shaft check Standard height Outlet 29 209 mm Cam shaft check Standard height Inlet 30 285 mm Cam shaft check Minimum admissible diame ter Bearing B diameter 19 950 mm Cam shaft check Minimum admissible diame ter Bearing A Ø 36 94 mm Cam shaft check Standard diameter Bearing B diame...

Page 125: ... the outside of the timing chain side and tighten them to the specified torque N B BEFORE INSTALLING THE HEAD MAKE SURE THAT THE LUBRICATION CHANNEL IS CLEAN USING A COM PRESSED AIR JET Locking torques N m Timing chain tensioner support screw 11 13 Refit the lower timing chain sprocket wheel on the crankshaft with the chamfer facing the insertion side Loop the timing chain around the sprocket on t...

Page 126: ...he fixing screw to the prescribed torque Fit the end stop ring on the automatic valve lifter cam and fit the automatic valve lifter cam to the cam shaft Fit the automatic valve lifter return spring During this operation the spring must be loaded by approximately 180 Fit the automatic valve lifter retaining dish using the counterweight screw fastener as a reference Tighten the clamping screw to the...

Page 127: ...torques N m Timing chain tensioner support screw 11 13 Spark plug 12 14 Starter ground screw 7 8 5 Timing chain tensioner slider screw 10 14 Starter ground support screw 11 15 Timing chain tensioner central screw 5 6 Camshaft re tention plate screw 4 6 MSS X9 Evolution 250 Engine ENG 127 ...

Page 128: ...the 5 clamping screws to the prescribed torque Make sure the gasket is positioned properly Locking torques N m Tappet cover screws 6 7 Nm Refitting the intake manifold Fit the intake manifold and do up the three screws Crankcase crankshaft Engine MSS X9 Evolution 250 ENG 128 ...

Page 129: ...e radial clearance on the connecting rod Check the surfaces that limit the axial free play are not scored and measure the width of the crank shaft between these surfaces as shown in the diagram If the axial clearance between crankshaft and crankcase is exceeding and the crankshaft does not have any defect the problem must be due to either excessive wear or wrong machining on the crankcase Check th...

Page 130: ...NGS Specific tooling 020262Y Crankcase splitting strip 020335Y Magnetic support for dial gauge Characteristic Axial crankshaft crankcase clearance Stand ard clearance 0 15 0 40 mm when cold Axial connecting rod crankshaft clearance Standard clearance 0 20 0 50 mm Radial connecting rod crankshaft clearance Standard clearance 0 036 0 054 mm Width of crankshaft with integral washers standard measurem...

Page 131: ...t be replaced and when cleaning the crankshaft be very careful that no impurities get in through the shaft s lubrication holes In order to prevent damaging the connecting rod bushings do not attempt cleaning the lubrication duct with compressed air Make sure that the 2 caps on the crankpin are properly fitted A wrong installation of a cap can seriously affect the bushing lubrication pressure N B T...

Page 132: ...t the coupling surfaces on the crankcase halves for scratches or deformation taking partic ular care with the cylinder crankcase surfaces and the crankcase halves surfaces Defects in the crankcase coupling gasket be tween the crankcase halves or the mating surfaces shown in the diagram could cause a drop in the oil pressure lubricating the main bearings and con nection rod Check the main bearing s...

Page 133: ... solid half bearing is intended to stand the thrusts caused by combustion and for this reason it is arranged opposite the cylinder To prevent obstructions in the oil feeding chan nels the matching surface of the two half bearings must be perfectly perpendicular to the cylinder ax is as shown in the figure The oil feeding channel section is also affected by the bushings driving depth compared with ...

Page 134: ...ng Possible fit ting A 1 29 025 29 040 Original B 1 29 019 29 034 Original and spare 2 29 028 29 043 C 2 29 022 29 037 Original Match the shaft with two category 1 crank webs with the category 1 crankcase or cat 2 with cat 2 Furthermore a spare crankcase cannot be matched with a crankshaft with mixed categories The spare crankshaft has half shafts of the same category Crankcase halves Engine half ...

Page 135: ...preferably on the transmission side to gether with the locating dowels Lubricate the main bushings and insert the crank shaft in the transmission side crankcase half Reassemble the two crankcase halves Fit the 10 screws and tighten them to the pre scribed torque Fit a new O ring on the pre filter and lubricate it Insert the filter on the engine with the relative cap Tighten to the prescribed torqu...

Page 136: ...rst remove the transmission cover and the com plete driving pulley Install the base of the appropriate tool on the oil guard using the screws provided Specific tooling 020622Y Transmission side oil guard punch Engine MSS X9 Evolution 250 ENG 136 ...

Page 137: ...to the crankshaft as far as it will go Use the nut to move the base of the tool until you can feel the end of the oil seal driving stroke Remove all of the tool components following the inverse procedure CAUTION DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO THE ENGINE CRANKCASE CAUTION ORIENT THE OIL GUARD BY POSITIONING THE CHAIN HOUSING CHANNEL FACING DOWNWARDS WHEN THE POSITION IS REACHED DO NOT...

Page 138: ...Oil pump Removal Undo the two clamping screws in the figure and remove the cover over the pump control crown Engine MSS X9 Evolution 250 ENG 138 ...

Page 139: ...e the clip retaining the innermost rotor Remove and wash the rotors thoroughly with pet rol and compressed air Reassemble the rotors in the pump body keep ing the two reference marks visible Replace the snap ring Check the clearance between the rotors in the position shown in the diagram using a thickness gauge Measure the distance between the outer rotor and the pump body see figure Check the axi...

Page 140: ...e engine crankcase The pump can only be fitted in one position Tighten the screws to the prescribed torque Fit the sprocket wheel with a new O ring Fit the chain Fit the central screw and the belleville washer Tighten to the prescribed torque Fit the oil pump cover by tightening the two screws to the prescribed torque N B FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY MAKE SURE...

Page 141: ...d the two rear brake fluid pipe fixing brackets Remove the screw the by pass piston the gas ket and centring dowels shown in the figure Inspecting the by pass valve Check the unloaded spring length Check that the small piston is not scored Ensure that it slides freely on the crankcase and that it guarantees a good seal If not eliminate any impurities or replace defec tive parts Characteristic By p...

Page 142: ...l and the transmission cover as de scribed in the Transmissions chapter When testing the lubrication system refer to chapter Crankcase and Crankshaft regard ing lubrication of the crankshaft and connect ing rod Locking torques N m Oil sump screws 10 14 SAS valve Inspecting the one way valve Remove the SAS valve Provisionally assemble the rubber coupling of the SAS valve outlet to ensure tightness ...

Page 143: ...vacuum value higher than 0 5 BAR Check that this value is kept all the time If a worn seal is detected replace it With a T bypass and flexible rubber hoses make a parallel connection between the rubber coupling and the vacuum intake of the CUT OFF valve Connect the bypass to the MITYVAC pump Set the pump set to the low pressure mode VACUUM Using a pair of long flat pliers choke the rubber hose nex...

Page 144: ...HE CUT OFF VALVE ALSO DAMAGES IDLE FUNCTIONING Specific tooling 020329Y MityVac vacuum operated pump Fuel supply Removing the carburettor Kehin To detach the carburettor from the engine it is necessary to move the air filter and remove the transmission throttle control the automatic starter connection the clamps anchoring the carburettor to the filter housing and to the inlet manifold the air deli...

Page 145: ...rter support with the gasket Remove the clamp and cover with the airing filter of the diaphragm chamber Remove the 4 fixing screws shown in the figure and the vacuum chamber cover WARNING DURING THE REMOVAL OF THE CARBURETTOR COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY MSS X9 Evolution 250 Engine ENG 145 ...

Page 146: ...cuum valve together with the di aphragm Unscrew the bayonet joint 1 8 of a turn and re move take out the spring and vacuum valve nee dle Remove the 4 screws indicated in the figure Engine MSS X9 Evolution 250 ENG 146 ...

Page 147: ... tank N B CAUTION THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES SPRING AND BALL N B AVOID REMOVING THE PISTON OF THE PUMP AND ITS CONTROL Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side Remove the float and the plunger Remove the maximum nozzle MSS X9 Evolution 250 Engine ENG 147 ...

Page 148: ... Remove the maximum nozzle Remove diffuser Engine MSS X9 Evolution 250 ENG 148 ...

Page 149: ... minimum flow set screw and the spring CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE CARBURETTOR BODY SUCH AS FUEL SUPPLY PIPE PLUNGER HOUSING STARTER NOZZLE PIT COVER FOR PROGRESSIONS AND INLET NOZZLE MINIMUM AND MAXIMUM AIR GAUGE THROTTLE VALVE CONTROL SHAFT DO NOT REMOVE THROTTLE SHAFT CONNEC TION SCREWS THE FIXING SCREWS ARE CAULKED AF TER ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT M...

Page 150: ...e fitting Take out the carburettor and rotate it so as to remove the screw with the water joint and the pipes 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 Remove the protection the bracket and the starter acting on the screw shown in the figure Remove...

Page 151: ...icated in the figure and the vacuum chamber cover N B DURING THE REMOVAL OF THE COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY Remove the vacuum valve together with the dia phragm MSS X9 Evolution 250 Engine ENG 151 ...

Page 152: ...yonet joint 1 8 of a turn remove it take out the spring and vacuum valve plunger Remove the 4 screws shown in the figure Remove the tank with the intake pump its control and gasket Engine MSS X9 Evolution 250 ENG 152 ...

Page 153: ... hood the O Ring and the spring from the tank as shown in the figure Adequately support the carburettor and using a rod and hammer remove the float pin acting from the throttle control side Remove the float and the plunger MSS X9 Evolution 250 Engine ENG 153 ...

Page 154: ... maximum nozzle Remove diffuser Remove the sprayer 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 Remove the minimum nozzle Engine MSS X9 Evolution 250 ENG 154 ...

Page 155: ...TS EMBEDDED IN THE CARBURETTOR BODY SUCH AS FUEL SUPPLY PIPE PLUNGER HOUSING STARTER NOZZLE PIT COVER FOR PROGRESSIONS AND INLET NOZZLE MINIMUM AND MAXIMUM AIR GAUGE THROTTLE VALVE CONTROL SHAFT DO NOT REMOVE THROTTLE SHAFT CONNEC TION SCREWS THE FIXING SCREWS ARE CAULKED AF TER THE ASSEMBLY AND THEIR REMOVAL DAMAGES THE SHAFT Refitting the carburettor MSS X9 Evolution 250 Engine ENG 155 ...

Page 156: ... controlled by flow screw progression holes near the throttle valve For the starter circuit blow the connection pipe properly with the jet This is necessary because the nozzle support hides other inaccessible internal calibrations Blow the intake nozzle properly N B THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE NOZZLE INCORRECT ORIENTATION RESULTS IN INADE...

Page 157: ...inimum nozzle properly and reassemble it Properly wash and blow the components of the sprayer maximum circuit the diffuser and the noz zle Introduce the sprayer in the carburettor body with the shortest cylindrical part directed to the diffuser Assemble the diffuser making sure the sprayer is being adequately inserted and lock it Assemble the maximum nozzle Check that the tapered pin does not show...

Page 158: ...ing Nozzle N B THE IN VALVE NOZZLE CORRESPONDING TO THE AC CELERATION PUMP IS MILLED Check the screw tightness introducing a small amount of fuel in the tank Assemble a new gasket on the tank Assemble the tank on the carburettor body fas tening the 4 screws Check that the control roller is free to rotate in its own seat N B MAKE SURE THE TANK GASKET IS CORRECTLY INTRO DUCED N B AVOID DEFORMING THE...

Page 159: ...y pipe and the plunger seat For maximum circuit check the air adjustment is correct as shown in the figure Carefully clean the air holes indicated in the fig ure For the minimum circuit make sure the following points are properly cleaned air gauging outlet section controlled by flow screw progression holes near the throttle valve N B THE MINIMUM AIR IS CONTROLLED BY TWO ADJUSTMENTS THE CUT OFF ONE...

Page 160: ...O AVOID DAMAGES DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS Wash and blow the minimum nozzle properly and reassemble it Properly wash and blow the components of the sprayer maximum circuit the diffuser and the noz zle Introduce the sprayer in the carburettor body with the shortest cylindric part directed to the diffuser Assemble the diffuser making sure the sprayer is being adequately ...

Page 161: ...l plate direction to obtain the position described above If the plate gets deformed make sure it remains parallel to the float pin N B WITH INVERTED CARBURETTOR THE FLOAT WEIGHT SHOULD NOT EXCEED THE TAPERED PIN SPRING THRUST OTHERWISE CHECK THAT THE FLOAT IS NOT HEAVY DUE TO FUEL INFILTRATION REPLACE THE FLOAT AND THE TAPERED PIN IF NECESSARY Wash and blow the carburettor duct cover prop erly and...

Page 162: ... that the acceleration pump piston contrast spring is not worn Assemble a new O Ring and a new bellows gas ket Reassemble the piston unit on the tank Assemble a new O Ring on the tank drainage screw and lock it Check the screw tightness introducing a small amount of fuel in the tank Assemble a new gasket on the tank Assemble the tank on the carburettor body fas tening the 4 screws Wash and blow th...

Page 163: ... the throttle valve open Lock the fixing screw of the rocking lever Make sure that the mechanism works correctly Inspecting the valve and needle Kehin Check that the tapered pin of the vacuum valve does not show wear Check that the depression valve does not show threads on the external surfaces Check that the vacuum intake hole is not clogged Check that the diaphragm is not damaged or has hardened...

Page 164: ...emble the spring with the pin lock Remove the cover of the vacuum chamber being careful to correctly insert the spring in its place on the cover Tighten the screws Wash and blow dry the filter sponge of the am bient pressure intake Engine MSS X9 Evolution 250 ENG 164 ...

Page 165: ... 2 fixing screws Walbro Check that the pin does not show signs of wear and that the lock is in the 3rd of the 3 notches Check that the valve does not show threads around its external diameter Check that the 2 vacuum supply holes are not clogged N B THE 2 VACUUM SUPPLY HOLES ARE OF DIFFERENT DI AMETERS MSS X9 Evolution 250 Engine ENG 165 ...

Page 166: ...ed to the valve the main vacuum supply hole is positioned axially with the diffuser on the throttle valve side Refit the spring on the valve Refit the vacuum chamber cover matching the reference mark with the orientation of the dia phragm Tighten the screws to the prescribed torque Check the cut off valve correct functioning Check that the diaphragm is not worn or has hard ened Check the free leng...

Page 167: ...e With a 12V battery power the automatic starter and check that the piston protrudes as much as possi ble The correct warm up time depends on the ambi ent temperature If protrusion resistance or timing values are dif ferent from the ones prescribed replace the start er Assemble the starter to the carburettor being careful to position the O Ring correctly insert the plate with the machined side con...

Page 168: ...the protrusion of the piston as shown in the figure and check its corresponding value Make sure that the starter is adjusted for the am bient temperature The starter should disconnect progressively by means of electrical heating Check the starter resistance when adjusted to the ambient temperature 20 25 C With a 12V battery power the automatic starter and check that the piston protrudes as much as...

Page 169: ...uld be in optimum conditions air filter clean and sealed and the exhaust system tight Warm up the engine by running it at least 5 mi nutes at approximately 50 kph Connect the vehicle to the exhaust fumes analy ser inserting the probe into a sealed extension pipe placed at the muffler exit end Connect a millimetre thermometer 020331y on the sump using a cover with oil expressly pre pared for probes...

Page 170: ...t idle it is normal to detect 200 400 PPM these emission values are deemed normal for an engine with a diagram of distribution for motorcycles Higher val ues can cause 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 were difficult to adjustment CO check accurately That the carburettor is clean That the automat...

Page 171: ...CT COUPLING OF THE RPM INDICATOR WILL BE INDICATED WHEN IT CAN READ RPM OVER 6000 8000 Characteristic Idle adjustment Pipe sizes Ø 40 mm Idle adjustment length 500 600 mm MSS X9 Evolution 250 Engine ENG 171 ...

Page 172: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 173: ...ar wiring retaining straps and disconnect the electric connectors from the brake levers Remove from the handlebar the hoses of both the front and rear brake pump and of the voltage dis tribution valve located on the front frame according to the Braking system chapter Remove the flexible transmission from the front and rear brake lever and remove the throttle grip Loosen the handlebar steering tube...

Page 174: ...rk Specific tooling 020055Y Wrench for steering tube ring nut Overhaul Remove the lower screw 1 Drain oil from suspension Slide off the stem Replace the sealing rings 3 4 with new ones Fit the new sealing rings only after lubricating their seats Refit the stem and the lower screw 1 Unscrew the cap 2 Pour 133 2 5 cm of Selenia Fork 10W oil per stem on the KAYABA fork recognisable by the mark stampe...

Page 175: ...gnisable by the label with the S on the sleeve external side near the wheel axle Refit all parts following the removal steps but in reverse order Recommended products SELENIA FORK 10W Oil for front fork SAE 10 W hydraulic oil MSS X9 Evolution 250 Suspensions SUSP 175 ...

Page 176: ...tta Inserire l anello distanziale Bloccare la ghiera superiore alla coppia prescrit ta Specific tooling 020055Y Wrench for steering tube ring nut Locking torques N m Upper steering ring nut 40 45 Steering lower ring nut 10 12 Steering bearing Suspensions MSS X9 Evolution 250 SUSP 176 ...

Page 177: ...with an appropriate tool N B USE THE APPROPRIATE TOOL AGAIN TO REMOVE THE LOWER HOUSING OF THE STEERING LOWER BEARING Specific tooling 020004Y Punch for removing fifth wheels from headstock MSS X9 Evolution 250 Suspensions SUSP 177 ...

Page 178: ...ng on the chassis using an appropriate tool N B ASSEMBLE THE LOWER HOUSING ON HE STEERING TUBE WITH A TUBE SECTION OF AN ADEQUATE DIAME TER Specific tooling 001330Y Tool for fitting steering seats Rear Suspensions MSS X9 Evolution 250 SUSP 178 ...

Page 179: ...order Locking torques N m Rear wheel axle 104 126 Rear wheel fixing screws 33 37 Swing arm Removal Removal Remove the chassis external nut on the left side Loosen the two nuts shown in the figure Slide off the bolt and remove the swinging arm Reassembly Carry out the previous operations in reverse order Locking torques N m swinging arm 8 12 Nm Shock absorbers MSS X9 Evolution 250 Suspensions SUSP ...

Page 180: ...er shock absorber clamp 33 41 Centre stand Removal Unhook the springs Loosen the nut Pull out the screw Reassembly Install the sealing rings on the support tube of the stand Carry out the operations described above in re verse order then insert the sealing rings into their seats CAUTION Lubricate the following parts with grease spring coupling pins bushings on stand fixing bracket Recommended prod...

Page 181: ...stand retaining bolt 20 25 MSS X9 Evolution 250 Suspensions SUSP 181 ...

Page 182: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 183: ... WILL RE SULT IN POOR BRAKING EFFICIENCY DUE TO A LOW BOILING POINT OF THE FLUID N B ALWAYS STORE THE FLUID IN SEALED CONTAINERS UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THE FLUID EVERY TWO YEARS IF THE BRAKES ARE USED INTENSELY AND OR IN HARSH CONDITIONS CHANGE THE FLUID MORE FREQUENTLY DURING INSTALLATION THE PARTS TO BE REUSED MUST BE ABSOLUTELY CLEAN AND FREE FROM ANY TRA...

Page 184: ...s out Remove the two screws indicated in the figure fixing the calliper to the support and remove the calliper repeat the same operations for the opposite cal liper necessary for combined braking Besides removing the oil pipe connected to the voltage dis tribution valve also remove the clamp fixing the odometer gear transmission when refitting tighten up the screws and the joint to the prescribed ...

Page 185: ...e the entire calliper that the guides of the fixed plate are not scratched or eroded otherwise replace the entire plate that the brake pad check spring works properly Refitting 1 insert the pistons 6 and the sealing rings 7 in the body 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 pad...

Page 186: ...bbers 9 Brake pad check spring 10 Pads CAUTION ALL THE SEALS AND GASKETS MUST BE REPLACED EV ERY TIME THE CALLIPER IS SERVICED Locking torques N m Brake fluid pipe calliper fitting 20 25 Pad fas tening pin 19 6 24 5 Front brake disc Removal Remove the wheel and check that the axial devi ation of the braking surface is within in the recom mended values If this is not the case replace the disc and r...

Page 187: ...racteristic Brake discs check Max axial deviat 0 1 mm Locking torques N m Disc tightening screw 5 6 5 Front brake pads Removal Proceed as follows disassemble the front wheel remove the two screws indicated in the figure remove the stop ring and withdraw the pin slide the two pads down repeat these operations for the brake calliper on the opposite side N B Minimise difficulty for this operation by ...

Page 188: ...PLACED IF THE FRICTION MATERIAL THICKNESS IS LESS THAN 1 5 MM Fill Front Rest the scooter on its stand on level ground Refill the brake circuit reservoir to the maximum level with the recommended fluid Connect the bleed fitting to the appropriate tool pipe Mityvac manual pump Actuate the tool at the bleed fitting at the same time constantly top up the brake reservoir to pre vent air being drawn in...

Page 189: ...king system and be sides controlling the rear brake calliper it also controls the front left calliper Therefore utmost care must be paid when bleeding these two callipers Specific tooling 020329Y MityVac vacuum operated pump Locking torques N m Oil bleed screw 8 12 Brake fluid level check The front and rear brake fluid tanks are placed on the pumps under the handlebar covers Proceed as follows 1 P...

Page 190: ...ew open the cover 2 and take out the diaphragm 3 2 Remove the cap and unscrew the internal parts in the specified order 3 Check that The body of the pump shows no signs of internal damage or corrosion The piston shows no sign of damage or abnormal wear The piston return spring is in good condition Refitting Reinstall the individual parts in the reverse order to the removal paying attention to the ...

Page 191: ...MSS X9 Evolution 250 Braking system BRAK SYS 191 ...

Page 192: ...INDEX OF TOPICS COOLING SYSTEM COOL SYS ...

Page 193: ...Circuit diagram MSS X9 Evolution 250 Cooling system COOL SYS 193 ...

Page 194: ... with fixing screw it is sufficient to remove the cap and install the com ponents of the special tool in its place The special tool can be prepared in advance depending on its use on presses equipped with piston with a threa ded type of coaxial coupling tang or cylindrical with stop groove Then prepare the threaded ring with the adapter suitable for the coupling of the press used Position the flyw...

Page 195: ...move the ceramic ring and sealing gasket from the flywheel cover N B IN THE EVENT YOU PLAN TO REUSE THE MECHANICAL SEAL PAY ATTENTION DURING THE DISASSEMBLY STAGES IN ORDER TO NOT CHIP THE CERAMIC RING Remove the joint from the seat inside the seal ring Position the flywheel cover in the press while sustaining it using the surface to be used for coupling with the engine case CAUTION CHECK THE POSI...

Page 196: ... pump service kit Before you reassemble wash all the components and continue with the following checks Flywheel cover Check that there are no cracks or oxidation on the seat of the ceramic seal Check the capacity loads of the bearings and of the seal ring Check the efficiency of the drain hole Cooling system MSS X9 Evolution 250 COOL SYS 196 ...

Page 197: ... wear on the seat for the oil seal seat and on the slots for the entrainment spring Heat the flywheel cover using the heat gun N B IF THE JOB IS PERFORMED WITH THE STATOR MOUN TED HEAT FROM THE EXTERNAL SIDE OF THE COVER Specific tooling 020151Y Air heater 020150Y Air heater support Properly support the cover and using the modular punch install the two bearings all the way down at the same time N ...

Page 198: ...AWAY FROM THE SIDE OF THE BEARINGS Mount the moving part of the ceramic seal on the shaft with the impeller The rubber part must rest against the impeller Position the flywheel cover on the press using the support base for the bearings that is part of the special tool Install the special punch with the im peller s template on the press piston Specific tooling 020628Y Water pump service kit Cooling...

Page 199: ...N B SO AS TO NOT DAMAGE THE FLYWHEEL COVER DURING THE DRIVING OPERATION SLIGHTLY TURN IT BY HAND IN ORDER TO BETTER PERCEIVE THE MOMENT OF CON TACT WITH THE PUNCH Specific tooling 020628Y Water pump service kit Remove the special punch from the press piston and support the flywheel cover from the impeller side with it Put the new oil seal on the special punch while being careful to position the se...

Page 200: ...it the punch with the template of the entrainment joint to the press punch Position the entrainment joint on the shaft and using the press drive it to the depth determined by the punch Specific tooling 020628Y Water pump service kit Lubricate the oil seal with motor oil Water pump ceramic seal Cooling system MSS X9 Evolution 250 COOL SYS 200 ...

Page 201: ...kcase This phenomenon is particularly visible there where the hole is more exposed Quasar and Master In such cases we recommend cleaning the casing in order to be able to check again for leaks after a distance of more than 1500 km If leaks continue or in the event of real losses the ceramic seal should be replaced For these operations observe the tools and instructions given in the relevant servic...

Page 202: ...TION TO EXECUTE THE TEST CORRECTLY MAKE SURE NEI THER THE THERMOSTAT NOR THE THERMOMETER TOUCHES THE CONTAINER Specific tooling 020331Y Digital multimeter 020151Y Air heater Characteristic Thermostat check opening travel 3 5 mm at 80 C Thermostat check Opening start temperature 69 5 72 5 C Refitting Place the thermostat with the bleeding hole at the highest point Make sure that the rubber gasket i...

Page 203: ...Thermostat cover screws 3 4 MSS X9 Evolution 250 Cooling system COOL SYS 203 ...

Page 204: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 205: ...ing the saddle plate to the centre cover and remove the saddle Rear handlebar cover Unscrew the 3 fixing screws Disconnect the electric connectors Remove the rear handlebar cover Front handlebar cover Remove the brake and oil pump covers on the handlebar cover Unscrew the 2 lower screws of the handlebar cover one per side Remove the front handlebar cover MSS X9 Evolution 250 Chassis CHAS 205 ...

Page 206: ...tical unit from the front Frame central cover Open the tank door Remove the fuel tank cap and the protective rub ber Unscrew the 2 fixing screws located inside of it Extract the centre cover in an upwards direction Remove the tank door opening transmission Chassis MSS X9 Evolution 250 CHAS 206 ...

Page 207: ...connection wiring Remove the stop lights support battery cover by extracting it upwards so as to disengage the cou pling teeth from the side panels Footrest With the help of a small slotted screwdriver re move the fixing caps and then the safety covers Unscrew the fixing screws on the frame at the rear shield and at the tunnel cover Remove the footrest board complete with the passenger boards MSS ...

Page 208: ...crew the 4 fixing screws on the rear frame Disconnect the electric connector of the number plate light Remove the number plate bracket support with the lamp socket N B WHEN SECURING THE NUMBER PLATE BRACKET ON THE SUPPORT PAY ATTENTION TO INSERTING THE RIV ETS WITH THE HEAD ON THE WHEEL SIDE SO AS TO PREVENT THE PROTRUDING PART OF THE RIVET FROM INTERFERING WITH THE TYRE WHEN THE VEHICLE IS IN USE...

Page 209: ... drive switch fixing screw has been replaced The new screw drawing 015911 differs from the previous one for a bigger lenght of 3mm Fuel tank Remove both footrests the central cover and the tunnel cover as described before Separate the electrical connections of the fuel gauge and disconnect the fuel supply line and tank breather Remove the horn after unscrewing its fixing screws indicated in the fi...

Page 210: ...N B this operation should be preferably be carried out with the tank empty Rear central cover Unscrew the 4 fixing screws Remove the rear centre cover Chassis MSS X9 Evolution 250 CHAS 210 ...

Page 211: ...xpansion tank support and remove the support Slide off the expansion tank downwards with the relative gasket after removing momentarily the cap Prepare a container for the coolant Close the cap again and remove the coolant de livery and reverse pipes Top case Unscrew the fixing screws from the electrical connection indicated in the figure Remove the expansion tank as described before Unscrew the s...

Page 212: ...il light Unscrew the screw in the upper part of the side panel Disconnect the optical unit wiring Remove the upper side panel by extracting it to wards the rear of the vehicle Digital panel support Unscrew the 3 fixing screws Disconnect the electric connectors while paying special attention to the coupling teeth Remove the support with digital panel Chassis MSS X9 Evolution 250 CHAS 212 ...

Page 213: ...the screws Remove the 2 centre screws B Remove the lower screw C found under the optical unit Flyscreen Unscrew the 3 screws retaining the upper wind screen with the relative spacers Remove the upper windscreen Extract the 6 plastic plugs and remove the pro tective rubber covers of the windscreen supports together with the central adjustment flange in order to get to the 2 upper fastenings of the ...

Page 214: ...Unscrew the 4 fixing screws with the washers lo cated under the rear view mirrors and beneath the front centre cover Remove the lower fairing N B BE SURE TO CORRECTLY INSERT THE SEALS IN THEIR SEATS WHEN REASSEMBLING Chassis MSS X9 Evolution 250 CHAS 214 ...

Page 215: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 216: ...t 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 low beam position and parking lights and the respective warning lights Adjusting the headlights according to the regulations currently in force Rear light parking light stop light Front and rear stop light switche...

Page 217: ...15 MINUTES AND SEEK MEDICAL ATTENTION AT ONCE IF IT IS SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK IMMEDIATE MEDICAL ATTENTION BATTERIES PRODUCE EXPLOSIVE GAS KEEP THEM AWAY FROM NAKED FLAMES SPARKS AND CIGARETTES IF THE BATTERY IS CHARGED IN A CLOSED PLACE TAKE CARE TO EN SURE ADEQUATE VENTILATION ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO BATTERIES KEEP OUT OF...

Page 218: ... NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST Functional inspection Functional check up Braking system hydraulic Lever travel Braking system mechanical Lever travel Clutch Proper functioning check Engine Throttle travel check Others Check documentation Check the frame and engine numbers Tool kit License plate fitting Check locks Check tyre pressures Installation of mirrors a...

Page 219: ...INDEX OF TOPICS TIME TIME ...

Page 220: ...on 1 001001 Engine from chassis replacement 2 001127 Engine Complete service 3 001136 Exhaust emissions Adjustment 4 003064 Engine oil Change 5 003057 Engine retainer Tighten nuts Crankcase CRANKCASE Code Action Duration 1 003056 Head Cylinder Nut tightening 2 001153 Crankcase halves gasket Replace ment 3 001133 Engine crankcase replace Time MSS X9 Evolution 250 TIME 220 ...

Page 221: ...Crankshaft CRANKSHAFT Code Action Duration 1 001117 Crankshaft Replacement MSS X9 Evolution 250 Time TIME 221 ...

Page 222: ...Service Cylinder head assy HEAD VALVE UNIT Code Action Duration 1 001126 Head Replacement 2 001045 Valves Replacement 3 001049 Valves Adjustment 4 001056 Head gasket change 5 007008 Cylinder head outlet rubber coupling Replacement 6 001057 Thermostat Replacement 7 001083 Thermistor Replacement Time MSS X9 Evolution 250 TIME 222 ...

Page 223: ...Rocker arms support assy ROCKING LEVER SUPPORT UNIT Code Action Duration 1 001148 Valve rocking levers Replacement 2 001044 Camshaft Replacement MSS X9 Evolution 250 Time TIME 223 ...

Page 224: ...ration 1 001093 Spark plug Replacement 2 001089 Head cover Replacement 3 001088 Head cover gasket Replacement 4 001074 Oil vapour recovery pipe Replace ment 5 001129 Chain tightener Overhaul and re placement 6 001124 By pass lubrication Replacement Time MSS X9 Evolution 250 TIME 224 ...

Page 225: ...Oil filter OIL FILTER Code Action Duration 1 001123 Oil filter Replacement 2 001160 Oil pressure sensor Replacement MSS X9 Evolution 250 Time TIME 225 ...

Page 226: ...riven pulley Replacement 5 001155 Clutch bell housing Replacement Oil pump OIL PUMP Code Action Duration 1 001100 Oil seal clutch side Replacement 2 001125 Chain guide pads Replacement 3 001051 Belt Timing chain Replacement 4 001042 Oil pump Service 5 001112 Oil pump change 6 001122 Oil pump chain Replacement 7 001130 Oil sump Replacement Time MSS X9 Evolution 250 TIME 226 ...

Page 227: ...UCTION GEAR Code Action Duration 1 001010 Gear reduction unit Inspection 2 001156 Gear reduction unit cover Replace ment 3 003065 Gear box oil Replacement 4 004125 Rear wheel axle Replacement MSS X9 Evolution 250 Time TIME 227 ...

Page 228: ... DRIVING PULLEY Code Action Duration 1 001086 Driving half pulley Replacement 2 001011 Driving belt Replacement 3 001006 rear view pulley Service 4 001066 driving pulley Replacement Time MSS X9 Evolution 250 TIME 228 ...

Page 229: ...motor ELECTRICAL START UP Code Action Duration 1 001141 Belt anti vibration roller Replace ment 2 001020 Starter motor Replacement 3 001017 Starter sprocket wheel Replace ment MSS X9 Evolution 250 Time TIME 229 ...

Page 230: ...ent 3 001173 Rotor replace 4 001067 Stator Replacement 5 001104 Start up freewheel Replacement 6 001151 Start up driven gearing Replace ment Belt cooling duct BELT COOLING TUBE Code Action Duration 1 001132 Transmission air inlet pipe Replace ment 2 001131 Transmission air intake Replace ment Time MSS X9 Evolution 250 TIME 230 ...

Page 231: ...1 001013 Intake manifold change 2 001081 Automatic choke Replacement 3 001008 Carburettor Inspection 4 001063 Carburettor Replacement 5 007020 Carburettor heat piping Replace ment 6 003058 Carburettor Adjustment MSS X9 Evolution 250 Time TIME 231 ...

Page 232: ...Exhaust pipe SILENCER Code Action Duration 1 001009 Muffler Replacement 2 001092 Exhaust manifold Replacement 3 001095 Muffler guard Replacement Time MSS X9 Evolution 250 TIME 232 ...

Page 233: ...cleaner AIR CLEANER Code Action Duration 1 001014 Air filter Replacement Cleaning 2 001015 Air filter box Replacement 3 004122 Air cleaner carburettor fitting Re placement MSS X9 Evolution 250 Time TIME 233 ...

Page 234: ... 1 004001 Frame replace 2 004146 Front frame Replacement 3 004116 Rear frame Replacement 4 004147 footboard support bracket one side Replacement 5 004148 footboard support bracket two sides Replacement Time MSS X9 Evolution 250 TIME 234 ...

Page 235: ...Centre stand SIDE CENTRAL STAND Code Action Duration 1 004102 Side stand Replacement 2 004004 Stand Replacement 3 005079 Stand switch Replacement MSS X9 Evolution 250 Time TIME 235 ...

Page 236: ...Replace ment 2 006012 Front shield Paintwork 3 004149 Shield central cover Replacement 4 006006 Headstock cover Paintwork 5 004066 Rear view mirrors Replacement 6 005067 Front direction indicator bulb Re placement 7 005012 Front turn indicator Replacement Time MSS X9 Evolution 250 TIME 236 ...

Page 237: ...r REAR SHIELD Code Action Duration 1 004065 Front shield rear part Removal and refitting 2 004081 Glove box door Replacement 3 002082 Fuel tank door opening drive Re placement MSS X9 Evolution 250 Time TIME 237 ...

Page 238: ...Mudguard FRONT MUDGUARD Code Action Duration 1 004053 Spoiler Replacement 2 004002 Front mudguard change 3 005081 Temperature sensor Replacement Time MSS X9 Evolution 250 TIME 238 ...

Page 239: ...lacement 2 004109 Fuel tank breather change 3 004005 Fuel tank replace 4 004073 Fuel pump Replacement 5 004137 Carburettor pump hose Replace ment 6 004086 Petrol pump depression tube Re placement 7 004089 Tank pump hose Replacement MSS X9 Evolution 250 Time TIME 239 ...

Page 240: ...n tank EXPANSION TANK Code Action Duration 1 007001 Expansion tank Replacement 2 007013 Expansion tank connection pipe Replacement 3 001052 Coolant and air bleed Replace ment Time MSS X9 Evolution 250 TIME 240 ...

Page 241: ...Code Action Duration 1 007014 Radiator thermal switch Replace ment 2 007002 Radiator Replacement 3 007016 Fan with support replace 4 007003 Coolant delivery and return pipe Re placement MSS X9 Evolution 250 Time TIME 241 ...

Page 242: ... Removal and Refitting Handlebar covers HANDLEBAR COVERS Code Action Duration 1 004151 Instrument panel support Replace ment 2 004018 Front handlebar covers Replace ment 3 004019 Handlebar rear section Replace ment 4 004152 Board computer cover Replace ment Time MSS X9 Evolution 250 TIME 242 ...

Page 243: ...er Replacement 3 002071 Left hand grip Replacement 4 002024 Front brake pump replace 5 003001 Handlebar Removal and refitting 6 002063 Throttle control transmission Re placement 7 002059 Right hand grip Replacement 8 003061 Accelerator transmission Adjust ment 9 002088 Integral brake pump Replacement MSS X9 Evolution 250 Time TIME 243 ...

Page 244: ...g arm SWING ARM Code Action Duration 1 001072 Engine frame swinging arm fitting Replacement 2 004058 Silent block Replacement 3 003081 Swinging arm support flange re place Time MSS X9 Evolution 250 TIME 244 ...

Page 245: ...ice pipe front cal liper Replacement 3 002089 Integral breaking device Replace ment 4 002087 Integral brake rear rigid pipe Re placement 5 002086 Integral brake front rigid pipe Re placement 6 002090 Integral brake fluid and bleeding sys tem Replacement 7 002021 Front brake piping Replacement MSS X9 Evolution 250 Time TIME 245 ...

Page 246: ...DLE Code Action Duration 1 004003 Saddle Replacement 2 004054 Saddle lock catch Replacement 3 004144 Port and or saddle cover Replace ment 4 004067 Rider backrest Replacement Time MSS X9 Evolution 250 TIME 246 ...

Page 247: ...Locks LOCKS Code Action Duration 1 005016 Key switch Replacement 2 004010 Antitheft lock Replacement 3 002083 Saddle opening transmission Re placement MSS X9 Evolution 250 Time TIME 247 ...

Page 248: ...ation 1 003037 Front wheel rim Replacement 2 003047 Front tyre Replacement 3 004123 Front wheel Replacement 4 003040 Tyre pressure Check 5 002041 Front brake disc Replacement 6 005089 Tone wheel Replacement Time MSS X9 Evolution 250 TIME 248 ...

Page 249: ...02011 movement sen sor replacement and 005089 tone wheel replace ment in the event of noise of the indicated components The grease recommended is TUTE LA MRM 2 soap based lithium grease with Mo lybdenum disulphide In the following points we indicate with an arrow the area to be greased 1 Drive 2 Tone wheel MSS X9 Evolution 250 Time TIME 249 ...

Page 250: ...ervice 6 002070 Rear brake disc Replacement 7 002028 Rear wheel hub Replacement Electric devices ELECTRIC DEVICES Code Action Duration 1 005040 Horn button Replacement 2 005041 Starter button Replacement 3 005039 Headlight switch Replacement 4 005006 Light switch or turn indicators re place 5 005003 Horn Replacement 6 005077 Emergency stop switch Replace ment 7 005084 Emergency light switch Replac...

Page 251: ...HEADLIGHT Code Action Duration 1 005002 Front headlamp change 2 005044 Front lights cable unit replace 3 005008 Front headlamp bulbs Replacement MSS X9 Evolution 250 Time TIME 251 ...

Page 252: ...WIRING WIRE UNIT Code Action Duration 1 005001 Electrical system Removal and re fitting 2 005025 Battery fuse box Replacement Time MSS X9 Evolution 250 TIME 252 ...

Page 253: ...2 005009 Voltage regulator Replacement 3 001023 Control unit Replacement 4 005035 Headlight remote control Replace ment 5 001094 Spark plug cap Replacement 6 001069 HV coil Replacement 7 005075 Stop remote control Replacement MSS X9 Evolution 250 Time TIME 253 ...

Page 254: ...05005 Taillight change 3 005030 Rear telltale light and headlamp ca ble assembly Replacement 4 005066 Rear light bulbs replace 5 004141 Cat s eye Replacement 6 005031 Licence plate light bulb Replace ment 7 005032 Transparent licence plate cover re place Time MSS X9 Evolution 250 TIME 254 ...

Page 255: ...KE CALIPERS Code Action Duration 1 002007 Front brake pads replace 2 002002 Rear brake pads Replacement 3 002039 Front brake calliper Replacement 4 002048 Rear brake caliper Replacement MSS X9 Evolution 250 Time TIME 255 ...

Page 256: ...Fuel tank filler flap TANK PORT FOOTBOARD Code Action Duration 1 004135 Fuel tank lid Replacement 2 004011 Central frame cover replace Time MSS X9 Evolution 250 TIME 256 ...

Page 257: ...Spark plug inspection flap Replace ment 7 004012 Rear fairing Replacement 8 004129 Rear fairing Replacement Steering column STEERING WHEEL Code Action Duration 1 004119 Bearing Steering support fifth wheel Replacement 2 003002 Steering fifth wheel Replacement 3 003073 Steering clearance Adjust 4 003051 Fork assembly Replacement 5 003079 Fork stem Replacement 6 003048 Fork oil seal Replacement MSS ...

Page 258: ...005033 Glove box light switch Replace ment 2 005026 Helmet compartment light Replace ment 3 005027 Helmet compartment bulb support Replacement 4 004142 electric socket Replacement 5 004016 Helmet compartment Replacement Time MSS X9 Evolution 250 TIME 258 ...

Page 259: ...Rear side fairings REAR MUDGUARD Code Action Duration 1 004009 Rear mudguard Replacement 2 005048 Licence plate holder Replacement MSS X9 Evolution 250 Time TIME 259 ...

Page 260: ...ONDARY AIR HOUSING Code Action Duration 1 001162 Secondary air housing Replace ment 2 001161 Secondary air filter Replacement Cleaning 3 001174 SAS valve Replacement 4 001163 SAS valve Head connection Re placement 5 001164 Crankcase secondary air connection Replacement Time MSS X9 Evolution 250 TIME 260 ...

Page 261: ...MSS X9 Evolution 250 Time TIME 261 ...

Page 262: ...urettor 12 35 144 155 231 E Engine oil 39 Engine stop F Fuel 49 144 209 239 256 Fuses 69 H Headlight 206 Horn Hub oil 38 I Identification 8 M Maintenance 7 32 O Oil filter 225 S Saddle Shock absorbers 179 Spark plug 37 64 Stand Start up T Tank 209 211 239 240 256 Transmission 9 50 81 95 Tyres 11 ...

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