Page 1 WORKSHOP MANUAL 618153 MSS X9 Evolution 250...
Page 2: Workshop Manual
Not all versions/models shown in this publication are available in all countries. The availability of each model should be checked at the official Piaggio sales network. "© Copyright 2008 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication in whole or in part is prohibited."...
Page 3 MSS X9 Evolution 250 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio- Gilera dealers. This manual is addressed to Piaggio service mechanics who are supposed to have a basic knowledge of mechanics principles and of vehicle fixing techniques and procedures.
Page 5: Index Of Topics
INDEX OF TOPICS PRE DE DELIVERY ECHNICAL TOOL OOLING MAIN AINTENANCE TROUBL ROUBLESHOOTING ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE SUSP USPENSIONS BRAK SYS RAKING SYSTEM COOL SYS OOLING SYSTEM CHAS HASSIS TIME...
Page 6 INDEX OF TOPICS PRE DE DELIVERY...
Page 7 MSS X9 Evolution 250 Pre-delivery Carry out the listed tests before delivering the vehicle. Warning - Handle fuel with care. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Locking check - Safety fasteners...
Page 8 MSS X9 Evolution 250 Pre-delivery - Horn - Starter 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.
Page 9: Static Test
MSS X9 Evolution 250 Pre-delivery Static test Static control after the test drive: - Warm start - Starter operation - Minimum holding (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
Page 10 INDEX OF TOPICS ECHNICAL...
Page 11: Safety Rules
Maintenance rules - Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or non-conforming spare parts may damage the vehicle. - Use only the appropriate tools designed for this vehicle.
Page 12: Vehicle Identification
Chassis prefix: ZAPMXXXX > XXXXXX Engine prefix: M23XM Engine Data ble> Characteristics Version 250 Type Single-cylinder, 4 stroke and 4 valves Piaggio QUASAR with secondary air sys- tem and catalytic converter. Cooling system Liquid Number of cylinders Bore 72 mm Stroke...
Page 13: Dimensions And Mass
MSS X9 Evolution 250 Technical Data Kehin Carburettor 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.
Page 14: Electric Components
MSS X9 Evolution 250 Technical Data Gas control transmission fixing Please take note that starting from the frame num- ber ZAPM2300004502417, the gas control trans- mission fixing has been changed, in fact a tear-off clamp and a sheath have been introduced, in order...
Page 15: Wheels And Tyres
MSS X9 Evolution 250 Technical Data • N°2 nuts drawing 968224 Brakes BRAKES Specification Desc./Quantity Front Twin disc in stainless steel Ø 240 mm with dual-piston floating calliper Ø 25.4 mm (front right and left) Rear Ø 240 mm stainless steel disc with Brembo "Serie Oro" floating calliper with Ø...
Page 16 MSS X9 Evolution 250 Technical Data manifold that cuts the air inlet in deceleration, to avoid explosions in the muffler. System description: Air is sucked in through the hole "B" and gets through the tube into the filter housing "C" where the filtering element "D"is.
Page 17: Tightening Torques
MSS X9 Evolution 250 Technical Data Specification Desc./Quantity Tapered pin stamping NDWA Minimum mixture set screw initial opening ± ¼ Throttle valve spring 150 ÷ 250 g Minimum air jet Minimum jet Max. jet Starter air jet Ø 1.5 (body) Starter diffuser nozzle Ø...
Page 18 MSS X9 Evolution 250 Technical Data Name Torque in Nm Fork plate screw 25 ÷ 34 CHASSIS Name Torque in Nm Centre stand bolt 25 - 30 Frame arm-engine arm bolt 60 ÷ 64 Swinging arm buffer nut 20 ÷ 25 Frame-swinging arm bolt 66 ÷...
Page 19 MSS X9 Evolution 250 Technical Data Name Torque in Nm Spark plug 12 to 14 LUBRICATION Name Torque in Nm Hub oil drainage plug 15 to 17 Oil filter on crankcase fitting 27 - 33 Engine oil drainage plug/ mesh filter...
Page 20: Piston Rings
MSS X9 Evolution 250 Technical Data Piston rings EALING RINGS Name Description Dimensions Initials Quantity Compression ring 72 x 1.5 0.15 - 0.30 Oil scraper ring 72 x 1 0.20 - 0.40 Oil scraper ring 72 x 2.5 0.20 - 0.40...
Page 21 MSS X9 Evolution 250 Technical Data Crankcase - crankshaft - connecting rod Characteristic Driving shaft / crankcase axial clearance A= 0,15 ÷ 0,43 (when cold) RANKSHAFT Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine Crankshaft Axial clearance between crankshaft and connecting rod...
Page 22 MSS X9 Evolution 250 Technical Data Slot packing system N.B. MEASUREMENT "A" TO BE TAKEN IS A VAL- UE OF PISTON RE-ENTRY, IT INDICATES BY HOW MUCH THE PLANE FORMED BY THE PIS- TON CROWN FALLS BELOW THE PLANE FORMED BY THE TOP OF THE CYLINDER. THE...
Page 23: Index Of Topics
INDEX OF TOPICS TOOL OOLING...
Page 24: Attrezzatura Specifica
MSS X9 Evolution 250 Tooling ATTREZZATURA SPECIFICA Stores code Description 020151Y Air heater 020331Y Digital multimeter 020333Y Single battery charger 020334Y Multiple battery charger 001467Y014 Calliper to extract ø 15-mm bearings TOOL - 24...
Page 25 MSS X9 Evolution 250 Tooling Stores code Description 020412Y 15-mm guide 020335Y Magnetic mounting for dial gauge 020565Y Flywheel lock calliper spanner 020439Y 17-mm guide 020359Y 42 x 47 mm Adaptor 020363Y 20-mm guide TOOL - 25...
Page 26 MSS X9 Evolution 250 Tooling Stores code Description 020459Y Punch for fitting the bearing on the steer- ing tube 020458Y Puller for lower bearing on steering tube 005095Y Engine support 008564Y Flywheel extractor 020434Y Union for oil pressure measurement 020382Y011...
Page 27 MSS X9 Evolution 250 Tooling Stores code Description 020424Y Driven pulley roller casing fitting punch 020431Y Valve oil seal extractor 020193Y Oil pressure gauge 020306Y Punch valve seal rings fitting 020360Y 52 x 55 mm adaptor 020364Y 25-mm guide TOOL - 27...
Page 28 MSS X9 Evolution 250 Tooling Stores code Description 020375Y 28 x 30 mm adaptor 020376Y Adaptor handle 020444Y Tool for installing/removing clutch on/ from driven pulley 020330Y Stroboscopic light to check timing 001467Y035 Bearing housing, external ø 47 mm 020368Y...
Page 29 MSS X9 Evolution 250 Tooling Stores code Description 020319Y Immobilizer check tester 020287Y Clamp for fitting piston on cylinder 020263Y Driven pulley assembly sheath 020262Y Crankcase splitting plate 020430Y Tool for fitting the pin snap rings 020428Y Piston position check mounting...
Page 30 MSS X9 Evolution 250 Tooling Stores code Description 020426Y Piston fitting fork 020425Y Punch for flywheel-side oil seal 020423Y Driven pulley lock wrench 020414Y 28-mm guide 020393Y Piston fitting ring 020382Y Valve cotters equipped with part 012 re- moval tool...
Page 31 MSS X9 Evolution 250 Tooling Stores code Description 020455Y 10-mm guide 020442Y Pulley lock wrench 020329Y Mity-Vac vacuum pump 020357Y 32 x 35-mm Adaptor 020456Y Ø 24 mm adaptor 020332Y Digital rpm indicator TOOL - 31...
Page 32 MSS X9 Evolution 250 Tooling Stores code Description 020074Y Support base for checking crankshaft alignment 020055Y Wrench for steering tube ring nut 002465Y Calliper for circlips 001330Y Tool for fitting steering seats 020454Y Tool for fitting the pin snap rings (200 -...
Page 33 MSS X9 Evolution 250 Tooling Stores code Description 020444Y011 adapter ring 020444Y009 wrench 46 x 55 001467Y Extractor for bearings for holes 001467Y013 Calliper to extract ø 15-mm bearings 020444Y010 adapter ring 020628Y Water pump service kit TOOL - 33...
Page 34: Maintenance
INDEX OF TOPICS MAIN AINTENANCE...
Page 35: Maintenance Chart
MSS X9 Evolution 250 Maintenance Maintenance chart Safety tightenings: refer to the chapter "Predelivery Operations" AT 1000 KM OR 4 MONTHS Action Engine oil - change Hub oil - change Engine oil filter - change Idle speed (*) - adjustment...
Page 36 MSS X9 Evolution 250 Maintenance (*) See rules in the «Adjusting the engine idle» section AT 18000 KM AND AT 54000 KM Action engine oil- change(125) Hub oil level - control Spark plug / electrode gap - check Air filter - cleaning...
Page 37: Every 2 Years
MSS X9 Evolution 250 Maintenance AT 36000 KM Action Engine oil - change Hub oil level - control Spark plug / electrode gap - check / replacement Air filter - cleaning Engine oil filter - change valve clearance 125 - check...
Page 38: Recommended Products
MSS X9 Evolution 250 Maintenance Action Secondary air filter (external/internal) - cleaning (125) EVERY 3,000 KM Action Engine oil - level check/ top-up Recommended products RODUCTS Product Description Specifications Calcium based grease Calcium grease Smooth-textured appearance; Ivory col- oured Specification TL 9150 066, symbol...
Page 39: Specific Tooling
MSS X9 Evolution 250 Maintenance 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).
Page 40 MSS X9 Evolution 250 Maintenance Spark advance variation Characteristic Operation threshold First threshold: 9600±50 Second threshold: 9800±50 Reactivation threshold First threshold: 9500±50 Second threshold: 9700±50 Spark elimination First threshold: 1 spark on 7 Second threshold: 2 sparks on 3 MAIN - 40...
Page 41: Spark Plug
MSS X9 Evolution 250 Maintenance Spark plug To inspect the spark plug the engine must be cold; proceed as follows: - Remove the saddle after loosening the knob lo- cated into the rear trunk. - Remove the spark plug cap.
Page 42: Air Filter
MSS X9 Evolution 250 Maintenance - Extract the bar and check that the oil level reaches the second notch of the bar from the bottom. - Screw the oil bar back on, checking that it is tightly in place. Recommended oil: TUTELA ZC 90 Tightening torque: Drainage cap: 15 - 17 N·m...
Page 43: Engine Oil
MSS X9 Evolution 250 Maintenance CAUTION WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE TABLE. Engine oil Replacement - Loosen the oil loading cap/bar. - Loosen the network filter unloading cap «A» on the flywheel side and let the oil drain out com- pletely.
Page 44: Checking The Ignition Timing
MSS X9 Evolution 250 Maintenance Engine oil top-up The oil should be topped up after having checked the level and in any case by adding oil without ever exceeding the MAX. level. Restoration of the level from MIN to MAX requires approximately 200 cm³.
Page 45: Cooling System
MSS X9 Evolution 250 Maintenance Intake: 0.10 mm (when cold) Exhaust: 0.15 mm (when cold) Cooling system Level check The engine is cooled by forced liquid circulation. The cooling circuit holds 1.8 litres of a coolant made up of 50% demineralised water and a solu- tion of glycol-ethylene anti-freeze and corrosion inhibitors.
Page 46: Braking System
MSS X9 Evolution 250 Maintenance expansion tank is completely dry, the cooling sys- tem needs to be investigated. The coolant must be replaced every 2 years. WARNING TO AVOID THE RISK OF SCALDING, DO NOT UNSCREW THE EXPANSION TANK COVER WHILE THE ENGINE IS STILL HOT.
Page 47 MSS X9 Evolution 250 Maintenance CO check Preparing the vehicle - Remove the 2 bottom sides as explained in the Body chapter. - Remove the 3 fastening screws of the filter box. - Remove the filter box to access the 6 screws M6 closing the crankcase and the heat guard plate at- tachments.
Page 48 MSS X9 Evolution 250 Maintenance OTHERWISE, CHECK THE FUEL LEVEL ADJUSTMENT IN THE TANK AND THE FUEL CIRCUIT. N.B. ALSO CHECK THE CARBURETION ADJUSTMENT IS OB- TAINED WITH THE FLOW SCREW OPEN BETWEEN 2 AND 4 TURNS. N.B. CHECK THAT THE RESULT IS OBTAINED WITH THE VALVE GAS IN CLOSED POSITION.
Page 49: Index Of Topics
INDEX OF TOPICS TROUBL ROUBLESHOOTING...
Page 50: Difficult Starting
MSS X9 Evolution 250 Troubleshooting This section makes it possible to find what solutions to apply when troubleshooting. For each failure, a list of the possible causes and pertaining operations is given. Engine Poor performance POOR PERFORMANCE Possible Cause Operation The carburettor is dirty;...
Page 51 MSS X9 Evolution 250 Troubleshooting Possible Cause Operation connect the cap to the spark plug, and this in turn to the ground. If the fuel tank is empty, refuel and start up. Automatic starter failure Check: mechanical movement, electric connection and fuel supply, replace if required.
Page 52: High Fuel Consumption
MSS X9 Evolution 250 Troubleshooting Engine tends to cut-off at idle ENGINE STOP IDLING Possible Cause Operation Incorrect timing Time the system and check the timing system components Cut off device failure Check that the following parts work properly: valve; diaphragm;...
Page 53 MSS X9 Evolution 250 Troubleshooting Transmission and brakes Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE Possible Cause Operation Faulty clutch Check that there is no grease on the masses. Check that the clutch mass contact surface with the bell is mainly in the centre with equivalent characteristics on the three masses.
Page 54: Turn Indicators Not Working
MSS X9 Evolution 250 Troubleshooting We inform you that a plug has been introduced starting with frame number ZAPM2300004501445 in order to prevent the possibile wear of the battery due to its rubbing against the rivets of the helmet compartment.
Page 55: Electrical System
INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
Page 56: Electric System Diagram
MSS X9 Evolution 250 Electrical system ELECTRIC SYSTEM DIAGRAM Specification Desc./Quantity Front left direction indicator 1 bulb 12V - 10W Outside temperature sensor Combined brake stop button Light switch Turn indicator switch Horn button Emergency flashing button "Reset" button Front fuse-box...
Page 57 MSS X9 Evolution 250 Electrical system Specification Desc./Quantity Digital instrument unit Front headlight N° 2 position bulbs 12V - 5W, N° 1 dipped beam bulb 12V- 55W, N° 1 upper beam bulb 12V - 55W Wheel RPM sensor Front brake stop button...
Page 58: Ignition Section
MSS X9 Evolution 250 Electrical system Ignition IGNITION SECTION Specification Desc./Quantity Pick-up Magneto flywheel Key switch contacts Electronic controller Spark plug H.V. coil Immobilizer aerial Voltage regulator Voltage regulator Diagnostic tester outlet Fuse Immobilizer LED Battery 12V-12Ah ELE SYS - 58...
Page 59 MSS X9 Evolution 250 Electrical system Headlights and automatic starter section HEADLIGHTS AND AUTOMATIC STARTER SECTION Specification Desc./Quantity Electronic control unit Voltage regulator Battery 12V 12Ah Automatic starter Key switch contacts Light switch Light switch Light remote control Fuse (headlight remote control protection)
Page 60 MSS X9 Evolution 250 Electrical system Battery recharge and starting BATTERY RECHARGE AND START-UP Specification Desc./Quantity Key switch contacts Magneto flywheel Fuse Start-up relay Voltage regulator Starter motor Battery 12V-12Ah Start-up enable and front stop button Start-up enable and rear stop button...
Page 61 MSS X9 Evolution 250 Electrical system Level indicators and enable signals section LEVEL INDICATORS AND ENABLE SIGNALS Specification Desc./Quantity Digitsl instrument Analogue instrument unit Thermistor Outside temperature sensor Wheel RPM sensor Fuel level transmitter Oil pressure sensor "Reset" button Emergency button...
Page 62: Turn Signal Lights
MSS X9 Evolution 250 Electrical system Specification Desc./Quantity Battery 12V - 12Ah Thermal switch Please be advised that from frame N. ZAPM2300003507739 (X9) ZAPM3620000003383 (X8) ZAPM2850000001025 (Beverly), a new thermal switch was introduced in order to prevent possible electric fan malfunctions.
Page 63: Checks And Inspections
MSS X9 Evolution 250 Electrical system Specification Desc./Quantity Fuse 15 A Checks and inspections Immobiliser The electric ignition system is fed with direct cur- rent and is protected by an antitheft immobilizer integrated to the control unit. The ignition system consists of:...
Page 64 MSS X9 Evolution 250 Electrical system - There is battery voltage between the terminal No. 4 (Red/Black) and terminal No. 8 (Negative) as shown in the figure. If no voltage is detected, check the wiring to the battery positive lead and see if the 15A fuse is in good conditions (see the start-up diagram) - There is battery voltage between terminals No.
Page 65: Diagnostic Codes
MSS X9 Evolution 250 Electrical system Sequence and times must be strictly observed or it will be necessary to repeat the procedure from the start. Once the control unit has been programmed, the control unit is inseparably matched with the MAS- TER key transponder.
Page 66: Ignition Circuit
MSS X9 Evolution 250 Electrical system When the 2-flash code is detected, carry out the following checks: - Check if the failure continues after changing key (MASTER key included). If the failure persists with any key, disconnect the aerial connector from the control unit and check the aerial continuity with the 020331Y multimeter.
Page 67 MSS X9 Evolution 250 Electrical system The Pick-Up is connected to the control unit by a single cable; then, for the ground circuit, the control unit is connected to the Pick-Up by the chassis and the engine ground lead. To avoid disturbances in the ignition system during start-up, it is very important that the engine-chassis ground connection bonding is efficient.
Page 68 MSS X9 Evolution 250 Electrical system HV coil secondary check Disconnect the spark plug cap from the HV cable and measure the resistance between the HV cable terminal and the HV coil negative terminal (see figure). If non-conforming values are measured, replace the HV coil.
Page 69: Stator Check
MSS X9 Evolution 250 Electrical system High voltage coil voltage value High voltage coil voltage value: > 100 Volt Stator check Disconnect the connector from the voltage regulator and check there is continuity between any yellow cable and the other two cables.
Page 70 MSS X9 Evolution 250 Electrical system VALUES ARE STATED AT AMBIENT TEMPERATURE. A CHECK WITH THE STATOR AT OPERATING TEMPERA- TURE MAY RESULT IN VALUES HIGHER THAN THOSE STATED. Voltage regulator check With a perfectly charged battery and lights off, measure voltage at the battery poles with a high running engine.
Page 71 MSS X9 Evolution 250 Electrical system Choke Inspection Refer to the engine section to check the resistance and operating conditions of the component. As re- gards voltage supply, keep the connector connec- ted to the system and check that the two terminals receive battery voltage when the engine is on (see figure).
Page 72 MSS X9 Evolution 250 Electrical system Stop lights 12V-2,3W x 5 Rear position lights 12V-5W x 2 Front turn indicator bulbs Front turn indicator bulbs 12V-10W x 2 Front position lights 12V-5W x 2 Upper beam light 12V-55W Dipped beam light...
Page 73 MSS X9 Evolution 250 Electrical system USES Specification Desc./Quantity Helmet compartment, 12-V socket 15 A General (battery recharge, lights, radiator electric fan, 15 A electronic control unit). Headlight (upper and dipped beams). 10 A Digital instrument panel 7.5 A Dashboard Vehicle X9 is provided with an instrument panel divided into 2 sections: the analogue section is fixed into the cap while the digital section is integral to the handlebar.
Page 74 MSS X9 Evolution 250 Electrical system A: Fitting for indicator light * B: Fitting for indicator light * C: Fitting for indicator light * D: Engine disabled E: Oil pressure F: Fuel reserve G: Position and dipped beam lights: green coloured...
Page 75 MSS X9 Evolution 250 Electrical system To reset one of the icons, press the «Reset» button for less than a second, then on the icon before that to be reset press «Reset» for at least 3" so as to display: - The selectionj of the desired icon through the relevant solid light.
Page 76 MSS X9 Evolution 250 Electrical system Besides upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if re- quired, before storing the vehicle and afterwards every six months. INSTRUCTIONS FOR THE BATTERY REFRESH AFTER OPEN-CIRCUIT STORAGE 1) Voltage check Before installing the battery on the vehicle, check the open circuit voltage with a standard tester.
Page 77 MSS X9 Evolution 250 Electrical system - Let it stand until ambient temperature is reached again (this phase may require up to 60 minutes). - Slightly tilt the battery to favour the removal of any air bubbles, then restore the levels using the same electrolyte.
Page 78 MSS X9 Evolution 250 Electrical system Dashboard WAY INSTRUMENT CONNECTOR Specification Desc./Quantity BATTERY POSITIVE LEAD (+30) BATTERY POSITIVE LEAD (+30) SPEEDOMETER SENSOR POWER SUPPLY SPEEDOMETER SENSOR POWER SUPPLY SPEEDOMETER SENSOR BACK TO GROUND SPEEDOMETER SENSOR BACK TO GROUND REVOLUTION SENSOR INPUT...
Page 79 MSS X9 Evolution 250 Electrical system Specification Desc./Quantity TURN INDICATOR OFF SWITCH INPUT TURN INDICATOR OFF SWITCH INPUT RESET SERVICE MANAGEMENT BUTTON INPUT RESET SERVICE MANAGEMENT BUTTON INPUT WATER TEMPERATURE SENSOR INPUT WATER TEMPERATURE SENSOR INPUT FUEL LEVEL SENSOR INPUT...
Page 80: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
Page 81 MSS X9 Evolution 250 Engine from vehicle Removal of the engine from the vehicle - Remove the saddle and the side covers, - Drain engine oil and coolant, - Disconnect the battery, - Remove the muffler assembly, - Remove the rear wheel,...
Page 82 MSS X9 Evolution 250 Engine from vehicle - Remove the nut shown in the figure, then take out the pin. The engine is now free. - Carry out the removal operations but in reverse order, observing the prescribed tightening torques.
Page 83 INDEX OF TOPICS NGINE...
Page 84: Automatic Transmission
MSS X9 Evolution 250 Engine Automatic transmission Transmission cover - To remove the transmission cover it is necessary to remove the plastic cover first, by inserting a screwdriver in the slotted holes. Using the clutch housing lock wrench shown in the figure, remove the driven pulley shaft locking nut and washer.
Page 85 MSS X9 Evolution 250 Engine - To remove the intake throat on the transmission cover, just remove the 3 fixing screws indicated in the figure. Removing the driven pulley shaft bearing - Remove the clip from the inside of the cover.
Page 86 MSS X9 Evolution 250 Engine Plastic roller - Check that the roller does not show signs of wear and that it turns freely. - Remove the special clamping screws as indica- ted in the picture - Check the outer diameter of the roller does not...
Page 87 MSS X9 Evolution 250 Engine Inspecting the clutch drum - Make sure that the clutch housing is not worn or damaged. - Measure the clutch housing inside diameter. Characteristic Clutch housing max. value Max. value: Ø 134.5 mm clutch housing standard value Standard value: Ø...
Page 88: Removing The Clutch
MSS X9 Evolution 250 Engine Removing the clutch Fit the driven pulley spring compressor specific tool with medium length pins screwed in position «C» on the tool internal side. - Introduce the adapter ring 11 with the chamfering facing the inside of the tool.
Page 89 MSS X9 Evolution 250 Engine 1 mm Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. N.B. USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL- N.B. BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O-RING SEAL.
Page 90 MSS X9 Evolution 250 Engine - Support the pulley properly using the bell as shown in the figure. Specific tooling 001467Y035 Bearing housing, external ø 47 - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø...
Page 91 MSS X9 Evolution 250 Engine Inspecting the driven sliding half-pulley - Remove the two seal rings and the two O-rings - Measure the movable half-pulley bushing inside diameter. - Check the contact surface with the belt to make sure there are no flaws.
Page 92 MSS X9 Evolution 250 Engine 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020424Y Driven pulley roller casing fitting punch Refitting the driven pulley - Insert the new oil seals and O-rings on the mov- able half-pulley. - Lightly grease the O-rings «A» shown in the fig- ure.
Page 93 MSS X9 Evolution 250 Engine Inspecting the clutch spring - Measure the free length of the mobile driven half- pulley spring. Characteristic Standard length (200 - 250) 123 mm Limit after use (200 - 250) 118 mm Refitting the clutch - Support the driven pulley spring compressor spe- cific tool with the control screw in vertical axis.
Page 94 MSS X9 Evolution 250 Engine - Lock the driven pulley again using the specific tool. - Preload the clutch return spring with a traction/ rotation combined action and place the belt in the smaller diameter rolling position. - Remove the driven pulley /belt unit from the tool.
Page 95: Removing The Driving Pulley
MSS X9 Evolution 250 Engine Drive-belt - Check that the driving belt is not damaged. - Check the belt width. Characteristic 250 four stroke Transmission belt - minimum width 19.5 mm 250 four stroke Transmission belt - standard width 21.3 ± 0.2 mm During the wear checks foreseen in the scheduled maintenance services at 6000 km, 18000 km, etc.,...
Page 96 MSS X9 Evolution 250 Engine - Insert the tool in the hollows and apply the reten- tion ring - Bring in the ring's clamping screws while keeping the tool to support the pulley Specific tooling 021021Y Driving pulley lock wrench...
Page 97 MSS X9 Evolution 250 Engine movable driving half-pulley bushing: Maxi- mum allowable diameter Ø 26.12 mm Sliding bushing: Standard Diameter Ø 25.959 - 25.98 mm Sliding bushing: Minimum diameter permitted Ø 25.95 mm Roller: Standard Diameter Diameter 20.5 - 20.7 mm Roller: Minimum diameter permitted Ø...
Page 98 MSS X9 Evolution 250 Engine Refitting the transmission cover - Check that there are 2 alignment dowels and that the sealing gasket for the oil sump on the trans- mission cover is adequately fitted. - Replace the cover and tighten the 10 screws to the specified torque.
Page 99 MSS X9 Evolution 250 Engine Removing the wheel axle - Remove the wheel axis complete with gear. - Remove the intermediate gear. Removing the hub bearings - Check the state of the bearings being examined (wear, clearance and noisiness). If faults are de- tected, do the following.
Page 100 MSS X9 Evolution 250 Engine Removing the wheel axle bearings - Take out the clip on the outside of the hub cover. - Support the hub cover and expel the bearing. By means of the appropriate tools, remove the oil seal as in the figure.
Page 101 MSS X9 Evolution 250 Engine Inspecting the hub shaft - Check the three shafts for wear or distortion of the toothed surfaces, the bearing housings, and the oil seal housings. - If faults are found, replace the damaged compo- nents.
Page 102 MSS X9 Evolution 250 Engine Refitting the hub cover bearings - To fit the hub housing bearings, the engine crank- case and the cover must be heated with the spe- cial heat gun. - The three 15 mm bearings must be fitted using the appropriate tools.
Page 103 MSS X9 Evolution 250 Engine 020363Y 20-mm guide Refitting the hub bearings - Assemble the 3 shafts in the engine crankcase as shown in the figure. Refitting the ub cover - Fit a new gasket together with the alignment dowels.
Page 104: Flywheel Cover
MSS X9 Evolution 250 Engine Flywheel cover Removing the hub cover - Remove the clip fixing the sleeve to the cylinder. - Remove the 10 clamps - Remove the flywheel cover. ENG - 104...
Page 105: Removing The Stator
MSS X9 Evolution 250 Engine Removing the stator - Remove the two pick-up screws and the screw holding the wiring support and the three stator clamping screws shown in the figure. - Remove the stator and its cable harness. Refitting the stator...
Page 106: Removing The Starter Motor
MSS X9 Evolution 250 Engine - Orient the water pump shaft with reference to the transmission gear seat as shown in the picture. - Refit the cover over the engine and tighten the screws to the prescribed torque. - Carry out the removal steps but in the reverse order.
Page 107: Specific Tooling
MSS X9 Evolution 250 Engine - Line up the two holes in the flywheel as shown in the picture - Screw in the guide bushing that is part of the special flywheel stop tool on the flywheel as shown in the picture...
Page 108 MSS X9 Evolution 250 Engine - Apply the recommended product to the end of the screws. Recommended products Loctite 243 Medium strength thread-locking sealant. Blue - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e.
Page 109: Removing The Intake Manifold
MSS X9 Evolution 250 Engine - Insert the free wheel on the flywheel as shown in the picture - Then refit the flywheel with free wheel and trans- mission gear - Using the special flywheel lock wrench, tighten up the flywheel fixing nut to the prescribed torque...
Page 110: Removing The Rocker-Arms Cover
MSS X9 Evolution 250 Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - First remove the parts listed below: transmission cover, drive pulley with belt, oil sump with spring...
Page 111 MSS X9 Evolution 250 Engine - Loosen the central screw on the tensioner first. - Remove the two fixings shown in the figure. - Remove the tensioner with its gasket. - Remove the internal hex screw and the counter- weight shown in the figure.
Page 112: Removing The Cam Shaft
MSS X9 Evolution 250 Engine Removing the cam shaft - Remove the 2 screws and the camshaft retainer shown in the diagram. - Remove the camshaft. - Remove the pins and the rocking levers from the flywheel side holes. N.B.
Page 113: Removing The Cylinder Head
MSS X9 Evolution 250 Engine Removing the cylinder head - Remove the spark plug. - Remove the 2 side retainers indicated in the fig- ure. - Loosen the 4 head-cylinder fixing nuts in two or three stages and in a criss-cross sequence.
Page 114 MSS X9 Evolution 250 Engine TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER. N.B. BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL. Inspecting the small end - Measure the internal diameter of the connecting rod small end using an internal micrometer.
Page 115 MSS X9 Evolution 250 Engine Inspecting the wrist pin - Measure the outer diameter of the gudgeon pin. - Calculate the coupling clearance between pin and connecting rod small end. Characteristic Pin diameter: Standard clearance 0.015 - 0.029 mm Pin diameter Standard diameter 14.996 - 15.000 mm...
Page 116 MSS X9 Evolution 250 Engine piston diameter 71.953 - 71.981 mm Fitting clearance 1st compression ring - standard coupling clearance 1st compression ring - 0.015 - 0.06 mm maximum clearance allowed after use 0.07 mm 2nd compression ring - standard coupling...
Page 117: Removing The Piston
MSS X9 Evolution 250 Engine Inspecting the piston rings Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing to- wards the exhaust. - Fit the wrist pin stop ring onto the appropriate tool...
Page 118 MSS X9 Evolution 250 Engine Choosing the gasket - Provisionally fit the piston into the cylinder, without any base gasket. - Assemble a dial gauge on the specific tool - Set the dial gauge to zero placing the tool on a contrasting surface. Keeping the zero position, as- semble the tool on the cylinder and lock it with 2 supplied nuts as shown in the figure.
Page 119 MSS X9 Evolution 250 Engine ENG - 119...
Page 120 MSS X9 Evolution 250 Engine Refitting the piston rings Fitting the sealing rings - Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the piston crown.
Page 121: Inspecting The Cylinder Head
MSS X9 Evolution 250 Engine Inspecting the cylinder head - Using a trued bar and a feeler gauge, check that the cylinder head surface is not worn or distorted. Maximum allowable run-out: 0.05 mm - Check that the camshaft and the rocking lever pin capacities exhibit no wear.
Page 122 MSS X9 Evolution 250 Engine Inspecting the timing system components - Check that the guide slider and the tensioner slider are not worn out. - Ensure that the camshaft control pulley chain as- sembly and the sprocket wheel are not worn.
Page 123 MSS X9 Evolution 250 Engine Inspecting the valve housings - Check the width of the imprint on the valve seat«V» wear limit Max. 1.6 mm. - Remove any carbon formation from the valve guides. - Measure the inside diameter of each valve guide.
Page 124 MSS X9 Evolution 250 Engine - Calculate the clearance between valve and valve guide. - Check that there are no signs of wear on the faying surface with the articulated set screw terminal. - If no anomalies are found during the above checks, you can use the same valves. For best sealing results, it is advisable to grind the valves.
Page 125 MSS X9 Evolution 250 Engine Inspecting the springs and half-cones - Check that the upper spring caps and the cotter halves show no signs of abnormal wear. ENG - 125...
Page 126: Inspecting The Cam Shaft
MSS X9 Evolution 250 Engine Refitting the valves - Lubricate the valve guides with engine oil. - Place the valve spring supports on the head. - Using the special punch, fit the four valve seal rings. - Fit the valves, the springs and the caps. Using the appropriate tool with adapter, compress the springs and insert the cotters in their seats.
Page 127 MSS X9 Evolution 250 Engine - Measure the internal diameter of each rocking lever. Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. Characteristic Rocking lever inside diameter: Standard diam- eter Ø...
Page 128 MSS X9 Evolution 250 Engine - Tighten up the nuts to a second pre-torque of 10 ±1 N·m - Rotate by an angle of 270° - To carry out the operations described above, fol- low the tightening sequence in the figure.
Page 129 MSS X9 Evolution 250 Engine - Holding this position insert the chain on the cam- shaft control pulley. - Insert the pulley on the camshaft while keeping the reference 4V in correspondence with the ref- erence mark on the head.
Page 130 MSS X9 Evolution 250 Engine ENG - 130...
Page 131: Crankcase - Crankshaft
MSS X9 Evolution 250 Engine Refitting the rocker-arms cover - Refit the cylinder head cover and tighten the 5 clamping screws to the specified 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.
Page 132 MSS X9 Evolution 250 Engine - Remove the two screws and the internal shield shown in the diagram. - Remove the oil seal on the flywheel side. - Remove the oil filter fitting shown in the diagram. - Check the axial clearance on the connecting rod.
Page 133 MSS X9 Evolution 250 Engine 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...
Page 134 MSS X9 Evolution 250 Engine 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.
Page 135 MSS X9 Evolution 250 Engine cylinder head and the oil drainage duct at the fly- wheel side oil seal. - Inspect 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.
Page 136 MSS X9 Evolution 250 Engine - The main bushings are comprised of two half- bearings, one with holes and channels for lubrica- tion whereas the other is solid. - The solid half-bearing is intended to stand the thrusts caused by combustion, and for this reason it is arranged opposite the cylinder.
Page 137 MSS X9 Evolution 250 Engine Bushing Crankcase Internal bushing Possible fit- category halves cat- diameter after fit- ting egory ting 29.025 - 29.040 Original 29.019 - 29.034 Original and 29.028 - 29.043 spare 29.022 - 29.037 Original Match the shaft with two category 1 crank webs with the category 1 crankcase (or cat.
Page 138 MSS X9 Evolution 250 Engine Refitting the crankcase halves - Fit the internal shield by locking the two screws to the prescribed torque. - Fit the oil filter fitting and tighten it to the prescri- bed torque. - Place a new gasket on one of the crankcase halves, preferably on the transmission side, to- gether with the alignment dowels.
Page 139: Crankshaft Oil Seals
MSS X9 Evolution 250 Engine Crankshaft oil seals Removal - Remove the transmission cover and the com- plete drive pulley beforehand - Install the base of the appropriate tool on the oil seal using the screws provided Specific tooling 020622Y Transmission-side oil seal punch - Screw the threaded bar onto the base of the tool and extract the oil seal.
Page 140 MSS X9 Evolution 250 Engine - Orientate the oil seal by inserting the bracket which is part of the specific tool. - Tighten the threaded bar onto 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.
Page 141: Oil Pump
MSS X9 Evolution 250 Engine Oil pump Removal - Undo the two clamping screws in the figure and remove the cover over the pump control sprocket. - Block the rotation of the oil pump driving pulley by inserting a screwdriver through one of its holes - Remove the central screw with cup washer, as shown in the diagram.
Page 142 MSS X9 Evolution 250 Engine Inspection - Remove the two screws and the oil pump cover. - Remove the cir-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.
Page 143 MSS X9 Evolution 250 Engine - Fit the pump cover in the position that permits the crankcase clamping screws to be aligned. - Make sure the gasket is positioned properly and refit the pump on the engine crankcase. The pump can only be fitted in one position.
Page 144 MSS X9 Evolution 250 Engine 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.
Page 145 MSS X9 Evolution 250 Engine Inspecting the one-way valve - Remove the SAS valve. - Provisionally assemble the rubber sleeve of the SAS valve outlet to ensure tightness. - Connect the MITYVAC vacuum pump to the rub- ber sleeve as shown in the photograph.
Page 146: Fuel Supply
MSS X9 Evolution 250 Engine - Set the pump set to the low-pressure mode (VACUUM). - Using a pair of long flat pliers, choke the rubber hose next to the valve. - Operate the pump until vacuum is higher than 0.5 BAR.
Page 147 MSS X9 Evolution 250 Engine 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 delivery pipe to the diaphragm, and the intake fitting.
Page 148 MSS X9 Evolution 250 Engine - 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.
Page 149 MSS X9 Evolution 250 Engine - Unscrew the bayonet joint 1/8 of a turn and re- move, take out the spring and vacuum valve nee- - Remove the 4 screws indicated in the figure. - Remove the chamber with the accelerating pump, its control and gasket.
Page 150 MSS X9 Evolution 250 Engine 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 -Remove the maximum nozzle.
Page 151 MSS X9 Evolution 250 Engine -Remove diffuser. - Remove the sprayer. N.B. WHEN CLEANING THE CARBURETTOR BODY REMOVE THE SPRAYER TO AVOID LOSING PARTS. IF THE SPRAY- ER IS FORCED IN ITS HOUSING DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
Page 152 MSS X9 Evolution 250 Engine - Remove the 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 INTAKE NOZZLE, MINIMUM AND MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL SHAFT.
Page 153 MSS X9 Evolution 250 Engine 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. N.B. DURING THE REMOVAL OF THE COVER TAKE SPECIAL CARE NOT TO RELEASE THE SPRING ACCIDENTALLY.
Page 154 MSS X9 Evolution 250 Engine Remove the vacuum valve together with the dia- phragm. Unscrew the bayonet joint 1/8 of a turn and re- move, take out the spring and vacuum valve nee- Remove the 4 screws shown in the figure.
Page 155 MSS X9 Evolution 250 Engine Remove the chamber with the accelerating pump, its control and gasket. Remove the accelerating pump piston from the chamber with the ring nut, the boot, the O-ring and the spring as illustrated in the figure.
Page 156 MSS X9 Evolution 250 Engine Remove the duct hood of the fuel to the starter jet indicated in the figure. -Remove the maximum nozzle. -Remove diffuser. ENG - 156...
Page 157 MSS X9 Evolution 250 Engine Remove the sprayer. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY. IF THE SPRAYER IS FORCED INTO ITS HOUSING, DO NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAMAGE IT.
Page 158 MSS X9 Evolution 250 Engine Remove the idle flow screw with the O-ring, the washer and the spring. -Remove the 2 fixing screws, the cover, the spring and the cut-off device membrane. CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE...
Page 159 MSS X9 Evolution 250 Engine - For the minimum circuit, make sure the following points are properly cleaned: air gauging, exhaust section 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.
Page 160 MSS X9 Evolution 250 Engine - 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.
Page 161 MSS X9 Evolution 250 Engine - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean. - Operate the acceleration pump piston repeatedly and blow with compressed air.
Page 162 MSS X9 Evolution 250 Engine Walbro - Before refitting, wash the carburettor body accu- rately with petrol and compressed air. - Pay special attention to the fuel supply pipe and the plunger seat. - For maximum circuit, check the air adjustment is correct as shown in the figure.
Page 163 MSS X9 Evolution 250 Engine - For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the nozzle support hides other inaccessible inter- nal calibrations. - Blow the intake nozzle properly. N.B. THE ACCELERATION NOZZLE EXHAUST IS EXTREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE.
Page 164 MSS X9 Evolution 250 Engine Level check Kehin - Place the carburettor inclined as shown in the figure. - Check that the float reference is parallel to the tank coupling surface - If different positions are detected, change the plunger control metal plate direction to obtain the position described above.
Page 165 MSS X9 Evolution 250 Engine - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump intake and supply valve is clean. - Because they are one-way valves, blow softly with compressed air into the intake valve from the side in the chamber and in the housing of the pump piston for the supply valve.
Page 166 MSS X9 Evolution 250 Engine - Adjust the carburettor by turning the screw three times from the close position. - Check that the acceleration pump command rocker is not abnormally worn. - Check that the rocker travel limit screw protrudes 3.2 mm.
Page 167 MSS X9 Evolution 250 Engine N.B. THE VALVE CAN BE INSERTED IN ONLY ONE POSSIBLE POSITION. - Reassemble 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.
Page 168 MSS X9 Evolution 250 Engine - Reassemble the filter with its clamp. - Wash and blow dry the starter support. Assemble a new gasket on the carburettor body and tighten the 2 fixing screws. Walbro - Check that the pin is not worn and that the stop is positioned in the 3rd of 3 notches.
Page 169 MSS X9 Evolution 250 Engine - Check that the membrane is not broken or hard- ened. Otherwise, proceed with replacement. - Refit with the tapered pin on the vacuum valve. - Make sure the spring is positioned correctly on the pin and the joint on the relative seat.
Page 170 MSS X9 Evolution 250 Engine Kehin - Check that the automatic starter piston is not de- formed or rusty. - Check that the piston slides freely from the seat to the support. - Check that the piston sealing gasket is not de- formed.
Page 171 MSS X9 Evolution 250 Engine XX - XX mm at approx. 20°C Check Max. protrusion of Kehin aut. starter XXX - XXX mm Check aut. Kehin Max. time starter 5 Min Walbro - Check that the automatic starter piston is not de- formed or rusty.
Page 172: Adjusting The Idle
MSS X9 Evolution 250 Engine Check the automatic starter: Walbro protru- sion value 12.5 - 13 mm at about 20°C Check Max. protrusion of Walbro aut. starter 18.5 - 19 mm Check Walbro aut. starter Max. time 5 Min Electric characteristic Walbro resistance about 40 Ω...
Page 173 MSS X9 Evolution 250 Engine - If the adjustment of the flow screw causes a rpm increase readjust the revs again and if necessary, the flow screw to reach stable values. - When the oil temperature, the numbers of revs and the percentage of carbon monoxide are re- spected the idle carburetion is considered correct.
Page 174 MSS X9 Evolution 250 Engine Characteristic Idle adjustment: Pipe sizes Ø 40 mm Idle adjustment: length 500 ÷- 600 mm ENG - 174...
Page 175 INDEX OF TOPICS SUSP USPENSIONS...
Page 176: Removing The Front Wheel
MSS X9 Evolution 250 Suspensions This section is dedicated to operations that can be carried out on the suspensions. Front Removing the front wheel Remove the two callipers according to what is de- scribed in the "Braking system" chapter. - Unscrew the wheel axle fixing nut;...
Page 177: Front Fork
MSS X9 Evolution 250 Suspensions Refitting Carry out the above operations by working in the reverse order from that used for removal. Locking torques (N*m) Handlebar fixing screw (*) 43 ÷ 47 Front fork Removal After removing the upper seat, lean the vehicle on one side and extract the steering tube completely from the fork.
Page 178 MSS X9 Evolution 250 Suspensions - Pour 145 cm³ of Selenia Fork 10W oil per stem on the MVP fork, recognisable 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.
Page 179: Steering Bearing
MSS X9 Evolution 250 Suspensions Refitting - Inserire il distanziale - Bloccare la ghiera inferiore alla coppia prescritta. - Inserire l'anello distanziale - Bloccare la ghiera superiore alla coppia prescrit- Specific tooling 020055Y Wrench for steering tube ring nut Locking torques (N*m)
Page 180: Specific Tooling
MSS X9 Evolution 250 Suspensions Removal Remove upper bearing 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 steering bearings from headstock SUSP - 180...
Page 181 MSS X9 Evolution 250 Suspensions Refitting Insert the lower and upper bearing 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...
Page 182: Removing The Rear Wheel
MSS X9 Evolution 250 Suspensions Removing the rear wheel Removal - Unscrew the four fixing screws and remove the muffler and the relevant bracket; - Unscrew the central retaining nut. Reassembly Carry out the previous operations in reverse order. Locking torques (N*m)
Page 183: Centre-Stand
MSS X9 Evolution 250 Suspensions Removal Proceed as follows: - Undo the screw fixing the shock absorber spring unit to the engine (A) on one side and the corre- sponding support (B) on the other; - remove the saddle and the helmet compartment;...
Page 184 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
Page 185: Rear Brake Calliper
MSS X9 Evolution 250 Braking system This section is dedicated to the description of the brake system components. Interventions rules General rules for maintenance operations on the hydraulic braking system. WARNING HYDRAULIC OIL IS CORROSIVE: ALWAYS WEAR PROTECTIVE GLOVES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THE CONTACT AREA WELL WITH COPIOUS AMOUNTS OF WATER.
Page 186: Front Brake Calliper
MSS X9 Evolution 250 Braking system Removal Proceed as follows: - remove the muffler, - repeat the operations above regarding front cal- liper removal. Front brake calliper Removal Proceed as follows: - remove the front wheel; - unscrew the fixing screws and open the oil res- ervoir cover;...
Page 187 MSS X9 Evolution 250 Braking system Overhaul Proceed as follows: 1) remove the two male hexagonal screws (1) and take out the two pads (10); 2) remove the two male hexagonal screws (2) and remove the reaction plate (3); 3) take out the fixed plate (4) from the guide;...
Page 188: Front Brake Disc
MSS X9 Evolution 250 Braking system The body and the reaction plate body work inte- grally and can move axially with respect of the fixed plate that is integral to the strut. The pistons, forced by pressure to push the pad to the disc, cause the reaction plate to push in turn the other pad towards the disc.
Page 189: Front Brake Pads
MSS X9 Evolution 250 Braking system When refitting, position the disc correctly, respect- ing the direction of rotation, and apply medium threadlock. N.B. THE SURFACE OF THE DISC WITH THE STAMPED AR- ROW INDICATING THE DIRECTION OF ROTATION MUST FACE THE SHOCK ABSORBER.
Page 190 MSS X9 Evolution 250 Braking system Removal Proceed as follows: - remove the muffler and rear wheel, following the instructions in the "Rear suspension" Chapter. - remove the two screws indicated in the figure. - remove the stop ring and withdraw the pin.
Page 191: Brake Fluid Level Check
MSS X9 Evolution 250 Braking system IF AIR CONTINUES TO COME OUT DURING THE BLEED OPERATION, EXAMINE ALL THE FITTINGS. IF SAID FIT- TINGS DO NOT SHOW SIGNS OF BEING FAULTY, LOOK FOR THE AIR INPUT AMONG THE VARIOUS SEALS ON THE PUMP AND CALLIPER PISTONS.
Page 192 MSS X9 Evolution 250 Braking system Removal 1) remove the front and rear handlebar covers; 2) placing a suitable container to catch the oil, dis- connect the oil pipe from the calliper and work the brake lever until no more oil comes out;...
Page 193 MSS X9 Evolution 250 Braking system BRAK SYS - 193...
Page 194 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
Page 195: Circuit Diagram
MSS X9 Evolution 250 Cooling system Circuit diagram COOL SYS - 195...
Page 196: Water Pump - Overhaul
MSS X9 Evolution 250 Cooling system Cooling plant We inform you that a tubes case spring has been added starting with frame number ZAPM2300004501449, in order to prevent possi- bile contacts between the pump/radiator tube and the secondary air tube. Place the spring at the dis- tance indicated in the drawing.
Page 197 MSS X9 Evolution 250 Cooling system Install the pin which is part of the specific tool on the press plunger. Direct the flywheel cover in order to allow insertion of the pin into the joint and eject the pump shaft from the bearing joint.
Page 198 MSS X9 Evolution 250 Cooling system Centre the cover in order to allow insertion of the pin and then eject the seal ring and the two ball bearings. Specific tooling 020628Y Water pump service kit Before refitting wash all components and carry out the following checks.
Page 199: Specific Tooling
MSS X9 Evolution 250 Cooling system Shaft: Check that there is no oxidation. Check that the impeller is in good condition. Ceramic seal: Check that the ceramic seals are not clogged, cracked or grooved. Check the integrity of the two rubber gaskets. Check the push spring.
Page 200 MSS X9 Evolution 250 Cooling system Let the flywheel cover cool and then manually fit the static part of the ceramic seal with the relative rubber gasket. N.B. TAKE CARE TO CORRECTLY FIT THE CERAMIC RING. THE CHAMFERED PART OF THE INTERNAL DIAMETER MUST BE FACING THE BEARINGS SIDE.
Page 201 MSS X9 Evolution 250 Cooling system Manually insert the pump shaft into the relative bearings. Keeping the bearings in contact with the support base, align the shaft with the press plunger and proceed with driving. The driving depth is deter- mined by the striking of the punch when it comes into contact with the flywheel cover.
Page 202 MSS X9 Evolution 250 Cooling system Fit the oil seal on the flywheel cover to the depth determined by the punch. Specific tooling 020628Y Water pump service kit Apply the punch to the press plunger with the shape of the driving joint.
Page 203 MSS X9 Evolution 250 Cooling system seal is achieved with the two ceramic surfaces, one static and one in motion, kept in contact with the drive of a coaxial spring at the pump shaft. Correct operation is achieved with careful machining of the ceramic parts and adequate cleaning of the components during fitting.
Page 204 MSS X9 Evolution 250 Cooling system - Warm up the container using the heat gun. - Check the temperature when the thermostat starts to open: - Heat up until the thermostat is completely open - Replace the thermostat if it does not work prop- erly.
Page 205 INDEX OF TOPICS CHAS HASSIS...
Page 206: Front Handlebar Cover
MSS X9 Evolution 250 Chassis This section è is dedicated to the operations that can be carried out on the vehicle's bodywork. Seat - Raise the saddle - Extract the coupling pin of the gas shock absorb- - Unscrew the 3 screws fixing the saddle plate to the centre cover and remove the saddle.
Page 207 MSS X9 Evolution 250 Chassis Headlight assy. - Unscrew the 3 fixing screws; - Disconnect the electric connectors; - Extract the optical unit from the front. Frame central cover - Open the tank door; - Remove the fuel tank cap and the protective rub- - Unscrew the 2 fixing screws located inside of it;...
Page 208 MSS X9 Evolution 250 Chassis Taillight assy. Unscrew the 2 fixing screws of the cover compo- nent of the saddle coupling; - Release it from the rear cover and remove it. - Unscrew the 2 fixing screws indicated on the fig- ure and remove them;...
Page 209: Side Fairings
MSS X9 Evolution 250 Chassis Side fairings - After having removed the panel union element, unscrew the rear screw of the lower panel; - Unscrew the lower screw connecting to the spoil- - Extract the lower side panel by pulling it towards the rear;...
Page 210 MSS X9 Evolution 250 Chassis Helmet bay - Remove all electric devices; - Remove the 4 fuse carrier enclosures; - Free the cables fixed to the frame with the relative support clamps; - Remove the battery; - Unscrew the fixing screws on the rear frame;...
Page 211 MSS X9 Evolution 250 Chassis 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. CHAS - 211...
Page 212: Radiator Fan
MSS X9 Evolution 250 Chassis Radiator fan - Prepare a container for the coolant. - Remove the delivery and reverse pipes of both the expansion tank and the radiator coolant; - Disconnect the connector from the thermostat pipe; - Unscrew the fixing screws and release the radi- ator and the electrical fan.
Page 213 MSS X9 Evolution 250 Chassis Handles and top side fairings - Remove the rubber plugs covering the fixing screws; - Unscrew the socket head screws and remove them; - Remove the passenger handles. - Unscrew the screw under the tail light.
Page 214 MSS X9 Evolution 250 Chassis Front central cover - To disassemble the front centre cover, it is nec- essary to first unscrew the screws «A» shown in the figure (2 per side) and remove them together with the right and left mirrors. You have to remove the rubber cover plugs in order to get to the screws.
Page 215 MSS X9 Evolution 250 Chassis - Unscrew and remove the 2 screws shown in the figure - 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.
Page 216 INDEX OF TOPICS TIME...
Page 217 MSS X9 Evolution 250 Time This section is dedicated to the time necessary to carry out repairs. For each operation, the description, code and time envisages are specified. Engine NGINE Code Action Duration 001001 Engine from chassis - replacement 001127...
Page 218 MSS X9 Evolution 250 Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 218...
Page 219: Cylinder Head Assy
MSS X9 Evolution 250 Time Cylinder assy. YLINDER PISTON PIN UNIT Code Action Duration 001002 Cylinder / Piston - Replacement 001154 Pin ring piston unit - Service Cylinder head assy. VALVE UNIT Code Action Duration 001126 Head - Replacement 001045...
Page 220 MSS X9 Evolution 250 Time Rocker arms support assy. OCKING LEVER SUPPORT UNIT Code Action Duration 001148 Valve rocking levers - Replacement 001044 Camshaft - Replacement TIME - 220...
Page 221: Cylinder Head Cover
MSS X9 Evolution 250 Time Cylinder head cover EAD COVER CHAIN TENSIONER PASS LUBRICATION Code Action Duration 001093 Spark plug - Replacement 001089 Head cover - Replacement 001088 Head cover gasket - Replacement 001074 Oil vapour recovery pipe - Replace-...
Page 222: Oil Filter
MSS X9 Evolution 250 Time Oil filter IL FILTER Code Action Duration 001123 Oil filter -Replacement 001160 Oil pressure sensor - Replacement TIME - 222...
Page 223: Driven Pulley
MSS X9 Evolution 250 Time Driven pulley RIVEN PULLEY Code Action Duration 001022 Clutch - Replacement 003072 Clutch - replacement Clutch assem- bly - Wear check 001012 Driven pulley - Service 001110 Driven pulley - Replacement 001155 Clutch bell housing - Replacement...
Page 224 MSS X9 Evolution 250 Time Final gear assy. INAL REDUCTION GEAR Code Action Duration 001010 Gear reduction unit - Inspection 001156 Gear reduction unit cover - Replace- ment 003065 Gear box oil - Replacement 004125 Rear wheel axle - Replacement...
Page 225: Driving Pulley
MSS X9 Evolution 250 Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 Drive belt - Replacement 001006 Driving pulley - Service 001066 rear-view pulley - Replacement TIME - 225...
Page 226: Starter Motor
MSS X9 Evolution 250 Time Starter motor LECTRICAL START UP Code Action Duration 001141 Belt anti-flapping roller - Replace- ment 001020 Starter motor - Replacement 001017 Start-up pinion - Replacement TIME - 226...
Page 227: Flywheel Magneto
MSS X9 Evolution 250 Time Flywheel magneto AGNETO FLYWHEEL Code Action Duration 001087 Flywheel cover - replace 001113 Water pump / Pump rotor - Replace- ment 001173 Rotor - replace 001067 Stator - Replacement 001104 Start-up freewheel - Replacement 001151...
Page 228 MSS X9 Evolution 250 Time Carburettor ARBURETTOR Code Action Duration 001013 Intake manifold - change 001081 Automatic choke - Replacement 001008 Carburettor - Inspection 001063 Carburettor - Replacement 007020 Carburettor heat piping. - Replace- ment 003058 Carburettor - Adjustment TIME - 228...
Page 229: Exhaust Pipe
MSS X9 Evolution 250 Time Exhaust pipe ILENCER Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replacement 001095 Muffler guard - Replacement TIME - 229...
Page 230: Air Cleaner
MSS X9 Evolution 250 Time Air cleaner IR CLEANER Code Action Duration 001014 Air filter - Replacement/Cleaning 001015 Air filter box - Replacement 004122 Air cleaner carburettor fitting - Re- placement TIME - 230...
Page 231 MSS X9 Evolution 250 Time Frame HASSIS Code Action Duration 004001 Frame - Replacement 004146 Front chassis - Replacement 004116 Rear frame - Replacement 004147 footrest support bracket one side - Replacement 004148 footboard support bracket two sides - Replacement...
Page 232 MSS X9 Evolution 250 Time Centre-stand CENTRAL STAND Code Action Duration 004102 Side stand - Replacement 004004 Stand - Replacement 005079 Stand switch - Replacement TIME - 232...
Page 233 MSS X9 Evolution 250 Time Legshield spoiler RILL SHIELDS Code Action Duration 004064 Front shield - front section - Replace- ment 006012 Front shield - Paintwork 004149 Shield central cover - Replacement 006006 Headstock cover - Paintwork 004066 Rear view mirrors - Replacement...
Page 234: Rear Cover
MSS X9 Evolution 250 Time Rear cover EAR SHIELD Code Action Duration 004065 Front shield, rear part - Removal and refitting 004081 Glove box door - Replacement 002082 Fuel tank door opening drive - Re- placement TIME - 234...
Page 235: Front Mudguard
MSS X9 Evolution 250 Time Mudguard RONT MUDGUARD Code Action Duration 004053 Spoiler - Replacement 004002 Front mudguard - change 005081 Temperature sensor - Replacement TIME - 235...
Page 236 MSS X9 Evolution 250 Time Fuel tank UEL TANK Code Action Duration 005010 Tank float - Replacement 004109 Fuel tank breather - change 004005 Fuel tank - replace 004073 Fuel pump - Replacement 004137 Carburettor - pump hose - Replace-...
Page 237 MSS X9 Evolution 250 Time Expansion tank XPANSION TANK Code Action Duration 007001 Expansion tank - Replacement 007013 Expansion tank connection pipe - Replacement 001052 Coolant and air bleed - Replace- ment TIME - 237...
Page 238 MSS X9 Evolution 250 Time Radiator ADIATOR Code Action Duration 007014 Radiator thermal switch - Replace- ment 007002 Radiator - Replacement 007016 Fan with support - replace 007003 Coolant delivery and return pipe - change TIME - 238...
Page 239: Rear Shock Absorber
MSS X9 Evolution 250 Time Rear shock-absorber EAR SHOCK ABSORBER Code Action Duration 003007 Rear shock ab- sorber - Removal and Refitting Handlebar covers ANDLEBAR COVERS Code Action Duration 004151 Instrument panel support - Replace- ment 004018 Front handlebar covers - Replace-...
Page 240: Handlebar Components
MSS X9 Evolution 250 Time Handlebar components ANDLEBAR COMPONENTS Code Action Duration 002060 Complete gas command - Replace- ment 002037 Brake or clutch lever - Replacement 002071 Left hand grip - Replacement 002024 Front brake pump - replace 003001 Handlebar - Removal and refitting...
Page 241 MSS X9 Evolution 250 Time Swing-arm WING ARM Code Action Duration 001072 Swinging arm connecting the engine to the frame - Replacement 004058 Silent block - Replacement 003081 Swinging arm support flange - Re- placement TIME - 241...
Page 242: Brake Hoses
MSS X9 Evolution 250 Time Brake hoses RAKE PIPING Code Action Duration 002084 Integral brake pump pipe, device - Replacement 002085 Integral brake device pipe- front cal- liper - Replacement 002089 Integral braking device - Replace- ment 002087 Integral brake rear rigid pipe- Re-...
Page 243 MSS X9 Evolution 250 Time Seat ADDLE Code Action Duration 004003 Saddle - Replacement 004054 Saddle lock catch - Replacement 004144 Port and/or saddle cover - Replace- ment 004067 Rider backrest - Replacement TIME - 243...
Page 244 MSS X9 Evolution 250 Time Locks OCKS Code Action Duration 005016 Key switch - Replacement 004010 Antitheft lock - Replacement 002083 Saddle opening transmission - Re- placement TIME - 244...
Page 245: Front Wheel
MSS X9 Evolution 250 Time Front wheel RONT WHEEL Code Action Duration 003037 Front wheel rim - Replacement 003047 Front tyre - Replacement 004123 Front wheel - Replacement 003040 Tyre pressure - Check 002041 Front brake disc - Replacement 005089...
Page 246 MSS X9 Evolution 250 Time Tone wheel or drive greasing Please note that the following code has been in- troduced: 900001 - Tone wheel or drive greasing -15'. Please do not use codes 002011 (drive replace- ment) and 005089 (tone wheel replacement) in- correctly if the indicated components are noisy.
Page 247: Rear Wheel
MSS X9 Evolution 250 Time Rear wheel EAR WHEEL Code Action Duration 001071 Rear wheel rim - Replacement 004126 Rear wheel tyre - Replacement 001016 Rear wheel - Replacement 003014 Rear suspension arm - Replacement 003077 silencer/rear shock absorber support...
Page 248 MSS X9 Evolution 250 Time EADLIGHT Code Action Duration 005002 Front headlamp - Replacement 005044 Front lights cable unit - replace 005008 Headlight bulbs - Replacement TIME - 248...
Page 249 MSS X9 Evolution 250 Time IRING WIRE UNIT Code Action Duration 005001 Electrical system - Removal and re- fitting 005025 Battery fuse holder - Change TIME - 249...
Page 250 MSS X9 Evolution 250 Time ATTERY Code Action Duration 005007 Battery - change 005009 Voltage regulator - Replacement 001023 Control unit - Replacement 005035 Headlight remote control - Replace- ment 001094 Spark plug cap - Replacement 001069 HV coil - Replacement...
Page 251 MSS X9 Evolution 250 Time LECTRIC DEVICES Code Action Duration 005068 Rear turn indicator bulb - Replace- ment 005005 Taillight - change 005030 Rear telltale light and headlamp ca- ble assembly - Replacement 005066 Rear light bulbs - replace 004141...
Page 252: Brake Callipers
MSS X9 Evolution 250 Time Brake callipers RAKE CALIPERS Code Action Duration 002007 Front brake pads - replace 002002 Rear brake pads - Replacement 002039 Front brake calliper - Replacement 002048 Rear brake caliper - Replacement TIME - 252...
Page 253 MSS X9 Evolution 250 Time Fuel tank filler flap ANK PORT FOOTBOARD Code Action Duration 004135 Fuel tank port - Replacement 004011 Central frame cover - replace TIME - 253...
Page 254: Steering Column
MSS X9 Evolution 250 Time Footrests Code Action Duration 004075 Front mat - Replacement 004076 Single rear mat - Replacement 004143 Footrest support - Replacement 004015 Footrest - Replacement 004068 One passenger grab handle - Re- placement 004059 Spark plug inspection flap - Replace-...
Page 255: Helmet Compartment
MSS X9 Evolution 250 Time Helmet bay ELMET COMPARTMENT Code Action Duration 005033 Glove-box light switch - Replace- ment 005026 Helmet compartment bulb - Replace- ment 005027 Helmet compartment bulb support - Replacement 004142 electric socket - Replacement 004016 Helmet compartment - Replacement...
Page 256 MSS X9 Evolution 250 Time Rear side fairings EAR MUDGUARD Code Action Duration 004009 Rear mudguard - Replacement 005048 Licence plate holder - Replacement TIME - 256...
Page 257 MSS X9 Evolution 250 Time Windscreen INDSCREEN Code Action Duration 004028 Windshield glass - Replacement Secondary air box ECONDARY AIR HOUSING Code Action Duration 001162 Secondary air housing - Replace- ment 001161 Secondary air filter - Replacement / Cleaning 001174...
Page 258 MSS X9 Evolution 250 Time TIME - 258...
Page 259 Air filter: 42 Battery: 53, 60, 75, 76 Brake: 185, 186, 188, 189, 191, 242, 252 Brake fluid: 191 Carburettor: 16, 38, 146, 158, 228 Checks: 63 Electric: 247 Engine oil: 43 Engine stop: Fuel: 52, 146, 210, 236, 253 Fuses: 72 Headlight: 207 Horn:...
Page 260 Tank: 210, 212, 236, 237, 253 Technical Data: 11 Transmission: 13, 53, 84, 98 Turn indicators: Tyres: 15 Vehicle: 12, 81...

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