PIAGGIO MSS X9 EVOLUTION 250 Workshop Manual
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PIAGGIO MSS X9 EVOLUTION 250 Workshop Manual

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WORKSHOP MANUAL
618153
MSS X9 Evolution 250

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Summary of Contents for PIAGGIO MSS X9 EVOLUTION 250

  • Page 1 WORKSHOP MANUAL 618153 MSS X9 Evolution 250...
  • Page 2 Not all versions/models shown in this publication are available in all countries. The availability of single models should be checked at the official Piaggio sales network. "© Copyright 2007 - 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 CHAR HARACTERISTICS 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 PRE DE DELIVERY TIME...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    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.

  • Page 8: Vehicle Identification

    MSS X9 Evolution 250 Characteristics Vehicle identification Chassis prefix: ZAPMXXXX > XXXXXX Engine prefix: M23XM Dimensions and mass IMENSIONS AND WEIGHT Specification Desc./Quantity Empty weight 173 Kg Wheelbase 1500 mm Overall height 1450 mm Saddle height 790 mm Overall length...
  • Page 9 MSS X9 Evolution 250 Characteristics Engine 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 60 mm Piston displacement...

  • Page 10: Electrical System

    MSS X9 Evolution 250 Characteristics 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 11: Wheels And Tyres

    MSS X9 Evolution 250 Characteristics • 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 12 MSS X9 Evolution 250 Characteristics 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 13: Tightening Torques

    MSS X9 Evolution 250 Characteristics 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 14: Crankcase And Crankshaft

    MSS X9 Evolution 250 Characteristics Name Torque in Nm Front wheel axle 45 ÷ 50 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 ÷...

  • Page 15: Assembly Clearances

    MSS X9 Evolution 250 Characteristics Name Torque in Nm Nuts fixing head to cylinder (*) 27 ÷ 29 Tappet cover screws 6 ÷ 7 Spark plug 12 ÷ 14 LUBRICATION Name Torque in Nm Hub oil drainage plug 15 ÷ 17 Oil filter on crankcase fitting 27 ÷...
  • Page 16 MSS X9 Evolution 250 Characteristics 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 17 MSS X9 Evolution 250 Characteristics 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 Crankshaft to crankcase axial clearance...
  • Page 18 MSS X9 Evolution 250 Characteristics 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 19 INDEX OF TOPICS TOOL OOLING...
  • Page 20 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 Pliers to extract ø 15-mm bearings TOOL - 20...
  • Page 21 MSS X9 Evolution 250 Tooling Stores 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 TOOL - 21...
  • Page 22 MSS X9 Evolution 250 Tooling Stores code Description 020363Y 20 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 TOOL - 22...
  • Page 23 MSS X9 Evolution 250 Tooling Stores code Description 020382Y011 adapter 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...
  • Page 24 MSS X9 Evolution 250 Tooling Stores code Description 020364Y 25-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...
  • Page 25 MSS X9 Evolution 250 Tooling Stores code Description 020368Y driving 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 TOOL - 25...
  • Page 26 MSS X9 Evolution 250 Tooling Stores code Description 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 TOOL - 26...
  • Page 27 MSS X9 Evolution 250 Tooling Stores code Description 020382Y Valve cotters 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-...
  • Page 28 MSS X9 Evolution 250 Tooling Stores code Description 020456Y Ø 24 mm 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...
  • Page 29 MSS X9 Evolution 250 Tooling Stores code Description 020454Y Tool for fitting 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...
  • Page 30 MSS X9 Evolution 250 Tooling Stores code Description 020444Y010 adapter ring 020628Y Water pump service kit TOOL - 30...
  • Page 31 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 32: 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 - replacement Hub oil - change Engine oil - change Idle speed (*) - adjustment Throttle lever - adjustment...
  • Page 33 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 - check Spark plug/ electrode gap - check Air filter - clean...
  • Page 34 MSS X9 Evolution 250 Maintenance AT 36000 KM Action Engine oil - replacement Hub oil level - check Spark plug / electrode gap - check / replacement Air filter - clean Engine oil - change valve clearance 125 - check...

  • Page 35: Checking The Spark Advance

    MSS X9 Evolution 250 Maintenance Action Secondary air filter (external/internal) - cleaning (125) EVERY 3,000 KM Action Engine oil - level check/ top-up Carburettor - Disassemble the carburettor in its parts, wash all of them with solvent, dry all body grooves with compressed air to ensure adequate cleaning.
  • Page 36 MSS X9 Evolution 250 Maintenance advance degrees indicated by the stroboscopic lamp. - Check that the advance degrees match the rev- olution speed as indicated in the tables. - In case of abnormal values, check the Pick-Up and the control unit supplies (positive-negative);...

  • Page 37: 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 38 MSS X9 Evolution 250 Maintenance - Install the spark plug, tighten by hand and then lock it by the special wrench at the prescribed tor- que. CAUTION THE SPARK PLUG MUST BE REMOVED WHEN THE MO- TOR IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 12,000 KM.

  • Page 39: Air Filter

    MSS X9 Evolution 250 Maintenance Replacement Hub oil replacement - Remove the oil loading cap «A». - Remove the oil drainage cap «B» and let the oil drain out completely. - Tighten the drainage cap again and fill the hub with oil (about 150 cc.).
  • Page 40 MSS X9 Evolution 250 Maintenance 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. - Extract the oil cartridge «B» filter using the two protruding tabs and remove it.

  • Page 41: Checking The Valve Clearance

    MSS X9 Evolution 250 Maintenance Checking the ignition timing - Remove the plastic cap on the flywheel cover -Turn the flywheel until the reference mark «T» on the rotor matches the reference mark on the fly- wheel cover as shown in the figure (TDC). Make...
  • Page 42 MSS X9 Evolution 250 Maintenance 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 43: Braking System

    MSS X9 Evolution 250 Maintenance IN ORDER TO AVOID BURNS, DO NOT UNSCREW THE EXPANSION TANK CAP WHILE THE ENGINE IS STILL HOT. WARNING IN ORDER TO AVOID HARMFUL FLUID LEAKS WHILE RID- ING, IT IS IMPORTANT TO MAKE SURE THAT THE LEVEL NEVER EXCEEDS THE MAXIMUM VALUE.
  • Page 44 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 45 MSS X9 Evolution 250 Maintenance 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. N.B. CHECK THE CONDITIONS DISPLAYED BY THE ANALY- SER AND THE ENGINE RPM AND ADJUST THE CO VALUE AT 3.8 ±...
  • Page 46 INDEX OF TOPICS TROUBL ROUBLESHOOTING...

  • Page 47: Rear Wheel Spins At Idle

    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 48 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 49: Troubleshooting

    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 50 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 casing is mainly in the centre with equivalent characteristics on the three masses.
  • Page 51 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 52 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 53 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 Indicators switch Horn button Emergency flashing button "Reset" button Front fuse holder box...
  • Page 54 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 55 MSS X9 Evolution 250 Electrical system Ignition IGNITION SECTION Specification Desc./Quantity Pick - up Magneto flywheel Key switch contacts Electronic controller Spark plug HV coil Immobilizer aerial Voltage regulator Voltage regulator Diagnostic tester outlet Fuse Immobilizer LED Battery 12V-12Ah ELE SYS - 55...
  • Page 56 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 switch Fuse (headlight remote control protection)

  • Page 57: Battery Recharge And Starting

    MSS X9 Evolution 250 Electrical system Battery recharge and starting BATTERY RECHARGE AND START-UP Specification Desc./Quantity Key switch contacts Magneto flywheel Fuse Remote starter switch Voltage regulator Starter motor Battery 12V-12Ah Start-up enable and front stop button Start-up enable and rear stop button...
  • Page 58 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 sender Oil pressure sensor "Reset" button Emergency button...
  • Page 59 MSS X9 Evolution 250 Electrical system Specification Desc./Quantity Battery 12V - 12Ah Thermal switch We inform you that a new thermal switch has been introduced starting with frame number ZAPM2300003507739 (X9) ZAPM3620000003383 (X8) ZAPM2850000001025 (Beverly), in order to prevent possible malfunctioning of the thermal switch.
  • Page 60 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 61 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 62 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 63 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 64 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 65 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 66 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 67 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 68 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 69 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 70 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 71 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 72 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 73 MSS X9 Evolution 250 Electrical system Besides, upon pre-delivery it is therefore necessary to check the battery charge and recharge it, if required, 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 regular tester.
  • Page 74 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 75 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 76 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 77 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 78 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 79 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 80 INDEX OF TOPICS NGINE...

  • Page 81: 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 bell lock wrench shown in the figure, remove the driven pulley shaft locking nut and washer.
  • Page 82 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 83: Removing The Driven Pulley

    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 photograph - Check the outside diameter of the roller does not...

  • Page 84: Inspecting The Clutch Drum

    MSS X9 Evolution 250 Engine Inspecting the clutch drum - Check that the clutch bell is not worn or damaged. - Measure the clutch bell inside diameter. Characteristic Max. value clutch bell Max. value: Ø 134.5 mm Clutch bell standard value Standard value: Ø...

  • Page 85: 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 No. 11 with the cham- fering facing the inside of the tool.
  • Page 86 MSS X9 Evolution 250 Engine Check minimum thickness 1 mm Pin retaining collar - Simultaneously turn and pull the collar manually to remove it. N.B. USE TWO SCREWDRIVERS IF YOU HAVE DIFFICULTY. N.B. BE CAREFUL NOT TO PUSH THE SCREW DRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD ENDANGER THE O-RING SEAL.
  • Page 87 MSS X9 Evolution 250 Engine - Support the pulley properly using the bell as shown in the figure. Specific tooling 001467Y035 Belle for OD 47-mm bearings - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 020456Y Ø...
  • Page 88 MSS X9 Evolution 250 Engine Inspecting the driven sliding half-pulley - Remove the two internal grommets 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 89: Refitting The Driven Pulley

    MSS X9 Evolution 250 Engine 020376Y Adaptor handle 020375Y Adaptor 28 x 30 mm 020424Y Driven pulley roller casing fitting punch Refitting the driven pulley - Insert the new oil guards and O-rings on the mov- able half-pulley. - Lightly grease the O-rings «A» shown in the fig- ure.
  • Page 90 MSS X9 Evolution 250 Engine Soap-based lithium grease containing NLGI 2 Mo- lybdenum disulphide; ISO-L-XBCHB2, DIN KF2K-20 Inspecting the clutch spring - Measure the free length of the mobile driven half- pulley spring. Characteristic Standard length (200 - 250) 123 mm...
  • Page 91 MSS X9 Evolution 250 Engine - Apply the clutch fixing nut and tighten it to the prescribed torque using the special 46x55 wrench. - Loosen the tool clamp and insert the belt accord- ing to its direction of rotation. - Lock the driven pulley again using the specific tool.

  • Page 92: 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 4T Transmission belt/minimum width 19.5 mm 250 4T Transmission belt/standard width 21.3 ± 0.2 mm During the wear checks foreseen in the scheduled maintenance services at 6,000 km;...
  • Page 93 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 020626Y Driving pulley lock wrench - Remove the fixing nut and the washer - Remove the stationary drive pulley half.
  • Page 94 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 admissible diame- Ø 25.95 mm Roller: Standard Diameter Diameter 20.5 - 20.7 mm Roller: Minimum diameter permitted Ø...
  • Page 95 MSS X9 Evolution 250 Engine Refitting the transmission cover - Check the presence of the 2 centring dowels and the correct installation of the sealing gasket for the oil sump on the transmission cover. - Replace the cover tightening the 10 screws at the specified torque.
  • Page 96 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 97 MSS X9 Evolution 250 Engine Removing the wheel axle bearings - Take out the clip on the outside of the gearbox cover. - Support the hub cover and expel the bearing. By means of the appropriate tools, remove the oil guard as in the figure.
  • Page 98 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. - In case of anomalies, replace the damaged com- ponents.
  • Page 99 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 100 MSS X9 Evolution 250 Engine 020363Y 20 mm guide Refitting the hub bearings - Install the three shafts in the engine crankcase as shown in the figure. Refitting the ub cover - Fit a new gasket together with the centring dow- els.
  • Page 101 MSS X9 Evolution 250 Engine Flywheel cover Removing the hub cover - Remove the clip fixing the hose to the cylinder. - Remove the 10 fixings - Remove the flywheel cover. ENG - 101...

  • Page 102: Removing The Stator

    MSS X9 Evolution 250 Engine Removing the stator - Remove the two pickup screws and the screw holding the wiring support and the three stator clamping screws shown in the figure. - Remove the stator and its wiring. Refitting the stator...
  • Page 103 MSS X9 Evolution 250 Engine - Orient the water pump shaft with reference to the transmission gear seat as shown in the photo. - Refit the cover over the engine and tighten the screws to the prescribed torque. - Carry out the steps in the reverse order from the dismantling procedure.
  • Page 104 MSS X9 Evolution 250 Engine - 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.
  • Page 105 MSS X9 Evolution 250 Engine - Apply the recommended product to the end of the screws. Recommended products Loctite 243 Medium strength threadlock Loctite 243 medium-strength threadlock - Fit the freewheel on the magneto flywheel making sure that the ground side is in contact with the fly- wheel itself, i.e.
  • Page 106 MSS X9 Evolution 250 Engine - Insert the free wheel on the flywheel as shown in the photo - Then refit the flywheel with free wheel and trans- mission gear - Using the special flywheel stop tool, tighten up the flywheel fixing nut to the prescribed torque...
  • Page 107 MSS X9 Evolution 250 Engine Removing the rocker-arms cover - Remove the 5 screws indicated in the figure Removing the timing system drive - Remove the parts listed below first: transmission cover, drive pulley with belt, oil sump with spring...
  • Page 108 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 109 MSS X9 Evolution 250 Engine Removing the cam shaft - Remove the two screws and the cam shaft re- tainer shown in the diagram. - Remove the cam shaft. - Remove the pins and the rocker arms from the flywheel side holes.

  • Page 110: Removing The Cylinder Head

    MSS X9 Evolution 250 Engine Removing the cylinder head - Remove the spark plug. - Remove the 2 side fixings shown in the figure. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion.

  • Page 111: Inspecting The Small End

    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 small end using an internal micrometer.

  • Page 112: Inspecting The Piston

    MSS X9 Evolution 250 Engine Inspecting the wrist pin - Measure the outside diameter of the gudgeon pin. - Calculate the coupling clearance between pin and connecting rod end. Characteristic Pin diameter: Standard clearance 0.015 ÷ 0.029 mm Pin diameter Standard diameter 14.996 - 15.000 mm...
  • Page 113 MSS X9 Evolution 250 Engine piston diameter 71.953 - 71.981 mm Fitting clearance Top piston ring - standard coupling clearance Top piston ring - maximum clear- 0.015 - 0.06 mm ance allowed after use Middle piston 0.07 mm ring - standard coupling clearance 0.015 - 0.06 mm...

  • Page 114: 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 115 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 116 MSS X9 Evolution 250 Engine ENG - 116...
  • Page 117 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 crown of the piston.

  • Page 118: Inspecting The Cylinder Head

    MSS X9 Evolution 250 Engine Inspecting the cylinder head - Using a trued bar and 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 rocker pin ca- pacities exhibit no wear.
  • Page 119 MSS X9 Evolution 250 Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Ensure that the camshaft control pulley chain as- sembly and the sprocket wheel are not worn.
  • Page 120 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 121 MSS X9 Evolution 250 Engine - Calculate the clearance between valve and valve guide. - Check that there are no signs of wear on the surface of contact with the articulated register terminal. - If the checks above give no failures, you can use the same valves. For best sealing results, it is advisable to grind the valves.
  • Page 122 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 - 122...
  • Page 123 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 seals. - 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 124 MSS X9 Evolution 250 Engine - Measure the internal diameter of each rocker arm. Check there are no signs of wear on the pad from contact with the cam and on the jointed adjustment plate. Characteristic Internal rocker arm diameter: Standard diame- Diameter 12.000 - 12.011 mm...
  • Page 125 MSS X9 Evolution 250 Engine Refitting the head and timing system components - Fit the timing chain guide pad. - Insert the centring dowel between the cylinder head to the cylinder, fit the cylinder head gasket and the cylinder head.
  • Page 126 MSS X9 Evolution 250 Engine - Lubricate the 2 bearings and insert the cam shaft in the cylinder head with the cams corresponding to the rockers. - Insert the retention plate and tighten the two screws shown in the figure to the prescribed tor- que.
  • Page 127 MSS X9 Evolution 250 Engine GREASE THE END STOP RING TO PREVENT IT COMING OUT AND FALLING INTO THE ENGINE. Locking torques (N*m) Timing chain tensioner support screw 11 ÷ 13 Spark plug Starter ground screw 12 ÷ 14 7 ÷ 8.5 Timing chain tensioner slider screw 10 ÷...
  • Page 128 MSS X9 Evolution 250 Engine Refitting the rocker-arms cover - Refit the cylinder head cover, tightening 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.
  • Page 129 MSS X9 Evolution 250 Engine Splitting the crankcase halves - Before opening the crankcase, it is advisable to check the axial clearance of the crankshaft. To do this, use a plate and a support with appropriate tool dial gauge. - Upper clearances are an indication of wear on the surfaces of the crankshaft casing support.
  • Page 130 MSS X9 Evolution 250 Engine INGS. FAILURE TO OBSERVE THIS PRECAUTION CAN DAMAGE THE MAIN BUSHINGS. CAUTION KEEP THE CRANKSHAFT IN ONE OF THE TWO HALVES OF THE CRANKCASE WHEN SEPARATING IT. IF YOU FAIL TO DO THIS, THE CRANKSHAFT MIGHT ACCIDENTALLY FALL.
  • Page 131 MSS X9 Evolution 250 Engine Inspecting the crankshaft alignment To install the drive shaft on the support and to measure the misalignment in the 4 points indicated in figure. - Check that the driving shaft cone, the tab seat, the oil seal capacity, the toothed gear and the threaded tangs are in good working order.
  • Page 132 MSS X9 Evolution 250 Engine Inspecting the crankcase halves - Before proceeding to check the crankcase halves, thoroughly clean all surfaces and oil ducts. - On the transmission-side crankcase half, take particular care when handling the oil pump com- partment and the oil ducts, the by-pass duct, the main bushings and the cooling jet on the trans- mission side (see diagram).
  • Page 133 MSS X9 Evolution 250 Engine THE HEAD LUBRICATION CHANNEL IS PROVIDED WITH A SHUTTER JET; THIS GIVES A "LOW PRESSURE" HEAD LUBRICATION; THIS CHOICE WAS MADE TO REDUCE THE OIL TEMPERATURE IN THE SUMP. THE JET CLOG- GING IMPAIRS THE HEAD LUBRICATION AND THE TIM- ING MECHANISMS.
  • Page 134 MSS X9 Evolution 250 Engine - The bushing housings in the crankcase are avail- able in two categories, Cat. 1 and Cat. 2, as are the crankshafts. - The main bushings are available in three thick- ness categories, identified by colour markings, as shown in the table below.
  • Page 135 MSS X9 Evolution 250 Engine CRANKCASES FOR REPLACEMENTS ARE SELECTED WITH CRANKCASE HALVES OF THE SAME CATEGORY AND ARE FITTED WITH CATEGORY B BUSHINGS (BLUE) Characteristic Standard driving depth 1.35 ÷ 1.6 Diameter of crankcase without bushing 32.953 ÷ 32.963...
  • Page 136 MSS X9 Evolution 250 Engine Lubrication Crankshaft oil seals Removal - First 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...
  • Page 137 MSS X9 Evolution 250 Engine - Screw the threaded bar onto the base of the tool and extract the oil guard. Specific tooling 020622Y Transmission-side oil guard punch Refitting - Use a new oil seal upon refitting. - Prepare the new oil seal, lubricating the sealing lip.
  • Page 138 MSS X9 Evolution 250 Engine Oil pump Removal - Undo the two clamping screws in the figure and remove the cover over the pump control crown. ENG - 138...
  • Page 139 MSS X9 Evolution 250 Engine - Block the rotation of the oil pump control pulley with a screwdriver inserted through one of its two holes. - Remove the central screw with Belleville washer, as shown in the diagram. - Remove the chain with the crown.
  • Page 140 MSS X9 Evolution 250 Engine Refitting - Check there are no signs of wear on the oil pump shaft or body. - Check there are no signs of scoring or wear on the oil pump cover. - If you detect non-conforming measurements or scoring, replace the faulty parts or the unit.
  • Page 141 MSS X9 Evolution 250 Engine Removing the oil sump - Remove the oil filler plug, the transmission cover, the complete driving pulley assembly with belt and the sprocket wheel, as described in the "Trans- mission" chapter. - Drain the oil as described previously.
  • Page 142 MSS X9 Evolution 250 Engine Refitting the oil sump - Refit the by-pass valve plunger in its housing. - Insert the pressure-regulating spring. - Fit a new sump seal. - Refit the two centring dowels. - Refit the sump, taking care to locate the spring in the appropriate recess machined into the inside of the sump.
  • Page 143 MSS X9 Evolution 250 Engine - Switch the pump to pressure mode (PRES- SURE). - Operate the pump slowly and check if there is an increase of pressure. A small leakage is consid- ered to be normal. If anomalies are detected, replace the pump.

  • Page 144: Fuel Supply

    MSS X9 Evolution 250 Engine the valve opens and the depression is suddenly set to zero. Lack of tightness or the fact that the valve opens at different vacuum values should be regarded as anomalies. In this case, replace it.
  • Page 145 MSS X9 Evolution 250 Engine - Remove the protection, the bracket and the start- er acting on the screw shown in the figure. - Remove the 2 screws and the starter support with the gasket. - Remove the clamp and cover with the airing filter of the diaphragm chamber.
  • Page 146 MSS X9 Evolution 250 Engine - Remove the vacuum 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- - Remove the 4 screws indicated in the figure.
  • Page 147 MSS X9 Evolution 250 Engine - Remove the chamber with the accelerating pump, its control and gasket. - Remove the oil pump seal. - Remove the intake and outlet valves of the intake pump from the tank N.B. CAUTION, THE ACCELERATION PUMP VALVES ARE MADE UP OF NOZZLES, SPRING AND BALL.
  • Page 148 MSS X9 Evolution 250 Engine -Remove the maximum nozzle. -Remove diffuser. ENG - 148...
  • Page 149 MSS X9 Evolution 250 Engine - 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 150 MSS X9 Evolution 250 Engine Walbro To detach the carburettor from the engine, it is necessary to move the air filter and remove the transmission throttle control, the automatic starter connexion, 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 151 MSS X9 Evolution 250 Engine Remove the 4 fixing screws indicated 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.
  • Page 152 MSS X9 Evolution 250 Engine Unscrew the bayonet 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.
  • Page 153 MSS X9 Evolution 250 Engine Remove the acceleration pump piston with the ring nut, the 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.
  • Page 154 MSS X9 Evolution 250 Engine Remove the cover of the duct from the carburettor to the starter nozzle as shown in the figure. -Remove the maximum nozzle. -Remove diffuser. Remove the sprayer. N.B. THIS OPERATION IS NECESSARY TO AVOID LOSING SPRAYER PARTS WHEN CLEANING THE CARBURETTOR BODY.
  • Page 155 MSS X9 Evolution 250 Engine Remove the minimum 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 diaphragm. CAUTION DO NOT ATTEMPT REMOVING PARTS EMBEDDED IN THE...
  • Page 156 MSS X9 Evolution 250 Engine Kehin - 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 157 MSS X9 Evolution 250 Engine - Check that the coupling surfaces, the tank and the diaphragm are not dented. -Check that the depression valve housing pipe is not scratched. - Check that the throttle valve and the shaft do not show abnormal wear.
  • Page 158 MSS X9 Evolution 250 Engine - Introduce the float with the rod on the fuel feeding tube side. N.B. INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY - Remove the drainage screw from the tank, wash and blow it properly and make sure the accelera- tion pump pipes are clean.
  • Page 159 MSS X9 Evolution 250 Engine - The screw final position should be determined by an exhaust fume analysis. - Adjust the carburettor by turning the screw twice from the close position. Walbro - Before refitting, wash the carburettor body accu- rately with petrol and compressed air.
  • Page 160 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 internal calibrations. - Blow the intake nozzle properly. N.B. THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE THROTTLE VALVE.
  • Page 161 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 162 MSS X9 Evolution 250 Engine - Remove the drainage screw from the tank, wash and blow the tank properly and make sure the ac- celeration pump intake and supply valve are clean. - Being the valves unidirectional, blow them care-...
  • Page 163 MSS X9 Evolution 250 Engine - Prepare the carburettor for adjustment by rotating the screw 3 turns from the close position. - Check that the rocking lever control of the accel- erating pump does not show abnormal wear. - Check that the end of stroke screw of the rocking lever protrudes 3.2 mm.
  • Page 164 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 165 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 does not show signs of wear and that the lock is in the 3rd of the 3 notches.
  • Page 166 MSS X9 Evolution 250 Engine - Check that the diaphragm is not worn or has hardened. If it does, replace it. - Refit the tapered pin on the vacuum valve. - Make sure the spring is in the correct position on the plunger and inserted in its housing.
  • Page 167 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 168 MSS X9 Evolution 250 Engine XX ÷ XX mm at approx. 20°C Check the automatic starter: Kehin maximum protrusion XXX ÷ XXX mm Check the automatic starter: Keihin maximum time 5 min Walbro - Check that the automatic starter piston is not de- formed or rusty.
  • Page 169 MSS X9 Evolution 250 Engine Check the auto starter: Protrusion Value for Walbro 12.5 ÷ 13 mm at approx. 20°C Check the automatic starter: Walbro maximum protrusion 18.5 ÷ 19 mm Check the automatic starter: Walbro max. time 5 min...
  • Page 170 MSS X9 Evolution 250 Engine loosened the CO value rises (rich mix). Tightening the screw decreases the CO (lean mix). - 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.
  • Page 171 MSS X9 Evolution 250 Engine CORRECT 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 ENG - 171...
  • Page 172 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 173: Removing The Front Wheel

    MSS X9 Evolution 250 Suspensions This section is devoted to operations that can be carried out on the suspension. 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 174: Front Fork

    MSS X9 Evolution 250 Suspensions Refitting Carry out the above operations by working in the reverse order from those of the 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 175 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 176 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 177 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 fifth wheels from headstock SUSP - 177...
  • Page 178 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 179: 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 180 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 181 MSS X9 Evolution 250 Suspensions stand retaining bolt 20 ÷ 25 SUSP - 181...
  • Page 182 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...

  • Page 183: Rear Brake Calliper

    MSS X9 Evolution 250 Braking system This section è is devoted to the description of the braking system components. Interventions rules General rules for maintenance operations on the hydraulic braking system. WARNING HYDRAULIC OIL IS CORROSIVE: ALWAYS WEAR PROTECTIVE GLOVES.
  • Page 184 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 185 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 186: 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 disk, cause the reaction plate to push in turn the other pad towards the disc.

  • Page 187: 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 188 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 189 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 190 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 191 MSS X9 Evolution 250 Braking system BRAK SYS - 191...
  • Page 192 INDEX OF TOPICS COOL SYS OOLING SYSTEM...
  • Page 193 MSS X9 Evolution 250 Cooling system Circuit diagram COOL SYS - 193...
  • Page 194 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 195 MSS X9 Evolution 250 Cooling system Install the pin that is part of the special tool on the press piston. Turn the flywheel cover until it permits insertion of the pin inside the joint and eject the pump shaft from the joint and bearings.
  • Page 196 MSS X9 Evolution 250 Cooling system Centre the cover until it permits insertion of the pin and then eject the seal ring and the two ball bear- ings. Specific tooling 020628Y Water pump service kit Before you reassemble, wash all the components and continue with the following checks.
  • Page 197 MSS X9 Evolution 250 Cooling system Shaft: Check to be sure there is no oxidation. Check that the impeller is in perfect condition. Ceramic seal: Check that the ceramic seals are not worn, cracked or scored. Check that the two rub- ber seals are in perfect condition.
  • Page 198 MSS X9 Evolution 250 Cooling system Let the flywheel cover guard cool down and then manually mount the static part of the ceramic seal with the relative rubber seal. N.B. PAY ATTENTION TO MOUNTING THE CERAMIC RING CORRECTLY. THE CHAMFER ON THE INTERNAL DIAME- TER MUST BE TURNED AWAY FROM THE SIDE OF THE BEARINGS.
  • Page 199 MSS X9 Evolution 250 Cooling system Manually insert the pump shaft in the relative bear- ings. While keeping the bearings in contact with the support base, line up the shaft with the press pis- ton and proceed with the driving. The driving depth is determined by the beat of the punch when it is in contact with the flywheel cover.
  • Page 200 MSS X9 Evolution 250 Cooling system Install the oil seal on the flywheel cover all the way to the depth determined by the punch. Specific tooling 020628Y Water pump service kit Fit the punch with the template of the entrainment joint to the press punch.
  • Page 201 MSS X9 Evolution 250 Cooling system Our Leader, Quasar, and Master liquid cooled engines are equipped with water pumps fitted with the ceramic seal in the subject. This component is intended to guarantee the leak tightness of the coolant in relation to the pump shaft. The seal achieved via two special ceramics, a static one and a spinning one, kept in contact by the thrust of a spring, coaxially mounted onto the pump shaft.
  • Page 202 MSS X9 Evolution 250 Cooling system Check - Visually check that the thermostat is not dam- aged. - Prepare a metal container with approx. 1 litre of water. - Immerse the thermostat, keeping it in the centre of the container.
  • Page 203 MSS X9 Evolution 250 Cooling system Thermostat cover screws 3 ÷ 4 COOL SYS - 203...
  • Page 204 INDEX OF TOPICS CHAS HASSIS...
  • Page 205 MSS X9 Evolution 250 Chassis This section è is devoted 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 206 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 207 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 208 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 209: Fuel Tank

    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 210 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 - 210...
  • Page 211 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 212 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 213 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 214 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 215 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 216 MSS X9 Evolution 250 Pre-delivery Carry out the listed tests before delivering the vehicle. Warning- be very careful when handling fuel. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Lock check...
  • Page 217 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 BATTERY LIFE.
  • Page 218 MSS X9 Evolution 250 Pre-delivery - Abnormal noise Static test Static control after the test ride: - Starting when warm - Starter operation - Minimum hold (turning the handlebar) - Uniform turning of the steering - Possible leaks CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
  • Page 219 INDEX OF TOPICS TIME...
  • Page 220 MSS X9 Evolution 250 Time This section is devoted 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 221 MSS X9 Evolution 250 Time Crankshaft RANKSHAFT Code Action Duration 001117 Crankshaft - Replacement TIME - 221...
  • Page 222 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 Valves - Replacement...
  • Page 223 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 - 223...

  • Page 224: 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 225: Oil Filter

    MSS X9 Evolution 250 Time Oil filter IL FILTER Code Action Duration 001123 Oil filter - Replacement 001160 Oil pressure sensor - Replacement TIME - 225...

  • Page 226: 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 227 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 228 MSS X9 Evolution 250 Time Driving pulley DRIVING PULLEY Code Action Duration 001086 Driving half-pulley - Replacement 001011 Driving belt - Replacement 001006 rear-view pulley - Service 001066 driving pulley - Replacement TIME - 228...

  • Page 229: Starter Motor

    MSS X9 Evolution 250 Time Starter motor LECTRICAL START UP Code Action Duration 001141 Belt anti-vibration roller - Replace- ment 001020 Starter motor - Replacement 001017 Starter sprocket wheel - Replace- ment TIME - 229...

  • Page 230: 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 231 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 - 231...
  • Page 232 MSS X9 Evolution 250 Time Exhaust pipe ILENCER Code Action Duration 001009 Muffler - Replacement 001092 Exhaust manifold - Replacement 001095 Muffler guard - Replacement TIME - 232...

  • Page 233: 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 - 233...
  • Page 234 MSS X9 Evolution 250 Time Frame HASSIS Code Action Duration 004001 Frame - replace 004146 Front frame - Replacement 004116 Rear frame - Replacement 004147 footboard support bracket one side - Replacement 004148 footboard support bracket two sides - Replacement...
  • Page 235 MSS X9 Evolution 250 Time Centre-stand CENTRAL STAND Code Action Duration 004102 Side stand - Replacement 004004 Stand - Replacement 005079 Stand switch - Replacement TIME - 235...
  • Page 236 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 237 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 - 237...
  • Page 238 MSS X9 Evolution 250 Time Mudguard RONT MUDGUARD Code Action Duration 004053 Spoiler - Replacement 004002 Front mudguard - change 005081 Temperature sensor - Replacement TIME - 238...
  • Page 239 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 240 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 - 240...
  • Page 241 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 - Re- placement TIME - 241...

  • Page 242: Handlebar Covers

    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 243 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 244 MSS X9 Evolution 250 Time Swing-arm WING ARM Code Action Duration 001072 Engine / frame swinging arm fitting - Replacement 004058 Silent block - Replacement 003081 Swinging arm support flange - re- place TIME - 244...
  • Page 245 MSS X9 Evolution 250 Time Brake hoses RAKE PIPING Code Action Duration 002084 Integral break pump pipe, device - Replacement 002085 Integral brake device pipe- front cal- liper - Replacement 002089 Integral breaking device - Replace- ment 002087 Integral brake rear rigid pipe- Re-...
  • Page 246 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 - 246...
  • Page 247 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 - 247...

  • Page 248: 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 Tone wheel - Replacement...
  • Page 249 MSS X9 Evolution 250 Time Grease tone wheel or drive Please take note that the code has been intro- duced: 900001 - Tone wheel / drive greasing - 15'. Never mistake the codes 002011 (movement sen- sor replacement) and 005089 (tone wheel replace- ment) in the event of noise of the indicated components.

  • Page 250: 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 muffler/rear shock absorber support...
  • Page 251 MSS X9 Evolution 250 Time EADLIGHT Code Action Duration 005002 Front headlamp - change 005044 Front lights cable unit - replace 005008 Front headlamp bulbs - Replacement TIME - 251...
  • Page 252 MSS X9 Evolution 250 Time IRING WIRE UNIT Code Action Duration 005001 Electrical system - Removal and re- fitting 005025 Battery fuse box - Replacement TIME - 252...
  • Page 253 MSS X9 Evolution 250 Time ATTERY Code Action Duration 005007 Battery - Replacement 005009 Voltage regulator - Replacement 001023 Control unit - Replacement 005035 Headlight remote control - Replace- ment 001094 Spark plug cap - Replacement 001069 HV coil - Replacement...
  • Page 254 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 255: 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 - 255...
  • Page 256 MSS X9 Evolution 250 Time Fuel tank filler flap ANK PORT FOOTBOARD Code Action Duration 004135 Fuel tank lid - Replacement 004011 Central frame cover - replace TIME - 256...

  • Page 257: 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 258 MSS X9 Evolution 250 Time Helmet bay ELMET COMPARTMENT Code Action Duration 005033 Glove-box light switch - Replace- ment 005026 Helmet compartment light - Replace- ment 005027 Helmet compartment bulb support - Replacement 004142 electric socket - Replacement 004016 Helmet compartment - Replacement...
  • Page 259 MSS X9 Evolution 250 Time Rear side fairings EAR MUDGUARD Code Action Duration 004009 Rear mudguard - Replacement 005048 Licence plate holder - Replacement TIME - 259...
  • Page 260 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 261 MSS X9 Evolution 250 Time TIME - 261...
  • Page 262 Air filter: 39 Battery: 50, 57, 72, 73 Brake: 183, 184, 186, 187, 189, 245, 255 Brake fluid: 189 Carburettor: 12, 35, 144, 155, 231 Engine oil: 39 Engine stop: Fuel: 49, 144, 209, 239, 256 Fuses: 69 Headlight: 206 Horn: Hub oil: 38 Identification: 8...

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