PIAGGIO MSS X9 EVOLUTION 250

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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

020622Y Transmission-side oil guard punch

Engine MSS X9 Evolution 250

ENG - 136

Main Page

Index of Topics5
Safety Rules7
Maintenance Rules7
Vehicle Identification8
Dimensions and Mass8
Dimensions and Weight8
Capacities10
Frame and Suspensions10
Gas Control Transmission Fixing10
Electrical System10
Brakes11
Wheels and Tyres11
Secondary Air11
Carburettor12
250Cc Version12
Walbro13
Tightening Torques13
Front Suspension13
Crankcase and Crankshaft14
Assembly Clearances15
Piston Rings16
Crankcase - Crankshaft - Connecting Rod17
Slot Packing System18
Products18
Maintenance Chart32
At 1000 Km or 4 Months32
At 6000 Km or 12 Months32
At 12000 Km or 24 Months and at 60000 Km32
At 18000 Km and at 54000 Km33
At 24000 Km and at 48000 Km33
At 30000 Km, at 42000 Km and at 66000 Km33
At 36000 Km34
At 72000 Km34
Every 2 Years34
Every 3,000 Km35
Checking the Spark Advance35
Spark Advance Variation36
Spark Plug37
Hub Oil38
Hub Oil Replacement39
Air Filter39
Engine Oil39
Oil Top up40
Checking the Ignition Timing41
Checking the Valve Clearance41
Cooling System41
Level Check42
Braking System43
CO Check44
SAS Filters Inspection and Cleaning45
Troubleshooting46
Engine Poor Performance47
Rear Wheel Spins at Idle47
Starting Difficulties47
Excessive Oil Consumption/Exhaust Smoke48
Insufficient Lubrication Pressure48
Engine Tends to Cut-Off at Full Throttle48
Engine Tends to Cut-Off at Idle49
Excessive Exhaust Noise49
High Fuel Consumption49
SAS Malfunctions49
Troubleshooting49
Clutch Grabbing or Performing Inadequately50
Insufficient Braking50
Brakes Overheating50
Battery50
Turn Signal Lights Malfunction51
Electrical System52
Electric System Diagram53
Conceptual Diagrams54
Wiring Colour Chart54
Ignition55
Headlights and Automatic Starter Section56
Battery Recharge and Starting57
Level Indicators and Enable Signals Section58
Turn Signal Lights59
Checks and Inspections60
Immobiliser60
Virgin Circuit61
Diagnostic Codes62
Diagnostic Code - 2 Flashes62
Diagnostic Code - 3 Flashes63
Ignition Circuit63
No Spark Plug64
HV Primary Coil Check64
Electric Characteristic64
HV Coil Secondary Check65
Stator Check66
Voltage Regulator Check67
Recharge System Voltage Check67
Choke Inspection68
Lights List68
Fuses69
Data Check Function72
Sealed Battery72
Dry-Charge Battery73
Instructions for the Battery Refresh after Open-Circuit Storage73
Connectors74
Dashboard75
12-Way Instrument Connector75
8-Way Instrument Connector75
16-Way Instrument Connector75
Engine from Vehicle77
Removal of the Engine from the Vehicle78
Engine80
Automatic Transmission81
Transmission Cover81
Air Duct81
Removing the Driven Pulley Shaft Bearing82
Refitting the Driven Pulley Shaft Bearing82
Baffle Roller82
Plastic Roller83
Removing the Driven Pulley83
Inspecting the Clutch Drum84
Removing the Clutch85
Inspecting the Clutch85
Pin Retaining Collar86
Removing the Driven Half-Pulley Bearing86
Inspecting the Driven Fixed Half-Pulley87
Inspecting the Driven Sliding Half-Pulley88
Refitting the Driven Half-Pulley Bearing88
Movable Driven Half-Pulley Dimensions88
Refitting the Driven Pulley89
Inspecting the Clutch Spring90
Refitting the Clutch90
Drive-Belt92
Removing the Driving Pulley92
Inspecting the Rollers Case93
Refitting the Driving Pulley94
Refitting the Transmission Cover95
End Gear95
Removing the Hub Cover95
Removing the Wheel Axle96
Removing the Hub Bearings96
Removing the Wheel Axle Bearings97
Inspecting the Hub Shaft98
Inspecting the Hub Cover98
Refitting the Wheel Axle Bearing98
Refitting the Hub Cover Bearings99
Refitting the Hub Bearings100
Refitting the Hub Cover100
Flywheel Cover101
Removing the Stator102
Refitting the Stator102
Refitting the Flywheel Cover102
Flywheel and Starting103
Removing the Starter Motor103
Removing the Flywheel Magneto103
Refitting the Free Wheel104
Refitting the Flywheel Magneto105
Refitting the Starter Motor106
Cylinder Assy. and Timing System106
Removing the Intake Manifold106
Removing the Rocker-Arms Cover107
Removing the Timing System Drive107
Removing the Cam Shaft109
Removing the Cylinder Head110
Removing the Valves110
Removing the Cylinder - Piston Assy.110
Inspecting the Small End111
Inspecting the Wrist Pin112
Inspecting the Piston112
Inspecting the Cylinder113
Inspecting the Piston Rings114
Removing the Piston114
Choosing the Gasket115
Refitting the Piston Rings117
Refitting the Cylinder117
Fitting the Sealing Rings117
Inspecting the Cylinder Head118
Inspecting the Timing System Components119
Inspecting the Valve Sealings119
Inspecting the Valve Housings120
Inspecting the Valves120
Inspecting the Springs and Half-Cones122
Refitting the Valves123
Inspecting the Cam Shaft123
Refitting the Head and Timing System Components125
Refitting the Rocker-Arms Cover128
Refitting the Intake Manifold128
Crankcase - Crankshaft128
Splitting the Crankcase Halves129
Inspecting the Crankshaft Alignment131
Inspecting the Crankcase Halves132
Inspecting the Crankshaft Plain Bearings133
Refitting the Crankcase Halves135
Lubrication136
Crankshaft Oil Seals Removal136
Crankshaft Oil Seals Refitting137
Oil Pump Removal138
Oil Pump Inspection139
Oil Pump Refitting140
Removing the Oil Sump141
Inspecting the By-Pass Valve141
Refitting the Oil Sump142
SAS Valve142
Inspecting the One-Way Valve142
Inspecting the Cut-Off143
Fuel Supply144
Removing the Carburettor144
Kehin144
Inspecting the Valve and Needle163
Inspecting the Automatic Choke Device166
Adjusting the Idle169
Suspensions172
Removing the Front Wheel173
Handlebar Removal173
Handlebar Refitting174
Front Fork Removal174
Front Fork Overhaul174
Front Fork Refitting176
Steering Bearing176
Removing the Rear Wheel179
Swing-Arm Removal179
Shock Absorbers179
Shock Absorbers Removal180
Shock Absorbers Refitting180
Centre-Stand180
Interventions Rules183
Rear Brake Calliper183
Front Brake Calliper184
Front Brake Disc Removal186
Front Brake Pads Removal187
Rear Brake Pads187
Fill Front188
Brake Fluid Level Check189
Front Brake Pump189
Cooling System Circuit Diagram193
Water Pump - Overhaul194
Cooling Plant194
Thermostat Removal201
Thermostat Check202
Thermostat Refitting202
Chassis204
Seat205
Rear Handlebar Cover205
Front Handlebar Cover205
Headlight Assy.206
Frame Central Cover206
Taillight Assy.207
Footrest207
Side Fairings208
License Plate Holder208
Helmet Bay209
Fuel Tank209
Rear Central Cover210
Radiator Fan211
Expansion Tank211
Top-Case211
Handles and Top Side Fairings212
Digital Panel Support212
Front Central Cover213
Flyscreen213
Pre-Delivery215
Aesthetic Inspection216
Tightening Torques Inspection216
Levels Check217
Road Test217
Static Test218
Functional Inspection218
Time219
Crankcase220
Crankshaft221
Cylinder Assy.222
Cylinder Head Assy.222
Rocker Arms Support Assy.223
Cylinder Head Cover224
Oil Filter225
Driven Pulley226
Oil Pump226
Final Gear Assy.227
Driving Pulley228
Starter Motor229
Flywheel Magneto230
Belt Cooling Duct230
Exhaust Pipe232
Air Cleaner233
Frame234
Legshield Spoiler236
Rear Cover237
Mudguard238
Radiator241
Rear Shock-Absorber242
Handlebar Covers242
Handlebar Components243
Swing-Arm244
Brake Hoses245
Locks247
Front Wheel248
Grease Tone Wheel or Drive249
Rear Wheel250
Electric Devices250
Brake Callipers255
Fuel Tank Filler Flap256
Footrests257
Steering Column257
Rear Side Fairings259
Windscreen260
Secondary Air Box260

PIAGGIO MSS X9 EVOLUTION 250 - Lubrication

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