Piaggio X9 250evo Workshop Manual

WORKSHOP MANUAL
618153
MSS X9 Evolution 250

WORKSHOP
MANUAL
The descriptions and illustrations given in this publication are not binding. While the basic specifications
as described and illustrated in this booklet remain unchanged, PIAGGIO-GILERA reserves the right, at
any time and without being required to update this publication beforehand, to make any changes to
components, parts or accessories, which it considers necessary to improve the product or which are
required for manufacturing or construction reasons.
Not all versions/models shown in this publication are available in all countries. The availability of single
models should be checked at the official Piaggio sales network.
"© Copyright 2007 - PIAGGIO & C. S.p.A. Pontedera. All rights reserved. Reproduction of this publication
in whole or in part is prohibited."
PIAGGIO & C. S.p.A. - After-Sales
V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)
WORKSHOP MANUAL
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. Any important
changes made to the vehicles or to specific fixing operations will be promptly reported by updates to this
manual. Nevertheless, no fixing work can be satisfactory if the necessary equipment and tools are
unavailable. It is therefore advisable to read the sections of this manual relating to specific tools, along
with the specific tool catalogue.
N.B. Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee.
INDEX OF TOPICS
CHARACTERISTICS CHAR
TOOLING TOOL
MAINTENANCE MAIN
TROUBLESHOOTING TROUBL
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
SUSPENSIONS SUSP
BRAKING SYSTEM BRAK SYS
COOLING SYSTEM COOL SYS
CHASSIS CHAS
PRE-DELIVERY PRE DE
TIME TIME
INDEX OF TOPICS
CHARACTERISTICS CHAR
MSS X9 Evolution 250 Characteristics
Rules
This section describes general safety rules for any maintenance operations performed on the vehicle.
Safety rules
- If work can only be done on the vehicle with the engine running, make sure that the premises are well-
ventilated, using special extractors if necessary; never let the engine run in an enclosed area. Exhaust
fumes are toxic.
- The battery electrolyte contains sulphuric acid. Protect your eyes, clothes and skin. Sulphuric acid is
highly corrosive; in the event of contact with your eyes or skin, rinse thoroughly with abundant water
and seek immediate medical attention.
- The battery produces hydrogen, a gas that can be highly explosive. Do not smoke and avoid sparks
or flames near the battery, especially when charging it.
- Fuel is highly flammable and it can be explosive given some conditions. Do not smoke in the working
area, and avoid open flames or sparks.
- Clean the brake pads in a well-ventilated area, directing the jet of compressed air in such a way that
you do not breathe in the dust produced by the wear of the friction material. Even though the latter
contains no asbestos, inhaling dust is harmful.
Maintenance rules
- Use original PIAGGIO spare parts and lubricants recommended by the Manufacturer. Non-original or
non-conforming spares may damage the vehicle.
- Use only the appropriate tools designed for this vehicle.
- Always use new gaskets, sealing rings and split pins upon refitting.
- After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all
the work surfaces except the tapered couplings before refitting.
- After refitting, make sure that all the components have been installed correctly and work properly.
- For removal, overhaul and refit operations use only tools with metric measures. Metric bolts, nuts and
screws are not interchangeable with coupling members with English measurement. Using unsuitable
coupling members and tools may damage the scooter.
- When carrying out maintenance operations on the vehicle that involve the electrical system, make
sure the electric connections have been made properly, particularly the ground and battery connections.
CHAR - 7
Characteristics MSS X9 Evolution 250
Vehicle identification
Chassis prefix: ZAPMXXXX > XXXXXX

Engine prefix: M23XM
Dimensions and mass
DIMENSIONS AND WEIGHT

Specification Desc./Quantity
Empty weight 173 Kg
Wheelbase 1500 mm
Overall height 1450 mm
Saddle height 790 mm
Overall length 2130 mm
Overall width 910 mm
CHAR - 8
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 1
Bore 72 mm
Stroke 60 mm
Piston displacement 244,29 cm3
Compression ratio 10,5 - 11,5 : 1
Timing system Single-head camshaft controlled by left
side chain, 3-arm rockers with threaded
register.
Valve clearance: 0,10 mm
intake 0,15 mm
exhaust
Walbro Carburettor WVFH
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.
Power supply Petrol (with minimum octane level 95,
lead-free) with vacuum pump and
through carburettor.
Max speed xxx Km/h
Spark plug CHAMPION RG4HC
Transmission
TRANSMISSIONS
Transmission With automatic expandable pulley variator, V belt, automatic
clutch, gear reduction unit and transmission housing with
forced-circulation air cooling.
CHAR - 9
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
to improve its passage
Capacities
CAPACITÀ
Rear hub 150 cc (recommended oil: TUTELA ZC 90)
Cooling system ~ 1.2 litres (recommended fluid PARAFLU MOTORIDER).
Fuel tank (including a ~ 2.5 l reserve) ~ 14.5 l
Engine oil approx. 1300 cc (recommended oil Selenia HI Scooter 4 Tech)
Electrical system
ELECTRIC COMPONENTS 250

Ignition type Electronic capacitive discharge ignition (CDI) and variable ad-
vance, with separate HV coil.
Spark plug CHAMPION RG4HC
Battery 12V-12Ah
Generator Three-phase alternating current
Variable spark advance 10° ± 1 at 2000 Rpm
28° ± 1 at 6500 Rpm
Frame and suspensions
CHASSIS AND SUSPENSIONS

Rear wheel max. travel 90 mm.
Rear suspension Engine with oscillating fork articulated to the chassis by means
of a double swinging arm. Double-acting hydraulic shock ab-
sorbers, coaxial helicoidal spring with variable step, adjustable
at preloading on 4 positions.
Front fork stroke 90 mm
Front suspension Hydraulic telescopic fork with Ø 35-mm stem
Type of chassis Welded tubular steel chassis with stamped sheet reinforce-
ments.
X9 Evolution 125-250-500:
Please take note that, starting from chassis serial number ZAPM2300003509521, the front small chas-
sis fixing system has changed in order to improve its locking to the chassis. Therefore we have
introduced:
• N°2 screws drawing 432142
• N°2 4x11x0 external teeth spring washers drawing 012533
CHAR - 10
• N°2 nuts drawing 968224
Brakes
BRAKES
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 34 mm twin plungers
Integral braking system Left lever acts on the left front and rear discs, through a valve
that distributes the pressure; the right lever acts on the right
front disc only
Wheels and tyres
WHEELS AND TYRES

Tyre pressure (when cold) Front: 2.1 bar Rear: 2.3 bar (2.5 bar with driver and luggage)
Tyres Front: 120/70-14" 55P Rear: 140/60-14" 64P
Light alloy rims Front rim: 3.50x14" Rear rim: 3.50x14"
Secondary air
General notes:
The SAS for Quasar 250 Euro 2 engines operates
in a similar manner to the SAS for 2T engines.
The differences are the following:
instead of entering through the muffler as for 2T
engine, the secondary air enters directly in the dis-
charge pipe on the head.
The 2T reed valve has a diaphragm. The unit
"A", indicated in the figure, has a cut-off device
connected to the depression intake on the inlet
CHAR - 11
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.
Now, the filtered air enters the diaphragm device
"A" and then is channelled to the head.
The air passes through a flanged pipe "E"connec-
ted to the air head and reaches a discharge joint
in order to supply oxygen to the unburned gases
before the catalytic converter, thus favouring an
improved reaction of the catalytic converter.
Carburettor
250cc Version
Keihin
KEHIN CARBURETTOR
Depression carburettor CVEK-30
Body stamping CVEK
Stamping 303A
Tapered pin notches position from top Fixed position
Max. air jet 70
Diffuser nozzle Ø 2.8
Starter jet 42
Starter device resistance ~ 20 Ω
Diffuser Ø 29
CHAR - 12
Tapered pin stamping NDWA
Minimum mixture set screw initial opening ±¼
Throttle valve spring 150 ÷ 250 g
Minimum air jet 115
Minimum jet 38
Max. jet 100
Starter air jet Ø 1.5 (body)
Starter diffuser nozzle Ø 1.5 (body)
N.B.
THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE
Walbro
WALBRO CARBURETTOR
Tapered pin notches position from top 3
Tapered pin stamping 465
Minimum mixture set screw initial opening 3 ± 1/4
Throttle valve spring 120 g
Minimum air jet 50
Max. air jet 150
Minimum jet 34
Max. jet 118
Body stamping 7HO
Vacuum type WVF-7H*
Diffuser Ø 29 (30.3x27.0)
Starter jet 50
Starter diffuser jet 130
Starter air jet 200
Diffuser nozzle Ø 2.7
Stamping
N.B.
THE IDENTIFICATION LETTER CAN VARY WITH EACH CARBURETTOR UPDATE
Tightening Torques
REAR BRAKE
Product Description Specifications
(°) Loctite 243 Medium-strength threadlock Apply LOCTITE 243 medium-strength
threadlock
FRONT BRAKE
Name Torque in Nm
Oil bleed screw 8÷12
Disc tightening screw (°) 5-6
Brake fluid pipe-calliper fitting 16 ÷ 20
Brake fluid pump-hose fitting 16 ÷ 20
Tightening screw for calliper support to the fork 45 ÷ 55
REAR SUSPENSION
Name Torque in Nm
Upper shock absorber clamp 33 ÷ 41
Lower shock absorber clamp 33 ÷ 41
Rear wheel axle 104 ÷ 126
FRONT SUSPENSION
Name Torque in Nm
Fork leg screw 6÷7
CHAR - 13
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 ÷ 25
Frame-swinging arm bolt 66 ÷ 80
Engine-swinging arm bolt 33 ÷ 41
STEERING
Name Torque in Nm
Upper steering ring nut 30 ÷ 36
Steering lower ring nut 10 ÷ 13 then loosen by 90°
Handlebar fixing screw (*) 45 ÷ 50
Fixing screws for handlebar control assembly U-bolts 7 ÷ 10
ENGINE - COOLING
(°) Loctite 243 Medium-strength threadlock Apply LOCTITE 243 medium-strength
threadlock
CRANKCASE AND CRANKSHAFT

Name Torque in Nm
Internal engine crankcase bulkhead (transmission-side half 4÷6
shaft) screws
Engine-crankcase coupling screws 11 ÷ 13
Starter motor screws 11 ÷ 13
Crankcase timing system cover screws (°) 3.5 ÷ 4.5
ENGINE - FLYWHEEL
Name Torque in Nm
Pick-Up clamping screws 3÷4
Stator assembly screws (°) 3÷4
Flywheel cover fixing screws 5-6
Flywheel nut (250) 94 ÷ 102
Screw fixing freewheel to flywheel 13 ÷ 15
ENGINE - TRANSMISSION
Name Torque in Nm
Rear hub cover screws 24 ÷ 27
Driven pulley shaft nut 54 ÷ 60
Transmission cover screws 11 ÷ 13
Drive pulley nut 75 ÷ 83
Clutch unit nut on driven pulley 55 ÷ 60
Belt support roller screw 11 ÷ 13
ENGINE - CYLINDER HEAD

Name Torque in Nm
Manifold-silencer retaining bolt 15 ÷ 20
Nut fixing muffler to cylinder head 16 ÷ 18
Camshaft retention plate screw 4÷6
Timing chain tensioner central screw 5-6
Timing chain tensioner support screw 11 ÷ 13
Starter ground support screw 11 ÷ 15
Timing chain tensioner slider screw 10 ÷ 14
Inlet manifold screws 11 ÷ 13
Tappet set screw lock nut 6÷8
Starter ground screw 7 ÷ 8.5
Head fixing side screws 11 ÷ 12
CHAR - 14
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 ÷ 33
Engine oil drainage plug/mesh filter 24 ÷ 30
Oil filter 4÷6
Oil pump cover screws 0.7 ÷ 0.9
Screws fixing oil pump to crankcase 5-6
Oil pump control crown screw 10 ÷ 14
Oil pump cover plate screws 4÷6
Oil sump screws 10 ÷ 14
Minimum oil pressure sensor 12 ÷ 14
N.B.
Before fitting the nuts, lubricate them with engine oil
N.B.
Use new nuts
NOTE DI ASSISTENZA TECNICA
For correct tightening, the expansion tank cap locking torque has been standardised to 2.5 Nm
Overhaul data
Assembly clearances
Cylinder - piston assy.
COUPLING CATEGORIES ENGINE 250

Name Initials Cylinder Piston Play on fitting
Cylinder / piston A 71.990 ÷ 71.997 71.953 ÷ 71.960 0.030 - 0.044
Cylinder / piston B 71.997 ÷ 72.004 71.960 ÷ 71.967 0.030 - 0.044
Cylinder / piston C 72.004 ÷ 72.011 71.967 ÷ 71.974 0.030 - 0.044
Cylinder / piston D 72.011 ÷ 72.018 71.974 ÷ 71.981 0.030 - 0.044
CHAR - 15
Piston rings
SEALING RINGS
Name Description Dimensions Initials Quantity
Compression ring 72 x 1.5 A 0.15 ÷ 0.30
Oil scraper ring 72 x 1 A 0.20 ÷ 0.40
Oil scraper ring 72 x 2.5 A 0.20 ÷ 0.40
CHAR - 16
Crankcase - crankshaft - connecting rod
Characteristic
Driving shaft / crankcase axial clearance
A= 0,15 ÷ 0,43 (when cold)
CRANKSHAFT
Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine
Crankshaft Crankshaft to crankcase axial
clearance
Crankshaft to crankcase axial clearance
CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name Description Dimensions Initials Quantity
Half-shaft, transmission 16.6 +0-0.05 A D = 0.20 - 0.50
side
Flywheel-side half-shaft 16.6 +0-0.05 B D = 0.20 - 0.50
Connecting rod 18 -0.10 -0.15 C D = 0.20 - 0.50
Spacer tool 51.4 +0.05 E D = 0.20 - 0.50
CHAR - 17
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
FURTHER THE PISTON FALLS INSIDE THE
CYLINDER, THE LESS THE BASE GASKET IS
TO BE APPLIED (TO RECOVER THE COM-
PRESSION RATIO) AND VICE VERSA.
ENGINE 250 SHIMMING

Name Measure A Thickness
shimming 3.70 - 3.60 0.4 ± 0.05
shimming 3.60 - 3.40 0.6 ± 0.05
shimming 3.40 - 3.30 0.8 ± 0.05
Products
PRODUCTS
AGIP GREASE PV2 Grease for steering bearings and spindle Soap-based lithium and zinc oxide
seats grease containing NLGI 2; ISO-L-
XBCIB2 of the swinging arm
MONTBLANC MOLYBDENUM Grease for driven pulley shaft adjusting Grease with Molybdenum disulphide
GREASE ring and movable driven pulley housing
AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-
creased adhesiveness
AGIP GREASE MU3 Grease for odometer transmission gear Soap-based lithium grease with NLGI 3;
case ISO-L-XBCHA3, DIN K3K-20
AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the
requirements of API SL, ACEA A3, JASO
MA specifications
AGIP GP 330 Calcium complex soap-based grease Grease (brake control levers, throttle
with NLGI 2; ISO-L-XBCIB2 grip)
AGIP CITY HI TEC 4T Four-stroke engine oil Lubricating oil for flexible shafts (throttle
control)
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-
quirements of API GL3 specifications
AGIP PERMANENT SPEZIAL coolant Monoethylene glycol-based antifreeze
fluid, CUNA NC 956-16
CHAR - 18
INDEX OF TOPICS
TOOLING TOOL
Tooling MSS X9 Evolution 250
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
MSS X9 Evolution 250 Tooling

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

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

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
TOOL - 23

020364Y 25-mm guide
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
TOOL - 24

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

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

020382Y Valve cotters equipped with part 012 re-
moval tool
020455Y 10-mm guide
020442Y Pulley lock wrench
020329Y MityVac vacuum-operated pump
020409Y Multimeter adaptor - Peak voltage detec-
tion
TOOL - 27

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
TOOL - 28

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
TOOL - 29

020628Y Water pump service kit
TOOL - 30
INDEX OF TOPICS
MAINTENANCE MAIN
Maintenance MSS X9 Evolution 250
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
Steering - adjustment
Brake control levers - greasing
Brake pads - check condition and wear
Brake fluid level - check
Safety locks - check
Electrical system and battery - check
Tyre pressure and wear - check
Vehicle and brake test - road test
(*) See rules in the «Adjusting the engine idle» section
AT 6000 KM OR 12 MONTHS
Action
engine oil- change(125)
Hub oil level - check
Spark plug/ electrode gap - check
Air filter - clean
oil filter - change(125)
valve clearance 125 - check
Sliding blocks / variable speed rollers - check
Driving belt - checking
Coolant level - check
AT 12000 KM OR 24 MONTHS AND AT 60000 KM

Action
Spark plug / electrode gap - check / replacement
Air filter - clean
Engine oil - change
Sliding block / variable speed rollers - change
Transmission elements - lubrication
Suspensions - check
Headlight - adjustment
Transmission Belt (125 cc) - Replacement
Transmission Belt - Check (250)
MAIN - 32
MSS X9 Evolution 250 Maintenance
AT 18000 KM AND AT 54000 KM

Action
Air filter - clean
250 cc Valve Play - Check
Sliding blocks / variable speed rollers - check
Radiator - external cleaning/ check
Secondary air filter (250) - Cleaning
Transmission Belt - Replacement (250)
AT 24000 KM AND AT 48000 KM

Action
Hub oil - change
Air filter - clean
Engine oil - change
Suspensions - check
Transmission Belt - Check (250)
AT 30000 KM, AT 42000 KM AND AT 66000 KM

Action
Air filter - clean
Variable speed rollers - check or replacement
Driving belt - checking
MAIN - 33
AT 36000 KM
Action
Air filter - clean
Engine oil - change
Driving belt - replacement
Brake fluid hoses - replacement
Suspensions - check
AT 72000 KM
Action
Hub oil - change
Air filter - clean
Engine oil - change
Driving belt - replacement
Brake fluid hoses - replacement
Suspensions - check
EVERY 2 YEARS
Action
Coolant - change
Brake fluid - change
MAIN - 34
Action
Secondary air filter (external/internal) - cleaning (125)
EVERY 3,000 KM
10'
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.
- Check carefully that the parts are in good condition.
- The throttle valve should move freely in the chamber. Replace it in case of excessive clearance due
to wear.
- If there are wear marks in the chamber causing inadequate tightness or a free valve slide (even if it
is new), replace the carburettor.
- It is advisable to replace the gaskets at every refit
WARNING
PETROL IS HIGHLY EXPLOSIVE ALWAYS REPLACE THE GASKETS TO AVOID PETROL LEAKS
Checking the spark advance
- To check the ignition advance, use the strobo-

scopic lamp with induction collet connected to the
spark plug power supply cable.
- Connect the induction collet according to the right
polarity (the arrow on the collet must be facing the
spark plug).
- Set the lamp selector to the central position (1
spark = 1 driving shaft revolution as in 2 stroke
engines).
- Start the engine and check that the lamp is in
good working order and that the rpm counter reads
high speeds too (e.g. 8,000 rpm).
- If you detect abnormal flashes or rpm reads, in-
crease the resistive load on the spark plug supply
line (10 - 15 KΩ in series with the H.V. cable).
- Remove the slit plastic cap on the flywheel cover.
- Adjust the lamp flash dephasing corrector to
make the reference on the flywheel cover collimate
with the level on the water pump drive. Read the
MAIN - 35
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);
replace the control unit, if required.
- A new control unit prevents the engine from ro-
tating at over 2,000 rpm.
- The programmed control unit allows the engine
revolution within the prescribed limits.
Specific tooling
020330Y Stroboscopic light to check timing
Characteristic
250 spark advance check
10° ± 1° at 2000 Rpm
32° ± 1° at 6000 Rpm
Spark advance variation
Characteristic
Operation threshold
First threshold : 9600±50
Second threshold : 9800±50
Reactivation threshold
First threshold : 9500±50
Second threshold : 9700±50
Spark elimination
First threshold : 1 spark on 7
Second threshold : 2 sparks on 3
MAIN - 36
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.
- Using the supplied spanner (provided with retain
rubber cap), remove the spark plug.
- Disconnect the spark plug lug and remove it.
- Inspect it carefully; if the insulator is damaged or
chipped, replace it.
- Measure the distance between the electrodes
using a thickness gauge, if required, adjust it by
carefully bending the external electrode.
- Make sure that the sealing washer is in good
working order.
MAIN - 37
- 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. THE USE OF NON CONFORMING IGNI-
TION CONTROL UNITS OR SPARK PLUGS OTHER THAN
THOSE PRESCRIBED CAN SERIOUSLY DAMAGE THE EN-
GINE.
Characteristic
Spark plug: electrode distance
0.7 mm ÷ 0.8 mm
Electric characteristic
Recommended spark plug:
CHAMPION RG4HC
Locking torques (N*m)

Spark plug 12 ÷ 14
Hub oil
Check
Level check:
- Move the vehicle to a flat ground and rest it on the stand.
- Unscrew the oil bar, dry it with a clean cloth and reinsert it, screwing it in thoroughly.
- Extract the bar and check that the oil level reaches the second notch of the bar from the bottom.
- 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
MAIN - 38
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.).
Air filter
Remove the air cleaner cap after undoing the re-

tainer screws, then extract the filter.
- Wash with water and neutral soap.
-Dry with a clean cloth and short blasts of com-
pressed air.
- Soak with a mixture of 50% petrol and 50% SE-
LENIA AIR FILTER OIL.
-Drip dry the filter and then squeeze it between the
hands without wringing.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE AIR FILTER,
THIS WOULD RESULT IN AN EXCESSIVE WEAR OF THE
PISTON AND CYLINDER.
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER
MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE
SCHEDULED MAINTENANCE CHART.
Engine oil
MAIN - 39
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.
- Install a new oil filter lubricating the filter sealing
O-Ring with engine oil.
- Tighten the drainage cap again and fill with ~ 600
- 650 cc oil.
- Start the engine, let it run for a few minutes and
then stop it.
- Wait a few minutes, then remove the cap - bar
and check the level. Fill in with the prescribed oil
up to reach the MAX level.
Check
This operation must be carried out with the engine cold and following the procedure below:
1. Place the vehicle on its centre stand and on flat ground.

2. Undo cap/dipstick "A", dry it off with a clean cloth and replace it, screwing down completely.
3. Remove the cap/dipstick again and check that the level is between the min and max. marks; top
up if necessary.
The MAX level mark indicates a quantity of around 1300 cc of engine oil. If the check is carried out after
the vehicle has been used, and therefore with a hot engine, the level line will be lower; in order to carry
out a correct check, wait at least 10 minutes after the engine has been stopped so as to get the correct
level.
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 cc.
MAIN - 40
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
sure that the 4V reference point on the camshaft
control pulley is aligned with the reference point on
the head as shown in the second figure. If the ref-
erence is opposite the indicator on the head, turn
the crankshaft once more.
For the use of this reference mark, remove the
spark plug and turn the engine in the direction that
is the reverse of the normal direction using a cal-
liper spanner applied to the camshaft command
pulley casing.
Checking the valve clearance
-To check valve clearance, centre the reference

marks of the timing system
- Use a thickness gauge to check that the clear-
ance between the valve and the register corre-
sponds with the indicated values. When the valve
clearance values, intake and drainage respective-
ly, are different from the ones indicated below,
adjust them by loosening the lock nut and operate
on the register with a screwdriver as shown in the
figure.
Intake: 0.10 mm (when cold)
Discharge: 0.15 mm (when cold)
Cooling system
MAIN - 41
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.
The packaged coolant supplied is ready-mixed
and ready for use.
To ensure correct engine performance, the cool-
ant temperature should be between 60°C min. and
105°C max. as indicated on the relevant instru-
ment «D» with the coloured references on the
analogue instrument panel. If the needle goes into
the red , switch the engine off, allow it to cool then
check the coolant level. If the fluid is within the
normal limits, perform the cooling system checks.
The coolant level should be checked every 6,000
km with the engine cold, following the instruction
given below.
a) Put the vehicle in an upright position on the
kickstand.
b) Remove the expansion tank cap «A» by turning
it anti-clockwise.
c) Look inside the expansion tank: the minimum
and maximum levels are marked on the plastic in-
side the expansion tank.
d) Top up if the level of coolant is beneath the min.
level mark inside the expansion tank.
The coolant level must always be between the min.
and max. levels. If the coolant level is close to the
min. marking, top up as required when the engine
is cold. If frequent topping up is required or if the
expansion tank is completely dry, the cooling sys-
tem needs to be investigated.
The coolant must be replaced every 2 years.
WARNING
MAIN - 42
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.
IN ORDER TO GUARANTEE THE PROPER FUNCTION OF
THE ENGINE, IT IS NECESSARY TO KEEP THE RADIATOR
GRILLE CLEAN.
Recommended products
AGIP PERMANENT SPEZIAL coolant
Monoethylene glycol-based antifreeze fluid, CU-
NA NC 956-16
Braking system
Level check
The front and rear brake fluid tanks are placed on

the pumps under the handlebar covers. Proceed
as follows:
1. Put the vehicle up on the central kickstand and
with the handlebar centred;
2. Remove cover «A» by unscrewing the fixing
screw «B»;
3. Check the fluid level using the relevant window
«C».
MAIN - 43
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.
- Remove the plate to access the flow adjustment
screw on the carburettor.
- Remove the gas cap on the exhaust pipe.
- Using the original washer, install the exhaust gas
collection Kit union.
- Suitably orientate the components (Figure 2).
- Close the gas outlet terminal of the tool. - Start
the engine and let it warn until the electric fan
starts.
- Stop the engine.
- Disconnect the vacuum feeding pipe from the
SAS control valve.
- Insert a conical plug into the vacuum feeding
pump.
- Connect the MITIVAC vacuum pump to the SAS
control valve using a suitable pipe having the same
size as the original fitted on the vehicle.
- Start the vacuum up to -0.6 -0.8 Bar so as to close
the valve and cut off the SAS system.
- Remove the exhaust gas collection Kit closing
cap and connect the analyser properly pre-heated.
N.B.
IN CASE OF 1000 PPM UNBURNED HYDROCARBONS
(HC) >, CHECK THE IGNITION SYSTEM, THE TIMING SYS-
TEM, THE VALVE CLEARANCE AND THE EXHAUST
VALVE TIGHTNESS.
N.B.
IN CASE OF UNSTABLE CO, CHECK THAT THE CARBU-
RETTOR IS CLEAN AND THAT THE FUEL SUPPLY SYS-
TEM AND THE DEPRESSION SEALS WORK ADEQUATE-
LY
N.B.
OTHERWISE, CHECK THE FUEL LEVEL ADJUSTMENT IN
THE TANK AND THE FUEL CIRCUIT.
N.B.
MAIN - 44
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 ± 0.7 AT 1,650 ± 50 RPM.
Specific tooling
020332Y Digital rev counter
494929Y Exhaust fumes analyser
SAS filters inspection and cleaning
Undo the 2 fixing screws of the secondary air filter

cover indicated in the figure, remove the cover and
then take out the filtering element.
- Wash with water and mild soap.
pressed air.
Remove the flywheel cover by operating on its
clamps and remove the primary filtering element.
- Wash with water and neutral soap.
pressed air.
Check that the filter housing is cleaned.
CAUTION
NEVER RUN THE ENGINE WITHOUT THE SECONDARY
AIR FILTER
CAUTION
WHEN TRAVELLING ON DUSTY ROADS, THE AIR FILTER
MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE
SCHEDULED MAINTENANCE CHART.
MAIN - 45
INDEX OF TOPICS
TROUBLESHOOTING TROUBL
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; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re-
place
Excess of encrustations in the combustion chamber Descale the cylinder, the piston, the head and the valves
Incorrect timing or worn timing system elements Time the system again or replace the worn parts
Muffler obstructed Replace
Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then
soak it in a mixture of 50% petrol and 50% of specific oil (Se-
lenia Air Filter Oil), then hand dry without squeezing, allow to
drip dry and then reassemble.
Automatic starter failure Check: mechanical movement, electric connection and fuel
supply, replace if required.
Oil level exceeds maximum Check for causes and fill to reach the correct level
Lack of compression: parts, cylinder and valves worn Replace the worn parts
Transmission belt worn Replace
Inefficient automatic transmission Check the rollers and the pulley movement, replace the dam-
aged parts and lubricate the driven pulley moveable guide with
Montblanc Molybdenum Grease
Clutch slipping Check the clutch system and/or the bell and replace if neces-
sary
Overheated valves Remove the head and the valves, grind or replace the valves
Wrong valve adjustment Adjust the valve clearance properly
Valve seat distorted Replace the head assembly
Air filter dirty Dismantle the sponge, wash with water and shampoo, then
Defective floating valve Check the proper sliding of the float and the functioning of the
valve
Rear wheel spins at idle
REAR WHEEL ROTATES WITH ENGINE AT IDLE

Idling rpms too high Adjust the engine idle speed and the CO%, if necessary.
Clutch fault Check the springs / clutch masses
Starting difficulties
DIFFICULT STARTING
Altered fuel characteristics Drain off the fuel no longer up to standard; then, refill
Rpm too low at start-up or engine and start-up system dam- Check the starter motor, the system and the torque limiter
aged
Incorrect valve sealing or valve adjustment Inspect the head and/or restore the correct clearance
- Engine flooded. Try starting-up with the throttle fully open. If the engine fails to
start, remove the spark plug, dry it and before refitting, make
the motor turn so as to expel the fuel excess taking care to
TROUBL - 47
Troubleshooting MSS X9 Evolution 250

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.
Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components
The carburettor is dirty; fuel pump or vacuum valve damaged Remove, wash with solvent and dry with compressed air or re-
place
Battery flat Check the charge of the battery, if there are any sulphur marks,
replace and use the new battery following the instructions
shown in the chapter
Intake coupling cracked or clamps incorrectly tightened Replace the intake coupling and check the clamps are tight-
ened
Defective floating valve Check the proper sliding of the float and the functioning of the
valve
Carburettor nozzles clogged Dismantle, wash with solvent and dry with compressed air
Excessive oil consumption/Exhaust smoke
EXCESSIVE OIL CONSUMPTION/SMOKEY EXHAUST

Worn valve guides Check and replace the head unit if required
Worn valve oil guard Replace the valve oil guard
Oil leaks from the couplings or from the gaskets Check and replace the gaskets or restore the coupling seal
Worn or broken piston rings or piston rings that have not been Replace the piston cylinder unit or just the piston rings
fitted properly
Insufficient lubrication pressure
POOR LUBRICATION PRESSURE

By-Pass remains open Check the By-Pass and replace if required. Carefully clean the
By-Pass area.
Oil pump with excessive clearance Perform the dimensional checks on the oil pump components
Oil filter too dirty Replace the cartridge filter
Oil level too low Restore the level using the recommended oil type (Selenia HI
Scooter 4 Tech)
Engine tends to cut-off at full throttle
ENGINE STOP FULL THROTTLE

Faulty fuel supply Check or replace the pump and the vacuum valve, check the
vacuum intake and the pipe sealing
Incorrect float level Restore the level in the tank by bending on the float the thrust-
ing reed of the petrol inlet rod so as to have the float parallel to
the tank level with the carburettor inverted.
Water in the carburettor Empty the tank through the appropriate bleed nipple.
Maximum nozzle dirty - lean mixture Wash the nozzle with solvent and dry with compressed air
TROUBL - 48
Engine tends to cut-off at idle
ENGINE STOP IDLING

Incorrect timing Time the system and check the timing system components
Cut off device failure Check that the following parts work properly: valve; diaphragm;
spring; and that the air calibration elements are clean; check if
the sponge filter is clean too
Incorrect idle adjustment Adjust using the rpm indicator
Pressure too low at the end of compression Check the thermal group seals and replace worn components
Faulty spark plug or incorrect ignition advance Replace the spark plug or check the ignition circuit components
The starter remains on Check: electric wiring, circuit not interrupted, mechanical
movement and power supply; replace if necessary
Minimum nozzle dirty Wash the nozzle with solvent and dry with compressed air
Excessive exhaust noise
EXCESSIVE EXHAUST NOISE

Secondary air device cut-off valve not working Replace the secondary air device
Depression intake pipe of the secondary air device disconnec- Replace the pipe
ted or dented
Reed valve of the secondary air device does not close correctly Replace the device and the coupling
and wears out the rubber coupling between the device and the
head pipe
High fuel consumption
HIGH FUEL CONSUMPTION

Float level Restore the level in the tank by bending on the float the thrust-
ing reed of the petrol inlet rod so as to have the float parallel to
the tank level with the carburettor inverted.
Loose nozzles Check the maximum and minimum nozzles are adequately
fixed in their fittings
Fuel pump failure Check that there is no fuel in the low-pressure duct
Starter inefficient Check: electric wiring, circuit continuity, mechanical sliding and
power supply
SAS malfunctions
ANOMALIES IN THE SECONDARY AIR DEVICE

Secondary air device cut-off valve not working Replace the secondary air device
Depression intake pipe of the secondary air device disconnec- Replace the pipe
ted or dented
Reed valve of the secondary air device does not close correctly Replace the device and the coupling
and wears out the rubber coupling between the device and the
head pipe
TROUBL - 49
Troubleshooting MSS X9 Evolution 250
Transmission and brakes
Clutch grabbing or performing inadequately
IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE

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.
Check that the clutch casing is not scored or worn in an anom-
alous way
Insufficient braking
INSUFFICIENT BRAKING
Inefficient braking system Check the pad wear (1.5 min). Check that the brake discs are
not worn, scored or warped. Check the correct level of fluid in
the pumps and change brake fluid if necessary. Check there is
no air in the circuits; if necessary, bleed the air. Check that the
front brake calliper moves in axis with the disc.
Fluid leakage in hydraulic braking system Failing elastic fittings, plunger or brake pump seals, replace
Brakes overheating
BRAKES OVERHEATING
Rubber gaskets swollen or stuck Replace gaskets.
Compensation holes on the pump clogged Clean carefully and blast with compressed air
Brake disc slack or distorted Check the brake disc screws are locked; use a dial gauge and
a wheel mounted on the vehicle to measure the axial shift of
the disc.
Defective piston sliding Check calliper and replace any damaged part.
Electrical system
Battery
BATTERY
Battery This is the device in the system that requires the most frequent
attention and the most thorough maintenance. If the vehicle is
not used for some time (1 month or more) the battery needs to
be recharged periodically. The battery runs down completely in
the course of 3 months. If the battery is fitted on a motorcycle,
be careful not to invert the connections, keeping in mind that
the black ground wire is connected to the negative terminal
while the red wire is connected to the terminal marked+.
Battery compartment plug
TROUBL - 50
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.
Turn signal lights malfunction
TURN INDICATOR NOT WORKING

Electronic ignition device failure With the key switch set to "ON" jump the contacts 1 (Blue -
Black) and 5 (Red/Blue) on the control unit connector. If by
operating the turn indicator control the lights are not steadily
on, replace the control unit; otherwise, check the cable harness
and the switch.
Steering and suspensions
Controls
STEERING CONTROLS AND SUSPENSIONS

Torque not conforming Check the tightening of the top and bottom ring nuts. If irregu-
larities in turning the steering continue even after making the
above adjustments, check the seats on which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.
Steering hardening Check the tightening of the top and bottom ring nuts. If irregu-
larities continue in turning the steering even after making the
above adjustments, check the seats in which the ball bearings
rotate: replace them if they are recessed or if the balls are flat-
tened.
Malfunctions in the suspension system If the front suspension is noisy, check: the efficiency of the front
shock absorbers; the condition of the ball bearings and relevant
lock-nuts, the limit switch rubber buffers and the movement
bushings. In conclusion, check the tightening torque of the
wheel hub, the brake calliper, the shock absorber disk in the
attachment to the hub and the steering tube.
Seal fault or breakage Replace the shock absorber Check the condition of wear of the
steering covers and the adjustments.
TROUBL - 51
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS

MSS X9 Evolution 250 Electrical system
ELECTRIC SYSTEM DIAGRAM

1 Front left direction indicator 1 bulb 12V - 10W
2 Outside temperature sensor
3 Combined brake stop button
4 Light switch
5 Indicators switch
6 Horn button
7 Emergency flashing button
8 "Reset" button
9 Front fuse holder box
10 Output for immobilizer diagnostic instrument
11 Fuse 7.5 A
12 Fuses 10A
13 Engine stop remote control switch
14 Headlight remote control switch
15 Connector fitting for PICS control unit
16 Diode
17 Connector fitting for PICS control unit
18 Analogue instrument unit
19 PICS display fitting
ELE SYS - 53
Electrical system MSS X9 Evolution 250
20 Digital instrument unit
21 Front headlight N° 2 position bulbs 12V - 5W, N° 1 dipped beam bulb
12V- 55W, N° 1 upper beam bulb 12V - 55W
22 Wheel RPM sensor
23 Front brake stop button
24 Engine stop switch
25 Front right direction indicator N° 1 bulb 12V - 10W
26 Connector fitting for saddle opening device
27 Fitting for accessories
28 Anti-theft alarm fitting
29 Start up button
30 Key switch
31 Immobilizer aerial
32 Radiatore electric fan motor
33 Thermal switch for electric fan
34 Electronic ignition
35 Fuel level sender
36 HV coil
37 Thermistor
38 Oil pressure sensor
39 Pick - up
40 Automatic starter
41 Magneto flywheel
42 Rear right headlight N° 1 bulb 12V - 55W for position light, N° 1 bulb 12V -
10W for flashing light
43 License plate light bulb Type: ALL GLASS
Power: 12V - 5W
Quantity: 1
44 Stop light N° 5 bulbs 12V-2.3W
45 Remote starter switch
46 Diodo
47 Battery 12V-12Ah
48 Fuse 15A
49 Fuse (Rear position light protection, number plate light, 7.5A
front position light)
50 Fuse 10 A
51 Rear fuse holder box
52 Helmet compartment lamp bulb 12V-5W
53 Helmet compartment lighting button
54 Socket for users 12V - 180W max
55 Starter motor
56 Rear left headlight N° 1 bulb 12V - 55W for position light, N° 1 bulb 12V -
10W for flashing light
57 Voltage regulator
58 Saddle opening button
59 Saddle opening actuator
60 Stand switch
61 Horn
Wiring colour chart:

B=White - Bl=Blue - G=Yellow - M=Brown - N=Black - BV=White-Green - GN=Yellow-Black - Gr=Grey
- Rs=Pink - R=Red - Vi=Purple - V=Green - VN=Green-Black - BN=White-Black - BBl=White-Blue -
GV=Yellow-Green - Ar=Orange - GrBl=Grey-Blue - GrN=Grey-Black - BR=White-Red - RN=Red-Black
- BlN=Blue-Black.
CAUTION
SHOULD ANY INTERVENTIONS TO THE ELECTRIC SYSTEM BE REQUIRED, MAKE SURE THAT
THE LEADS TO THE ELECTRONIC IGNITION DEVICE ARE PROPERLY CONNECTED ACCORD-
ING TO POLARITY AND TO THE LEAD COLOURS.
Conceptual diagrams
ELE SYS - 54
Ignition
IGNITION SECTION
1 Pick - up
2 Magneto flywheel
3 Key switch contacts
4 Electronic controller
5 Spark plug
6 HV coil
7 Immobilizer aerial
8 Voltage regulator
9 Voltage regulator
10 Diagnostic tester outlet
11 Fuse 15A
12 Immobilizer LED
13 Battery 12V-12Ah
ELE SYS - 55
Headlights and automatic starter section
HEADLIGHTS AND AUTOMATIC STARTER SECTION

1 Electronic control unit
2 Voltage regulator
3 Battery 12V 12Ah
4 Automatic starter
6 Light switch
7 Light switch
8 Light remote control switch
9 Fuse (headlight remote control protection) 10 A
10 Helmet compartment lamp bulb 12V-5W
11 Fuse (upper beam protection) 10 A
12 Bulb for upper beams 12V-55W
13 Bulb for dipped beams 12V-55W
14 Fuse (Rear position light protection, number plate light, 7.5A
front position light)
15 Bulbs N° 2 12v-3w front pos. Lights, n° 2 12v-5w rear pos.
Lights, n° 1 12v-5w number plate light
16 Fuse 15A
17 Socket for users 12V - 180W max
18 Helmet compartment lighting button
ELE SYS - 56
Battery recharge and starting
BATTERY RECHARGE AND START-UP

2 Magneto flywheel
3 Fuse 5A
4 Remote starter switch
5 Voltage regulator
6 Starter motor
7 Battery 12V-12Ah
8 Start-up enable and front stop button
9 Start-up enable and rear stop button
10 Digital instrument
11 Start up button
12 Fuse 15 A
13 Diode 1A
14 Stop light N° 5 bulbs 12V-2.3W
15 Electronic ignition
16 Engine stop relay
17 Engine stop switch
18 Stand switch
19 Engine not enable indicator
ELE SYS - 57
Level indicators and enable signals section
LEVEL INDICATORS AND ENABLE SIGNALS

1 Digitsl instrument
2 Analogue instrument unit
3 Thermistor
4 Outside temperature sensor
5 Wheel RPM sensor
6 Fuel level sender
7 Oil pressure sensor
8 "Reset" button
9 Emergency button
10 Fuse 10 A
12 Radiatore electric fan motor
13 Thermal switch for electric fan
14 Magneto flywheel
15 Voltage regulator
16 Fuse 15A
ELE SYS - 58
17 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.
Turn signal lights
FLASHING LIGHTS, HORN AND ACCESSORY FITTINGS

1 Digital instrument unit
2 Direction indicators N° 2 + 2 bulbs 12V-10W
3 Indicators switch
4 Fitting for accessories
5 Horn button
6 Horn
7 Fuse 10 A
9 Fuses 10A
ELE SYS - 59
10 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:
- electronic control unit
- immobilizer aerial
- master and service keys with built-in transponder
- HV coil
- diagnosis LED
-The diagnostic LED also works as a deterring
blinker. This function is activated every time the
key switch is turned to "OFF" and it remains active
48 hours so as not to damage the battery charging
process.
When the key switch is turned to "ON", this blinking
function is deactivated. A flash then confirms the
system has switched to "ON".
The duration of the flash depends on the electronic
control unit program (see figure).
If the led turns off and remains so when switching
to "ON", it is necessary to check if there is battery
voltage in the electric control unit.
Connect the immobilizer tester to the diagnosis
socket (see ET4 125 manual) located below the
spark plug inspection port.
If the serial LED remains off, proceed to check the
control unit supply as follows:
- Disconnect the control unit connector and check
if:
- There is battery voltage between terminal No. 4
(Red/Black) and the ground lead.
ELE SYS - 60
- 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. 5
and No. 8 with the key switch set to "ON", the side
stand retracted and the emergency switch set to
"RUN".
If no faults are found, replace the control unit; oth-
erwise check the wiring and the following compo-
nents:
- Engine stop remote control;
- Emergency cut-off switch;
- Side stand contacts;
- Key switch contacts.
Virgin circuit
If the ignition system has not been programmed,

the engine can be started but it will run limited to
2000 rpm. When trying to accelerate, some evi-
dent loss of power may be felt.
Program the system with the MASTER (Brown)
and SERVICE (Black) keys as follows:
- Insert the MASTER key, turn it to "ON" and keep
it in that position for 2 seconds (limit values: 1 ÷ 3
seconds).
- Alternately insert all the available black keys and
turn each one of them to "ON" for 2 seconds.
- Insert the MASTER key again and turn it to "ON"
for 2 seconds.
The maximum time to change keys is 10 seconds.
A maximum of 7 (Black) service keys can be pro-
grammed at one time.
ELE SYS - 61
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.
This matching allows programming further service
keys in case of loss, replacement, etc. Each new
time new data is programmed the previously stor-
ed one is deleted.
If a service key setting is lost, it is essential to
carefully check the efficiency of the high voltage
system:
Shielded cap resistance ~ 5000 Ω.
In any case it is advisable to use resistive spark
plugs.
Diagnostic codes
The flash indicating the switching to "ON" can be followed by a phase of programmed failure warnings.
That is, the led is off for 2 seconds, and then diagnosis codes are transmitted with 0.5-second flashes.
After the failure code indication, a steadily on LED signals that ignition is disabled; see the table:
2-FLASH CODE - Example with programmed control unit, no transponder and/or malfunctioning aerial.
Ignition disabled-Vehicle immobilised
3-FLASH CODE - Example with programmed control unit, aerial working properly and unknown trans-
ponder code. Ignition disabled-Vehicle immobilised
Diagnostic code - 2 flashes

Diagnosis code: 2-flashes
ELE SYS - 62
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.
If non-conforming values are measured, replace the aerial.
If no failures are found in the aerial, replace the control unit.
CAUTION
BEFORE PROGRAMMING THE NEW ELECTRONIC CONTROL UNIT CHECK THAT NO FAILURE
CODE IS INDICATED. THIS IS NECESSARY TO AVOID SPOILING A NEW CONTROL UNIT
immobilizer aerial
~ 7 ÷ 9 Ohm
Diagnostic code - 3 flashes
If the 3-flash code is detected, check if the failure

occurs when the MASTER key in inserted into the
key switch.
- If the failure disappears when the MASTER key
is used, proceed to encode the service keys
(Black).
- If the failure persists, it means that the MASTER
key and the control unit are not linked; in this case,
replace the control unit and then encode the keys.
The immobilizer system is efficient when, after
switching over to "ON", only a 0.7-second flash is
detected (see diagram).
In this case, the engine can be started.
Example with programmed control unit, trans-
ponder, programmed key and aerial working prop-
erly.
Ignition is enabled (regular conditions of use)
Ignition circuit
Once the immobilizer system is enabled, the HV coil and the signals from the Pick-Up will produce a
spark in the spark plug.
The battery provides the basic power supply. The system is adjusted so that the start-up system im-
mediately detects an eventual battery voltage drop, but this is practically irrelevant for the ignition
system.
ELE SYS - 63
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.
No spark plug
Once the lack of power to the spark plug has been

detected and the LED indicates it can be ignited,
follow this procedure:
- Pick-Up check.
Disconnect the control unit connector and check
that the cable between terminal No. 2 (Green) and
terminal No. 8 (Black) is not interrupted. Check the
Pick-Up and its power line:
Pick-up resistance value
Pick-up resistance value: 105 ÷ 124 Ohm
If a break in the circuit is found, check again the flywheel and the engine ground connectors (see engine
manual). If non-conforming values are detected, replace the Pick-Up, otherwise check the cable har-
ness and the connections. In case conforming values are measured and the wiring and connections
check is OK, try replacing the control unit (without programming) and make sure the failure has been
solved by checking sparks are produced in the spark plug; only then program the control unit. If no
sparks are produced with the new control unit, proceed as follows.
- HV primary coil check

Disconnect the two connectors on the HV coil and
check continuity (see figure). If non-conforming
values are measured, replace the HV coil. If con-
forming values are measured, check the cable
harness taking into account that the HV coil posi-
tive wire has a branch that comes into the digital
instrument panel (violet cable). Therefore, make
sure this line is in perfect conditions. If failures are
detected, check the HV coil secondary.
High voltage coil primary resistance value
High voltage coil primary resistance value: 0.4 ÷
0.5 Ohm
ELE SYS - 64
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. To carry out a more complete diagnosis, check the peak voltage with the multimeter adaptor.
High voltage coil secondary resistance value
High voltage coil secondary resistance value: ~ 3000 ± 300 Ohm
- Pick-Up.
- Disconnect the control unit connector and con-
nect the positive terminal to connector No. 2 and
the negative terminal to connector No. 8 (see fig-
ure).
Use the start-up system to run the engine and
measure the voltage produced by the Pick-Up.
Replace Pick-Up if non-conforming values are
measured.
Pick-Up voltage value
Pick-Up voltage value: > 2 Volt
- HV coil
With the control unit and HV coil connected, meas-
ure the voltage of the coil primary during the start-
up test with the voltage peak adaptor and con-
necting the positive terminal to the ground one and
the negative to the coil positive connector.
If non-conforming values are measured, replace
the control unit.
N.B.
THE PLASTIC CAP OF THE POSITIVE TERMINAL ON THE
HV COIL PRIMARY IS BLACK AND THE NEGATIVE TER-
MINAL ONE IS GREEN.
ELE SYS - 65
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.
Ohm value:
0.7 ÷ 0.9 Ohm
Also check that all yellow cables are insulated from

the ground connection.
If non-conforming values are detected, repeat the
checks directly to the stator. In case of further rep-
etitions of incorrect values replace the stator or
repair the wiring.
- Using a tester, check the continuity between con-

nection 4-3, 4-1 and 3-1.
- Check the earth insulation on the three stator
phases 4-earth, 3-earth and 1-earth.
Indicative resistance of each phase: 0.7 ÷ 0.9 Ω
Pick-Up Check
- Check that there is a resistance of about 105 ÷
124 Ω at 20°C between connection 2 and earth.
- If you read values other those stated, replace the
defective parts.
N.B.
ELE SYS - 66
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.
The voltage should not exceed 15.2 Volt.
In case higher voltages are detected, replace the
regulator.
In case of voltage values lower than 14 Volt, check
the stator and the corresponding cable harness.
Recharge system voltage check
Connect an ammeter induction clamp to the volt-

age regulator positive terminal, measure the bat-
tery voltage and turning on the vehicles lights with
engine off, wait for the voltage to set at about 12
V. Start the engine and measure the current gen-
erated by the system with lights on and a high
running engine.
In case the generated current value is lower than
10A, repeat the test using a new regulator and/
stator alternatively.
The recharge system is provided with a three phase generator with permanent magneto flywheel. The
generator is directly connected to the voltage regulator. In turn, the latter is directly connected to earth
and to the battery positive passing through the 15A safety fuse. This system therefore requires no
connection to the key switch. The three phase generator allows a considerable recharge power and at
lower rpm it enables a good combination of delivered power and idle steadiness. For this reason, idle
speed must be adjusted according to the prescriptions.
ELE SYS - 67
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).
If voltage is detected, replace the automatic starter
as it is surely failing.
If no voltage is detected, connect the multimeter
negative terminal to the earth terminal and the
positive terminal to the automatic starter orange
cable; with the key switch set to «ON» check
whether there is battery voltage; if there is no volt-
age, check the wiring connections to the key
switch and that the 15A fuse works properly.
If there is voltage, check again the ignition control
unit connector. After disconnecting the starter,
start the engine and keep it at idle speed. Check if
there is voltage when the multimeter positive
probe is connected to the terminal No. 5 (Sky blue)
and the negative one to the terminal No. 7 (Black/
White) (see figure).
Replace the control unit if there is no voltage; oth-
erwise, check the wiring connections between the
starter and the control unit.
Lights list
List of lamps
Number plate lights
12V-5W
Trunk lights
12V-5W
Instrument panel lights
12V-2W x 5
Rear direction indicator lights
12V-10W x 2
ELE SYS - 68
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
12V-55W
Fuses
The electric system is equipped with:

- four protective fuses «A» into the helmet com-
partment,
- four fuses «B» for the system circuitry safety, lo-
cated inside the port in the rear left side of the
shield.
The tables shows the features of the fuses on the
vehicle.
CAUTION
BEFORE REPLACING A BLOWN FUSE, FIND AND SOLVE
THE FAILURE THAT CAUSED IT TO BLOW. NEVER TRY
TO REPLACE THE FUSE USING ANY OTHER MATERIAL
(A PIECE OF ELECTRICAL WIRE, FOR EXAMPLE) OR A
FUSE OF A DIFFERENT RATING THAN THAT SPECIFIED.
Light indicator on digital instrument panel,
front and rear side/taillights
7.5 A
Digital instrument panel, diagnostic led indi-
cator on analogue instrument.
10 A
Brake lights, vehicle start-up enabling signal
7.5 A
Horn, upper beam and indicator on "Passing"
function
10 A
ELE SYS - 69
FUSES
1 Helmet compartment, 12-V socket 15 A
2 General (battery recharge, lights, radiator electric fan, 15 A
electronic control unit).
3 Headlight (upper and dipped beams). 10 A
4 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.
The analogue section includes:
- Tachometer with dual scale (MPH/KMH) controlled by the fifth wheel;
- RPM counter controlled by the signal sent by the H.V. coil.
- Fuel level indicator controlled by a resistive sensor (into the tank)
- Cooling fluid temperature indicator controlled by a resistive sensor (on the head)
These instruments are electrical and managed by stepping motors.
The instrument panel digital section is completed by a liquid crystal display and 4 control buttons.
The display has 3 icons:
- Oil
- Service
- Belt
- The «Oil» icon flashes when 1,000 Km are reached, after that every 3,000 Km.
- The «Service» icon flashes when 1,000 Km or 1 year is reached. After that, it flashes every 6,000 km
or 1 year.
- The «Belt» icon warns the user of the need of replacing the driving belt. This occurs every 12,000 Km
ELE SYS - 70
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
H: Upper beams on
I: Left direction indicator
L: Emergency lights (four direction indicators)
M: Right direction indicator
* The DGT instrument does not include the LEDs for the indicator light fittings
The fuel reserve, direction indicators and emergency flashing functions are activated by the instrument
electronics. For example, the fuel reserve indicator light only turns on when the reserve indication com-
ing from the engine lasts at least 13.5 seconds. This prevents the intermitting turning on of the reserve
light indicator.
- The intermitting function is built in the instrument electronics: this allows operating the emergency
lights with switch in position «OFF» and control switch off. The control switch is only active when the
instrument panel is on.
To ensure safety while riding, the «direction indicators control» function is connected to the odometer.
If the indicator is left on, it automatically stops after 1 kilometre travelled.
- The «engine disabled» indicator is activated by the side stand switch and by the emergency switch
on the right side of the handlebar.
- The LCD display gives a 5 digit indication for the total kilometres covered by the vehicle. It can be
expressed in kilometres or in miles: of course, this indication cannot be reset. To select the indication,
press "Trip" and «M» at the same time, then tirn the key switch to «ON»; keep these 2 buttons
pressed for more than 3" to display «SET» on the display, then the display switches from miles
to kilometres, or vice versa.
After servicing by the authorised workshop, the

icon message must be reset by the "Reset" button
located in the front side of the vehicle under the
fairing.
The "Reset" button allows resetting the kilometres
covered and, in the case of "Service", also the year
count. This count remains active even if the battery
is disconnected for a short time.
ELE SYS - 71
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.
- The flashing of this light confirms the reset.
- For example, to reset the «Service» icon, go to
«Oil» and press the «Reset» button for at least 3".
To reset «Oil», repeat the above procedure going
to «Belt».
This procedure must be repeated since the selec-
tion of the icon and its reset are operations to be
made at the same time (it is not possible to view
the desired function and reset by two different but-
ton pressures since in this way the next icon would
be reset).
Data check function
Date and check function

Date should be adjusted out when delivering the vehicle to the customer. This is because the clock
activation starts the year count for the "Service" function. If the clock has been previously activated,
reset the "Oil", "Service" and "Belt" functions. The calendar is programmed from 2000 to 2050. For date
and time adjustment act on the "Clock" and "Set" buttons.
To guarantee vehicle safety, each time the key switch is set to "ON", there is an automatic checking of
all the indicators on the digital section.
The digital section provides also a functional checking of the 4 analogue instruments and of the turn
indicator control. To activate this checking, press and holed the "Clock" and "Set" buttons simultane-
ously and then set the key switch to "ON". Within 4 seconds max, the software version is displayed, the
gauges go to the end of scale and the turn indicators light up.
At the end of the operation above, the normal warning light bulbs check is carried out.
Sealed battery
If the vehicle is provided with a sealed battery, the only maintenance required is the check of its charge
and recharging, if necessary.
These operations should be carried out before delivering the vehicle, and on a six-month basis while
the vehicle is stored in open circuit.
ELE SYS - 72
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.
- If voltage exceeds 12.60 V, the battery can be installed without any renewal recharge.
- If voltage is below 12.60 V, a renewal recharge is required as explained in 2).
2) Constant voltage battery charge mode
- Constant voltage charge equal to 14.40 ÷ 14.70V
- Initial charge voltage equal to 0.3 ÷ 0.5 for Nominal capacity
- Charge time:
10 to 12 h recommended
Minimum 6 h
Maximum 24 h
3) Constant current battery charge mode
- Charge current equal to 1/10 of the nominal capacity of the battery
- Charge time: 5 h
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
CHARGE THE BATTERY BEFORE USE TO ENSURE OPTIMUM PERFORMANCE. INADEQUATE
CHARGING OF THE BATTERY WITH A LOW ELECTROLYTE LEVEL BEFORE IT IS FIRST USED
SHORTENS THE LIFE OF THE BATTERY.
IF THE VEHICLE IS NOT USED FOR SOME TIME (1 MONTH OR MORE) THE BATTERY NEEDS
TO BE RECHARGED PERIODICALLY. THE BATTERY RUNS DOWN COMPLETELY IN THE
COURSE OF THREE MONTHS. IF IT IS NECESSARY TO REFIT THE BATTERY IN THE VEHICLE,
BE CAREFUL NOT TO REVERSE THE CONNECTIONS TAKING INTO ACCOUNT THAT THE
GROUND WIRE (BLACK) MARKED(-) MUST BE CONNECTED TO THE - NEGATIVE TERMINAL
WHILE THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMINAL
MARKED WITH THE +POSITIVE SIGN
WARNING
WHEN THE BATTERY IS REALLY FLAT (WELL BELOW 12.6V) IT MIGHT OCCUR THAT 5 HOURS
OF RECHARGING ARE NOT ENOUGH TO ACHIEVE OPTIMAL PERFORMANCE.
GIVEN THESE CONDITIONS IT IS HOWEVER ESSENTIAL NOT TO EXCEED 8 HOURS OF CON-
TINUOUS RECHARGING SO AS NOT TO DAMAGE THE BATTERY ITSELF.
Dry-charge battery
- Remove the battery ventilation duct closing cap and remove the caps from the single elements.
- Fill the battery with electrolyte having a density of 1.270+/-0.01 Kg/l (corresponding to 31+/-1 Bé) with
minimum ambient temperature of 15 °C, up to the top level indicated on the single block.
- Slightly tilt the battery to remove any air bubbles formed during the filling.
- Place the caps on the filling holes of the single elements without tightening them and let the battery
stand. During this phase, the battery undergoes a gasification phenomenon and temperature rises.
ELE SYS - 73
- 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.
Within 24 hours, refill as follows:
- Connect the battery charger terminals according to the right polarity;
- Using the battery charger dwg. 020333Y and/or dwg. 020334Y, select the battery capacity;
- If the battery charger is not available, charge the battery with a constant current of 1/10 of the rated
capacity (for example for a battery with rated capacity of 9Ah, the charge current must be 0.9-1.0A), for
approx. 4-6 hours.
- Let the battery stand with open circuit for approx. 4-6 hours, then check the voltage using a normal
tester.
- If the open circuit voltage is more or equal to 12.6V, the battery charge is good. Slightly tilt the battery
to eliminate any air bubbles formed while recharging.
- Check the electrolyte level again, restore if required up to the tol reference using distilled water, tighten
the caps of the single elements and install it on the vehicle.
- If lower voltages are detected, recharge the battery for 4-6 hours more as described above.
N.B.
BATTERIES STORED FOR A LONG TIME CAN REQUIRE LONGER TIMES. BATTERY CHARGERS
DWG. 020333Y AND DWG. 020334Y HAVE AN AUTOMATIC PROTECTION THAT STOPS THE
RECHARGE AFTER 12 HOURS TO PREVENT OVERHEATING THE BATTERY. IN THIS CASE, THE
TURNING ON OF THE GREEN LED DOES NOT INDICATE THE END OF THE CHARGE BUT THE
START OF THE SAFETY SYSTEM.
N.B.
THIS IS THE LAST TIME THAT ELECTROLYTE CAN BE ADDED. FUTURE TOP UPS MUST BE
MADE USING ONLY DISTILLED WATER
N.B.
WITH BATTERY CHARGER DWG. 020334Y YOU CAN CHECK THE BATTERY CHARGE LEVEL
BY THE FUNCTION CHECK. THE VALUE SHOWN ON THE DISPLAY MUST BE HIGHER THAN
THAT INDICATED IN THE TABLE; IF NOT, RECHARGE AS DESCRIBED ABOVE.
Connectors
ELE SYS - 74
Dashboard
12-WAY INSTRUMENT CONNECTOR

1 BATTERY POSITIVE LEAD (+30) BATTERY POSITIVE LEAD (+30)
2 SPEEDOMETER SENSOR POWER SUPPLY SPEEDOMETER SENSOR POWER SUPPLY
3 SPEEDOMETER SENSOR BACK TO GROUND SPEEDOMETER SENSOR BACK TO GROUND
4 REVOLUTION SENSOR INPUT REVOLUTION SENSOR INPUT
5 BATTERY POSITIVE LEAD (+30) BATTERY POSITIVE LEAD (+30)
6 ANTITHEFT DEVICE LED ANTITHEFT DEVICE LED
7 KEY POSITIVE TERMINAL (+15) KEY POSITIVE TERMINAL (+15)
8 SPEEDOMETER SENSOR INPUT SPEEDOMETER SENSOR INPUT
9 GROUND GROUND
10 AIR TEMPERATURE SENSOR BACK TO GROUND AIR TEMPERATURE SENSOR BACK TO GROUND
11 EMERGENCY LIGHT BUTTON (HAZARD) INPUT EMERGENCY LIGHT BUTTON (HAZARD) INPUT
12 LIGHTS ON INPUT LIGHTS ON INPUT

1 GROUND ANALOGUE CHART GROUND ANALOGUE CHART
2 BATTERY POSITIVE LEAD (+30) FOR ANALOGUE BATTERY POSITIVE LEAD (+30) FOR ANALOGUE
CARD CHART
3 ANALOGUE CARD SERIAL CLOCK OUTPUT ANALOGUE CARD SERIAL CLOCK OUTPUT
4 ANTITHEFT DEVICE LED OUTPUT ANTITHEFT DEVICE LED OUTPUT
5 ANALOGUE CARD SERIAL DATE OUTPUT ANALOGUE CARD SERIAL DATE OUTPUT
6 LIGHTS ON OUTPUT LIGHTS ON OUTPUT
7 (Not connected)
8 (Not connected)

1 GENERAL USE WARNING LIGHT INPUT GENERAL USE WARNING LIGHT INPUT
2 ABS WARNING LIGHT INPUT (NOT CONNECTED) ABS WARNING LIGHT INPUT (NOT CONNECTED)
3 STOP LIGHT NOT WORKING OUTPUT STOP LIGHT NOT WORKING OUTPUT
4 RIGHT TURN INDICATOR OUTPUT RIGHT TURN INDICATOR OUTPUT
5 RIGHT TURN INDICATOR BUTTON INPUT RIGHT TURN INDICATOR BUTTON INPUT
6 LEFT TURN INDICATOR BUTTON INPUT LEFT TURN INDICATOR BUTTON INPUT
7 HIGH-BEAM WARNING LIGHT INPUT HIGH-BEAM WARNING LIGHT INPUT
8 AIR TEMPERATURE SENSOR INPUT AIR TEMPERATURE SENSOR INPUT
9 ENGINE UNABLE TO START WARNING LIGHT INPUT ENGINE UNABLE TO START WARNING LIGHT INPUT
10 OIL PRESSURE WARNING LIGHT INPUT OIL PRESSURE WARNING LIGHT INPUT
11 STOP LIGHT NOT WORKING WARNING LIGHT IN- STOP LIGHT NOT WORKING WARNING LIGHT IN-
PUT PUT
12 LEFT TURN INDICATOR OUTPUT LEFT TURN INDICATOR OUTPUT
ELE SYS - 75
13 TURN INDICATOR OFF SWITCH INPUT TURN INDICATOR OFF SWITCH INPUT
14 RESET SERVICE MANAGEMENT BUTTON INPUT RESET SERVICE MANAGEMENT BUTTON INPUT
15 WATER TEMPERATURE SENSOR INPUT WATER TEMPERATURE SENSOR INPUT
16 FUEL LEVEL SENSOR INPUT FUEL LEVEL SENSOR INPUT
ELE SYS - 76
INDEX OF TOPICS
ENGINE FROM VEHICLE ENG VE

Engine from vehicle MSS X9 Evolution 250
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,
- Remove the throttle grip transmission,
- Disconnect the electrical devices,
- Disconnect the hoses (petrol-oil-vacuum-operated cock control).
WARNING
Wear safety goggles when using hitting tools.
WARNING
BE VERY CAREFUL WHEN HANDLING FUEL.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE LEAD.
Silencer fixing
Please take note that, starting from chassis serial number ZAPM2300004503144, the three M8 x 50
silencer bracket fixing screws have been replaced by three M8 x 60 flanged head screws in order to
strengthen this fixing.
- Remove the nut shown in the figure, then take

out the pin.
ENG VE - 78
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.

Lower shock absorber clamp 33 ÷ 41 Engine-swinging arm bolt 33 ÷ 41
ENG VE - 79
INDEX OF TOPICS
ENGINE ENG
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.
Specific tooling
- Remove the cap/dipstick from the engine oil filling

hole.
- Remove the ten screws.
- Remove the transmission cover.
If this operation is carried out directly on the vehi-
cle, remove the cooling air supply coupling of the
transmission housing.
Air duct
- Remove the five screws on two different levels

as well as the small casing.
ENG - 81
Engine MSS X9 Evolution 250
- 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.

- Remove the bearing from the crankcase by
means of:
Specific tooling
020412Y 15 mm guide
Refitting the driven pulley shaft bearing
- Slightly heat the crankcase from the inside so as

not to damage the painted surface.
- Insert the bearing in its seat.
- Refit the seeger ring.
CAUTION
USE AN APPROPRIATE REST SURFACE TO AVOID DAM-
AGING THE COVER PAINT.
N.B.
ALWAYS REPLACE THE BEARING WITH A NEW ONE
UPON REFITTING.
Specific tooling
020412Y 15 mm guide
Baffle roller
ENG - 82
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

have defects that could jeopardise belt functioning
- For refitting, place the roller with the belt contain-
ment edge on the engine crankcase side
- Tighten the wrench to the prescribed torque.

Anti-flapping roller 12 - 16
Removing the driven pulley
- Remove the spacer, the clutch bell and the whole

driven pulley unit.
N.B.
THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING
PULLEY MOUNTED.
ENG - 83
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 134 - 134.2 mm
Checking the bell working surface eccentricity

- Install the bell on a driven pulley shaft using 2
bearings (inner diameter 15 and 17 mm).
- Lock with the original spacer and nut.
- Place the bell/shaft assembly on the support to
check the crankshaft alignment.
- Using a feeler pin gauge and the magnetic base,

measure the bell eccentricity.
- Repeat the measurement in 3 positions (Central,
internal, external).
- If faults are found, replace the bell.
Specific tooling
alignment
Characteristic
clutch bell inspection: Limit eccentricity.
Admissible limit eccentricity: 0.15 mm
ENG - 84
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.
- Fit the driven pulley unit on the tool with the in-
sertion of the 3 pins in the ventilation holes in the
mass holder support.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to loosen/tight-
en the clutch nut.
- Use the special 46x55 wrench component No. 9
to remove the nut fixing the clutch in place.
- Dismantle the driven pulley components (Clutch
and spring with its plastic holder)
CAUTION
THE TOOL MUST BE FIRMLY FIXED IN THE CLAMP AND
THE CENTRAL SCREW MUST BE BROUGHT INTO CON-
TACT WITH THE TOOL. EXCESSIVE TORQUE CAN CAUSE
THE SPECIFIC TOOL TO BUCKLE.
Specific tooling
020444Y009 46x55 Wrench
020444Y Tool for fitting/ removing the driven
pulley clutch
Inspecting the clutch
- Check the thickness of the clutch mass friction

material.
- The masses must not show traces of lubricants;
otherwise, check the driven pulley unit seals.
N.B.
UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN-
TRAL CONTACT SURFACE AND MUST NOT BE DIFFER-
ENT FROM ONE ANOTHER.
VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO
TEAR.
CAUTION
DO NOT OPEN THE MASSES USING TOOLS TO PREVENT
A VARIATION IN THE RETURN SPRING LOAD.
Characteristic
ENG - 85
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.
- Remove the four torque server pins and pull the pulley halves apart.
Removing the driven half-pulley bearing
- Check there are no signs of wear and/or noisi-

ness; - Replace with a new one if there are.
- Remove the retaining ring using two flat blade
screwdrivers.
- Support the pulley bushing adequately from the
threaded side using a wooden surface.
- Using a hammer and pin, knock the ball bearing
out as shown in the figure.
ENG - 86
- Support the pulley properly using the bell as

Specific tooling
001467Y035 Belle for OD 47-mm bearings
- Remove the roller bearing using the modular punch.
Specific tooling
020456Y Ø 24 mm adaptor
020363Y 20 mm guide
Inspecting the driven fixed half-pulley
Version 250
- Measure the outside diameter of the pulley bush-
ing.
- Check the contact surface with the belt to make
sure there are no flaws.
- Check the riveted joints are functional.
- Check the evenness of the belt contact surface.
Characteristic
Half-pulley minimum diameter
Minimum admissible diameter Ø 40.96 mm
Half-pulley standard diameter
Standard diameter: Ø 40.985 mm
Wear limit
0.3 mm
ENG - 87
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.
- Check the riveted joints are functional.
- Check the evenness of the belt faying surface.
MOVABLE DRIVEN HALF-PULLEY DIMENSIONS

Wear limit 0.3 mm
standard diameter Diameter 41.000 - 41.035 mm
maximum allowable diameter Ø 41.08 mm
- Remove the belt and slide the movable half-pulley with the relevant bush, taking care of the falling
free assembled rollers.
- Remove the return rollers plate with the relative guide pads.
Refitting the driven half-pulley bearing
- Support the pulley bushing adequately from the

threaded side using a wooden surface.
- Fit a new roller sleeve as in the figure.
- For the fitting of the new ball bearing, follow the
example in the figure using a modular punch.
Fit the snap ring
WARNING
N.B.
FIT THE BALL BEARING WITH THE VISIBLE SHIELD
Specific tooling
ENG - 88

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.
- Fit the half-pulley over the bushing using the spe-
cific tool.
- Check that the pins are not worn and proceed to
refitting them in their slots.
- Refit the torque server closure collar.
- Using a curved-spout grease gun, lubricate the
driven pulley unit with approximately 6 gr. of
grease. Apply the grease through one of the holes
in the bushing until it comes out through the hole
on the opposite side. This operation is necessary
to avoid the presence of grease beyond the O-
rings.
N.B.
THE TORQUE SERVER CAN BE GREASED WHETHER
WITH BEARINGS FITTED OR WHEN THEY ARE BEING RE-
PLACED; UNDERTAKING THE OPERATION WHEN THE
BEARINGS ARE BEING SERVICED MIGHT BE EASIER.
Specific tooling
020263Y Sheath for driven pulley fitting
AGIP GREASE SM 2 Grease for the tone wheel
revolving ring
ENG - 89
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
Limit after use (200 - 250)
118 mm
Refitting the clutch
- Support the driven pulley spring compressor ap-

propriate tool with the control screw in vertical axis.
- Arrange the tool with the medium length pins
screwed in position "C" on the inside.
- Introduce the adapter ring 11 with the chamfering
facing upwards.
- Insert the clutch on the adapter ring.
- Lubricate the end of the spring that abuts against
the servo-system closing collar.
- Insert the spring with its plastic holder in contact
with the clutch.
- Insert the driving belt into the pulley unit accord-
ing to their direction of rotation.
- Insert the pulley unit with the belt into the tool.
- Slightly preload the spring.
- Make sure that the clutch is perfectly inserted into
the adapter ring before proceeding to tighten the
clutch nut.
- Place the tool in the clamp with the control screw
on the horizontal axis.
- Fully preload the spring.
ENG - 90
- 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.
- 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.
N.B.
DURING THE SPRING PRELOADING PHASE, BE CARE-
FUL NOT TO DAMAGE THE PLASTIC SPRING STOP AND
THE BUSHING THREADING.
N.B.
FOR DESIGN REASONS, THE NUT IS SLIGHTLY ASYM-
METRIC; THE FLATTEST SURFACE SHOULD BE MOUN-
TED IN CONTACT WITH THE CLUTCH.
Specific tooling
020444Y Tool for fitting/ removing the driven
pulley clutch
020444Y009 46x55 Wrench

Nut locking clutch unit on pulley 55 ÷ 60 Nm
Refitting the driven pulley
- Reassemble the clutch bell and spacer.
ENG - 91
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; 18,000 km;
etc., check that the rim bottom of the toothing does
not show signs of incisions or cracking (see figure):
The rim bottom of the tooth must not have incisions
or cracking; if it does, change the belt.
Removing the driving pulley
- Turn the crankshaft until the ropes of the pulley

are on a horizontal axis
- Insert the adaptor sleeve of the appropriate tool

in the hole shown in the photograph
ENG - 92
- 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.
Inspecting the rollers case
- Check that the internal bushing shown in the fig-

ure is not abnormally worn and measure inner
diameter.
- Measure outer diameter B of the pulley sliding
bushing shown in the figure.
- Check that the rollers are not damaged or worn.
- Check the guide shoes for the variator back-plate
are not worn.
- Check the wear of the roller housings and of the
belt contact surfaces on both pulley halves.
- Check that stationary driving pulley does not
show signs of abnormal wear on the grooved edge
and on the surface in contact with the belt.
- Check that the O-ring is not pushed out of shape.
CAUTION
DO NOT LUBRICATE OR CLEAN SINTERED BUSHINGS
Characteristic
Movable driving half-pulley bushing: Standard
Diameter
26.000 - 26.021 mm
ENG - 93
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-
ter
Ø 25.95 mm
Roller: Standard Diameter
Diameter 20.5 - 20.7 mm
Roller: Minimum diameter permitted
Ø 20 mm
Refitting the driving pulley
- Fit the steel shim in contact with the bushing and

the stationary drive pulley.
- Install the appropriate tool as described in the re-
moval phase.
-Tighten the nut with washer to the prescribed tor-
que.
Specific tooling
020626Y Driving pulley lock wrench

Drive pulley nut 75 ÷ 83
ENG - 94
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.
- Refit the oil loading cap/bar.
- refit the steel washer and the driven pulley nut.
- Tighten the nut to the prescribed torque using the
lock wrench and the torque wrench tools.
- Replace the plastic cover.
Specific tooling

Transmission cover screws 11 ÷ 13 Driven pul-
ley shaft nut 54 ÷ 60
End gear
Removing the hub cover
- Empty the rear hub through the oil drainage plug.

- Remove the 7 flanged screws indicated in the
figure.
- Remove the hub cover and its gasket.
ENG - 95
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.
- Use the specific bearing extractor to remove the
three 15 mm bearings (2 in the crankcase and 1 in
the hub cover).
Specific tooling
ENG - 96
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.
Specific tooling
020477Y Adaptor 37 mm
020483Y 30 mm guide
020489Y Hub cover support stud bolt set
Removing the driven pulley shaft bearing
- As you need to remove the driven pulley shaft, its

bearing and oil guard, remove the transmission
cover as described above.
- Extract the driven pulley shaft from its bearing.
- Remove the oil guard using a screwdriver, work-
ing from inside the bearing and being careful not
to damage the housing, make it come out of the
belt transmission side.
- Remove the seeger ring shown in the figure
Remove the driven pulley shaft bearing using the
modular punch.
Specific tooling
020363Y 20 mm guide
ENG - 97
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.
Inspecting the hub cover
- Check that the fitting surface is not dented or distorted.

- Check the bearing bearings.
- In case of anomalies, replace the damaged components.
Refitting the wheel axle bearing
- Support the hub cover on a wooden surface.

- Heat the crankcase cover with the specific heat
gun.
- Fit the wheel shaft bearing with a modular punch
as shown in the figure.
- Fit the seeger ring.
- Fit the oil guard with seal lip towards the inside
of the hub and place it flush with the internal sur-
face by means of the appropriate tool used from
the 52 mm side.
The 52 mm side of the adapter must be turned to-
wards the bearing.
Specific tooling
020483Y 30 mm guide
ENG - 98
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.
The 42 mm side of the adapter must be turned to-
wards the bearing.
- Refit the driven pulley shaft bearing with a mod-
ular punch as shown in the figure.
- Refit the Seeger ring with the opening facing the
bearing and the new oil guard flush with the crank-
case on the pulley side.
N.B.
TO FIT THE BEARING ON THE COVER, SUPPORT THE
COVER WITH THE STUD BOLT SET.
N.B.
IF THE BEARING HAS AN ASYMMETRICAL BALL RETAIN-
ER, PLACE IT SO THAT THE BALLS ARE VISIBLE FROM
THE HUB INNER SIDE.
N.B.
WHEN FITTING THE BEARINGS ON THE ENGINE CRANK-
CASE, SUPPORT THE CRANKCASE PREFERABLY ON A
SURFACE TO ALLOW THE BEARINGS TO BE DRIVEN
VERTICALLY.
Specific tooling
020150Y Air heater support
020151Y Air heater
020412Y 15 mm guide
ENG - 99
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.
- Seal the gasket of the breather pipe using black
silicone sealant.
- Fit the gearbox cover, making sure the breather
pipe is in the correct position.
- Place the 3 shortest screws, identifiable by their
different colour, as shown in the figure.
- Fasten the breather pipe support bracket with the
lower short screw.
- Assemble the remaining 4 screws and tighten the
7 screws to the prescribed torque.

Rear hub cover screws 24 ÷ 27
ENG - 100
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
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
- Refit the stator and flywheel carrying out the re-

moval procedure in reverse, tightening the retain-
ers to the specified torque.

Stator assembly screws (°) 3 ÷ 4
Refitting the flywheel cover
- Position the spline clip on the crankshaft and ori-

ent the end as shown in the figure.
ENG - 102
- 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.
CAUTION
TAKE CARE TO CORRECTLY POSITION THE FLYWHEEL CONNECTOR. MAKE SURE THE CEN-
TRING DOWELS ARE PRESENT.
Flywheel cover screws 11 - 13
Flywheel and starting
Removing the starter motor
- Remove the two screws indicated in the figure.

- Take the starter motor out of its seat
Removing the flywheel magneto
- Remove the water pump shaft and crankshaft

spline clip
ENG - 103
- Line up the two holes in the flywheel as shown in

the photo
- Screw in the guide bushing that is part of the

special flywheel stop tool on the flywheel as shown
in the photo.
- Insert the special flywheel stop tool on the fly-

wheel as shown in the photo
Specific tooling
020627Y Flywheel lock wrench
- Remove the flywheel nut with its washer

- Do up the flywheel nut by three or four threads
so that the flywheel does not fall accidentally on
extraction
- Screw the extractor onto the flywheel and extract
it as shown in the photograph
Specific tooling
020467Y Flywheel extractor
Refitting the free wheel

- Make sure the freewheel faying surfaces are in good condition.
- Thoroughly clean the free wheel to remove LOCTITE residue.
- Degrease the threading of the holes in the free wheel and the clamping screws.
ENG - 104
- Apply the recommended product to the end of the screws.
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. with wheel seeger ring visible.
- Lock the six clamping screws in criss-cross fash-
ion to the prescribed torque.

Screw fixing freewheel to flywheel 13 ÷ 15
- Oil the free wheel "rollers".
Refitting the flywheel magneto
- Remove the freewheel retaining plate indicated

in the photograph
- Remove the transmission gear and the freewheel
ENG - 105
- 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
-Refit the retention plate
Specific tooling
020627Y Flywheel lock wrench

Flywheel nut 94 ÷ 102
Refitting the starter motor
- Fit a new O-ring on the starter motor and lubricate it.

- Fit the starter on the crankcase, locking the two screws to the prescribed torque.

Starter motor screws 11 ÷ 13
Cylinder assy. and timing system
Removing the intake manifold
- Loosen the 3 crews and remove the intake mani-

fold.
ENG - 106
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
and by-pass piston, oil pump pulley cover, O-ring
on the crankshaft and the sprocket wheel separa-
tion washer.
- Remove the tappet cover.
- Remove the central screw fastener and the au-
tomatic valve-lifter retaining cover, as shown in the
figure.
- Remove the return spring of the automatic valve

lifter unit and the automatic valve lifter unit and its
end of stroke washer.
ENG - 107
- 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.
- Remove the camshaft control pulley with its

washer.
- Remove the command sprocket wheel and the

timing chain.
- Remove the screws indicated in the figure, the
spacer bar and the tensioner slider.
The chain tensioning pad must be removed from
the transmission side. As regards the lower chain
guide pad, it may only be removed after the head
has been removed.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
ENG - 108
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.
N.B.
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH
THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING
BRACKET. THE HEAD CAN ALSO BE REMOVED WITH-
OUT REMOVING THE CHAIN AND THE DRIVING SHAFT
CHAIN TIGHTENER.
ENG - 109
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.
- Remove the head, the two centring dowels and
the gasket.
N.B.
IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH
THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING
BRACKET. THE HEAD CAN ALSO BE REMOVED WITH-
OUT REMOVING THE CHAIN AND THE DRIVING SHAFT
CHAIN TIGHTENER.
Removing the valves
- Using the appropriate tool fitted with an adaptor,

remove the cotters, caps, springs and valves.
- Remove the oil guards with the appropriate tool.
- Remove the lower spring supports.
CAUTION
REPLACE THE VALVES IN SUCH A WAY AS TO RECOG-
NISE THEIR ORIGINAL POSITION ON THE HEAD.
Specific tooling
020382Y Valve cotters equipped with part 012
removal tool
020306Y Punch for assembling valve seal
rings
Removing the cylinder - piston assy.
- Remove the chain guide pad.

- Pull out the cylinder.
- Remove the cylinder base gasket.
- Remove the two stop rings, the wrist pin and the piston.
- Remove the piston seals.
CAUTION
ENG - 110
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.
N.B.
REPLACE THE CRANKSHAFT IF THE DIAMETER OF THE
ROD SMALL END EXCEEDS THE STANDARD DIAMETER
OR IT SHOWS SIGNS OF WEAR OR OVERHEATING.
Characteristic
Rod small end check-up: Maximum diameter
15.030 mm
Rod small end check-up: Standard diameter
15 +0.015+0.025 mm
ENG - 111
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
Inspecting the piston
- Measure the diameter of the wrist pin seat on the

piston.
- Calculate the piston pin coupling clearance.
- Measure the outside diameter of the piston, per-
pendicular to the gudgeon pin axis.
- Take the measurement at 5 mm from the base in
the position shown in the figure.
- Carefully clean the seal housings.
- Measure the coupling clearance between the
sealing rings and the grooves using suitable sen-
sors, as shown in the diagram.
- If the clearance is greater than that indicated in
the table, replace the piston.
N.B.
MEASURE THE CLEARANCE BY INSERTING THE BLADE
OF THE FEELER THICKNESS GAUGE FROM THE SECOND
SEAL SIDE.
N.B.
THE PIN HOUSINGS HAVE 2 LUBRICATION CHANNELS.
FOR THIS REASON MEASUREMENT OF THE DIAMETER
MUST BE CARRIED OUT ACCORDING TO THE AXIS OF
THE PISTON.
Characteristic
Wrist pin seat on the piston: Standard diameter
15.001 ÷ 15.006 mm
Diameter of the wrist pin seat on the piston:
Standard clearance
0.001 ÷ 0.010 mm
ENG - 112
piston diameter
71.953 - 71.981 mm
Fitting clearance
Top piston ring - standard coupling clearance
0.015 - 0.06 mm Top piston ring - maximum clear-
ance allowed after use 0.07 mm Middle piston
ring - standard coupling clearance 0.015 - 0.06 mm
Middle piston ring - maximum clearance al-
lowed after use 0.07 mm oil scraper ring - stand-
ard coupling clearance 0.015 - 0.06 mm oil scraper
ring - maximum clearance allowed after use
0.07 mm
Inspecting the cylinder
- Using a bore gauge, measure the internal diam-

eter of the cylinder following the directions given in
the figure and at three different heights.
- Check that the plane of coupling with the head
does not show wear or deformations.
- The pistons and cylinders are classified with cat-
egories depending on the diameters. The coupling
is carried out matched (A-A, B-B, C-C, D-D).
Characteristic
cylinder: standard diameter
71.990 - 72.018 mm (at 33 mm)
Maximum allowable run-out:
0.05 mm
ENG - 113
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
- With opening in the position indicated on the tool
S = left
D= right
- Place the wrist pin stop ring into position using a
punch
- Fit the wrist pin stop using the plug as shown in
the figure
N.B.
THE TOOL FOR INSTALLING THE STOP RINGS MUST BE
USED MANUALLY.
CAUTION
USING A HAMMER MIGHT DAMAGE THE STOPS' HOUS-
ING.
Specific tooling
020454Y Tool for fitting piston pin stops (200 -
250)
ENG - 114
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.
- Rotate the crankshaft until TDC (the inverted point of the dial gauge rotation)
- Position the dial gauge on the piston as shown in the figure and measure how much the piston pro-
trudes.
- Identify the thickness of the cylinder base gasket to be used for reassembly by the table below. Cor-
rectly identify the cylinder base gasket thickness to keep the correct compression ratio.
- Remove the special tool and the cylinder.
N.B.
MEASUREMENT "A" TO BE TAKEN IS A VALUE OF PISTON RE-ENTRY, IT INDICATES BY HOW
MUCH THE PLANE FORMED BY THE PISTON CROWN FALLS BELOW THE PLANE FORMED BY
THE TOP OF THE CYLINDER. THE FURTHER THE PISTON FALLS INSIDE THE CYLINDER, THE
LESS THE BASE GASKET IS TO BE APPLIED (TO RECOVER THE COMPRESSION RATIO) AND
VICE VERSA.
Specific tooling
020428Y Piston position check support
ENGINE 250 SHIMMING

Name Measure A Thickness
shimming 3.70 - 3.60 0.4 ± 0.05
shimming 3.60 - 3.40 0.6 ± 0.05
shimming 3.40 - 3.30 0.8 ± 0.05
ENG - 115
ENG - 116
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.
The chamfered side of the oil scraper ring should
always be facing the piston crown.
- Fit the middle piston ring with the identification
letter facing the crown of the piston. In any case,
the step must be facing opposite the piston top.
- Fit the top piston ring with the word 'TOP' or the
reference mark facing the crown of the piston.
- Offset the piston ring gaps on the three rings by
120° to each other as shown in the figure.
- Lubricate the components with engine oil.
- The top piston ring on the 250 engine has an L
cross section.
N.B.
THE TWO PISTON RINGS ARE MADE WITH A TAPERED
CYLINDRICAL CONTACT CROSS-SECTION. THIS IS TO
ACHIEVE A BETTER BEDDING.
Refitting the cylinder
- Insert the cylinder base gasket with the thickness determined above.
- Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure.
N.B.
BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL
THE CYLINDER BARREL.
Specific tooling
020426Y Piston fitting fork
020393Y Piston fitting band
ENG - 117
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.
- Check that the cylinder head cover surface, the
intake manifold and the exhaust manifold are not
worn.
Characteristic
bearing «A»
Ø 12.000 - 12.018 mm
bearing «B»
Ø 20.000 ÷ 20.021 mm
bearing «C»
Ø 37.000 - 37.025 mm
ENG - 118
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.
- If you encounter wear, replace the parts or, if the
chain, sprocket wheel and pulley are worn replace
the whole assembly.
- Remove the centre screw with the washer and
the tensioner spring. Check that the one-way
mechanism is not worn.
- Check the condition of the tensioner spring.
- If examples of wear are found, replace the whole
assembly.
Inspecting the valve sealings
- Insert the valves into the cylinder head.

- Alternatively check the intake and exhaust
valves.
- The test is carried out by filling the manifold with
petrol and checking that the head does not ooze
through the valves when these are just pressed
with the fingers.
ENG - 119
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.
- Take the measurement at three different heights
in the rocker arm push direction.
- If the width of the impression on the valve seat or
the diameter of the valve guide exceed the speci-
fied limits, replace the cylinder head.
Characteristic
Valve seat wear Intake guide
limit accepted: 5.022
Valve seat wear Intake guide
Standard diameter: 5.000 ÷ 5.012 mm
Valve seat wear Exhaust guide
Accepted limit 5.022
Valve seat wear Exhaust guide
Standard diameter: 5.000 ÷ 5.012 mm
Inspecting the valves

- Measure the width of the sealing surface on the
valve seats and on the valves.
Sealing surface width: After use: Intake and ex-
haust: 1.6 mm
- If any of the sealing surfaces on the valves is
wider than the specified limit or is damaged in one
or more points, or curved, replace the valve with a
new one.
CAUTION
DO NOT REVERSE THE FITTING POSITIONS OF THE
VALVES (RIGHT - LEFT).
Characteristic
Valve wear check Standard: Intake and ex-
haust:
0.99 - 1.27 mm
- Measure the diameter of the valve stems in the three positions indicated in the diagram.
ENG - 120
- 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. Grind the valves gently with a fine-grained lapping compound. During the
grinding, keep the cylinder head with the valve axes in a horizontal position. This will prevent the lapping
compound residues from penetrating between the valve stem and the guide (see figure).
CAUTION
TO AVOID SCORING THE FAYING SURFACE, DO NOT KEEP ROTATING THE VALVE WHEN NO
LAPPING COMPOUND IS LEFT. CAREFULLY WASH THE CYLINDER HEAD AND THE VALVES
WITH A SUITABLE PRODUCT FOR THE TYPE OF LAPPING COMPOUND BEING USED.
N.B.
DO NOT CHANGE THE POSITIONS THE VALVES ARE FITTED IN
Characteristic
Valve check standard length
Outlet: 94.4 mm
Valve check standard length
Inlet: 94.6 mm
Valve check Maximum admissible clearance
Outlet: 0.072 mm
Valve check Maximum admissible clearance
Inlet: 0.062 mm
Valve check standard clearance
Outlet: 0.025 ÷ 0.052 mm
Valve check standard clearance
Inlet: 0.013 ÷ 0.040 mm
Valve check Minimum admissible diameter
Outlet: 4.95 mm
Valve check Minimum admissible diameter
Inlet: 4.96 mm
Valve check Standard diameter:
Inlet: 4.972 ÷ 4.987 mm
Valve check Standard diameter:
Outlet: 4.96 ÷ 4.975 mm
ENG - 121
Inspecting the springs and half-cones
- Check that the upper spring caps and the cotter

halves show no signs of abnormal wear.
ENG - 122
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.
N.B.
DO NOT CHANGE THE VALVE FITTING POSITION. FIT THE
VALVE SPRINGS WITH THE REFERENCE COLOUR ON
COTTER SIDE (TURNS WITH GREATER PITCH).
Specific tooling
020306Y Punch for assembling valve seal
rings
020382Y Valve cotters equipped with part 012
removal tool
Inspecting the cam shaft
- Inspect the cam shaft for signs of abnormal wear

on the cams.
- Check the cam height.
- Check there is no wear on the cam shaft retaining
plate and its associated groove on the cam shaft.
- If any of the above dimensions are outside the
specified limits, or there are signs of excessive
wear, replace the defective components with new
ones.
- Check there are no signs of wear on the auto-
matic valve-lifter cam, or the end-of stroke roller,
or the rubber buffer on the automatic valve-lifter
retaining cover.
- Check that the valve lifting spring has not yielded.
- Replace any defective or worn components.
- Check the rocker pins do not show signs of wear
or scoring.
ENG - 123
- 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-
ter
Diameter 12.000 - 12.011 mm
Rocking lever pin diameter: Standard diameter
Diameter 11.977 - 11.985 mm
Cam shaft check: Maximum admissible axial
clearance
0.42 mm
Cam shaft check: Standard axial clearance:
0.11 - 0.41 mm
Cam shaft check: Standard height
Outlet: 29.209 mm
Cam shaft check: Standard height
Inlet: 30.285 mm
Cam shaft check: Minimum admissible diame-
ter
Bearing B diameter: 19.950 mm
Cam shaft check: Minimum admissible diame-
ter
Bearing A Ø: 36.94 mm
Cam shaft check: Standard diameter
Bearing B diameter: 19.959 ÷ 19.98 mm
Cam shaft check: Standard diameter
Bearing A Ø: 36.95 ÷ 36.975 mm
ENG - 124
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.
- Lubricate the stud bolt threading.
- Tighten up the nuts to an initial pre-torque of 7±1
N·m
- 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.
- Fit the two screws on the outside of the timing
chain side and tighten them to the specified torque.
N.B.
BEFORE INSTALLING THE HEAD, MAKE SURE THAT THE
LUBRICATION CHANNEL IS CLEAN USING A COM-
PRESSED AIR JET.

- Refit the lower timing chain sprocket wheel on the

crankshaft, with the chamfer facing the insertion
side.
- Loop the timing chain around the sprocket on the
crankshaft.
- Fit the chain tensioner slider from the cylinder
head side.
- Fit the spacer and the screw fastener.
- Tighten the screws to the prescribed torque.
- Fit the pins and rocker arms.
- Lubricate the two rocking levers through the
holes at the top.
ENG - 125
- 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.
- Refit the spacer on the cam shaft.
- Rotate the engine so that the piston is at top dead
centre, using the reference marks on the flywheel
and the crankcase.
- Holding this position insert the chain on the cam-
shaft control pulley.
- Insert the pulley on the cam shaft while keeping
the reference 4V in correspondence with the ref-
erence mark on the head.
- Fit the counterweight and tighten the fixing screw
to the prescribed torque.
-Fit the end-stop ring on the automatic valve-lifter
cam and fit the automatic valve-lifter cam to the
cam shaft.
- Fit the automatic valve-lifter return spring.
- During this operation the spring must be loaded
by approximately 180°.
- Fit the automatic valve-lifter retaining dish, using
the counterweight screw fastener as a reference.
- Tighten the clamping screw to the prescribed tor-
que.
- Set the tensioner cursor in the rest position.
- Fit the chain tensioner on the cylinder, using a
new gasket, and tight the two screws to the pre-
scribed torque.
- Insert the chain tensioning screw, together with
the spring and washer, tightening it to the prescri-
bed torque.
- Adjust the valve clearance.
- Fit the spark plug.
Electrode distance 0.8 mm
N.B.
ENG - 126
GREASE THE END STOP RING TO PREVENT IT COMING

OUT AND FALLING INTO THE ENGINE.

Spark plug 12 ÷ 14 Starter ground screw 7 ÷ 8.5
Timing chain tensioner slider screw 10 ÷ 14
Starter ground support screw 11 ÷ 15 Timing
chain tensioner central screw 5 - 6 Camshaft re-
tention plate screw 4 ÷ 6
ENG - 127
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.

Tappet cover screws 6 - 7 Nm
Refitting the intake manifold
Fit the intake manifold and do up the three screws.
Crankcase - crankshaft
ENG - 128
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.
- Remove the 10 crankshaft coupling screws.
- Separate the crankcase while keeping the crank-
shaft in one of the two halves of the crankcase.
- Remove the crankshaft.
- Remove the half crankcase coupling gasket.
- Remove the two screws and the internal cover
shown in the diagram.
- Remove the oil guard on the flywheel side.
- Remove the oil filter fitting shown in the diagram.
- Check the axial clearance on the connecting rod.
- Check the radial clearance on the connecting rod.
-Check the surfaces that limit the axial free-play
are not scored and measure the width of the crank-
shaft between these surfaces, as shown in the
diagram.
- If the axial clearance between crankshaft and
crankcase is exceeding and the crankshaft does
not have any defect, the problem must be due to
either excessive wear or wrong machining on the
crankcase.
- Check the diameters of both the bearings of the
crankshaft in accordance with the axes and surfa-
ces shown in the figure. The half-shafts are clas-
sified in two categories Cat. 1 and Cat. 2 as shown
the chart below.
CAUTION
THE CRANKSHAFT CAN BE REUSED WHEN THE WIDTH
IS WITHIN THE STANDARD VALUES AND THE SURFACES
SHOW NO SIGNS OF SCORING.
CAUTION
WHILE OPENING THE CRANKCASES AND REMOVING
THE DRIVING SHAFT, CHECK THAT THE THREADED
SHAFT ENDS DO NOT INTERFERE WITH THE MAIN BUSH-
ENG - 129
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.
N.B.
WHEN MEASURING THE WIDTH OF THE CRANKSHAFT,
MAKE SURE THAT THE MEASUREMENTS ARE NOT
MODIFIED BY THE RADIUSES OF FITTINGS WITH THE
CRANKSHAFT BEARINGS.
Specific tooling
020262Y Crankcase splitting strip
Characteristic
Axial crankshaft/crankcase clearance: Stand-
ard clearance
0.15 - 0.40 mm (when cold)
Axial connecting rod - crankshaft clearance
Standard clearance
0.20 ÷ 0.50 mm
Radial connecting rod - crankshaft clearance
Standard clearance
0.036 ÷ 0.054 mm
Width of crankshaft with integral washers:
standard measurements
55.67 ÷ 55.85 mm
Crankshaft bearings: Standard diameter: Cat.
1
28.994 ÷ 29.000
Crankshaft bearings: Standard diameter: Cat.
2
29.000 ÷ 29.006
ENG - 130
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.
- In case of failures, replace the crankshaft.
The connecting rod head bushings cannot be re-
placed. For the same reason, the connecting rod
may not be replaced and, when cleaning the
crankshaft, be very careful that no impurities get in
through the shaft's lubrication holes.
In order to prevent damaging the connecting rod
bushings, do not attempt cleaning the lubrication
duct with compressed air.
- Make sure that the 2 caps on the crankpin are
properly fitted.
- A wrong installation of a cap can seriously affect
the bushing lubrication pressure.
N.B.
THE MAIN BEARINGS ARE NOT GRINDABLE
Specific tooling
alignment
Characteristic
Off-line maximum admitted
A = 0.15 mm
B = 0.01 mm
C = 0.01 mm
D = 0.10 mm
ENG - 131
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).
- Take particular care, also, that there are no signs
wear in the oil by-pass valve housing (see Chapter
Lubrication), as this could prevent a good seal in
the valve, which regulates the oil pressure.
- On the flywheel side crankcase half, take partic-
ular care cleaning the oil ducts for the main bush-
ings, the oil duct for the jet that lubricates the
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.
- Defects in the crankcase coupling gasket be-
tween the crankcase halves or the mating surfaces
shown in the diagram, could cause a drop in the
oil pressure lubricating the main bearings and con-
nection rod.
- Check the main bearing seats that limit axial
clearance in the crankshaft show no signs of wear.
The dimension between these seats is measured
by way of the procedure described previously for
measuring the crankshaft axial clearance and di-
mensions.
N.B.
THE JET IS FED THROUGH THE MAIN BUSHINGS. PROP-
ER OPERATION OF THIS COMPONENT IMPROVES THE
PISTON TOP COOLING. CLOGGING HAS EFFECTS THAT
ARE DIFFICULT TO DETECT (PISTON TEMPERATURE IN-
CREASE). FAILURE OR LEAK CAN CONSIDERABLY DE-
CREASE THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
N.B.
ENG - 132
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. A JET FAILURE CAUSES A DE-
CREASE OF THE MAIN BUSHING AND CONNECTING ROD
LUBRICATION PRESSURE.
Inspecting the crankshaft plain bearings
-T
o obtain a good bushing lubrication it is necessary
to have both an optimal lubricating pressure (3.2
bar) and a good oil flow rate; the bushings must be
correctly positioned so as not to obstruct the oil
supply channels.
- 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.
- To prevent obstructions in the oil feeding chan-
nels, the matching surface of the two half-bearings
must be perfectly perpendicular to the cylinder ax-
is, as shown in the figure.
- The oil feeding channel section is also affected
by the bushings driving depth compared with the
crankshaft axial clearance of the limiting surface.
- Check the inside diameter of the main bushings
in the three directions indicated in the diagram.
- Repeat the measurements for the other bushing
half. see diagram.
- There are three crankcase versions: with RED
main bushings, with BLUE main bushings and with
YELLOW main bushings.
- There is only one type of main bushing housing
hole in the crankcase
The standard bushing diameter after driving is var-
iable on the basis of a coupling selection.
ENG - 133
- 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.
TYPE IDENTIFICATION
A RED
B BLUE
C YELLOW
Type "A" - Type "B" - Type "C" -
RED BLUE YELLOW
Crankshaft 1.970 ÷ 1.9703 ÷ 1.976 ÷
half-bearing 1.973 1.976 1.979
Bushing Crankcase Internal bushing Possible fit-
category halves cat- diameter after fitting
egory ting
A 1 29.025 ÷ 29.040 Original
B 1 29.019 ÷ 29.034 Original and
2 29.028 ÷ 29.043 spare
C 2 29.022 ÷ 29.037 Original
Match the shaft with two category 1 crank webs

with the category 1 crankcase (or cat. 2 with cat.
2) Furthermore a spare crankcase cannot be
matched with a crankshaft with mixed categories.
The spare crankshaft has half-shafts of the same
category.
Crankcase halves Engine half- Bushing
shaft
Cat. 1 Cat. 1 B
Cat. 2 Cat. 2 B
Cat. 1 Cat. 2 A
Cat. 2 Cat. 1 C
N.B.
DO NOT TAKE THE MEASUREMENT ON THE TWO HALF-
SHELL COUPLING SURFACE SINCE THE ENDS ARE RE-
LIEVED TO ALLOW BENDING DURING THE DRIVING
OPERATION.
N.B.
ENG - 134
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
Refitting the crankcase halves
- Fit the internal bulkhead by locking the two

screws to the prescribed torque.
- Fit the oil filter fitting and tighten it to the specified
torque.
- Place a new gasket on one of the crankcase
halves, preferably on the transmission side, to-
gether with the locating dowels.
- Lubricate the main bushings and insert the crank-
shaft in the transmission side crankcase half.
- Reassemble the two crankcase halves.
- Fit the 10 screws and tighten them to the pre-
scribed torque.
- Fit a new O-ring on the pre-filter and lubricate it.
- Insert the filter on the engine with the relative cap.
Tighten to the prescribed torque.

Internal engine crankcase bulkhead (transmis-
sion-side half shaft) screws 4 ÷ 6 Engine-crank-
case coupling screws 11 ÷ 13 Oil filter on
crankcase fitting 27 ÷ 33 Engine oil drainage
plug/mesh filter 24 ÷ 30
ENG - 135
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
ENG - 136
- Screw the threaded bar onto the base of the tool

and extract the oil guard.
Specific tooling
Refitting
- Use a new oil seal upon refitting.

- Prepare the new oil seal, lubricating the sealing
lip.
- Preassemble the oil seal with the specific tool,
positioning the screws.
- Place the sheath over the crankshaft.
- Insert the tool with the oil seal on the crankshaft
until it comes into contact with the crankcase.
- 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.
- Remove all of the tool components following the
inverse procedure
CAUTION
DO NOT LUBRICATE THE SURFACE FOR KEYING ONTO
THE ENGINE CRANKCASE.
CAUTION
ORIENT THE OIL GUARD BY POSITIONING THE CHAIN
HOUSING CHANNEL FACING DOWNWARDS. WHEN THE
POSITION IS REACHED, DO NOT RETRACT THE OIL
GUARD. FAILURE TO COMPLY WITH THIS RULE CAN
CAUSE A WRONG POSITIONING OF THE OIL GUARD
SHEATH.
CAUTION
FAILURE TO COMPLY WITH THIS ASSEMBLY PROCE-
DURE CAN SERIOUSLY DAMAGE THE ENGINE DUE TO
THE WRONG TENSIONING OF THE OIL PUMP CONTROL
CHAIN.
Specific tooling
ENG - 137
Oil pump
Removal
- Undo the two clamping screws in the figure and

remove the cover over the pump control crown.
ENG - 138
- 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.
- Remove the control sprocket with relative O-ring.
- Remove the oil pump by undoing the two screws
in the figure.
- Remove the oil pump seal.
N.B.
IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO EN-
SURE THAT THE INITIAL DIRECTION OF ROTATION IS
MAINTAINED.
Inspection
- Remove the two screws and the oil pump cover.

- Remove the clip retaining the innermost rotor.
- Remove and wash the rotors thoroughly with pet-
rol and compressed air.
- Reassemble the rotors in the pump body, keep-
ing the two reference marks visible Replace the
snap ring.
- Check the clearance between the rotors in the
position shown in the diagram using a thickness
gauge.
Measure the distance between the outer rotor and
the pump body (see figure).
- Check the axial clearance of the rotors using a
trued bar as shown in the figure.
Characteristic
Axial rotor clearance
Limit values admitted: 0.09 mm
Distance between the outer rotor and the pump
body
Admissible limit clearance: 0.20 mm
Distance between the rotors
Admissible limit clearance: 0.12 mm
ENG - 139
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.
- Fit the pump cover in the position that permits the crankcase fixing 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. - Tighten the screws to the prescribed torque.
- Fit the sprocket wheel with a new O-ring.
- Fit the chain.
- Fit the central screw and the belleville washer. Tighten to the prescribed torque.
- Fit the oil pump cover by tightening the two screws to the prescribed torque.
N.B.
FIT THE BELLEVILLE WASHER SO THAT ITS OUTER RIM TOUCHES THE PULLEY. MAKE SURE
THAT THE PUMP TURNS FREELY.
Screws fixing oil pump to crankcase 5 - 6 Oil pump control crown screw 10 ÷ 14 Oil pump cover
screws 0.7 ÷ 0.9
ENG - 140
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.
- Remove the seven screws, shown in the dia-
gram, and the two rear brake fluid pipe fixing
brackets.
- Remove the screw, the by-pass piston, the gas-
ket and centring dowels shown in the figure.
Inspecting the by-pass valve
- Check the unloaded spring length.

- Check that the small piston is not scored.
- Ensure that it slides freely on the crankcase and
that it guarantees a good seal.
- If not, eliminate any impurities or replace defec-
tive parts.
Characteristic
By-pass check up: Standard length
54.2 mm
ENG - 141
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.
- Refit the rear brake cable brackets and the
screws in the reverse order from which they were
removed.
- Refit the drive pulley assembly, the drive belt, the
sprocket wheel and the transmission cover, as de-
scribed in the "Transmissions" chapter.
- When testing the lubrication system, refer to
chapter "Crankcase and Crankshaft", regard-
ing lubrication of the crankshaft and connect-
ing rod

Oil sump screws 10 ÷ 14
SAS valve
Inspecting the one-way valve
- Remove the SAS valve.

- Provisionally assemble the rubber coupling of the
SAS valve outlet to ensure tightness.
- Connect the MITYVAC vacuum pump to the rub-
ber coupling as shown in the photograph.
- Set the pump to the low-pressure position (VAC-
UUM).
- Operate the pump slowly.
- Check that the one way valve allows the air to
pass through causing a slight vibration.
ENG - 142
- 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.
N.B.
A MALFUNCTIONING ONE-WAY VALVE CAN RESULT IN
RUBBER COUPLING AND FILTER OVERHEATING
N.B.
ABSENCE OF VIBRATION INDICATES INEFFICIENT SEAL-
ING
Specific tooling
Inspecting the cut-off
- Remove the SAS valve.

- Connect the MITYVAC pump in low-pressure
mode (VACUUM) to the CUT-OFF valve vacuum
intake.
- Apply a vacuum value higher than 0.5 BAR.
- Check that this value is kept all the time.
- If a worn seal is detected, replace it.
- With a "T" bypass and flexible rubber hoses make
a parallel connection between the rubber coupling
and the vacuum intake of the CUT-OFF valve.
- Connect the bypass to the MITYVAC pump.
- Set the pump set to the low-pressure mode
(VACUUM).
- Using a pair of long flat pliers, choke the rubber
hose next to the valve.
- Operate the pump until vacuum is higher than 0.5
BAR.
- Release the hose and check how the vacuum re-
acts. - Under normal functioning conditions the
vacuum undergoes a slight fall and then readjusts.
There follows a slow and continuous loss of de-
pression up to approximately 0.4 BAR. At this point
ENG - 143
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.
N.B.
LACK OF TIGHTNESS IN THE CUT-OFF VALVE RESULTS
IN EXHAUST NOISE (EXPLOSIONS IN THE MUFFLER). IN-
CORRECT CUT-OFF VALVE CALIBRATION CAN RESULT
IN CATALYTIC CONVERTER MALFUNCTIONING
N.B.
A FAULTY CUT-OFF VALVE DIAPHRAGM, BESIDES
JEOPARDISING THE CORRECT OPERATION OF THE
CUT-OFF VALVE, ALSO DAMAGES IDLE FUNCTIONING
Specific tooling
Fuel supply
Removing the carburettor
Kehin
- To detach the carburettor from the engine, it is

necessary to move the air filter and remove the
transmission throttle control, the automatic starter
connection, the clamps anchoring the carburettor
to the filter housing and to the inlet manifold, the
air delivery pipe to the diaphragm, and the intake
fitting.
- Take out the carburettor and rotate it so as to
remove the screw with the water joint and the
pipes.
N.B.
THIS LAST OPERATION IS NECESSARY SO AS NO TO
EMPTY THE COOLING SYSTEM.
ENG - 144
- 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.
- 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.
ENG - 145
- 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-
dle
- Remove the 4 screws indicated in the figure.
ENG - 146
- 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.
N.B.
AVOID REMOVING THE PISTON OF THE PUMP AND ITS
CONTROL.
Adequately support the carburettor and using a

rod and hammer remove the float pin acting from
the throttle control side.
- Remove the float and the plunger.
- Remove the maximum nozzle
ENG - 147
-Remove the maximum nozzle.
-Remove diffuser.
ENG - 148
- 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.
-Remove the minimum nozzle.
- 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 INLET NOZZLE, MINIMUM AND
MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL
SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNEC-
TION SCREWS. THE FIXING SCREWS ARE CAULKED AF-
TER ASSEMBLY AND THEIR REMOVAL DAMAGES THE
SHAFT.
ENG - 149
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.
- Take out the carburettor and rotate it so as to
remove the screw with the water joint and the
pipes
N.B.
THIS OPERATION IS NECESSARY TO AVOID LOSING
SPRAYER PARTS WHEN CLEANING THE CARBURETTOR
BODY. IF THE SPRAYER IS FORCED IN ITS HOUSING DO
NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM-
AGE IT.
Remove the protection, the bracket and the starter

acting on the screw shown in the figure.
Remove the clamp and cover with the airing filter

of the diaphragm chamber.
ENG - 150
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.
ENG - 151
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.
ENG - 152
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.
Remove the float and the plunger.
ENG - 153
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. IF THE SPRAYER IS FORCED IN ITS HOUSING DO
NOT ATTEMPT TO REMOVE IT AS THIS WILL ONLY DAM-
AGE IT.
-Remove the minimum nozzle.
ENG - 154
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
CARBURETTOR BODY SUCH AS: FUEL SUPPLY PIPE,
PLUNGER HOUSING, STARTER NOZZLE, PIT COVER FOR
PROGRESSIONS AND INLET NOZZLE, MINIMUM AND
MAXIMUM AIR GAUGE, THROTTLE VALVE CONTROL
SHAFT. DO NOT REMOVE THROTTLE-SHAFT CONNEC-
TION SCREWS. THE FIXING SCREWS ARE CAULKED AF-
TER THE ASSEMBLY AND THEIR REMOVAL DAMAGES
THE SHAFT.
Refitting the carburettor
ENG - 155
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.
- For the minimum circuit, make sure the following

points are properly cleaned: air gauging, outlet
section controlled by flow screw, progression
holes near the throttle valve.
- For the starter circuit, blow the connection pipe properly with the jet. This is necessary because the
nozzle support hides other inaccessible internal calibrations.
- Blow the intake nozzle properly.
N.B.
THE ACCELERATION NOZZLE OUTLET IS EXTREMELY SMALL AND IS ORIENTED TO THE
THROTTLE VALVE. NOZZLE INCORRECT ORIENTATION RESULTS IN INADEQUATE SPRAY-
ING.
- Check that there are 5 closing ball joints for the operating pipes on the carburettor body.
ENG - 156
- 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.
- Check that the plunger seat does not show abnormal wear.
- Replace the carburettor in case of irregularities.
- Check that the return spring of the accelerating pump rocking lever is not deformed by over-stretching.
N.B.
TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.
- Wash and blow the minimum nozzle properly and
reassemble it.
- Properly wash and blow the components of the

sprayer maximum circuit, the diffuser and the noz-
zle.
- Introduce the sprayer in the carburettor body with
the shortest cylindrical part directed to the diffuser.
- Assemble the diffuser making sure the sprayer is
being adequately inserted and lock it.
-Assemble the maximum nozzle.
- Check that the tapered pin does not show signs

of wear on the sealing surfaces of the shock ab-
sorber pin and the return clamp.
- Replace the rod if worn out.
- Check that the float is not worn on the pin housing or on the contact plate with the plunger and that
there are no fuel infiltration.
- Replace it in case of anomalies.
ENG - 157
- 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.
- Operate the acceleration pump piston repeatedly
and blow with compressed air.
- Reassemble the acceleration pump valves fol-
lowing this order:
INTAKE VALVE (A)
• Spring
• Ball
• Nozzle
IN VALVE (M)
• Ball
• Spring
• Nozzle
N.B.
THE IN VALVE NOZZLE, CORRESPONDING TO THE AC-
CELERATION PUMP, IS MILLED.
-Check the screw tightness introducing a small

amount of fuel in the tank.
- Assemble a new gasket on the tank.
- Assemble the tank on the carburettor body fas-
tening the 4 screws.
- Check that the control roller is free to rotate in its
own seat.
N.B.
MAKE SURE THE TANK GASKET IS CORRECTLY INTRO-
DUCED
N.B.
AVOID DEFORMING THE ACCELERATION PUMP CON-
TROL ROCKING LEVER.
- Wash and blow the flow screw properly.

- Check that screw is not deformed and/or rusty.
- Assemble the spring on the screw.
- Screw the flow screw on the carburettor body.
ENG - 158
- 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.
- 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.
- Carefully clean the air holes indicated in the fig-
ure.
- For the minimum circuit, make sure the following points are properly cleaned: air gauging, outlet section
controlled by flow screw, progression holes near the throttle valve.
N.B.
THE MINIMUM AIR IS CONTROLLED BY TWO ADJUSTMENTS. THE CUT-OFF ONE IS INDICATED
DIRECTLY IN THE CARBURETTOR BODY.
ENG - 159
- For the starter circuit, blow the connection pipe

properly with the jet.This is necessary because the
nozzle support hides other inaccessible internal
calibrations.
- Blow the intake nozzle properly.
N.B.
THE ACCELERATION NOZZLE OUTLET IS EXTREMELY
SMALL AND IS ORIENTED TO THE THROTTLE VALVE.
NOZZLE INCORRECT ORIENTATION RESULTS IN INADE-
QUATE SPRAYING.
- Check that there are 5 closing ball joints for the operating pipes on the carburettor body.
- 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.
- Check that the plunger seat does not show abnormal wear.
- Replace the carburettor in case of irregularities.
N.B.
TO AVOID DAMAGES, DO NOT INTRODUCE METAL OBJECTS IN THE ADJUSTED SECTIONS.
- Wash and blow the minimum nozzle properly and
reassemble it.
- Properly wash and blow the components of the
sprayer maximum circuit, the diffuser and the noz-
zle.
- Introduce the sprayer in the carburettor body with
the shortest cylindric part directed to the diffuser.
- Assemble the diffuser making sure the sprayer is
being adequately inserted and lock it.
-Assemble the maximum nozzle.
- Check that the tapered pin does not show signs
of wear on the sealing surfaces of the shock ab-
sorber pin and the return clamp.
- Replace the rod if worn out.
- Check that the float is not worn on the pin housing or on the contact plate with the plunger and that
there are no fuel infiltration.
- Replace it in case of anomalies.
- Assemble the float with the plunger introducing the pin on the carburettor feeding tube side.
N.B.
INTRODUCE THE RETURN SPRING ON THE FLOAT PLATE ADEQUATELY
ENG - 160
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.
Walbro
- Make sure the float coupling surface is parallel to the tank surface with the carburettor in inverted
position.
- If different positions are detected, change the plunger control metal plate direction to obtain the position
described above.
- If the plate gets deformed, make sure it remains parallel to the float pin.
N.B.
WITH INVERTED CARBURETTOR, THE FLOAT WEIGHT SHOULD NOT EXCEED THE TAPERED
PIN SPRING THRUST. OTHERWISE, CHECK THAT THE FLOAT IS NOT HEAVY DUE TO FUEL
INFILTRATION. REPLACE THE FLOAT AND THE TAPERED PIN, IF NECESSARY.
- Wash and blow the carburettor duct cover prop-
erly and introduce it in the starter nozzle.
N.B.
INCORRECT ASSEMBLY OF CARBURETTOR DUCT COV-
ER ON THE STARTER NOZZLE CAUSES A NEGATIVE
COLD START-UP SITUATION: THE STARTER NOZZLE
TAKES UP THE OLD FUEL FROM THE BOTTOM OF THE
TANK.
ENG - 161
- 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-
fully with compressed air, at the inner side of the
tank for the intake valve and at the pump piston
housing for the supply valve.
- Check that there are no signs of wear in the ac-
celeration pump piston and its corresponding seat
in the tank.
- In case of wear, replace the defective parts.
- Check that the acceleration pump piston contrast
spring is not worn.
- Assemble a new O-Ring and a new bellows gas-
ket. Reassemble the piston unit on the tank.
- Assemble a new O-Ring on the tank drainage
screw and lock it.
-Check the screw tightness introducing a small

amount of fuel in the tank.
- Assemble a new gasket on the tank.
- Assemble the tank on the carburettor body fas-
tening the 4 screws.
- Wash and blow the flow screw properly and as-

semble a new O-Ring.
- Preassemble the components on the screw as
follows: spring, washer and O-ring.
- Screw the flow screw on the carburettor body.
- The screw final position should be determined by
an exhaust fumes analysis.
ENG - 162
- 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.
Check that the return spring of the rocking lever is

not loaded.
- Preassemble the spring and rocking lever as
- Assemble the rocking lever on the carburettor
keeping the throttle valve open.
- Lock the fixing screw of the rocking lever.
- Make sure that the mechanism works correctly.
Inspecting the valve and needle
Kehin
- Check that the tapered pin of the vacuum valve

does not show wear.
- Check that the depression valve does not show
threads on the external surfaces.
- Check that the vacuum intake hole is not clogged.
- Check that the diaphragm is not damaged or has
hardened, otherwise replacement the whole valve.
- Insert the tapered pin into the vacuum valve
housing.
- Reassemble the vacuum valve on the carburettor
body taking care that the tapered pin is inserted
into the sprayer.
ENG - 163
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.
- Tighten the screws.
- Wash and blow dry the filter sponge of the am-

bient pressure intake.
ENG - 164
- 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.
- Check that the valve does not show threads
around its external diameter.
- Check that the 2 vacuum supply holes are not
clogged.
N.B.
THE 2 VACUUM SUPPLY HOLES ARE OF DIFFERENT DI-
AMETERS.
ENG - 165
- 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.
- Assemble the coupling by rotating it 1/8 of a turn.
- Reassemble the vacuum gas valve on the car-

burettor body being careful that the tapered pin is
inserted into the sprayer.
- Time the vacuum valve rotation inserting the di-
aphragm tab in its place.
When the diaphragm is correctly assembled to the
valve, the main vacuum supply hole is positioned
axially with the diffuser, on the throttle valve side.
- Refit the spring on the valve.
- Refit the vacuum chamber cover matching the
reference mark with the orientation of the dia-
phragm.
- Check the cut-off valve correct functioning. -
Check that the diaphragm is not worn or has hard-
ened. Check the free length of the spring.
Characteristic
Walbro: Standard length of cut-off spring
24 mm
- Reassemble the diaphragm and the metal pin placed on the valve.
- Reassemble the spring and the cover. The vacuum intake should be facing upwards.
Inspecting the automatic choke device
ENG - 166
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.
- The starter must be more or less functional de-
pending on the ambient temperature.
- Measure the protrusion of the piston as shown in
the figure and check its corresponding value.
- Make sure that the starter is adjusted for the am-
bient temperature.
- The starter should disconnect progressively by
means of electrical heating.
- Check the starter resistance when adjusted to the
ambient temperature.
With a 12V battery power the automatic starter and
check that the piston protrudes as much as possi-
ble.
- The correct warm up time depends on the ambi-
ent temperature.
- If protrusion, resistance or timing values are dif-
ferent from the ones prescribed, replace the start-
er.
- Assemble the starter to the carburettor being
careful to position the O-Ring correctly, insert the
plate with the machined side contacting the starter,
tighten the fixing screws.
- Position the starter as shown in the figure.
- Assemble the protection casing.
N.B.
TO CARRY OUT THIS CHECK PAY SPECIAL ATTENTION
NOT TO GENERATE SHORT CIRCUITS USE A CABLE
SECTION WITH A TERMINAL SUITABLE TO BE CONNEC-
TED TO THE STARTER.
Characteristic
Check the automatic starter: Kehin: Protrusion
value
ENG - 167
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.
- Check that the piston slides freely from the seat
to the support.
- Check that the piston sealing gasket is not de-
formed.
- The starter must be more or less functional de-
pending on the ambient temperature.
- Measure the protrusion of the piston as shown in
the figure and check its corresponding value.
- Make sure that the starter is adjusted for the am-
bient temperature.
- The starter should disconnect progressively by
means of electrical heating.
- Check the starter resistance when adjusted to the
ambient temperature (20 - 25° C).
With a 12V battery power the automatic starter and
check that the piston protrudes as much as possi-
ble.
- The correct warm up time depends on the ambi-
ent temperature.
- If protrusion, resistance or timing values are dif-
ferent from the ones prescribed, replace the start-
er.
Characteristic
ENG - 168
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
Walbro Resistance
approx. 40 Ω
Adjusting the idle
- The engine does not need frequent idle adjust-

ments, however it is very important to make any
adjustments fully respecting some standards.
- Before adjusting the carburettor make sure to re-
spect the lubrication requirements, valve clear-
ance, and complying timing, spark plug should be
in optimum conditions, air filter clean and sealed,
and the exhaust system tight.
- Warm up the engine by running it at least 5 mi-
nutes at approximately 50 kph.
- Connect the vehicle to the exhaust fumes analy-
ser inserting the probe into a sealed extension pipe
placed at the muffler exit end.
- Connect a millimetre thermometer (020331y) on
the sump, using a cover with oil expressly pre-
pared for probes.
- Start the motor and before adjusting the idle
speed make sure that the oil temperature is be-
tween 70 ÷ 80°C.
- Using the rpm indicator or any other instrument
(020332y), adjust the idle screw to obtain 1600
rpm ÷ 1700 rpm
- Adjust the flow screw until the carbon monoxide
(CO) percentage is 3.1 ÷ 4.5%, when the screw is
ENG - 169
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.
- When the oil temperature, the numbers of revs
and the percentage of carbon monoxide are re-
spected the idle carburetion is considered correct.
From the analyser we can draw further informa-
tion:
- carbon dioxide percentages (CO2), the percent-
age of carbon dioxide has an inverted course com-
pared to the percentage of(CO), values over
12.5% are considered correct. Non complying val-
ues indicate lack of tightness in the exhaust sys-
tem.
- Unburned hydrocarbons (HC) are measured in
parts per million (PPM). The HC value decreases
while the rpm increases; with the engine at idle it
is normal to detect 200 ÷ 400 PPM, these emission
values are deemed normal for an engine with a
diagram of distribution for motorcycles. Higher val-
ues can cause loss of engine blows as the mixture
is too lean (low CO), ignition failure or, incorrect
timing or a clogged or unsealed exhaust valve.
- If it were difficult to ???? adjustment CO check
accurately:
- That the carburettor is clean
- That the automatic starter is efficient
- Tapered pin housing efficiency
- Tank level adjustments
N.B.
THE EXTENSION TUBE IS INDISPENSABLE SO AS NOT
TO SEND POLLUTED EXHAUST FUMES TO THE AMBIENT
OXYGEN. IT IS INDISPENSABLE TO USE AN EXHAUST
FUMES ANALYSER PREVIOUSLY HEATED AND PRE-
PARED TO GUARANTEE THE RESET OF THE READING
OF GASES AND THE CORRECT GAS CAPACITY. FAILURE
TO RESPECT THESE REGULATIONS RESULTS IN INAC-
CURATE READINGS.
N.B.
THE WASTED SPARK IGNITION SYSTEM OFFERS RE-
MARKABLE POWER. READINGS MAY NOT BE ACCU-
RATE IF INADEQUATE RPM INDICATORS ARE USED.
ENG - 170
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
INDEX OF TOPICS
SUSPENSIONS SUSP
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;
- Loosen the fork-wheel axle retainer clamp by
slightly unscrewing the two screws located on the
fork
- Slide off the axle and remove the front wheel, re-
leasing the odometer gear.
Handlebar
Removal
- Remove the digital panel support, the front and

rear parts of the handlebar cover according to
"Bodywork" chapter.
- Remove the handlebar wiring retaining straps
and disconnect the electric connectors from the
brake levers.
- Remove from the handlebar the hoses of both the
front and rear brake pump and of the voltage dis-
tribution valve located on the front frame according
to the "Braking system" chapter.
- Remove the flexible transmission from the front
and rear brake lever and remove the throttle grip.
- Loosen the handlebar steering tube retaining
clamp indicated in the figure and slide off the han-
dlebar, removing the plastic support.
N.B.
IF THE HANDLEBAR IS BEING REMOVED TO REMOVE
THE STEERING, IT IS ONLY NECESSARY TO TILT THE
HANDLEBAR FORWARD ONTO THE FRONT PART OF THE
VEHICLE WITHOUT REMOVING THE PARTS FITTED SO
AS TO AVOID DAMAGING THE SHAFTS.
SUSP - 173
Suspensions MSS X9 Evolution 250
Refitting
Carry out the above operations by working in the

reverse order from those of the removal.

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.
Specific tooling
Overhaul
- Remove the lower screw (1);

- Drain oil from suspension;
- Slide off the stem;
- Replace the sealing rings (3-4) with new ones;
- Fit the new sealing rings only after lubricating their seats;
- Refit the stem and the lower screw (1);
- Unscrew the cap (2);
- Pour 133±2.5 cm³ of Selenia Fork 10W oil per stem on the KAYABA fork, recognisable by the mark
stamped on the sleeves inner side (wheel side)
SUSP - 174
- 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.
SELENIA FORK 10W Oil for front fork
SAE 10 W hydraulic oil
SUSP - 175
Refitting
- Inserire il distanziale
- Bloccare la ghiera inferiore alla coppia prescritta.
- Inserire l'anello distanziale
- Bloccare la ghiera superiore alla coppia prescrit-
ta.
Specific tooling

Upper steering ring nut 40 ÷ 45 Steering lower
ring nut 10 ÷ 12
Steering bearing
SUSP - 176
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
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
Rear
SUSP - 178
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.

Rear wheel axle 104 ÷ 126 Rear wheel fixing
screws 33÷37
Swing-arm
Removal
Removal
- Remove the chassis external nut on the left side.
- Loosen the two nuts shown in the figure.
- Slide off the bolt and remove the swinging arm.
Reassembly
Carry out the previous operations in reverse order.

swinging arm 8 ÷ 12 Nm
Shock absorbers
SUSP - 179
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;
- undo the two upper nuts (one on each side) fixing
the shock absorber spring unit to the chassis and
remove the shock absorbers.
Refitting
Carry out the previous operations but in reverse order.

Lower shock absorber clamp 33 ÷ 41 Upper shock absorber clamp 33 ÷ 41
Centre-stand
Removal
- Unhook the springs.
- Loosen the nut.
- Pull out the screw.
Reassembly
- Install the sealing rings on the support tube of the
stand;
- Carry out the operations described above in re-
verse order, then insert the sealing rings into their
seats.
CAUTION
Lubricate the following parts with grease: spring coupling
pins, bushings on stand fixing bracket.
AGIP GREASE PV2 Grease for control levers
on the engine
White anhydrous-calcium based grease to protect
roller bearings; temperature range between -20 °
C and +120 °C; NLGI 2; ISO-L-XBCIB2
SUSP - 180
stand retaining bolt 20 ÷ 25
SUSP - 181
INDEX OF TOPICS
BRAKING SYSTEM BRAK SYS

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.
IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THE CONTACT AREA WELL
WITH COPIOUS AMOUNTS OF WATER.
USED HYDRAULIC OIL CAN HARM THE ENVIRONMENT. COLLECTION AND DISPOSAL
SHOULD BE CARRIED OUT IN COMPLIANCE WITH CURRENT REGULATIONS.
N.B.
FOR TOPPING UP AND CHANGE, USE ONLY BRAKE FLUID DOT4 - NHTSA 116.
OBSERVE THE MAXIMUM DEGREE OF CLEANLINESS. HYDRAULIC FLUID IS EXTREMELY
CORROSIVE FOR PAINTED SURFACES.
BRAKE FLUID IS HYGROSCOPIC; THAT IS, IT ABSORBS MOISTURE FROM THE SURROUND-
ING AIR.
IF THE MOISTURE CONTENT IN THE BRAKE FLUID EXCEEDS A CERTAIN VALUE, IT WILL RE-
SULT IN POOR BRAKING EFFICIENCY DUE TO A LOW BOILING POINT OF THE FLUID.
N.B.
ALWAYS STORE THE FLUID IN SEALED CONTAINERS.
UNDER NORMAL DRIVING AND CLIMATIC CONDITIONS YOU SHOULD CHANGE THE FLUID
EVERY TWO YEARS. IF THE BRAKES ARE USED INTENSELY AND/OR IN HARSH CONDITIONS,
CHANGE THE FLUID MORE FREQUENTLY.
DURING INSTALLATION, THE PARTS TO BE REUSED MUST BE ABSOLUTELY CLEAN AND
FREE FROM ANY TRACES OF OIL, FUEL AND GREASE: IT IS THEREFORE NECESSARY TO
CLEAN THOROUGHLY WITH DENATURED ALCOHOL.
N.B.
RUBBER PARTS SHOULD NEVER BE LEFT IN ALCOHOL LONGER THAN 20 SECONDS. AFTER
WASHING, THE PIECES MUST BE DRIED WITH A BLAST OF COMPRESSED AIR AND A CLEAN
CLOTH.
THE SEAL RINGS MUST BE IMMERSED IN THE OPERATING FLUID; THE USE OF PRF1 PRO-
TECTIVE DEVICE IS ALLOWED.
WARNING
THE PRESENCE OF BRAKE FLUID ON THE DISC OR BRAKE PADS REDUCES BRAKING EFFI-
CIENCY.
IN THIS CASE, REPLACE THE PADS AND CLEAN THE DISC WITH A HIGH-QUALITY SOLVENT.
Rear brake calliper
BRAK SYS - 183

Braking system MSS X9 Evolution 250
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;
- Place a suitable container to collect the oil, dis-
connect the oil pipe from the calliper and actuate
on the brake lever until no more oil comes out;
- Remove the two screws (indicated in the figure)
fixing the calliper to the support and remove the
calliper.
- repeat the same operations for the opposite cal-
liper, necessary for combined braking. Besides
removing the oil pipe connected to the voltage dis-
tribution valve, also remove the clamp fixing the
odometer gear transmission.
- when refitting, tighten up the screws and the joint
to the prescribed torque and bleed the system.

Screw tightening calliper to the support 20 ÷ 25
BRAK SYS - 184

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;
4) remove the internal elements from the floating
body (5) with the help of short blows of com-
pressed air through the brake fluid pipe in order to
facilitate the expulsion of pistons (6).
5) Check:
- that the plates and the body are whole and in
good condition;
- that the cylinder and the floating body of the cal-
liper do not show signs of scratches or erosion,
otherwise replace the entire calliper;
- that the guides of the fixed plate are not scratched
or eroded, otherwise replace the entire plate;
- that the brake pad check spring works properly.
Refitting
1) insert the pistons (6) and the sealing rings (7) in
the body;
2) place the guide rubbers (8) and refit the fixed
plate (4);
3) assemble the reaction plate (3) tightening the
screws (2), insert the brake pad check spring (9)
and then the pads, fixing them with the corre-
sponding screws (1);
5) place the calliper on the disc and lock it to the
strut by tightening the fixing screws;
6) fix the pipe joint on the calliper at the prescribed
torque.
Functioning
This is a floating type calliper.
It takes advantage of the action and reaction prin-
ciple to obtain the thrust for both pads.
BRAK SYS - 185

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.
The brake pad lock spring
1. Pad fixing screws
2. Reaction plate fixing screws
3. Reaction plate
4. Fixed plate
5. Floating body
6. Piston
7. Piston sealing rings
8. Guide protection rubbers
9. Brake pad check spring
10. Pads
CAUTION
ALL THE SEALS AND GASKETS MUST BE REPLACED EV-
ERY TIME THE CALLIPER IS SERVICED.

Brake fluid pipe-calliper fitting 20 ÷ 25 Pad fas-
tening pin 19.6 ÷ 24.5
Front brake disc
Removal
Remove the wheel and check that the axial devi-

ation of the braking surface is within in the recom-
mended values:
- If this is not the case, replace the disc and repeat
the test.
If the problem persists, check and replace the
wheel hub if necessary.
Front/rear disc replacement
1) disassemble the front/rear wheel;
2) loosen the two fixing screws and remove the
disc.
BRAK SYS - 186

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.
(°) Loctite 243 Medium-strength threadlock
Apply LOCTITE 243 medium-strength threadlock
Characteristic
Brake discs check: Max. axial deviat.
0.1 mm

Disc tightening screw (°) 5 ÷ 6.5
Front brake pads
Removal
Proceed as follows:
- disassemble the front wheel.
- remove the two screws indicated in the figure.
- remove the stop ring and withdraw the pin.
- slide the two pads down.
- repeat these operations for the brake calliper on
the opposite side.
N.B.
Minimise difficulty for this operation by removing the callipers
from their supports without removing the oil pipe.
Rear brake pads
BRAK SYS - 187

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.
- slide the two pads down.
- fit the new pads and tighten the screws (1) so that
they fit in the pad centring holes.
CAUTION
The brake pads are asymmetrical and cannot be interchanged
A = shock absorber side
B = wheel side
CAUTION
PADS MUST BE REPLACED IF THE FRICTION MATERIAL
THICKNESS IS LESS THAN 1.5 MM.
Fill
Front
- Rest the scooter on its stand on level ground.

- Refill the brake circuit reservoir to the maximum
level with the recommended fluid;
- Connect the bleed fitting to the appropriate tool
pipe (Mityvac manual pump);
- Actuate the tool at the bleed fitting, at the same
time constantly top up the brake reservoir to pre-
vent air being drawn into the system, until no more
air escapes at the bleed fitting:
The operation is finished when only oil comes out
of the bleed screws;
- Close the bleed screw and tighten to the prescri-
bed torque.
N.B.
BRAK SYS - 188

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. WHEN CARRYING
OUT THE OPERATION, BRAKE FLUID MAY LEAK FROM
THE BLEED SCREW ON THE CALLIPER AND ON THE
DISC. IN THIS CASE; CAREFULLY CLEAN THE CALLIPER
AND DEGREASE THE BRAKE DISC.
CAUTION
The left brake pump is for the integral braking system and, be-
sides controlling the rear brake calliper, it also controls the front
left calliper. Therefore utmost care must be paid when bleeding
these two callipers.
Specific tooling

Oil bleed screw 8÷12
Brake fluid level check
The front and rear brake fluid tanks are placed on

the pumps under the handlebar covers. Proceed
as follows:
1. Put the vehicle up on the central kickstand and
with the handlebar centred;
2. Remove cover «A» by unscrewing the fixing
screw «B»;
3. Check the fluid level using the relevant window
«C».
Front brake pump
BRAK SYS - 189

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;
3) disconnect the oil pipe from the pump then un-
screw the two u-bolt clamping screws and remove
the pump.
- On refitting, tighten up the fitting to the specified
torque and bleed the system.

Overhaul
1) Remove the brake lever by loosening the fixing screw;

open the cover (2) and take out the diaphragm (3);
2) Remove the cap and unscrew the internal parts in the specified order;
3) Check that:
- The body of the pump shows no signs of internal damage or corrosion;
- The piston shows no sign of damage or abnormal wear;
- The piston return spring is in good condition.
Refitting
Reinstall the individual parts in the reverse order to the removal, paying attention to the correct posi-
tioning of the rubber parts in order to ensure leak tightness.
1. Tank cover screw
2. Tank cover
3. Diaphragm
4. Bellows
5. Seal ring
6. Piston
7. Gasket
8. Spring
9. Tank
CAUTION
ALL THE SEALS AND GASKETS MUST BE REPLACED EVERY TIME THE PUMP IS SERVICED.
BRAK SYS - 190

BRAK SYS - 191

INDEX OF TOPICS
COOLING SYSTEM COOL SYS

MSS X9 Evolution 250 Cooling system
Circuit diagram
COOL SYS - 193

Cooling system MSS X9 Evolution 250
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.
Water pump - overhaul
- Remove the complete flywheel cover

- Remove the stator
- Remove the pump cover by loosening the 3 fixing
screws
- Remove the sealing gasket
The pump can be services using the special tool
and a press. The special tool is designed to be
used with the presses most commonly found in
workshops. For those presses equipped with a 35-
mm piston and protective cap with fixing screw, it
is sufficient to remove the cap and install the com-
ponents of the special tool in its place. The special
tool can be prepared in advance depending on its
use on presses equipped with piston with a threa-
ded type of coaxial coupling tang or cylindrical with
stop groove. Then prepare the threaded ring with
the adapter suitable for the coupling of the press
used.
- Position the flywheel cover in the hydraulic press
by inserting the impeller in the ring that is part of
the special tool, as shown in the photo
N.B.
POSITION THE BASE WITH THE SURFACE PROVIDED
WITH BETTER FINISH TURNED TOWARDS THE FLY-
WHEEL COVER. FAILURE TO COMPLY WITH THIS IN-
STRUCTION MAY RESULT IN DETERIORATION OF THE
SURFACE INTENDED FOR THE COOLANT'S SEAL.
Specific tooling
COOL SYS - 194

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.
Specific tooling
Remove the ceramic seal from the pump shaft.

Using a screwdriver, remove the ceramic ring and
sealing gasket from the flywheel cover.
N.B.
IN THE EVENT YOU PLAN TO REUSE THE MECHANICAL
SEAL, PAY ATTENTION DURING THE DISASSEMBLY
STAGES IN ORDER TO NOT CHIP THE CERAMIC RING.
- Remove the joint from the seat inside the seal ring.
- Position the flywheel cover in the press while sustaining it using the surface to be used for coupling
with the engine case.
CAUTION
CHECK THE POSITIONING OF THE CENTRING DOWELS. PROPERLY PROTECT THE COUPLING
SURFACE.
COOL SYS - 195

Centre the cover until it permits insertion of the pin

and then eject the seal ring and the two ball bear-
ings.
Specific tooling
Before you reassemble, wash all the components

and continue with the following checks.
Flywheel cover: Check that there are no cracks or
oxidation on the seat of the ceramic seal. Check
the capacity loads of the bearings and of the seal
ring. Check the efficiency of the drain hole.
COOL SYS - 196

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. Check the thrust
spring.
Bearings: Check that they do not have irregular
plays or are noisy.
Entrainment joint: Check that there is no abnormal

wear on the seat for the oil seal seat and on the
slots for the entrainment spring.
Heat the flywheel cover using the heat gun

N.B.
IF THE JOB IS PERFORMED WITH THE STATOR MOUN-
TED, HEAT FROM THE EXTERNAL SIDE OF THE COVER.
Specific tooling
020151Y Air heater
020150Y Air heater support
Properly support the cover and using the modular

punch, install the two bearings all the way down at
the same time.
N.B.
WORK IN AN UPRIGHT POSITION
Specific tooling
020441Y 26 x 28 mm adaptor
020629y 8 mm guide
COOL SYS - 197

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.
Mount the moving part of the ceramic seal on the

shaft with the impeller. The rubber part must rest
against the impeller.
Position the flywheel cover on the press using the

support base for the bearings that is part of the
special tool. Install the special punch with the im-
peller's template on the press piston.
Specific tooling
COOL SYS - 198

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.
N.B.
SO AS TO NOT DAMAGE THE FLYWHEEL COVER DURING
THE DRIVING OPERATION, SLIGHTLY TURN IT BY HAND
IN ORDER TO BETTER PERCEIVE THE MOMENT OF CON-
TACT WITH THE PUNCH.
Specific tooling
Remove the special punch from the press piston
and support the flywheel cover from the impeller
side with it.
Put the new oil seal on the special punch while

being careful to position the seal lip starting from
the side of the handle.
COOL SYS - 199

Install the oil seal on the flywheel cover all the way
to the depth determined by the punch.
Specific tooling
Fit the punch with the template of the entrainment

joint to the press punch.
Position the entrainment joint on the shaft and using the press, drive it to the depth determined by the
punch.
Specific tooling
Lubricate the oil seal with motor oil.
Water pump ceramic seal
COOL SYS - 200

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. The efficiency of
this system is guaranteed by the accurate machining and cleaning of the components as they are fitted;
in any case, ceramic seals are subjected to a running in period. During this period (1,000 ± 1,500 km),
there may be small leaks through draining holes, which remain visible on the aluminium crankcase.
This phenomenon is particularly visible there where the hole is more exposed (Quasar and Master). In
such cases we recommend cleaning the casing in order to be able to check again for leaks after a
distance of more than 1500 km. If leaks continue or in the event of real losses, the ceramic seal should
be replaced. For these operations, observe the tools and instructions given in the relevant service
station manuals.
Note: The ceramic seal may be overhauled according to the following couplings:
• Coupling "A": seal ring no. 485084 with ceramic seal no. 486216
• Coupling "B": seal ring no. 841329 with ceramic seal no. 841330
The couplings above may be selected according to their availability, as they are interchangeable.
Thermostat
Removal
- Loosen the two screws indicated in the figure and

remove the thermostat cover.
- Remove the thermostat with its gasket.
COOL SYS - 201

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.
- Immerse the multimeter temperature probe, near
the thermostat.
- 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.
CAUTION
TO EXECUTE THE TEST CORRECTLY, MAKE SURE NEI-
THER THE THERMOSTAT NOR THE THERMOMETER
TOUCHES THE CONTAINER.
Specific tooling
020331Y Digital multimeter
020151Y Air heater
Characteristic
Thermostat check: opening travel
3.5 mm at 80°C
Thermostat check: Opening start temperature
69.5 ÷ 72.5°C
Refitting
- Place the thermostat with the bleeding hole at the

highest point.
- Make sure that the rubber gasket is positioned
properly.
- Fit the thermostat cover with the connection for
the carburettor heating pipe facing the flywheel.
- Tighten the two screw to the torque indicated be-
low.
COOL SYS - 202

Thermostat cover screws 3 ÷ 4
COOL SYS - 203

INDEX OF TOPICS
CHASSIS CHAS
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-
er;
- Unscrew the 3 screws fixing the saddle plate to
the centre cover and remove the saddle.
Rear handlebar cover
- Unscrew the 3 fixing screws;

- Disconnect the electric connectors;
- Remove the rear handlebar cover.
Front handlebar cover
- Remove the brake and oil pump covers on the

handlebar cover;
- Unscrew the 2 lower screws of the handlebar
cover (one per side).
- Remove the front handlebar cover.
CHAS - 205
Chassis MSS X9 Evolution 250
Headlight assy.

- 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-
ber
- Unscrew the 2 fixing screws located inside of it;
- Extract the centre cover in an upwards direction;
- Remove the tank door opening transmission.
CHAS - 206
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;
- Disconnect the stop lights connection wiring;
- Remove the stop lights support (battery cover) by
extracting it upwards so as to disengage the cou-
pling teeth from the side panels.
Footrest
- With the help of a small slotted screwdriver, re-

move the fixing caps and then the safety covers;
- Unscrew the fixing screws on the frame at the
rear shield and at the tunnel cover;
- Remove the footrest board complete with the
passenger boards.
CHAS - 207
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-
er;
- Extract the lower side panel by pulling it towards
the rear;
License plate holder
- Unscrew the 4 fixing screws on the rear frame;

- Disconnect the electric connector of the number
plate light;
- Remove the number plate bracket support with
the lamp socket.
N.B.
WHEN SECURING THE NUMBER PLATE BRACKET ON
THE SUPPORT, PAY ATTENTION TO INSERTING THE RIV-
ETS WITH THE HEAD ON THE WHEEL SIDE SO AS TO
PREVENT THE PROTRUDING PART OF THE RIVET FROM
INTERFERING WITH THE TYRE WHEN THE VEHICLE IS IN
USE.
CHAS - 208
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;
- Remove the rear frame by lifting it from the front
and extracting it from behind.
- Remove the saddle closing coupling;
- Unscrew the remaining fixing screws on the
frame;
- Extract the helmet compartment.
Please take note that, starting from chassis serial number ZAPM2300004505518, the helmet bay light-
ing drive switch fixing screw has been replaced. The new screw drawing 015911 differs from the
previous one for a bigger lenght of 3mm
Fuel tank
- Remove both footrests, the central cover and the tunnel cover as described before;
- Separate the electrical connections of the fuel gauge and disconnect the fuel supply line and tank
breather;
- Remove the horn after unscrewing its fixing screws indicated in the figure and after disconnecting the
electrical connections.
- Unscrew the four fixing screws of the holding bracket indicated in the figure and remove it;
- Unscrew the two fuel tank fixing screws, located on the upper part;
- Slide off the tank downward after tilting it slightly.
CHAS - 209
N.B.
this operation should be preferably be carried out with the tank empty.
Rear central cover

- Remove the rear centre cover.
CHAS - 210
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.
Expansion tank
- Unscrew the fixing screws from the expansion

tank support and remove the support;
- Slide off the expansion tank downwards with the
relative gasket after removing momentarily the
cap;
- Prepare a container for the coolant.
- Close the cap again and remove the coolant de-
livery and reverse pipes.
Top-case
- Unscrew the fixing screws from the electrical

connection indicated in the figure;
- Remove the expansion tank as described before;
- Unscrew the screw inside the case and remove
it together with the saddle latch transmission.
CHAS - 211
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.
- Unscrew the screw in the upper part of the side
panel;
- Disconnect the optical unit wiring;
- Remove the upper side panel by extracting it to-
wards the rear of the vehicle.
Digital panel support

- Disconnect the electric connectors while paying
special attention to the coupling teeth;
- Remove the support with digital panel;
CHAS - 212
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.
- Remove the 2 centre screws «B»
- Remove the lower screw «C» found under the
optical unit
Flyscreen
Unscrew the 3 screws retaining the upper wind-

screen with the relative spacers;
- Remove the upper windscreen
- Extract the 6 plastic plugs and remove the pro-
tective rubber covers of the windscreen supports
together with the central adjustment flange in order
to get to the 2 upper fastenings of the lower wind-
screen.
CHAS - 213
- 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.
N.B.
BE SURE TO CORRECTLY INSERT THE SEALS IN THEIR
SEATS WHEN REASSEMBLING.
CHAS - 214
INDEX OF TOPICS
PRE-DELIVERY PRE DE
Pre-delivery MSS X9 Evolution 250
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
- Safety locks
- clamping screws
Safety locks
Rear shock absorber upper fixing
Rear shock absorber lower fixing
Front wheel axle nut
Wheel hub nut
Frame - swinging arm bolt *
Swinging arm bolt - Engine
Engine arm pin - Frame arm
Handlebar lock nut
Steering lower ring nut
Upper steering ring nut
Electrical system
Electrical system:
- Main switch
- Headlamps: high beam, low beam, position and parking lights and the respective warning lights
- Adjusting the headlights according to the regulations currently in force
- Rear light, parking light, stop light
- Front and rear stop light switches
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator
- Instrument panel warning lights
PRE DE - 216
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.
WARNING
BEFORE RECHARGING THE BATTERY, REMOVE THE CAPS OF EACH CELL.
KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED.
REMOVE THE BATTERY FROM THE SCOOTER, DISCONNECTING THE NEGATIVE TERMINAL
FIRST.
CAUTION
WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG-
ATIVE LEAD.
WARNING
BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL-
PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH EYES OR SKIN, RINSE WITH ABUNDANT WATER FOR ABOUT 15
MINUTES AND SEEK MEDICAL ATTENTION AT ONCE.
IF IT IS SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE
OIL. SEEK IMMEDIATE MEDICAL ATTENTION.
BATTERIES PRODUCE EXPLOSIVE GAS; KEEP THEM AWAY FROM NAKED FLAMES, SPARKS
AND CIGARETTES. IF THE BATTERY IS CHARGED IN A CLOSED PLACE, TAKE CARE TO EN-
SURE ADEQUATE VENTILATION. ALWAYS PROTECT YOUR EYES WHEN WORKING CLOSE TO
BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
Level check:
- Hydraulic braking system fluid level.
- Rear hub oil level
- Engine coolant level.
Road test
Test ride
- Cold start
- Instrument operations
- Response to the throttle control
- Stability on acceleration and braking
- Rear and front brake efficiency
- Rear and front suspension efficiency
PRE DE - 217
Pre-delivery MSS X9 Evolution 250
- 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.
CAUTION
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES OR TYRES MAY BURST.
Functional inspection
Functional check up:

Braking system (hydraulic)
- Lever travel
Braking system (mechanical)
- Lever travel
Clutch
- Proper functioning check
Engine
- Throttle travel check
Others
- Check documentation
- Check the frame and engine numbers
- Tool kit
- License plate fitting
- Check locks
- Check tyre pressures
- Installation of mirrors and any accessories
PRE DE - 218
INDEX OF TOPICS
TIME TIME
Time MSS X9 Evolution 250
This section is devoted to the time necessary to carry out repairs.

For each operation, the description, code and time envisages are specified.
Engine
ENGINE
Code Action Duration
1 001001 Engine from chassis - replacement
2 001127 Engine - Complete service
3 001136 Exhaust emissions - Adjustment
4 003064 Engine oil - Change
5 003057 Engine retainer - Tighten nuts
Crankcase
CRANKCASE
1 003056 Head/Cylinder - Nut tightening
2 001153 Crankcase halves gasket - Replace-
ment
3 001133 Engine crankcase - replace
TIME - 220
MSS X9 Evolution 250 Time
Crankshaft
CRANKSHAFT
1 001117 Crankshaft - Replacement
TIME - 221
Cylinder assy.
CYLINDER - PISTON - PIN UNIT

1 001002 Cylinder-Piston - Replacement
2 001154 Pin ring piston unit - Service
Cylinder head assy.
HEAD - VALVE UNIT

1 001126 Head - Replacement
2 001045 Valves - Replacement
3 001049 Valves - Adjustment
4 001056 Head gasket - change
5 007008 Cylinder head outlet rubber coupling
- Replacement
6 001057 Thermostat - Replacement
7 001083 Thermistor - Replacement
TIME - 222
Rocker arms support assy.
ROCKING LEVER SUPPORT UNIT

1 001148 Valve rocking levers - Replacement
2 001044 Camshaft - Replacement
TIME - 223
Cylinder head cover
HEAD COVER - CHAIN TENSIONER - BY-PASS LUBRICATION

1 001093 Spark plug - Replacement
2 001089 Head cover - Replacement
3 001088 Head cover gasket - Replacement
4 001074 Oil vapour recovery pipe - Replace-
ment
5 001129 Chain tightener - Overhaul and re-
placement
6 001124 By pass lubrication - Replacement
TIME - 224
Oil filter
OIL FILTER
1 001123 Oil filter - Replacement
2 001160 Oil pressure sensor - Replacement
TIME - 225
Driven pulley
DRIVEN PULLEY
1 001022 Clutch - Replacement
2 003072 Clutch - replacement Clutch assem-
bly - Wear check
3 001012 Driven pulley - Service
4 001110 Driven pulley - Replacement
5 001155 Clutch bell housing - Replacement
Oil pump
OIL PUMP
1 001100 Oil seal, clutch side - Replacement
2 001125 Chain guide pads - Replacement
3 001051 Belt/ Timing chain - Replacement
4 001042 Oil pump - Service
5 001112 Oil pump - change
6 001122 Oil pump chain - Replacement
7 001130 Oil sump - Replacement
TIME - 226
Final gear assy.
FINAL REDUCTION GEAR

1 001010 Gear reduction unit - Inspection
2 001156 Gear reduction unit cover - Replace-
ment
3 003065 Gear box oil - Replacement
4 004125 Rear wheel axle - Replacement
TIME - 227
Driving pulley
DRIVING PULLEY
1 001086 Driving half-pulley - Replacement
2 001011 Driving belt - Replacement
3 001006 rear-view pulley - Service
4 001066 driving pulley - Replacement
TIME - 228
Starter motor
ELECTRICAL START UP
1 001141 Belt anti-vibration roller - Replace-
ment
2 001020 Starter motor - Replacement
3 001017 Starter sprocket wheel - Replace-
ment
TIME - 229
Flywheel magneto
MAGNETO FLYWHEEL
1 001087 Flywheel cover - replace
2 001113 Water pump / Pump rotor - Replace-
ment
3 001173 Rotor - replace
4 001067 Stator - Replacement
5 001104 Start-up freewheel - Replacement
6 001151 Start-up driven gearing - Replace-
ment
Belt cooling duct
BELT COOLING TUBE

1 001132 Transmission air inlet pipe - Replace-
ment
2 001131 Transmission air intake - Replace-
ment
TIME - 230
Carburettor
CARBURETTOR
1 001013 Intake manifold - change
2 001081 Automatic choke - Replacement
3 001008 Carburettor - Inspection
4 001063 Carburettor - Replacement
5 007020 Carburettor heat piping. - Replace-
ment
6 003058 Carburettor - Adjustment
TIME - 231
Exhaust pipe
SILENCER
1 001009 Muffler - Replacement
2 001092 Exhaust manifold - Replacement
3 001095 Muffler guard - Replacement
TIME - 232
Air cleaner
AIR CLEANER
1 001014 Air filter - Replacement/Cleaning
2 001015 Air filter box - Replacement
3 004122 Air cleaner carburettor fitting - Re-
placement
TIME - 233
Frame
CHASSIS
1 004001 Frame - replace
2 004146 Front frame - Replacement
3 004116 Rear frame - Replacement
4 004147 footboard support bracket one side -
Replacement
5 004148 footboard support bracket two sides
- Replacement
TIME - 234
Centre-stand
SIDE / CENTRAL STAND

1 004102 Side stand - Replacement
2 004004 Stand - Replacement
3 005079 Stand switch - Replacement
TIME - 235
Legshield spoiler
GRILL SHIELDS
1 004064 Front shield - front section - Replace-
ment
2 006012 Front shield - Paintwork
3 004149 Shield central cover - Replacement
4 006006 Headstock cover - Paintwork
5 004066 Rear view mirrors - Replacement
6 005067 Front direction indicator bulb - Re-
placement
7 005012 Front turn indicator - Replacement
TIME - 236
Rear cover
REAR SHIELD
1 004065 Front shield, rear part - Removal and
refitting
2 004081 Glove box door - Replacement
3 002082 Fuel tank door opening drive - Re-
placement
TIME - 237
Mudguard
FRONT MUDGUARD
1 004053 Spoiler - Replacement
2 004002 Front mudguard - change
3 005081 Temperature sensor - Replacement
TIME - 238
Fuel tank
FUEL TANK
1 005010 Tank float - Replacement
2 004109 Fuel tank breather - change
3 004005 Fuel tank - replace
4 004073 Fuel pump - Replacement
5 004137 Carburettor - pump hose - Replace-
ment
6 004086 Petrol pump depression tube - Re-
placement
7 004089 Tank-pump hose - Replacement
TIME - 239
Expansion tank
EXPANSION TANK
1 007001 Expansion tank -
Replacement
2 007013 Expansion tank
connection pipe -
Replacement
3 001052 Coolant and air
bleed - Replace-
ment
TIME - 240
Radiator
RADIATOR
1 007014 Radiator thermal switch - Replace-
ment
2 007002 Radiator - Replacement
3 007016 Fan with support - replace
4 007003 Coolant delivery and return pipe - Re-
placement
TIME - 241
Rear shock-absorber
REAR SHOCK ABSORBER

1 003007 Rear shock ab-
sorber - Removal
and Refitting
Handlebar covers
HANDLEBAR COVERS
1 004151 Instrument panel support - Replace-
ment
2 004018 Front handlebar covers - Replace-
ment
3 004019 Handlebar rear section - Replace-
ment
4 004152 Board computer cover - Replace-
ment
TIME - 242
Handlebar components
HANDLEBAR COMPONENTS
1 002060 Complete gas command - Replace-
ment
2 002037 Brake or clutch lever - Replacement
3 002071 Left hand grip - Replacement
4 002024 Front brake pump - replace
5 003001 Handlebar - Removal and refitting
6 002063 Throttle control transmission - Re-
placement
7 002059 Right hand grip - Replacement
8 003061 Accelerator transmission - Adjust-
ment
9 002088 Integral brake pump - Replacement
TIME - 243
Swing-arm
SWING ARM
1 001072 Engine / frame swinging arm fitting -
Replacement
2 004058 Silent block - Replacement
3 003081 Swinging arm support flange - re-
place
TIME - 244
Brake hoses
BRAKE PIPING
1 002084 Integral break pump pipe, device -
Replacement
2 002085 Integral brake device pipe- front cal-
liper - Replacement
3 002089 Integral breaking device - Replace-
ment
4 002087 Integral brake rear rigid pipe- Re-
placement
5 002086 Integral brake front rigid pipe- Re-
placement
6 002090 Integral brake fluid and bleeding sys-
tem - Replacement
7 002021 Front brake piping - Replacement
TIME - 245
Seat
SADDLE
1 004003 Saddle - Replacement
2 004054 Saddle lock catch - Replacement
3 004144 Port and/or saddle cover - Replace-
ment
4 004067 Rider backrest - Replacement
TIME - 246
Locks
LOCKS
1 005016 Key switch - Replacement
2 004010 Antitheft lock - Replacement
3 002083 Saddle opening transmission - Re-
placement
TIME - 247
Front wheel
FRONT WHEEL
1 003037 Front wheel rim- Replacement
2 003047 Front tyre - Replacement
3 004123 Front wheel - Replacement
4 003040 Tyre pressure - Check
5 002041 Front brake disc - Replacement
6 005089 Tone wheel - Replacement
TIME - 248
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. The grease recommended is TUTE-
LA MRM 2 (soap-based lithium grease with Mo-
lybdenum disulphide).
In the following points we indicate with an arrow
the area to be greased (1 - Drive, 2 - Tone wheel)
TIME - 249
Rear wheel
REAR WHEEL
1 001071 Rear wheel rim - Replacement
2 004126 Rear wheel tyre - Replacement
3 001016 Rear wheel - Replacement
4 003014 Rear suspension arm - Replacement
5 003077 muffler/rear shock absorber support
arm - Service
6 002070 Rear brake disc - Replacement
7 002028 Rear wheel hub - Replacement
Electric devices
ELECTRIC DEVICES
1 005040 Horn button - Replacement
2 005041 Starter button - Replacement
3 005039 Headlight switch - Replacement
4 005006 Light switch or turn indicators - re-
place
5 005003 Horn - Replacement
6 005077 Emergency stop switch - Replace-
ment
7 005084 Emergency light switch - Replace-
ment
TIME - 250
HEADLIGHT
1 005002 Front headlamp - change
2 005044 Front lights cable unit - replace
3 005008 Front headlamp bulbs - Replacement
TIME - 251
WIRING (WIRE UNIT)

1 005001 Electrical system - Removal and re-
fitting
2 005025 Battery fuse box - Replacement
TIME - 252
BATTERY
1 005007 Battery - Replacement
2 005009 Voltage regulator - Replacement
3 001023 Control unit - Replacement
4 005035 Headlight remote control - Replace-
ment
5 001094 Spark plug cap - Replacement
6 001069 HV coil - Replacement
7 005075 Stop remote control - Replacement
TIME - 253
ELECTRIC DEVICES
1 005068 Rear turn indicator bulb - Replace-
ment
2 005005 Taillight - change
3 005030 Rear telltale light and headlamp ca-
ble assembly - Replacement
4 005066 Rear light bulbs - replace
5 004141 Cat's eye - Replacement
6 005031 Licence plate light bulb - Replace-
ment
7 005032 Transparent licence plate cover - re-
place
TIME - 254
Brake callipers
BRAKE CALIPERS
1 002007 Front brake pads - replace
2 002002 Rear brake pads - Replacement
3 002039 Front brake calliper - Replacement
4 002048 Rear brake caliper - Replacement
TIME - 255
Fuel tank filler flap
TANK PORT FOOTBOARD

1 004135 Fuel tank lid - Replacement
2 004011 Central frame cover - replace
TIME - 256
Footrests
MATS
1 004075 Front mat - Replacement
2 004076 Single rear mat - Replacement
3 004143 Footrest support - Replacement
4 004015 Footrest - Replacement
5 004068 One passenger grab handle - Re-
placement
6 004059 Spark plug inspection flap - Replace-
ment
7 004012 Rear fairing - Replacement
8 004129 Rear fairing - Replacement
Steering column
STEERING WHEEL
1 004119 Bearing / Steering support fifth wheel
- Replacement
2 003002 Steering fifth wheel - Replacement
3 003073 Steering clearance - Adjust
4 003051 Fork assembly - Replacement
5 003079 Fork stem - Replacement
6 003048 Fork oil seal - Replacement
TIME - 257
Helmet bay
HELMET COMPARTMENT
1 005033 Glove-box light switch - Replace-
ment
2 005026 Helmet compartment light - Replace-
ment
3 005027 Helmet compartment bulb support -
Replacement
4 004142 electric socket - Replacement
5 004016 Helmet compartment - Replacement
TIME - 258
Rear side fairings
REAR MUDGUARD
1 004009 Rear mudguard - Replacement
2 005048 Licence plate holder - Replacement
TIME - 259
Windscreen
WINDSCREEN
1 004028 Windshield glass - Replacement
Secondary air box
SECONDARY AIR HOUSING

1 001162 Secondary air housing - Replace-
ment
2 001161 Secondary air filter - Replacement /
Cleaning
3 001174 SAS valve - Replacement
4 001163 SAS valve / Head connection - Re-
placement
5 001164 Crankcase secondary air connection
- Replacement
TIME - 260
TIME - 261
A
Air filter: 39
B
Battery: 50, 57, 72, 73
Brake: 183, 184, 186, 187, 189, 245, 255
Brake fluid: 189
C
Carburettor: 12, 35, 144, 155, 231
E
Engine oil: 39
Engine stop:
F
Fuel: 49, 144, 209, 239, 256
Fuses: 69
H
Headlight: 206
Horn:
Hub oil: 38
I
Identification: 8
M
Maintenance: 7, 32
O
Oil filter: 225
S
Saddle:
Shock absorbers: 179
Spark plug: 37, 64
Stand:
Start-up:
T
Tank: 209, 211, 239, 240, 256
Transmission: 9, 50, 81, 95
Tyres: 11

Piaggio X9 250evo Workshop Manual

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Piaggio X9 250evo Workshop Manual

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WORKSHOP MANUAL

MSS X9 Evolution 250

MSS X9 Evolution 250

ELECTRICAL SYSTEM ELE SYS

ENGINE FROM VEHICLE ENG VE

BRAKING SYSTEM BRAK SYS

COOLING SYSTEM COOL SYS

Chassis prefix: ZAPMXXXX > XXXXXX

Dimensions and mass

DIMENSIONS AND WEIGHT

Characteristics Version 250

Type Single-cylinder, 4 stroke and 4 valves

Piaggio QUASAR with secondary air sys-

tem and catalytic converter.

Cooling system Liquid

Piston displacement 244,29 cm3

Compression ratio 10,5 - 11,5 : 1

Timing system Single-head camshaft controlled by left

side chain, 3-arm rockers with threaded

Valve clearance: 0,10 mm

Walbro Carburettor WVFH

Kehin Carburettor CVK 30

Air filter Sponge, impregnated with mixture (50%

Selenia Air Filter Oil and 50% lead-free

Start-up system electric starter

Lubrication with twin-screw pump (inside the crank-

case) controlled by chain and dual filter:

net and paper filter.

Power supply Petrol (with minimum octane level 95,

lead-free) with vacuum pump and

Max speed xxx Km/h

Spark plug CHAMPION RG4HC

Gas control transmission fixing

ELECTRIC COMPONENTS 250

Frame and suspensions

CHASSIS AND SUSPENSIONS

• N°2 nuts drawing 968224

Wheels and tyres

WHEELS AND TYRES

manifold that cuts the air inlet in deceleration, to

CRANKCASE AND CRANKSHAFT

ENGINE - CYLINDER HEAD

NOTE DI ASSISTENZA TECNICA

Cylinder - piston assy.

COUPLING CATEGORIES ENGINE 250

Crankcase - crankshaft - connecting rod

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Slot packing system

ENGINE 250 SHIMMING

020331Y Digital multimeter

020333Y Single battery charger

020334Y Multiple battery charger

001467Y014 Pliers to extract ø 15-mm bearings

Stores code Description

020335Y Magnetic support for dial gauge

020565Y Flywheel lock calliper spanner

020359Y 42x47-mm adaptor

Stores code Description

020459Y Punch for fitting bearing on steering tube