User manual PIAGGIO VESPA RALLY 200

[. . . ] "© Copyright 2007 - PIAGGIO & C. Reproduction of this publication in whole or in part is prohibited. " PIAGGIO & C. - After-Sales V. le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi) WORKSHOP MANUAL MSS X9 Evolution 250 This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of PiaggioGilera dealers. [. . . ] - Measure the coupling clearance between the sealing rings and the grooves using suitable sensors, 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. 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 MSS X9 Evolution 250 Engine piston diameter 71. 953 - 71. 981 mm Fitting clearance Top piston ring - standard coupling clearance 0. 015 - 0. 06 mm Top piston ring - maximum clearance allowed after use 0. 07 mm Middle piston ring - standard coupling clearance 0. 015 - 0. 06 mm Middle piston ring - maximum clearance allowed after use 0. 07 mm oil scraper ring - standard 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 diameter 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 categories 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 Engine MSS X9 Evolution 250 Inspecting the piston rings Removing the piston - Install piston and wrist pin onto the connecting rod, aligning the piston arrow the arrow facing towards 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' HOUSING. Specific tooling 020454Y Tool for fitting piston pin stops (200 250) ENG - 114 MSS X9 Evolution 250 Engine Choosing the gasket - Provisionally fit the piston into the cylinder, without any base gasket. - 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 Engine MSS X9 Evolution 250 Inspecting the valve housings - Check the width of the imprint on the valve seat«V» wear limit max. - 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 specified 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 exhaust: 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 exhaust: 0. 99 - 1. 27 mm - Measure the diameter of the valve stems in the three positions indicated in the diagram. [. . . ] 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 Chassis MSS X9 Evolution 250 N. B. this operation should be preferably be carried out with the tank empty. Rear central cover - Unscrew the 4 fixing screws; - Remove the rear centre cover. CHAS - 210 MSS X9 Evolution 250 Chassis Radiator fan - Prepare a container for the coolant. - Remove the delivery and reverse pipes of both the expansion tank and the radiator coolant; - Disconnect the connector from the thermostat pipe; - Unscrew the fixing screws and release the radiator 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. [. . . ]