User manual PIAGGIO MSS X9 EVOLUTION 250

[. . . ] WORKSHOP MANUAL 618153 MSS X9 Evolution 250 WORKSHOP MANUAL MSS X9 Evolution 250 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. [. . . ] - 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, assemble 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 protrudes. - Identify the thickness of the cylinder base gasket to be used for reassembly by the table below. Correctly 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 shimming shimming shimming Measure A 3. 70 - 3. 60 3. 60 - 3. 40 3. 40 - 3. 30 Thickness 0. 4 ± 0. 05 0. 6 ± 0. 05 0. 8 ± 0. 05 ENG - 115 Engine MSS X9 Evolution 250 ENG - 116 MSS X9 Evolution 250 Engine Refitting the piston rings Fitting the sealing rings - Place the oil scraper spring on the piston. - Refit the oil scraper ring with the join of spring ends on the opposite side from the ring gap and the word 'TOP' towards the crown of the piston. 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 Engine MSS X9 Evolution 250 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 capacities 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 MSS X9 Evolution 250 Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Ensure that the camshaft control pulley chain assembly 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. [. . . ] - Close the cap again and remove the coolant delivery 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 Chassis MSS X9 Evolution 250 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 towards the rear of the vehicle. Digital panel support - Unscrew the 3 fixing screws; - Disconnect the electric connectors while paying special attention to the coupling teeth; - Remove the support with digital panel; CHAS - 212 MSS X9 Evolution 250 Chassis Front central cover - To disassemble the front centre cover, it is necessary 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. [. . . ]