Piaggio MSS X9 EVOLUTION 250 User Manual

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.

"© 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

MSS X9 Evolution 250

This workshop manual has been drawn up by Piaggio & C. Spa to be used by the workshops of Piaggio­Gilera 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 well­ventilated, 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

Specification

Empty weight 173 Kg

Wheelbase 1500 mm
Overall height 1450 mm
Saddle height 790 mm
Overall length 2130 mm

Overall width 910 mm

DIMENSIONS AND WEIGHT

Desc./Quantity

CHAR - 8

MSS X9 Evolution 250 Characteristics

Engine

Characteristics Version 250
Type Single-cylinder, 4 stroke and 4 valves

Piaggio QUASAR with secondary air sys-

tem and catalytic converter.
Cooling system Liquid
Number of cylinders 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:
intake
exhaust
Walbro Carburettor WVFH
Kehin Carburettor CVK 30
Air filter Sponge, impregnated with mixture (50%

Start-up system electric starter
Lubrication with twin-screw pump (inside the crank-

Power supply Petrol (with minimum octane level 95,

0,10 mm

0,15 mm

Selenia Air Filter Oil and 50% lead-free

fuel).

case) controlled by chain and dual filter:

net and paper filter.

lead-free) with vacuum pump and

through carburettor.
Max speed xxx Km/h
Spark plug CHAMPION RG4HC

Transmission

TRANSMISSIONS

Specification

Transmission With automatic expandable pulley variator, V belt, automatic

clutch, gear reduction unit and transmission housing with

Desc./Quantity

forced-circulation air cooling.

CHAR - 9

Characteristics MSS X9 Evolution 250

Gas control transmission fixing

Please take note that starting from the frame num­ber ZAPM2300004502417, the gas control trans­mission fixing has been changed, in fact a tear-off
clamp and a sheath have been introduced, in order
to improve its passage

Capacities

CAPACITÀ

Specification Desc./Quantity

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

Specification

Ignition type Electronic capacitive discharge ignition (CDI) and variable ad-

Spark plug CHAMPION RG4HC

Battery 12V-12Ah

Generator Three-phase alternating current

Variable spark advance 10° ± 1 at 2000 Rpm

Frame and suspensions

Specification

Rear wheel max. travel 90 mm.

Rear suspension Engine with oscillating fork articulated to the chassis by means

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-

X9 Evolution 125-250-500:

ELECTRIC COMPONENTS 250

Desc./Quantity

vance, with separate HV coil.

28° ± 1 at 6500 Rpm

CHASSIS AND SUSPENSIONS

Desc./Quantity

of a double swinging arm. Double-acting hydraulic shock ab-

sorbers, coaxial helicoidal spring with variable step, adjustable

at preloading on 4 positions.

ments.

Please take note that, starting from chassis serial number ZAPM2300003509521, the front small chas­sis 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

MSS X9 Evolution 250 Characteristics

• N°2 nuts drawing 968224

Brakes

BRAKES

Specification Desc./Quantity

Front Twin disc in stainless steel Ø 240 mm with dual-piston floating
Rear Ø 240 mm stainless steel disc with Brembo "Serie Oro" floating

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

calliper Ø 25.4 mm (front right and left)

calliper with Ø 34 mm twin plungers

front disc only

Wheels and tyres

WHEELS AND TYRES

Specification

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 dis­charge pipe on the head.
The 2T reed valve has a diaphragm. The unit

"A", indicated in the figure, has a cut-off device

Desc./Quantity

connected to the depression intake on the inlet

CHAR - 11

Characteristics MSS X9 Evolution 250

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

Depression carburettor CVEK-30

Tapered pin notches position from top Fixed position

Starter device resistance ~ 20 Ω

CHAR - 12

KEHIN CARBURETTOR

Specification

Body stamping CVEK

Stamping 303A

Max. air jet 70

Diffuser nozzle Ø 2.8

Starter jet 42

Diffuser Ø 29

Desc./Quantity

MSS X9 Evolution 250 Characteristics

Specification Desc./Quantity

Tapered pin stamping NDWA

Minimum mixture set screw initial opening ± ¼

Throttle valve spring 150 ÷ 250 g

Minimum air jet 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

Specification Desc./Quantity

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

Product

(°) Loctite 243 Medium-strength threadlock Apply LOCTITE 243 medium-strength

Name

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

Name

Upper shock absorber clamp 33 ÷ 41
Lower shock absorber clamp 33 ÷ 41

Rear wheel axle 104 ÷ 126

Name

Fork leg screw 6 ÷ 7

REAR BRAKE

Description Specifications

threadlock

FRONT BRAKE

Torque in Nm

REAR SUSPENSION

Torque in Nm

FRONT SUSPENSION

Torque in Nm

CHAR - 13

Characteristics MSS X9 Evolution 250

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

Product Description Specifications

(°) Loctite 243 Medium-strength threadlock Apply LOCTITE 243 medium-strength

threadlock

CRANKCASE AND CRANKSHAFT

Name

Internal engine crankcase bulkhead (transmission-side half

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

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

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

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

Torque in Nm

4 ÷ 6

Torque in Nm

Torque in Nm

Torque in Nm

CHAR - 14

MSS X9 Evolution 250 Characteristics

Name Torque in Nm

Nuts fixing head to cylinder (*) 27 ÷ 29

Tappet cover screws 6 ÷ 7

Spark plug 12 ÷ 14

LUBRICATION

Name Torque in Nm

Hub oil drainage plug 15 ÷ 17

Oil filter on crankcase fitting 27 ÷ 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

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

Initials Cylinder Piston Play on fitting

CHAR - 15

Characteristics MSS X9 Evolution 250

Piston rings

SEALING RINGS

Name

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

Description Dimensions Initials Quantity

CHAR - 16

MSS X9 Evolution 250 Characteristics

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

Crankshaft to crankcase axial clearance

clearance

CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE

Name

Half-shaft, transmission

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

Description Dimensions Initials Quantity

16.6 +0-0.05 A D = 0.20 - 0.50

CHAR - 17

Characteristics MSS X9 Evolution 250

Slot packing system

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.

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

Product

AGIP GREASE PV2 Grease for steering bearings and spindle

MONTBLANC MOLYBDENUM

GREASE

AGIP FILTER OIL Oil for air filter sponge Mineral oil with specific additives for in-

AGIP GREASE MU3 Grease for odometer transmission gear

AGIP CITY HI TEC 4T Engine oil SAE 5W-40 Synthetic oil that exceed the

AGIP GP 330 Calcium complex soap-based grease
AGIP CITY HI TEC 4T Four-stroke engine oil Lubricating oil for flexible shafts (throttle
AGIP ROTRA 80W-90 Rear hub oil SAE 80W/90 Oil that exceeds the re-

AGIP PERMANENT SPEZIAL coolant Monoethylene glycol-based antifreeze

Grease for driven pulley shaft adjusting
ring and movable driven pulley housing

Description Specifications

seats

case

with NLGI 2; ISO-L-XBCIB2

Soap-based lithium and zinc oxide

grease containing NLGI 2; ISO-L-

XBCIB2 of the swinging arm

Grease with Molybdenum disulphide

creased adhesiveness

Soap-based lithium grease with NLGI 3;

ISO-L-XBCHA3, DIN K3K-20

requirements of API SL, ACEA A3, JASO

Grease (brake control levers, throttle

quirements of API GL3 specifications

fluid, CUNA NC 956-16

MA specifications

grip)

control)

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

Stores code Description

020412Y 15 mm guide

020335Y Magnetic support for dial gauge

020565Y Flywheel lock calliper spanner

020439Y 17 mm guide

020359Y 42x47-mm adaptor

TOOL - 21

Tooling MSS X9 Evolution 250

Stores code Description

020363Y 20 mm guide

020459Y Punch for fitting bearing on steering tube

020458Y Puller for lower bearing on steering tube

005095Y Engine support

008564Y Flywheel extractor

TOOL - 22

020434Y Oil pressure control fitting

MSS X9 Evolution 250 Tooling

Stores code Description

020382Y011 adapter for valve removal tool

020424Y Driven pulley roller casing fitting punch

020431Y Valve oil seal extractor

020193Y Oil pressure gauge

020306Y Punch for assembling valve seal rings

020360Y Adaptor 52 x 55 mm

TOOL - 23

Tooling MSS X9 Evolution 250

Stores code Description

020364Y 25-mm guide

020375Y Adaptor 28 x 30 mm

020376Y Adaptor handle

020444Y Tool for fitting/ removing the driven pulley

020330Y Stroboscopic light to check timing

clutch

TOOL - 24

001467Y035 Belle for OD 47-mm bearings

MSS X9 Evolution 250 Tooling

Stores code Description

020368Y driving pulley lock wrench

020319Y Immobilizer check tester

020287Y Clamp to assemble piston on cylinder

020263Y Sheath for driven pulley fitting

020262Y Crankcase splitting strip

020430Y Pin lock fitting tool

TOOL - 25

Tooling MSS X9 Evolution 250

Stores code Description

020428Y Piston position check support

020426Y Piston fitting fork

020425Y Punch for flywheel-side oil seal

020423Y driven pulley lock wrench

020414Y 28-mm guide

020393Y Piston fitting band

TOOL - 26

MSS X9 Evolution 250 Tooling

Stores code Description

020382Y Valve cotters equipped with part 012 re-

020455Y 10-mm guide

020442Y Pulley lock wrench

moval tool

020329Y MityVac vacuum-operated pump

020357Y Adaptor 32 x 35 mm
020409Y Multimeter adaptor - Peak voltage detec-

tion

TOOL - 27

Tooling MSS X9 Evolution 250

Stores code Description

020456Y Ø 24 mm adaptor

020332Y Digital rev counter

020074Y Support base for checking crankshaft

020055Y Wrench for steering tube ring nut

002465Y Pliers for circlips

alignment

TOOL - 28

001330Y Tool for fitting steering seats

MSS X9 Evolution 250 Tooling

Stores code Description

020454Y Tool for fitting piston pin stops (200 - 250)

020622Y Transmission-side oil guard punch

020444Y011 adapter ring

020444Y009 46x55 Wrench

001467Y Extractor for bearings for holes

001467Y013 Pliers to extract ø 15-mm bearings

TOOL - 29

Tooling MSS X9 Evolution 250

Stores code Description

020444Y010 adapter ring

020628Y Water pump service kit

TOOL - 30