PIAGGIO 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 manual 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 each model should be checked at the official Piaggio sales network. "© Copyright 2008 - 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. - Aftersales V.le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi)

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.

PRE-DELIVERY PRE DE TECHNICAL DATA DT 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 TIME TIME

Warning - Handle fuel with care. Aesthetic inspection Appearance check: - Paintwork - Fitting of plastics - Scratches - Dirt Tightening torques inspection Locking check - Safety fasteners - Fixing screws Safety fasteners: Rear shock absorber upper fixing Rear shock absorber lower fixing Front wheel axle nut Wheel hub nut Swinging arm - frame pin Engine - swinging arm pin Engine arm pin - Chassis arm Handlebar lock nut Lower steering ring nut Upper steering ring nut Electrical system Electrical system: - Main switch - Headlamps: high beam lights, low beam lights, tail lights, parking lights and their warning lights - Headlight adjustment according to regulations 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 MSS X9 Evolution 250 Pre-delivery PRE DE - 7

INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS THE LIFE OF THE BATTERY. WARNING KEEP THE BATTERY AWAY FROM NAKED FLAMES OR SPARKS WHILE IT IS CHARGED. REMOVE THE BATTERY FROM THE VEHICLE, DISCONNECTING THE NEGATIVE TERMINAL FIRST. CAUTION WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG- ATIVE ONE. WARNING BATTERY ELECTROLYTE IS TOXIC AND IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SUL- PHURIC ACID. AVOID CONTACT WITH EYES, SKIN AND CLOTHING. IF IT ACCIDENTALLY COMES INTO CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUN- DANT WATER FOR APPROX. 15 MIN. AND SEEK IMMEDIATE MEDICAL ATTENTION. IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL. SEEK IMMEDIATE MEDICAL ATTENTION. BATTERIES PRODUCE EXPLOSIVE GAS; KEEP CLEAR OF NAKED FLAMES, SPARKS OR CIG- ARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE PRO- TECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES. KEEP OUT OF THE REACH OF CHILDREN. CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THAT RECOMMENDED. 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 throttle control - Stability on acceleration and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Pre-delivery MSS X9 Evolution 250 PRE DE - 8

- Warm start - Starter operation - Minimum holding (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 SINCE THE TYRES MAY BURST. Functional inspection Functional Checks: Braking system (hydraulic) - Lever travel Braking system (mechanical) - Lever travel Clutch - Proper functioning check Engine - Check throttle control travel Others - Check documentation - Check the frame and engine numbers - Tool kit - Licence plate fitting - Locks checking - Tyre pressure check - Fitting of mirrors and possible accessories MSS X9 Evolution 250 Pre-delivery PRE DE - 9

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 naked 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 spare parts may damage the vehicle. - Use only the appropriate tools designed for this vehicle. - Always use new gaskets, sealing rings and cotter pins upon refitting. - After removal, clean the components using non-flammable or low flash-point solvents. Lubricate all the work surfaces, except tapered couplings, before refitting these parts. - After refitting, make sure that all the components have been installed correctly and work properly. - Use only equipment with metric sizes for removal, service and reassembly operations. Metric bolts, nuts and screws are not interchangeable with coupling members using English measurements. Using unsuitable coupling members and tools may damage the vehicle. - When carrying out maintenance operations on the vehicle that involve the electrical system, make sure the electrical connections have been made properly, particularly the ground and battery connec- tions. MSS X9 Evolution 250 Technical Data DT - 11

Engine prefix: M23XM Engine Data ble> 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 0,10 mm 0,15 mm Walbro Carburettor WVFH Technical Data MSS X9 Evolution 250 DT - 12

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 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 Transmission TRANSMISSIONS Specification Desc./Quantity Transmission With automatic expandable pulley variator, V belt, automatic clutch, gear reduction unit and transmission housing with forced-circulation air cooling. MSS X9 Evolution 250 Technical Data DT - 13

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 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 cm³ (recommended oil Selenia HI Scooter 4 Tech) Electrical system ELECTRIC COMPONENTS 250 Specification Desc./Quantity 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 Specification Desc./Quantity 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. Frame type 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 Technical Data MSS X9 Evolution 250 DT - 14

Brakes BRAKES Specification Desc./Quantity 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 Specification Desc./Quantity 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 MSS X9 Evolution 250 Technical Data DT - 15

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 Specification Desc./Quantity 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 nozzle 42 Starter device resistance ~ 20 Ω Diffuser Ø 29 Technical Data MSS X9 Evolution 250 DT - 16

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 nozzle 50 Starter diffuser nozzle 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 threadlocking sealant . Blue FRONT BRAKE Name Torque in Nm Oil bleed screw 8 - 12 Disc tightening screw (°) 5 to 6 Brake fluid pipe-calliper fitting 16 - 20 Brake fluid pump-hose joint 16 - 20 Tightening screw for calliper support to the fork 45 ÷ 55 REAR SUSPENSION Name Torque in Nm Shock absorber upper 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 Front wheel axle 45 - 50 MSS X9 Evolution 250 Technical Data DT - 17

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 Lower steering ring nut 10 - 13 then loosen by 90° Handlebar fixing screw (*) 45 - 50 Fixing screws for the handlebar control unit U-bolts 7 - 10 ENGINE - COOLING Product Description Specifications Loctite 243 Medium strength threadlocking sealant . Blue CRANKCASE AND CRANKSHAFT Name Torque in Nm Internal engine crankcase bulkhead (transmission-side half shaft) screws 4 - 6 Engine-crankcase coupling screws 11 to 13 Starter screws 11 to 13 Crankcase timing system cover screws (°) 3.5 - 4.5 ENGINE - FLYWHEEL Name Torque in Nm Pick-up fixing 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 to 60 Transmission cover screws 11 to 13 Driver 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 silencer to cylinder head 16 - 18 Camshaft retention plate screw 4 to 6 Timing chain tensioner central screw 5 to 6 Timing chain tensioner support screw 11 to 13 Starter counterweight support screw 11 to 15 Timing chain tensioner slider screw 10 - 14 Intake manifold screws 11 - 13 Tappet adjustment check nut 6 - 8 Starter ground screw 7 to 8.5 Head fixing side screws 11 - 12 Nuts fixing head to cylinder (*) 27 ÷ 29 Tappet cover screws 6 - 7 Technical Data MSS X9 Evolution 250 DT - 18

Spark plug 12 to 14 LUBRICATION Name Torque in Nm Hub oil drainage plug 15 to 17 Oil filter on crankcase fitting 27 - 33 Engine oil drainage plug/ mesh filter 24 to 30 Oil filter 4 - 6 Oil pump cover screws 0.7 - 0.9 Screws fixing oil pump to the crankcase 5 to 6 Oil pump command sprocket screw 10 - 14 Oil pump cover plate screws 4 - 6 Oil sump screws 10 to 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 MSS X9 Evolution 250 Technical Data DT - 19

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 Technical Data MSS X9 Evolution 250 DT - 20

Characteristic Driving shaft / crankcase axial clearance A= 0,15 ÷ 0,43 (when cold) CRANKSHAFT Titolo Durata/Valore Testo Breve (< 4000 car.) Indirizzo Immagine Crankshaft Axial clearance between crankshaft and connecting rod Axial clearance between crankshaft and connecting rod CRANKSHAFT/ CRANKCASE AXIAL CLEARANCE Name Description Dimensions Initials Quantity Transmissionside half- shaft 16.6 +0-0.05 A D = 0.20 - 0.50 Flywheel-side halfshaft 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 MSS X9 Evolution 250 Technical Data DT - 21

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 Technical Data MSS X9 Evolution 250 DT - 22

020334Y Multiple battery charger 001467Y014 Calliper to extract ø 15-mm bearings Tooling MSS X9 Evolution 250 TOOL - 24

020565Y Flywheel lock calliper spanner 020439Y 17-mm guide 020359Y 42 x 47 mm Adaptor 020363Y 20-mm guide MSS X9 Evolution 250 Tooling TOOL - 25

ing tube 020458Y Puller for lower bearing on steering tube 005095Y Engine support 008564Y Flywheel extractor 020434Y Union for oil pressure measurement 020382Y011 adapter for valve removal tool Tooling MSS X9 Evolution 250 TOOL - 26

020431Y Valve oil seal extractor 020193Y Oil pressure gauge 020306Y Punch valve seal rings fitting 020360Y 52 x 55 mm adaptor 020364Y 25-mm guide MSS X9 Evolution 250 Tooling TOOL - 27

020376Y Adaptor handle 020444Y Tool for installing/removing clutch on/ from driven pulley 020330Y Stroboscopic light to check timing 001467Y035 Bearing housing, external ø 47 mm 020368Y driving pulley lock wrench Tooling MSS X9 Evolution 250 TOOL - 28

020287Y Clamp for fitting piston on cylinder 020263Y Driven pulley assembly sheath 020262Y Crankcase splitting plate 020430Y Tool for fitting the pin snap rings 020428Y Piston position check mounting MSS X9 Evolution 250 Tooling TOOL - 29

020425Y Punch for flywheel-side oil seal 020423Y Driven pulley lock wrench 020414Y 28-mm guide 020393Y Piston fitting ring 020382Y Valve cotters equipped with part 012 re- moval tool Tooling MSS X9 Evolution 250 TOOL - 30

020329Y Mity-Vac vacuum pump 020357Y 32 x 35-mm Adaptor 020456Y Ø 24 mm adaptor 020332Y Digital rpm indicator MSS X9 Evolution 250 Tooling TOOL - 31

alignment 020055Y Wrench for steering tube ring nut 002465Y Calliper for circlips 001330Y Tool for fitting steering seats 020454Y Tool for fitting the pin snap rings (200 - 250) 020622Y Transmission-side oil seal punch Tooling MSS X9 Evolution 250 TOOL - 32

001467Y Extractor for bearings for holes 001467Y013 Calliper to extract ø 15-mm bearings 020444Y010 adapter ring 020628Y Water pump service kit MSS X9 Evolution 250 Tooling TOOL - 33

AT 1000 KM OR 4 MONTHS Action Engine oil - change Hub oil - change Engine oil filter - change Idle speed (*) - adjustment Throttle control - adjustment Steering - adjustment Brake levers - greasing Brake pads - check for condition and wear Brake fluid level - check Safety fasteners - check Electrical system and battery - check Tyre pressure and wear - check Vehicle test 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 - control Spark plug / electrode gap - check Air filter - cleaning oil filter - change(125) valve clearance 125 - check Sliding shoes / CVT rollers - check Drive belt - checking Coolant level - check Brake pads - check for condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle test and brake test - Road test AT 12000 KM OR 24 MONTHS AND AT 60000 KM Action Engine oil - change Hub oil level - control Spark plug / electrode gap - check / replacement Air filter - cleaning Engine oil filter - change Idle speed (*) - adjustment Sliding shoes / CVT rollers - replace Throttle control - adjustment Coolant level - check Steering - adjustment Brake levers - greasing Brake pads - check for condition and wear Brake fluid level - check Transmission - lubrication Safety fasteners - check Suspension - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle test and brake test - Road test Transmission Belt (125 cc) - Replacement Transmission Belt - Check (250) MSS X9 Evolution 250 Maintenance MAIN - 35

AT 18000 KM AND AT 54000 KM Action engine oil- change(125) Hub oil level - control Spark plug / electrode gap - check Air filter - cleaning oil filter - change(125) valve clearance 125 - check 250 cc Valve Play - Check Sliding shoes / CVT rollers - check Coolant level - check Radiator - external cleaning/check Brake pads - check for condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle test and brake test - Road test Secondary air filter (250) - Cleaning Transmission Belt - Replacement (250) Transmission Belt (125 cc) - Replacement AT 24000 KM AND AT 48000 KM Action Engine oil - change Hub oil - change Spark plug / electrode gap - check / replacement Air filter - cleaning Engine oil filter - change Idle speed (*) - adjustment Sliding shoes / CVT rollers - replace Throttle control - adjustment Coolant level - check Steering - adjustment Brake levers - greasing Brake pads - check for condition and wear Brake fluid level - check Transmission - lubrication Safety fasteners - check Suspension - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Vehicle test and brake test - Road test Transmission Belt - Check (250) Transmission Belt (125 cc) - Replacement (*) See rules in the «Adjusting the engine idle» section AT 30000 KM, AT 42000 KM AND AT 66000 KM Action Hub oil level - control Spark plug / electrode gap - check Air filter - cleaning CVT rollers - check or replacement Drive belt - checking Coolant level - check Brake pads - check for condition and wear Brake fluid level - check Electrical system and battery - check Tyre pressure and wear - check Vehicle test and brake test - Road test engine oil- change(125) oil filter - change(125) Maintenance MSS X9 Evolution 250 MAIN - 36

Action Engine oil - change Hub oil level - control Spark plug / electrode gap - check / replacement Air filter - cleaning Engine oil filter - change valve clearance 125 - check 250 cc Valve Play - Check Idle speed (*) - adjustment Sliding shoes / CVT rollers - replace Throttle control - adjustment Drive belt - replacement Coolant level - check Radiator - external cleaning/check Steering - adjustment Brake levers - greasing Brake pads - check for condition and wear Brake fluid hoses - replacement Brake fluid level - check Transmission - lubrication Safety fasteners - check Suspension - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Secondary air filter (250) - Cleaning Vehicle test and brake test - Road test (*) See rules in the «Adjusting the engine idle» section AT 72000 KM Action Engine oil - change Hub oil - change Spark plug / electrode gap - check / replacement Air filter - cleaning Engine oil filter - change valve clearance 125 - check 250 cc Valve Play - Check Idle speed (*) - adjustment Sliding shoes / CVT rollers - replace Throttle control - adjustment Drive belt - replacement Coolant level - check Radiator - external cleaning/check Steering - adjustment Brake levers - greasing Brake pads - check for condition and wear Brake fluid hoses - replacement Brake fluid level - check Transmission - lubrication Safety fasteners - check Suspension - check Electrical system and battery - check Headlight - adjustment Tyre pressure and wear - check Secondary air filter (250) - Cleaning Vehicle test and brake test - Road test (*) See rules in the «Adjusting the engine idle» section EVERY 2 YEARS Action Coolant - change Brake fluid - change MSS X9 Evolution 250 Maintenance MAIN - 37

EVERY 3,000 KM 10' Action Engine oil - level check/ top-up Recommended products PRODUCTS Product Description Specifications Calcium based grease Calcium grease Smooth-textured appearance; Ivory col- oured Specification TL 9150 066, symbol NATO G 460 MONTBLANC MOLYBDENUM GREASE MONTBLANC MOLYBDENUM GREASE Molybdenum disulphide grease, ivory coloured; Specification TL 9150 066, symbol NATO G 460 Oil for filter sponges Special product for impregnating sponge filtering elements. - Lithium-based grease Lithium-based grease, suitable for vari- ous uses. Yellow grease ISO L-X-BCHA 3 - DIN 51 825 K3K -20 Engine oil 5W -40 Synthetic-based lubricant for four-stroke engines. SAE 5W-40; JASO MA, MA2; API SL; ACEA A3 Water repellent spray grease Water repellent pouring calcium spray grease. R.I.D./A.D.R. 2 10°b) 2 R.I.Na. 2.42 - I.A.T.A. 2 - I.M.D.G. class 2 UN 1950 Page 9022 EM 25-89 Engine oil 5W -40 Synthetic-based lubricant for four-stroke engines. SAE 5W-40; JASO MA, MA2; API SL; ACEA A3 Transmission oil 80W-90 Lubricant for gearboxes and transmis- sions. SAE 80W-90; API GL-4 Anti-freeze liquid, ready to use, colour red Ethylene glycol antifreeze liquid with or- ganic inhibition additives. Red, ready to use. ASTM D 3306 - ASTM D 4656 - ASTM D 4985 - CUNA NC 956-16 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 Maintenance MSS X9 Evolution 250 MAIN - 38

- 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 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 MSS X9 Evolution 250 Maintenance MAIN - 39

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 Maintenance MSS X9 Evolution 250 MAIN - 40

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. - 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 EN- GINE IS COLD. THE SPARK PLUG MUST BE REPLACED EVERY 12,000 KM. USE OF NOT CONFORMING START- ERS OR SPARK PLUGS DIFFERENT FROM THOSE DE- SCRIBED CAN SERIOUSLY DAMAGE THE ENGINE. 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 to 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. MSS X9 Evolution 250 Maintenance MAIN - 41

- 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 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. Maintenance MSS X9 Evolution 250 MAIN - 42

MUST BE CLEANED MORE OFTEN THAN SHOWN IN THE SCHEDULED MAINTENANCE TABLE. Engine oil 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 required. The MAX. level mark indicates a quantity of around 1300 cm³ of engine oil. If the check is carried out after the vehicle has been used, and therefore with a hot engine, the level 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. MSS X9 Evolution 250 Maintenance MAIN - 43

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 cm³. 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 feeler gauge to check that the clearance between the valve and the register corresponds with the indicated values. When the valve clear- ance values, intake and drainage respectively, 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. Maintenance MSS X9 Evolution 250 MAIN - 44

Exhaust: 0.15 mm (when cold) Cooling system 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 MSS X9 Evolution 250 Maintenance MAIN - 45

tem needs to be investigated. The coolant must be replaced every 2 years. WARNING TO AVOID THE RISK OF SCALDING, DO NOT UNSCREW THE EXPANSION TANK COVER WHILE THE ENGINE IS STILL HOT. WARNING TO PREVENT AVOID HARMFUL FLUID LEAKAGE WHILE RIDING, ENSURE THAT THE LEVEL NEVER EXCEEDS THE MAXIMUM VALUE. TO ENSURE CORRECT ENGINE OPERATION, KEEP THE RADIATOR GRILLE CLEAN. Recommended products Anti-freeze liquid, ready to use, colour red Eth- ylene glycol antifreeze liquid with organic in- hibition additives. Red, ready to use. ASTM D 3306 - ASTM D 4656 - ASTM D 4985 - CUNA 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». Maintenance MSS X9 Evolution 250 MAIN - 46

- 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. MSS X9 Evolution 250 Maintenance MAIN - 47

THE TANK AND THE FUEL CIRCUIT. N.B. 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 rpm indicator 494929Y Exhaust fumes analyser 020329Y Mity-Vac vacuum pump 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. -Dry with a clean cloth and short blasts of com- pressed air. Remove the flywheel cover by operating on its clamps and remove the primary filtering element. - Wash with water and neutral soap. -Dry with a clean cloth and short blasts of com- 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 TABLE. Maintenance MSS X9 Evolution 250 MAIN - 48

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 scales 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 Silencer obstructed Replace Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then soak in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then squeeze lightly without wringing, let it drip dry and refit. Automatic starter failure Check: mechanical movement, electric connection and fuel supply, replace if required. Engine 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 Drive 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 unit Air filter dirty Dismantle the sponge, wash with water and shampoo, then soak in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then squeeze lightly without wringing, let it drip dry and refit. 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 Possible Cause Operation Idling rpm too high Adjust the engine idle speed and the CO%, if necessary. Clutch fault Check the springs / clutch masses Starting difficulties DIFFICULT STARTING Possible Cause Operation 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- aged Check the starter motor, the system and the torque limiter 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 engine turn so as to expel the fuel excess taking care to Troubleshooting MSS X9 Evolution 250 TROUBL - 50

If the fuel tank is empty, refuel and start up. Automatic starter failure Check: mechanical movement, electric connection and fuel supply, replace if required. Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then soak in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then squeeze lightly without wringing, let it drip dry and refit. 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 Flat battery 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/SMOKY EXHAUST Possible Cause Operation Worn valve guides Check and replace the head unit if required Worn valve oil seal Replace the valve oil seal 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 fitted properly Replace the piston cylinder unit or just the piston rings Insufficient lubrication pressure LOW LUBRICATION PRESSURE Possible Cause Operation 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 adding the recommended oil type Engine tends to cut-off at full throttle ENGINE STOP FULL THROTTLE Possible Cause Operation Faulty fuel supply Check and, if necessary, replace the vacuum pump and valve. Check the vacuum inlet and pipe seal Incorrect float level Restore the level in the chamber by bending on the float the thrusting reed of the petrol intake rod so as to have the float parallel to the chamber 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 MSS X9 Evolution 250 Troubleshooting TROUBL - 51

ENGINE STOP IDLING Possible Cause Operation 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 Possible Cause Operation Secondary air device cut-off valve not working Replace the secondary air device Depression intake pipe of the secondary air device disconnec- ted or dented Replace the pipe Reed valve of the secondary air device does not close correctly and wears out the rubber coupling between the device and the head pipe Replace the device and the coupling High fuel consumption HIGH FUEL CONSUMPTION Possible Cause Operation Float level Restore the level in the chamber by bending on the float the thrusting reed of the petrol intake rod so as to have the float parallel to the chamber level with the carburettor inverted. Loose nozzles Check the maximum and minimum nozzles are adequately fixed in their fittings Faulty fuel pump Check that there is no fuel in the vacuum pipe Inefficient Starter Check: electric wiring, circuit continuity, mechanical sliding and power supply Air filter blocked or dirty. Dismantle the sponge, wash with water and shampoo, then soak in a mixture of 50% petrol and 50% of specific oil (Selenia Air Filter Oil), then squeeze lightly without wringing, let it drip dry and refit. SAS malfunctions ANOMALIES IN THE SECONDARY AIR DEVICE Possible Cause Operation Secondary air device cut-off valve not working Replace the secondary air device Depression intake pipe of the secondary air device disconnec- ted or dented Replace the pipe Reed valve of the secondary air device does not close correctly and wears out the rubber coupling between the device and the head pipe Replace the device and the coupling Troubleshooting MSS X9 Evolution 250 TROUBL - 52

Clutch grabbing or performing inadequately IRREGULAR CLUTCH PERFORMANCE OR SLIPPAGE Possible Cause Operation Faulty clutch Check that there is no grease on the masses. Check that the clutch mass contact surface with the bell is mainly in the centre with equivalent characteristics on the three masses. Check that the clutch housing is not scored or worn in an anomalous way Insufficient braking INSUFFICIENT BRAKING Possible Cause Operation 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 replace 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 Possible Cause Operation 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 Possible Cause Operation 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 MSS X9 Evolution 250 Troubleshooting TROUBL - 53

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 INDICATORS NOT WORKING Possible Cause Operation Electronic ignition device failure With the ignition switch set to "ON" jump the contacts 1 (Blue- Black) and 5 (Red/Blue) on the control unit connector. If by operating the turn indicators 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 Possible Cause Operation Torque not conforming 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. 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. Faults 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 disc in the attachment to the hub and the steering tube. Faulty or broken seals Replace the shock absorber. Check the condition of wear of the steering covers and the adjustments. Troubleshooting MSS X9 Evolution 250 TROUBL - 54

Specification Desc./Quantity 1 Front left direction indicator 1 bulb 12V - 10W 2 Outside temperature sensor 3 Combined brake stop button 4 Light switch 5 Turn indicator switch 6 Horn button 7 Emergency flashing button 8 "Reset" button 9 Front fuse-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 Electrical system MSS X9 Evolution 250 ELE SYS - 56

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 Starter button 30 Key switch 31 Immobilizer aerial 32 Radiator electric fan motor 33 Electric fan thermal switch 34 Electronic ignition 35 Fuel level transmitter 36 H.V. 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 Licence plate light bulb Type: CAPLESS Power: 12V - 5W Quantity: 1 44 Stop light N° 5 bulbs 12V-2.3W 45 Start-up relay 46 Diode 47 Battery 12V-12Ah 48 Fuse 15A 49 Fuse (Rear position light protection, number plate light, front position light) 7.5A 50 Fuse 10 A 51 Rear fuse holder box 52 Helmet compartment light bulb 12V - 5W 53 Helmet compartment light switch 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 switch 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 MSS X9 Evolution 250 Electrical system ELE SYS - 57

4 Electronic controller 5 Spark plug 6 H.V. coil 7 Immobilizer aerial 8 Voltage regulator 9 Voltage regulator 10 Diagnostic tester outlet 11 Fuse 15A 12 Immobilizer LED 13 Battery 12V-12Ah Electrical system MSS X9 Evolution 250 ELE SYS - 58

HEADLIGHTS AND AUTOMATIC STARTER SECTION Specification Desc./Quantity 1 Electronic control unit 2 Voltage regulator 3 Battery 12V 12Ah 4 Automatic starter 5 Key switch contacts 6 Light switch 7 Light switch 8 Light remote control 9 Fuse (headlight remote control protection) 10 A 10 Helmet compartment light 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, front position light) 7.5A 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 light switch MSS X9 Evolution 250 Electrical system ELE SYS - 59

BATTERY RECHARGE AND START-UP Specification Desc./Quantity 1 Key switch contacts 2 Magneto flywheel 3 Fuse 5A 4 Start-up relay 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 Starter button 12 Fuse 15 A 13 Diode 1 A 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 Electrical system MSS X9 Evolution 250 ELE SYS - 60

LEVEL INDICATORS AND ENABLE SIGNALS Specification Desc./Quantity 1 Digitsl instrument 2 Analogue instrument unit 3 Thermistor 4 Outside temperature sensor 5 Wheel RPM sensor 6 Fuel level transmitter 7 Oil pressure sensor 8 "Reset" button 9 Emergency button 10 Fuse 10 A 11 Key switch contacts 12 Radiator electric fan motor 13 Electric fan thermal switch 14 Magneto flywheel 15 Voltage regulator 16 Fuse 15A MSS X9 Evolution 250 Electrical system ELE SYS - 61

Thermal switch Please be advised that from frame N. ZAPM2300003507739 (X9) ZAPM3620000003383 (X8) ZAPM2850000001025 (Beverly), a new thermal switch was introduced in order to prevent possible electric fan malfunctions. Turn signal lights FLASHING LIGHTS, HORN AND ACCESSORY FITTINGS Specification Desc./Quantity 1 Digital instrument unit 2 Direction indicators N° 2 + 2 bulbs 12V-10W 3 Turn indicator switch 4 Fitting for accessories 5 Horn button 6 Horn 7 Fuse 10 A 8 Ignition switch contacts 9 Fuses 10A Electrical system MSS X9 Evolution 250 ELE SYS - 62

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. MSS X9 Evolution 250 Electrical system ELE SYS - 63

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 2,000 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 service keys (Black) can be pro- grammed at one time. Electrical system MSS X9 Evolution 250 ELE SYS - 64

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. With this link established, it is now possible to en- code new service keys, in the event of losses, replacements, etc. Each new programming dele- tes the previous one. 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-sec flashes. After the failure code indication, a steadily on LED signals that ignition is disabled; see the table: 2-FLASH CODE - Example with programmed electronic control unit, no transponder and/or aerial mal- function. Ignition disabled-Vehicle immobilised 3-FLASH code - Example with programmed electronic control unit, aerial working properly and un- known transponder code. Ignition disabled-Vehicle immobilised Diagnostic code - 2 flashes Diagnosis code: 2-flashes MSS X9 Evolution 250 Electrical system ELE SYS - 65

- 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 TO AVOID SPOILING A NEW CONTROL UNIT UNNECESSARILY Electric characteristic 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. Electrical system MSS X9 Evolution 250 ELE SYS - 66

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: Electric characteristic 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. Electric characteristic High voltage coil primary resistance value High voltage coil primary resistance value: 0.4 - 0.5 Ohm MSS X9 Evolution 250 Electrical system ELE SYS - 67

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. Electric characteristic 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. Electric characteristic 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. Electric characteristic Electrical system MSS X9 Evolution 250 ELE SYS - 68

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. Electric characteristic 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. MSS X9 Evolution 250 Electrical system ELE SYS - 69

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. Electrical system MSS X9 Evolution 250 ELE SYS - 70

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 Electric characteristic Number plate lights 12V-5W Trunk lights 12V-5W Instrument panel lights 12V-2W x 5 Rear direction indicator lights 12V-10W x 2 MSS X9 Evolution 250 Electrical system ELE SYS - 71

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 A BLOWN FUSE WITH A FUSE OF A DIF- FERENT RATING THAN THAT SPECIFIED OR USING OTH- ER MATERIAL (FOR EXAMPLE, A PIECE OF ELECTRICAL WIRE). Electric characteristic 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 Electrical system MSS X9 Evolution 250 ELE SYS - 72

15 A 2 General (battery recharge, lights, radiator electric fan, electronic control unit). 15 A 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 MSS X9 Evolution 250 Electrical system ELE SYS - 73

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. Electrical system MSS X9 Evolution 250 ELE SYS - 74

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. MSS X9 Evolution 250 Electrical system ELE SYS - 75

quired, 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 standard 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 to 14.70V - Initial charge voltage equal to 0.3 to 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 THAT RECOMMENDED. THE USE OF A FUSE OF UNSUITABLE CAPACITY MAY RESULT IN SERIOUS DAMAGES TO THE WHOLE VE- HICLE 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, WHEREAS THE OTHER TWO RED WIRES MARKED (+) MUST BE CONNECTED TO THE TERMI- NAL 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. Electrical system MSS X9 Evolution 250 ELE SYS - 76

- 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 MSS X9 Evolution 250 Electrical system ELE SYS - 77

Specification Desc./Quantity 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 8-WAY INSTRUMENT CONNECTOR Specification Desc./Quantity 1 GROUND ANALOGUE CHART GROUND ANALOGUE CHART 2 BATTERY POSITIVE LEAD (+30) FOR ANALOGUE CARD BATTERY POSITIVE LEAD (+30) FOR ANALOGUE 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) 16-WAY INSTRUMENT CONNECTOR Specification Desc./Quantity 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- PUT STOP LIGHT NOT WORKING WARNING LIGHT IN- PUT 12 LEFT TURN INDICATOR OUTPUT LEFT TURN INDICATOR OUTPUT Electrical system MSS X9 Evolution 250 ELE SYS - 78

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 MSS X9 Evolution 250 Electrical system ELE SYS - 79

- 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 PROCEED WITH THE UTMOST CAUTION WHEN HANDLING PETROL. CAUTION WHEN INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG- ATIVE ONE. 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. MSS X9 Evolution 250 Engine from vehicle ENG VE - 81

out the pin. The engine is now free. - Carry out the removal operations but in reverse order, observing the prescribed tightening torques. Locking torques (N*m) Lower shock absorber clamp 33 - 41 Engine-swinging arm bolt 33 - 41 Engine from vehicle MSS X9 Evolution 250 ENG VE - 82

to remove the plastic cover first, by inserting a screwdriver in the slotted holes. Using the clutch housing lock wrench shown in the figure, remove the driven pulley shaft locking nut and washer. Specific tooling 020423Y Driven pulley lock wrench - 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 5 screws, found on two different lev- els, as well as the small casing. Engine MSS X9 Evolution 250 ENG - 84

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 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 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 020376Y Adaptor handle 020357Y 32 x 35-mm Adaptor 020412Y 15-mm guide Baffle roller MSS X9 Evolution 250 Engine ENG - 85

and that it turns freely. - Remove the special clamping screws as indica- ted in the picture - Check the outer 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. Locking torques (N*m) Anti-flapping roller 12 - 16 Removing the driven pulley - Remove the spacer, the clutch housing and the whole driven pulley unit. N.B. THE UNIT CAN ALSO BE REMOVED WITH THE DRIVING PULLEY MOUNTED. Engine MSS X9 Evolution 250 ENG - 86

- Make sure that the clutch housing is not worn or damaged. - Measure the clutch housing inside diameter. Characteristic Clutch housing max. value Max. value: Ø 134.5 mm clutch housing 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 (inside diameter: 15 and 17 mm). - Lock with the original spacer and nut. - Place the bell/shaft unit on the support to check the crankshaft alignment. - Using a dial gauge and the magnetic base, meas- ure the bell eccentricity. - Repeat the measurement at 3 positions (Central, internal, external). - In case of faults, replace the bell. Specific tooling 020074Y Support base for checking crankshaft alignment 020335Y Magnetic mounting for dial gauge Characteristic clutch housing check: Limit eccentricity. Admissible limit eccentricity: 0.15 mm MSS X9 Evolution 250 Engine ENG - 87

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 11 with the chamfering 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 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 VICE AND THE CENTRAL SCREW MUST TOUCH THE TOOL. EXCESSIVE TORQUE CAN CAUSE THE SPECIFIC TOOL TO BUCKLE. Specific tooling 020444Y011 adapter ring 020444Y009 wrench 46 x 55 020444Y Tool for installing/removing clutch on/from driven pulley Inspecting the clutch - Check the thickness of the clutch mass friction material. - The masses must exhibit no traces of lubricants; in that case, check the driven pulley unit seals. N.B. UPON RUNNING-IN, THE MASSES MUST EXHIBIT A CEN- TRAL FACING SURFACE AND MUST NOT BE DIFFERENT FROM ONE ANOTHER. VARIOUS CONDITIONS CAN CAUSE THE CLUTCH TO TEAR. CAUTION DO NOT USE TOOLS TO OPEN THE MASSES TO AVOID VARIATION IN THE RETURN SPRING LOAD. Characteristic Check minimum thickness Engine MSS X9 Evolution 250 ENG - 88

- Simultaneously turn and pull the collar manually to remove it. N.B. USE TWO SCREWDRIVERS IF YOU HAVE ANY DIFFICUL- TY. N.B. BE CAREFUL NOT TO PUSH THE SCREWDRIVERS IN TOO FAR TO AVOID DAMAGE THAT COULD COMPROMISE THE O-RING SEAL. - Remove the 4 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 retainer 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. MSS X9 Evolution 250 Engine ENG - 89

shown in the figure. Specific tooling 001467Y035 Bearing housing, external ø 47 mm - Remove the roller bearing using the modular punch. Specific tooling 020376Y Adaptor handle 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 faying 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 Engine MSS X9 Evolution 250 ENG - 90

- Remove the two seal rings 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 contact surface. MOVABLE DRIVEN HALF-PULLEY DIMENSIONS Specification Desc./Quantity Wear limit 0.3 mm standard diameter Ø 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 sliders. Refitting the driven half-pulley bearing - Support the pulley bushing adequately from the threaded side using a wooden surface. - Fit a new roller bearing as shown in the figure. - For the fitting of the new ball bearing, follow the example in the figure using a modular punch. Fit the retainer ring WARNING N.B. FIT THE BALL BEARING WITH THE VISIBLE SHIELDING Specific tooling MSS X9 Evolution 250 Engine ENG - 91

020375Y 28 x 30 mm adaptor 020424Y Driven pulley roller casing fitting punch Refitting the driven pulley - Insert the new oil seals 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 grams of grease. Apply 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 Driven pulley assembly sheath Recommended products Molybdenum disulphide grease Lithium grease with molybdenum disulphide Grey black grease. Engine MSS X9 Evolution 250 ENG - 92

- 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 spe- cific 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 No. 11 with the cham- fering facing upwards. - Insert the clutch on the adapter ring. - Lubricate the end of the spring that abuts against the torque server closing collar. - Insert the spring with its plastic holder in contact with the clutch. - Insert the drive belt into the pulley unit according 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. - 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. MSS X9 Evolution 250 Engine ENG - 93

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 PRE-LOADING 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 CONTACTING THE CLUTCH. Specific tooling 020444Y Tool for installing/removing clutch on/from driven pulley 020444Y011 adapter ring 020444Y009 wrench 46 x 55 Locking torques (N*m) Nut locking clutch unit on pulley 55 - 60 Nm Refitting the driven pulley - Reassemble the clutch housing and spacer. Engine MSS X9 Evolution 250 ENG - 94

- Check the belt width. Characteristic 250 four stroke Transmission belt - minimum width 19.5 mm 250 four stroke Transmission belt - standard width 21.3 ± 0.2 mm During the wear checks foreseen in the scheduled maintenance services at 6000 km, 18000 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 picture MSS X9 Evolution 250 Engine ENG - 95

tion ring - Bring in the ring's clamping screws while keeping the tool to support the pulley Specific tooling 021021Y 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 Engine MSS X9 Evolution 250 ENG - 96

mum allowable diameter Ø 26.12 mm Sliding bushing: Standard Diameter Ø 25.959 - 25.98 mm Sliding bushing: Minimum diameter permitted 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 021021Y Driving pulley lock wrench Locking torques (N*m) Driver pulley nut 75 - 83 MSS X9 Evolution 250 Engine ENG - 97

- Check that there are 2 alignment dowels and that the sealing gasket for the oil sump on the trans- mission cover is adequately fitted. - Replace the cover and tighten the 10 screws to 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. - Refit the plastic cover. Specific tooling 020423Y Driven pulley lock wrench Locking torques (N*m) Transmission cover screws 11 to 13 Driven pul- ley shaft nut 54 to 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. Engine MSS X9 Evolution 250 ENG - 98

- 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 001467Y013 Calliper to extract ø 15-mm bear- ings MSS X9 Evolution 250 Engine ENG - 99

- Take out the clip on the outside of the hub cover. - Support the hub cover and expel the bearing. By means of the appropriate tools, remove the oil seal as in the figure. Specific tooling 020376Y Adaptor handle 020477Y Adapter 37 mm 020483Y 30-mm guide 020359Y 42 x 47 mm Adaptor 020489Y Hub cover support stud bolt kit Removing the driven pulley shaft bearing - As you need to remove the driven pulley shaft, its bearing and oil seal, remove the transmission cov- er as described above. - Extract the driven pulley shaft from its bearing. - Remove the oil seal using a screwdriver, working 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 020376Y Adaptor handle 020375Y 28 x 30 mm adaptor 020363Y 20-mm guide Engine MSS X9 Evolution 250 ENG - 100