User manual PIAGGIO VESPA RALLY 200

[. . . ] Reproduction of this publication in whole or in part is prohibited. " PIAGGIO & C. - After-Sales V. le Rinaldo Piaggio, 23 - 56025 PONTEDERA (Pi) WORKSHOP MANUAL MSS X9 Evolution 250 This workshop manual has been drawn up by Piaggio & C. 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. [. . . ] - Remove the screws indicated in the figure, the spacer bar and the tensioner slider. As regards the lower chain guide pad, it may only be removed after the head has been removed. N. B. IT IS ADVISABLE TO MARK THE CHAIN IN ORDER TO ENSURE THAT THE INITIAL DIRECTION OF ROTATION IS MAINTAINED. ENG - 108 MSS X9 Evolution 250 Engine Removing the cam shaft - Remove the two screws and the cam shaft retainer shown in the diagram. - Remove the pins and the rocker arms from the flywheel side holes. N. B. IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER. ENG - 109 Engine MSS X9 Evolution 250 Removing the cylinder head - Remove the spark plug. - Loosen the 4 head-cylinder fastening nuts in two or three stages and in criss-cross fashion. IN CASE OF NEED, THE HEAD MAY BE REMOVED WITH THE CAMSHAFT, PINS, ROCKING LEVERS AND FIXING BRACKET. THE HEAD CAN ALSO BE REMOVED WITHOUT REMOVING THE CHAIN AND THE DRIVING SHAFT CHAIN TIGHTENER. Removing the valves - Using the appropriate tool fitted with an adaptor, remove the cotters, caps, springs and valves. - Remove the lower spring supports. CAUTION REPLACE THE VALVES IN SUCH A WAY AS TO RECOGNISE THEIR ORIGINAL POSITION ON THE HEAD. Specific tooling 020382Y011 adapter for valve removal tool 020382Y Valve cotters equipped with part 012 removal tool 020306Y Punch for assembling valve seal rings Removing the cylinder - piston assy. - Remove the chain guide pad. - Remove the piston seals. CAUTION ENG - 110 MSS X9 Evolution 250 Engine TO AVOID DAMAGING THE PISTON, SUPPORT IT WHILE REMOVING THE CYLINDER. N. B. BE CAREFUL NOT TO DAMAGE THE SEALING RINGS DURING REMOVAL. Inspecting the small end - Measure the internal diameter of the small end using an internal micrometer. N. B. - Fit the middle piston ring with the identification letter facing the crown of the piston. - Fit the top piston ring with the word 'TOP' or the reference mark facing the crown of the piston. - Offset the piston ring gaps on the three rings by 120° to each other as shown in the figure. THE TWO PISTON RINGS ARE MADE WITH A TAPERED CYLINDRICAL CONTACT CROSS-SECTION. THIS IS TO ACHIEVE A BETTER BEDDING. Refitting the cylinder - Insert the cylinder base gasket with the thickness determined above. - Using the fork support and the piston ring retaining band, refit the cylinder as shown in the figure. N. B. BEFORE FITTING THE CYLINDER, CAREFULLY BLOW OUT THE LUBRICATION DUCT AND OIL THE CYLINDER BARREL. Specific tooling 020426Y Piston fitting fork 020393Y Piston fitting band ENG - 117 Engine MSS X9 Evolution 250 Inspecting the cylinder head - Using a trued bar and feeler gauge check that the cylinder head surface is not worn or distorted. Maximum allowable run-out: 0. 05 mm - Check that the camshaft and the rocker pin capacities exhibit no wear. - Check that the cylinder head cover surface, the intake manifold and the exhaust manifold are not worn. Characteristic bearing «A» Ø 12. 000 - 12. 018 mm bearing «B» Ø 20. 000 ÷ 20. 021 mm bearing «C» Ø 37. 000 - 37. 025 mm ENG - 118 MSS X9 Evolution 250 Engine Inspecting the timing system components - Check that the guide shoe and the tensioner shoe are not worn out. - Ensure that the camshaft control pulley chain assembly and the sprocket wheel are not worn. - If you encounter wear, replace the parts or, if the chain, sprocket wheel and pulley are worn replace the whole assembly. - If examples of wear are found, replace the whole assembly. Inspecting the valve sealings - Insert the valves into the cylinder head. [. . . ] - Unscrew the 2 fixing screws indicated on the figure and remove them; - Disconnect the stop lights connection wiring; - Remove the stop lights support (battery cover) by extracting it upwards so as to disengage the coupling teeth from the side panels. Footrest - With the help of a small slotted screwdriver, remove the fixing caps and then the safety covers; - Unscrew the fixing screws on the frame at the rear shield and at the tunnel cover; - Remove the footrest board complete with the passenger boards. CHAS - 207 Chassis MSS X9 Evolution 250 Side fairings - After having removed the panel union element, unscrew the rear screw of the lower panel; - Unscrew the lower screw connecting to the spoiler; - Extract the lower side panel by pulling it towards the rear; License plate holder - Unscrew the 4 fixing screws on the rear frame; - Disconnect the electric connector of the number plate light; - Remove the number plate bracket support with the lamp socket. N. B. WHEN SECURING THE NUMBER PLATE BRACKET ON THE SUPPORT, PAY ATTENTION TO INSERTING THE RIVETS WITH THE HEAD ON THE WHEEL SIDE SO AS TO PREVENT THE PROTRUDING PART OF THE RIVET FROM INTERFERING WITH THE TYRE WHEN THE VEHICLE IS IN USE. CHAS - 208 MSS X9 Evolution 250 Chassis Helmet bay - Remove all electric devices; - Remove the 4 fuse carrier enclosures; - Free the cables fixed to the frame with the relative support clamps; - Remove the battery; - Unscrew the fixing screws on the rear frame; - Remove the rear frame by lifting it from the front and extracting it from behind. - Remove the saddle closing coupling; - Unscrew the remaining fixing screws on the frame; - Extract the helmet compartment. Please take note that, starting from chassis serial number ZAPM2300004505518, the helmet bay lighting drive switch fixing screw has been replaced. The new screw drawing 015911 differs from the previous one for a bigger lenght of 3mm Fuel tank - Remove both footrests, the central cover and the tunnel cover as described before; - Separate the electrical connections of the fuel gauge and disconnect the fuel supply line and tank breather; - Remove the horn after unscrewing its fixing screws indicated in the figure and after disconnecting the electrical connections. [. . . ]