MOTO GUZZI Stelvio 1200 MY11 2011, Service Station Manual

Page 1: ...SERVICE STATION MANUAL B043090 Stelvio 1200 NTX MY11 ...

Page 2: ...ted during the bike designing phase Moto Guzzi Original Spare Parts are subject to systematic quality control procedures so that their reliability and performance over time is guaranteed The descriptions and illustrations given in this publication are not binding While the basic features as described and illustrated in this booklet remain unchanged Moto Guzzi reserves the right at any time and wit...

Page 3: ... and changes in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult Moto Guzzi CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on upda...

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Page 5: ...ERISTICS CHAR SPECIAL TOOLS S TOOLS MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE FROM VEHICLE ENG VE ENGINE ENG POWER SUPPLY P SUPP SUSPENSIONS SUSP CHASSIS CHAS BRAKING SYSTEM BRAK SYS BODYWORK BODYW PRE DELIVERY PRE DE ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR ...

Page 7: ...T WITH NAKED FLAMES SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE DO NOT DISPERSE FUEL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components become very hot and remain hot for some time after the engine has been switched off When handling these components wear insulating gloves or wait until the engine and the exhaust s...

Page 8: ...THE BATTERY RELEASES EXPLOSIVE GASES KEEP IT AWAY FROM FLAMES SPARKS CIGARETTES OR ANY OTHER HEAT SOURCES ENSURE ADE QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE DO NOT POUR IT OR SPILL IT PARTICULARLY ON PLASTIC COMPONENTS ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT TERY TO BE ACTIVATED Maintenance rules ...

Page 9: ...e refitting them Smear a light layer of lithium based grease on the oil guard rims Reassemble oil guards and bearings with the brand or lot number facing outward visible side ELECTRIC CONNECTORS Electric connectors must be disconnected as described below failure to comply with this procedure causes irreparable damage to both the connector and the cable harness Press the relevant safety hooks if an...

Page 10: ...AR AS SOON AS THE CLUTCH PLATES GET ADAPTED IT IS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN IN HOWEVER MAKE SURE NOT TO OVERDO THIS CAUTION THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT THE END OF THE RUNNING IN PERIOD Follow these guidelines Do not twist the throttle grip abruptly and completely when the engine is working at a low revs either during or after ru...

Page 11: ...cap Dimensions and mass WEIGHT AND DIMENSIONS Specification Desc Quantity Maximum width without accessories 2305 mm 90 75 in Maximum width at handlebar 956 mm 37 64 in Maximum width of vehicle with accessories 1080 mm 42 52 in Minimum maximum height adjustable windshield 1436 1492 mm 56 53 58 74 in Saddle height 800 mm 31 5 in Minimum earth clearance 185 mm 7 3 in Wheelbase 1535 mm 60 43 in Kerb w...

Page 12: ...f the engine Gear ratios 1st gear 17 38 1 2 2353 Gear ratios 2nd gear 20 34 1 1 7 Gear ratios 3rd gear 23 31 1 1 3478 Gear ratios 4th gear 26 29 1 1 1154 Gear ratios 5th gear 31 30 1 0 9677 Gear ratios 6th gear 29 25 1 0 8621 Final drive with U joint Ratio 12 44 1 3 6667 Capacities CAPACITIES Specification Desc Quantity Engine oil Oil change and oil filter replacement 3 500 cm 214 cu in Gearbox oi...

Page 13: ...lic fork with 45mm 1 77 in di am stanchions and radial calliper mounting bracket with ad justable spring preload and hydraulic compression and re bound damping Front wheel travel 170 mm 6 69 in Rear single arm with progressive linkage single shock absorber with spring preload hydraulic compression and rebound damping adjustment Unloaded shock absorber spring length 180 mm 7 09 in Rear wheel travel...

Page 14: ...R91 4 25 x 17 150 70 R17 69V 2 9 bar 290 kPa 42 1 PSI 2 9 bar 290 kPa 42 1 PSI THE USE OF M S TYRES IS ALLOWED ONLY ON VEHICLES WITHOUT THE ABS SYSTEM WITH THIS TYRE TYPE THE MAXIMUM SPEED ALLOWED IS 170 km h 105 63 mi WHEN FITTING M S TYRES THE MAXIMUM SPEED WARNING LABEL INCLUDED WITH TYRES MUST BE APPLIED TO THE SPEEDOMETER USE EXTREME CAUTION WHEN RIDING ON TARMAC ROADS WITH OFF ROAD ALLROUND ...

Page 15: ... lbf ft 2 Viti fissaggio freccie anteriori M4 2 3 Nm 2 21 lbf ft 3 Vite fissaggio superiore fanale a carozzeria M4 1 3 Nm 2 21 lbf ft 4 Viti fissaggio fanale a carozzeria M4x25 2 3 Nm 2 21 lbf ft 5 Viti TCEI fissaggio fanale a telaietto M5x25 5 6 Nm 4 42 lbf ft Stelvio 1200 NTX MY11 Characteristics CHAR 15 ...

Page 16: ...fil fissaggio supporto cruscotto 5x14 3 Manual 4 Viti autofil fissaggio supporto cruscotto a cor nice 3 9x14 4 Manual 5 Viti autofil fissaggio cornice 4 Manual 6 Viti TCE M5 2 6 Nm 4 42 lbf ft FRONT FORK pos Description Type Quantity Torque Notes 1 Viti piede forcella M8 1 1 25 Nm 18 44 lbf ft 2 Viti chiusura mozzetti M6x30 2 2 10 Nm 7 38 lbf ft 3 Fork cap 1 1 Nm lbf ft Characteristics Stelvio 120...

Page 17: ...iastra fermatubi 2 6 Nm 4 42 lbf ft 2 Viti fissaggio piastre M8x30 6 20 Nm 14 75 lbf ft 3 Headstock ring nut 1 40 Nm 29 50 lbf ft 4 Headstock counter lock ring 1 manual 90 degrees 5 Upper yoke fixing cap 1 100 Nm 73 76 lbf ft Stelvio 1200 NTX MY11 Characteristics CHAR 17 ...

Page 18: ...ription Type Quantity Torque Notes 1 Viti fissaggio parabrezza M6 4 10 Nm 7 38 lbf ft 2 Viti TBEI Flang fissaggio cupolino M5x12 4 6 Nm 4 42 lbf ft 3 Viti fissaggio deflettori superiori M5 4 6 Nm 4 42 lbf ft 4 Colonnette fissaggio deflettori M5 2 6 Nm 4 42 lbf ft 5 Viti TE Flang fissaggio staffa parabrezza M6x16 4 10 Nm 7 38 lbf ft 6 Perno filettato fissaggio supporto parabrezza M8 2 25 Nm 18 44 l...

Page 19: ...fixing screws M8x40 2 25 Nm 18 44 lb ft 2 TE Screws Flang M6x20 2 10 Nm 7 38 lb ft HANDLEBAR AND CONTROLS pos Description Type Quantity Torque Notes 1 TCC handlebar upper U bolt fixing screws M8x30 4 25 Nm 18 44 lb ft Stelvio 1200 NTX MY11 Characteristics CHAR 19 ...

Page 20: ...lb ft Loct 243 6 Rear view mirror fixing connections M10 2 30 Nm 22 13 lb ft FRONT BRAKE LEVER pos Description Type Quantity Torque Notes 1 Viti TBEI fissaggio interruttore M4x12 1 3 Nm 2 21 lbf ft 2 Lever pin M6 1 5 7 Nm 3 69 5 16 lbf ft 3 Viti fissaggio tappo serbatoio 2 0 8 1 5 Nm 0 59 1 11 lbf ft 4 Dado perno leva M6 1 10 Nm 7 38 lbf ft 5 Viti fissaggio cavallotto M6 2 10 Nm 7 38 lbf ft 6 Viti...

Page 21: ...f ft 2 Viti TE Flang fissaggio cilindro comando fri zione M6 3 10 Nm 7 38 lbf ft 3 Viti fissaggio tappo serbatoio 2 0 8 1 5 Nm 0 59 1 11 lbf ft 4 Lever pin 1 5 7 Nm 3 69 5 16 lbf ft 5 Dado perno leva M6 1 10 Nm 7 38 lbf ft 6 Viti fissaggio cavallotto 2 10 Nm 7 38 lbf ft Stelvio 1200 NTX MY11 Characteristics CHAR 21 ...

Page 22: ...riore M5x12 6 6 Nm 4 42 lbf ft FRONT WHEEL pos Description Type Quantity Torque Notes 1 Viti TE Flang fissaggio dischi freno M8x20 12 25 Nm 18 44 lbf ft 2 Nut fixing wheel pin 1 80 Nm 59 00 lbf ft 3 Vite flang fissaggio sensore 1 6 Nm 4 42 lbf ft Loct 243 Characteristics Stelvio 1200 NTX MY11 CHAR 22 ...

Page 23: ...es 4 Vite TCB fissaggio passacavo M4x6 1 3 Nm 2 21 lbf ft FRONT BRAKE CALLIPERS pos Description Type Quantity Torque Notes 1 Viti TE Flang fissaggio pinze M10x55 4 50 Nm 36 88 lbf ft Central part Stelvio 1200 NTX MY11 Characteristics CHAR 23 ...

Page 24: ...ggio sensore di fase 2 3 Nm 2 21 lbf ft CAVALLETTO CENTRALE E LATERALE pos Description Type Quantity Torque Notes 1 Viti TCEI fissaggio cavalletto centrale M10x30 2 50 Nm 36 88 lbf ft Loct 270 2 Viti TE Flang fissaggio piastre M8 2 25 Nm 18 44 lbf ft 3 Screw M8x35 1 25 Nm 18 44 lbf ft 4 Viti TBEI fissaggio piastre M12x35 4 80 Nm 59 00 lbf ft 5 Viti TCEI fissaggio interruttore cavalletto M5 2 6 Nm ...

Page 25: ...TCEI fissaggio leva rinvio cambio M6x20 1 10 Nm 7 38 lbf ft 2 Dadi fissaggio tirante 2 10 Nm 7 38 lbf ft 3 Vite TCEI fissaggio piolo leva freno M6x16 1 10 Nm 7 38 lbf ft 4 Brake lever pin M8 1 15 Nm 11 06 lbf ft Loct 243 Stelvio 1200 NTX MY11 Characteristics CHAR 25 ...

Page 26: ...lbf ft 6 Vite TE Flang fissaggio supporto serbatoio M6x16 1 10 Nm 7 38 lbf ft 7 Vite SWP autofil per supporto serbatoio M5x20 1 Manual EXHAUST SYSTEM pos Description Type Quantity Torque Notes 1 Dadi Flang fissaggio collettori M8 4 25 Nm 18 44 lbf ft 2 Oxygen sensor fastener 2 38 Nm 28 03 lbf ft 3 Vite TE Flang fissaggio parte centrale M10x55 1 25 Nm 18 44 lbf ft 4 Viti fissaggio protezione 2 10 N...

Page 27: ...2 25 Nm 18 44 lbf ft 2 Joint with brake pipes retainer bleeding on the calliper M10 3 25 Nm 18 44 lbf ft 3 Brake pipes joint on the ABS hydraulic unit 3 25 Nm 18 44 lbf ft 4 Brake pipes joint on the ABS hydraulic unit M12 1 30 34 Nm 22 13 25 08 lbf ft Stelvio 1200 NTX MY11 Characteristics CHAR 27 ...

Page 28: ...supporto pedane M8x25 1 25 Nm 18 44 lbf ft 5 Vite fissaggio supporto pedane 1 25 Nm 18 44 lbf ft 6 Vite TCEI fissaggio supporto pedane M8x60 1 25 Nm 18 44 lbf ft 7 Vite fissaggio supporto pedane 1 25 Nm 18 44 lbf ft PASSENGER FOOTRESTS pos Description Type Quantity Torque Notes 1 Viti TE Flang fissaggio piastrine 4 10 Nm 7 38 lbf ft 2 Viti TE Flang fissaggio protezione pedana passeggero SX M6x12 2...

Page 29: ...bf ft 2 Vite TE Flang fissaggio posteriore M6x25 2 10 Nm 7 38 lbf ft 3 Viti TCEI fissaggio tappo benzina M5x15 4 4 Nm 2 95 lbf ft COPERTURA SERBATOIO CARBURANTE pos Description Type Quantity Torque Notes 1 Vite TBEI Flang fissaggio copertura 4 5 Nm 3 69 lbf ft Stelvio 1200 NTX MY11 Characteristics CHAR 29 ...

Page 30: ...lbf ft 2 Pin M12x260 1 50 Nm 36 88 lbf ft 3 Viti TCEI fissaggio anteriore motore a telaio M12x50 2 80 Nm 59 00 lbf ft 4 Screws M8x14 2 25 Nm 18 44 lbf ft 5 Viti TE Flang M8x25 4 25 Nm 18 44 lbf ft 6 Screws M10 2 50 Nm 36 88 lbf ft Characteristics Stelvio 1200 NTX MY11 CHAR 30 ...

Page 31: ... piastra batteria M5x20 4 Manual 2 Viti TBEI Flang fissaggio fianchetti e para spruzzi M5x9 10 6 Nm 4 42 lbf ft 3 Viti TE Flang fissaggio supporti valigie M6 4 10 Nm 7 38 lbf ft 4 Viti TBEI Flang fissaggio paraspruzzi M5x12 2 6 Nm 4 43 lbf ft Stelvio 1200 NTX MY11 Characteristics CHAR 31 ...

Page 32: ... M5 2 6 Nm 4 43 lbf ft 2 Viti TBEI speciali 2 6 Nm 4 43 lbf ft 3 Dado autobloc flang fissaggio catadiottro M5 1 6 Nm 4 43 lbf ft TRANSMISSION CONNECTION ENGINE pos Description Type Quantity Torque Notes 1 Reaction rod fixing screw M10x55 2 50 Nm 36 87 lbf ft Characteristics Stelvio 1200 NTX MY11 CHAR 32 ...

Page 33: ...on the bushing M6x25 2 10 Nm 7 37 lbf ft 2 2 Swingarm fixing screw on the transmission housing M10x35 4 50 Nm 36 87 lbf ft 3 Swingarm pin on the swingarm M12 1 60 Nm 44 25 lbf ft 4 Preloading bushing to the swingarm pin M25 1 10 Nm 7 37 lbf ft Stelvio 1200 NTX MY11 Characteristics CHAR 33 ...

Page 34: ...fissaggio maniglione passeggero M6x25 4 10 Nm 7 38 lbf ft 2 Vite TCEI fissaggio maniglione passeggero M8 2 25 Nm 18 44 lbf ft 3 Vite fissaggio portatarga a maniglione M5 2 6 Nm 4 42 lbf ft 4 Vite TBEI fissaggio supporti portapacchi M8x20 2 25 Nm 18 44 lbf ft 5 Vite TBEI fissaggio supporti portapacchi M8x30 2 25 Nm 18 44 lbf ft 6 Vite TSPEI fissaggio coperchio portapacchi M6x35 2 10 Nm 7 38 lbf ft ...

Page 35: ...ity Torque Notes 1 Vite TE Flang fissaggio ruota fonica 6 25 Nm 18 44 lbf ft 2 Vite TE Flang fissaggio sensore 1 10 Nm 7 38 lbf ft 3 Vite TE Flang fissaggio sensore M12x65 1 110 Nm 81 13 lbf ft Stelvio 1200 NTX MY11 Characteristics CHAR 35 ...

Page 36: ... TE fissaggio biella doppia ammortizza tore M10x47 1 40 Nm 29 50 lbf ft 4 Vite TE flang fissaggio biella singola biella doppia M10x95 1 50 Nm 36 88 lbf ft 5 Vite TE flang fissaggio biella singola al telaio M10x85 1 50 Nm 36 88 lbf ft SADDLE pos Description Type Quantity Torque Notes 1 Vite TBEI fissaggio piastra attacco sella M6 2 10 Nm 7 38 lbf ft 2 Dado serratura 1 Manual Characteristics Stelvio...

Page 37: ...m 14 75 lb ft 3 Nipple on the radiator and the oil pipe M16x1 5 2 20 Nm 14 75 lb ft Apply Vaseline oil 4 Oil delivery pipe to radiator slot screw M14x1 5 1 35 Nm 25 81 lb ft 5 Jets fixing screw 3 Using a T spanner close by hand Loctite 243 6 Minimum oil pressure sensor M12 1 25 Nm 18 44 lb ft 7 Intake oil filter fixing screw 2 4 Nm 2 95 lb ft Stelvio 1200 NTX MY11 Characteristics CHAR 37 ...

Page 38: ...rque Notes 1 Generator control pulley locking nut M16 1 100 Nm 73 76 lb ft Loctite 243 2 Generator upper fixing screw M8 1 22 Nm 16 23 lb ft 3 Generator lower fixing screw M10x60 1 30 Nm 22 13 lb ft Characteristics Stelvio 1200 NTX MY11 CHAR 38 ...

Page 39: ...the crankcase 2 25 Nm 18 44 lb ft 5 Flange fixing screw under the crankcase M6x60 2 10 Nm 7 37 lb ft 6 Flange fixing screw under the crankcase 2 10 Nm 7 37 lb ft 7 Oil sump fixing screw filter contour M6x35 4 10 Nm 7 37 lb ft 8 Oil sump fixing screw M6 14 10 Nm 7 37 lb ft 9 Cover on the flange under the crankcase 2 20 Nm 14 75 lb ft 10 Magnetic oil drainage cap 1 20 Nm 14 75 lb ft 11 Gear to engin...

Page 40: ...1 40 Nm 29 50 lb ft 2 Oil filter joint 1 10 Nm 7 37 lb ft Loctite 243 3 Oil sump pipe 1 20 Nm 14 75 lb ft Loctite 648 4 Oil filter 1 15 Nm 11 06 lb ft Engine oil 5 Rose pipe fixing screw M6 10 Nm 7 37 lb ft 6 Maximum pressure valve cover M18 1 40 Nm 29 50 lb ft Characteristics Stelvio 1200 NTX MY11 CHAR 40 ...

Page 41: ...5x10 2 8 Nm 5 90 lb ft GENERATOR COVER pos Description Type Quantity Torque Notes 1 Timing system cover cap fixing screw M6x20 2 10 Nm 7 38 lb ft Loctite 243 2 Timing system cover fixing screw M8x55 4 25 Nm 18 44 lb ft 3 Timing system cover fixing screw M6x30 9 12 Nm 8 85 lb ft 4 Generator cover fixing screw M6x16 5 12 Nm 8 85 lb ft Stelvio 1200 NTX MY11 Characteristics CHAR 41 ...

Page 42: ...er box fastening screw to frame 2 10 Nm 7 38 lb ft 2 Air filter box cover fastening screw SWP 5x20 6 3 Nm 2 21 lb ft THROTTLE BODY pos Description Type Quantity Torque Notes 1 Intake pipe fixing screw 6 10 Nm 7 37 lb ft Characteristics Stelvio 1200 NTX MY11 CHAR 42 ...

Page 43: ... 1 Clutch to crankshaft fixing screw 6 42 Nm 30 98 lb ft Tighten with cross sequence 2 Clutch external flange fixing screw on flywheel M7x16 6 20 Nm 14 75 lb ft Loctite 243 3 Start up crown fixing screw on flywheel 6 10 Nm 7 37 lb ft Loctite 243 4 Clutch control cylinder fixing screw 3 10 Nm 7 37 lb ft Loctite 243 Stelvio 1200 NTX MY11 Characteristics CHAR 43 ...

Page 44: ...40 Nm 29 50 lb ft Pre tightening 2 Connecting rod screws 4 80 Nm 59 00 lb ft Final tightening 3 Right hydraulic tensioner cover 1 42 Nm 30 98 lb ft 4 Left hydraulic tensioner cover 1 30 Nm 22 13 lb ft FUEL SUPPLY SYSTEM pos Description Type Quantity Torque Notes 1 Vite fissaggio protezioni corpo farfallato M6 2 10 Nm 7 38 lbf ft Characteristics Stelvio 1200 NTX MY11 CHAR 44 ...

Page 45: ...s 1 Vite fissaggio distanziale vaso espansione Blow By a motore SWP M5x14 1 10 Nm 7 38 lbf ft 2 Reduction joint for oil return pipe 1 20 Nm 14 75 lbf ft 3 Oil return pipe on sump 1 20 Nm 14 75 lbf ft Vaseline oil Stelvio 1200 NTX MY11 Characteristics CHAR 45 ...

Page 46: ...f ft 3 Starter motor cover fixing screw M6x10 2 8 Nm 5 90 lbf ft OIL PUMP pos Description Type Quantity Torque Notes 1 Oil pump fixing screw M6x45 3 10 Nm 7 37 lb ft Loctite 243 2 Oil pump driven gear locking nut M6 1 8 Nm 5 90 lb ft Loctite 243 3 Oil pressure valve cap 1 40 Nm 29 50 lb ft Characteristics Stelvio 1200 NTX MY11 CHAR 46 ...

Page 47: ... Notes 1 Screws fixing radiator to chassis M6x30 3 10 Nm 7 38 lb ft RIGHT CYLINDER HEAD pos Description Type Quantity Torque Notes 1 Movable chain tensioner pad fixing screw 1 20 Nm 14 75 lb ft Loctite 243 Stelvio 1200 NTX MY11 Characteristics CHAR 47 ...

Page 48: ...xing screw 1 18 Nm 13 28 lb ft LEFT CYLINDER HEAD pos Description Type Quantity Torque Notes 1 Movable chain tensioner pad fixing screw 1 20 Nm 14 75 lb ft Loctite 243 2 Head tightening nut M10x1 25 4 15 Nm 11 06 lb ft Engine Oil Pre tightening 2 Head tightening nut M10x1 25 4 42 Nm 30 98 lb ft Final tightening 3 Head tightening screws chain compartment M6x120 2 10 Nm 7 37 lb ft 4 Plate locking sc...

Page 49: ... Bearing fixing screw M6x16 1 10 Nm 7 37 lb ft Loctite 243 3 Driving gears locking nut on the crankshaft M25 1 200 Nm 147 51 lb ft Loctite 601 4 Timing system driven gear locking nut M18 1 25 Nm 18 44 lb ft Pre tightening 4 Timing system driven gear locking nut M18 1 150 Nm 110 63 lb ft Final tightening Stelvio 1200 NTX MY11 Characteristics CHAR 49 ...

Page 50: ...rance between cylinders and pistons on the selected diameter if it exceeds the value speci fied it is necessary to replace cylinders and pistons The pistons of an engine must be balanced a weight difference of up to 1 5 g 0 0033 lb is allowed PISTON CYLINDER SELECTION TYPES Specification Desc Quantity Piston diameter selection D 94 935 94 945 mm 3 73759 3 73798 in Cylinder diameter selection D 95 ...

Page 51: ...ted in the cylinder Top and middle piston ring 0 40 0 65 mm 0 00158 0 00255 in Oil scraper piston ring 0 30 0 60 mm 0 00118 0 00236 in Crankcase crankshaft connecting rod CRANKSHAFT SEAT TIMING SYSTEM SIDE Specification Desc Quantity Diameter of crankshaft main journal timing system side 37 975 37 959 mm 1 49507 1 49444 in Inside diameter of crankshaft bushing timing system side 38 016 38 0 mm 1 4...

Page 52: ... Dial gauge support for piston position checking Reset the micrometer on the cylinder rim Move the tool so that the micrometer feeler reaches the top point of the piston crown Take note of the measurement and according to the values found consult the chart at the bottom of the page to decide the thickness of the gasket to be fitted between cylinder and head Unlock crankshaft rotation Rotate the cr...

Page 53: ...ODUCTS TABLE Product Description Specifications ENI i RIDE PG RACING 10W 60 Engine oil SAE 10W 60 As an alternative for rec ommended oils top branded oils that meet or exceed the requirements of CCMC G 4 A P I SG specifications can be used AGIP GEAR SAE 80 W 90 Transmission oil API GL 4 AGIP GEAR MG S SAE 85 W 90 Gearbox oil API GL 5 AGIP ARNICA SA 32 Fork oil ISO L HV AGIP GREASE SM2 Lithium grea...

Page 54: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS ...

Page 55: ...lt tensioning 05 91 17 30 Front cover insertion cone 020716Y Connecting rod locking 020470Y Pin snap ring fitting tool 05 92 72 30 Timing system cover sealing ring punch 01 92 91 00 Wrench for removing the cover on sump and filter Stelvio 1200 NTX MY11 Special tools S TOOLS 55 ...

Page 56: ...1 18 01 Tool to lock the flywheel and the starting ring gear 12 91 36 00 Tool to remove the flywheel side flange AP8140179 Support for valve fitting removal AP9100838 Tool for valve pressure plate 14 92 71 00 Tool to fit the sealing ring on the flywheel side flange Special tools Stelvio 1200 NTX MY11 S TOOLS 56 ...

Page 57: ... crankshaft 19 92 71 00 Tool to fit the seal ring on the flywheel side flange 020673Y Graduated dial hub 020672Y Clutch spring centre and pusher 020674Y Piston ring clamp 020675Y Service shaft gear lock 020676Y Dial gauge support for piston position checking Stelvio 1200 NTX MY11 Special tools S TOOLS 57 ...

Page 58: ...t lock for fixing 020954Y Centring cam shaft cup spring 05 91 25 30 Gearbox opening CHASSIS Stores code Description AP8140190 Tool for steering tightening GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body Special tools Stelvio 1200 NTX MY11 S TOOLS 58 ...

Page 59: ... 27 30 Gearbox support 05 90 27 31 Gearbox oil seal buffer 05 90 27 32 Buffer handgrip 05 90 27 33 Ball joint sealing buffer 05 90 27 34 Wrench for pinion ring nut 05 90 27 35 Pinion oil seal buffer Stelvio 1200 NTX MY11 Special tools S TOOLS 59 ...

Page 60: ...FRONT FORK Stores code Description AP8140146 Weight AP8140149 Protection for fitting operations 9100903 Marzocchi fork oil seal ø 45 mm 1 77 in Special tools Stelvio 1200 NTX MY11 S TOOLS 60 ...

Page 61: ...INDEX OF TOPICS MAINTENANCE MAIN ...

Page 62: ... 1 60 37 3 70 43 5 80 49 7 Exhaust pipe flange bolts I I I I I Spark plugs R R R R R R R R Throttle body C C C C Stands 5 I I I I I I I I Transmission cables and controls I I I I I I I I I Alternator belt A A R A A Steering bearings and steering clearance I I I I I I I I I Wheel bearings I I I I I I I I Diagnosis by tool I I I I I I I I I Brake discs I I I I I I I I I Air filter I R I R I R I R En...

Page 63: ... the cap dipstick 1 If the oil is lower than specified top up until it reaches the cap dipstick hole 1 CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER EL EMENT MAKE SURE IT IS PERFECTLY CLEAN Replacement CAUTION THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS FLUID AND THEREFORE EASY TO DRAIN NOTE RIDE SOME km miles TO WAR...

Page 64: ...he vehicle upright with both wheels on the ground Pull the filler plug oil level dipstick 1 straight out Wipe the oil level dipstick 1 clean and reinsert it Pull it out again and check the oil level The oil level is correct when it is close to the MAX mark Otherwise top up with engine oil CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SU...

Page 65: ...ainer allow several minutes for oil to drain out com pletely Insert the oil filler plug engine oil level dipstick 4 Check and if necessary replace the drainage plug 3 sealing washers Remove any metal deposits attached to the drainage plug 3 magnet Screw and tighten the drainage plug 3 DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIE...

Page 66: ... ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE OIL AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM 10 miles Shut off the engine Keep the vehicle upright with both wheels on the ground Undo and remove the dipstick opening 1 located on the right side of the gear box The level is correct if the oil is close to the hole of the dips...

Page 67: ...l minutes for oil to drain out com pletely Check and if necessary replace the sealing washers of drainage plug 2 Remove any metal scrap attached to the drainage plug 2 magnet Screw and tighten the drainage plug 2 Pour in new oil until it reaches the cap dipstick opening 1 Tighten the filler cap 1 CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER EL EMEN...

Page 68: ...ntity Torque Notes 1 Air filter box fastening screw to frame 2 10 Nm 7 38 lb ft 2 Air filter box cover fastening screw SWP 5x20 6 3 Nm 2 21 lb ft Undo and remove the six screws Lift the filter housing cover Maintenance Stelvio 1200 NTX MY11 MAIN 68 ...

Page 69: ...E TDC IN COMPRESSION STROKE VALVES CLOSED Disconnect the spark plug by leverag ing a screwdriver through the slot CAUTION PAY ATTENTION TO APPLY LEVERAGE ON THE RUBBER OF THE SPARK PLUG CAP ITSELF IN ORDER TO AVOID DAMAGES Unscrew and remove the four head cover fixing screws and collect the sealing O rings Remove the head cover together with the gasket Loosen the nut 1 Use a screwdriver to act on ...

Page 70: ...le upright so that the fluid in the reservoir is at the same level with the plug Make sure that the fluid level in the reservoir is above the MIN reference mark MIN minimum level MAX maximum level If the fluid does not reach at least the MIN reference mark Check brake pads and disc for wear If the pads and or the disc do not need replacing top up the fluid Top up Front brake Unscrew the two screws...

Page 71: ...ING UP KEEP THE TANK PARALLEL TO THE RESERVOIR EDGE IN HORIZONTAL POSITION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN DO NOT EXCEED THE MAX LEVEL MARK WHEN TOP PING UP TOP UP TO MAX LEVEL MARK ONLY WHEN BRAKE PADS ARE NEW WHEN TOPPING UP DO NOT EXCEED THE MAX LEVEL MARK WHEN BRAKE PADS ARE WORN AS YOU RISK SPILLING...

Page 72: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS ...

Page 73: ... 10 Nm 7 38 lbf ft 2 Viti TCEI fissaggio bobine 2 2 2 Nm 1 47 lbf ft 3 Viti TCEI fissaggio centralina 2 10 Nm 7 38 lbf ft 4 Viti TCEI fissaggio supporto sensore temp olio M10x20 1 11 Nm 8 11 lbf ft Loct 243 5 Viti TCEI fissaggio sensore di fase 2 3 Nm 2 21 lbf ft Stelvio 1200 NTX MY11 Electrical system ELE SYS 73 ...

Page 74: ...Components arrangement key 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector 5 Throttle valve potentiometer Electrical system Stelvio 1200 NTX MY11 ELE SYS 74 ...

Page 75: ...adlamps 24 ABS Control unit 25 Rear ABS sensor 26 ABS Fuses Electrical system installation INTRODUCTION Scope and applicability This document aims at defining the cable harness routing in order to achieve the vehicle reliability targets Materials used and corresponding quantities The electrical system consists of the following cable harnesses and parts 1 Main cable harness 1 Ground lead 1 Headlamp...

Page 76: ...ector Key Connector Right Light Switch Connectors Left Light Switch Connectors ABS connector and correct positioning of the cap Front and rear speed sensor connector Auxiliary Fuses rubber housing correct positioning and closing Intake air temperature sensor Fuel injector connectors The connectors in the list are circled in the different pictures The listed connectors are con sidered more critical...

Page 77: ... grommet 4 Headlamp cable harness TABLE B 1 Rubber clamps TABLE C 1 Front brake switch 2 Faston Check the faston are connected up to the end TABLE D 1 Cable grommets 2 Pipe tightening clamp 3 Front ABS sensor Stelvio 1200 NTX MY11 Electrical system ELE SYS 77 ...

Page 78: ...TABLE E 1 Main cable harness 2 Small clamp 3 Middle clamp TABLE F 1 Middle clamp 2 Clamp already present on the cable harness Electrical system Stelvio 1200 NTX MY11 ELE SYS 78 ...

Page 79: ...to the inside of the support so as not to obstruct the forks TABLE I 1 Clamp that groups the cable harness of the right light switch the front stop switch the front ABS sensor and the key TABLE L 1 Medium clamps 2 Small clamps Stelvio 1200 NTX MY11 Electrical system ELE SYS 79 ...

Page 80: ...ted as in the photo 3 Small clamp 4 Cable grommet TABLE O 1 Medium clamps TABLE P 1 Clamp that has the cable harness of the left light switch and the key on the metal relay 2 Clamp that has the cable harness of the left light switch on the pipe 3 Middle clamp Electrical system Stelvio 1200 NTX MY11 ELE SYS 80 ...

Page 81: ...clamp TABLE S 1 Hook the clamp on the specific hole present in the support 2 Middle clamp TABLE T 1 Front plug socket 2 Plug socket connector 3 Correct alignment 4 Medium clamp to be placed after fitting the cap so as to avoid it can remove Stelvio 1200 NTX MY11 Electrical system ELE SYS 81 ...

Page 82: ...l part TABLE A 1 Main cable harness 2 Motor main cable harness 3 Grey taping as reference that must remain be tween the two covers TABLE B 1 Engine oil pressure sensor 2 Small clamp TABLE C 1 Generator 2 Sensor 3 Alternator positive Electrical system Stelvio 1200 NTX MY11 ELE SYS 82 ...

Page 83: ...lamp that fastens the right pick Up ca ble to the chassis TABLE E 1 Reused clamp TABLE F 1 Cable guide 2 Plastic cable guides TABLE G 1 Neutral switch Correctly fit the hood on the gear switch Stelvio 1200 NTX MY11 Electrical system ELE SYS 83 ...

Page 84: ...he steel clip is correctly placed after the connection TABLE L 1 Middle clamp 2 Big clamp 3 Right light switch key and front ABS sensor connections 4 Heated hand grips connectors 5 Small clamp that blocks the heated hand grips connectors to the brake pipe Electrical system Stelvio 1200 NTX MY11 ELE SYS 84 ...

Page 85: ...sor 4 Clamp to keep the starter motor cable harness far from the throttle bodies control pin TABLE N 1 Starter motor Make sure that the end is oriented to the inside to avoid touching the protec tion of the starter motor Stelvio 1200 NTX MY11 Electrical system ELE SYS 85 ...

Page 86: ... grommet Hook the cable grommet with the inter nal cable harness of the oxygen sensor TABLE Q 1 Fuel pump 2 Fuel pump connector 3 Small clamp TABLE R 1 Horn 2 Horn cable harness 3 Middle clamp TABLE S 1 ABS control unit connector The initial position of the connector fastener lever must be as shown in the figure Electrical system Stelvio 1200 NTX MY11 ELE SYS 86 ...

Page 87: ...control unit must be 7 5 mm 0 29 in TABLE V If the initial position of the connector and the pulling level is not as the one in TABLE S the connector will not hook correctly and the distance meas ured will be higher than approximately 12 mm 0 47 in In this case repeat the operation as described in TABLE T and TABLE U It is advisable to create a jig in order to check the correct connector insertion...

Page 88: ...sensor 3 Filter box 4 Secondary fuse protection injection system TABLE B 1 Medium clamp 2 Main cable harness TABLE C 1 Rear plug socket 2 Cable grommet 3 ECU diagnosis connector TABLE D 1 Adhesive cable grommet Electrical system Stelvio 1200 NTX MY11 ELE SYS 88 ...

Page 89: ...s TABLE F 1 Medium clamp that groups the oxygen sensor leads the rear stop and the rear taillight cable har ness TABLE G 1 Fall sensor connector with cover TABLE H 1 Cable grommets Stelvio 1200 NTX MY11 Electrical system ELE SYS 89 ...

Page 90: ...grommet 2 Lambda leads TABLE L 1 Reused clamps 2 Small clamp that has the lambda and the rear stop cable together with the pipes group General wiring diagram OPTION 01 Electrical system Stelvio 1200 NTX MY11 ELE SYS 90 ...

Page 91: ...key 1 MULTIPLE CONNECTORS 2 CLUTCH SWITCH 3 START UP RELAY 4 MAINTENANCE RELAY 5 LIGHT LOGIC RELAY 6 FOG LAMP RELAY Stelvio 1200 NTX MY11 Electrical system ELE SYS 91 ...

Page 92: ...CH 23 FRONT STOP SWITCH 24 ABS CONTROL UNIT 25 FRONT WHEEL SPEED SENSOR 26 REAR WHEEL SPEED SENSOR 27 ANTITHEFT CONTROL UNIT OPTIONAL EQUIPMENT 28 29 SECONDARY FUSES 30 STARTER MOTOR 31 MAIN FUSES 2 32 MAIN FUSES 1 33 BATTERY 34 PLUG SOCKET 1 35 GENERATOR 36 MAIN INJECTION RELAY 37 AUXILIARY INJECTION RELAY 38 OIL PRESSURE SENSOR 39 NEUTRAL SENSOR 40 OXYGEN SENSOR 41 SIDE STAND SWITCH 42 FUEL RESE...

Page 93: ...NT 55 PICK UP 56 ECU 57 FOG LIGHTS 58 FRONT LEFT TURN INDICATOR 59 COMPLETE HEADLAMP 60 TAIL LIGHT BULB 61 HIGH LOW BEAM BULB 62 FRONT RIGHT TURN INDICATOR 63 INSTRUMENT PANEL DIAGNOSIS 64 ECU DIAGNOSIS 65 HIGH BEAM LIGHT RELAY 66 PLUG SOCKET 2 67 OXYGEN SENSOR RH Cable colour Ar orange Az sky blue B blue Bi white G yellow Gr grey M brown N black R red Ro pink V green Vi purple OPTION 02 Stelvio 1...

Page 94: ...key 1 MULTIPLE CONNECTORS 2 CLUTCH SWITCH 3 START UP RELAY 4 MAINTENANCE RELAY 5 LIGHT LOGIC RELAY 6 FOG LAMP RELAY Electrical system Stelvio 1200 NTX MY11 ELE SYS 94 ...

Page 95: ...RONT STOP SWITCH 24 ABS CONTROL UNIT 25 FRONT WHEEL SPEED SENSOR 26 REAR WHEEL SPEED SENSOR 27 ANTITHEFT CONTROL UNIT OPTIONAL EQUIPMENT 28 MAIN FUSE 3 29 AUXILIARY FUSES 30 STARTER MOTOR 31 MAIN FUSES 2 32 MAIN FUSES 1 33 BATTERY 34 PLUG SOCKET 1 35 ALTERNATOR 36 MAIN INJECTION RELAY 37 AUXILIARY INJECTION RELAY 38 OIL PRESSURE SENSOR 39 NEUTRAL SENSOR 40 LAMBDA PROBE LEFT 41 SIDE STAND SWITCH 42...

Page 96: ...IPMENT 55 PICK UP 56 ECU 57 FOG LIGHTS 58 FRONT LEFT TURN INDICATOR 59 COMPLETE HEADLAMP 60 TAIL LIGHT BULB 61 HIGH LOW BEAM BULB 62 RIGHT FRONT TURN INDICATOR 63 INSTRUMENT PANEL DIAGNOSIS 64 ECU DIAGNOSIS 65 HIGH BEAM LIGHT RELAY 66 PLUG SOCKET 2 67 LAMBDA PROBE RIGHT Cable colour Ar orange Az sky blue B blue Bi white G yellow Gr grey M brown N black R red Ro pink V green Vi purple Electrical sy...

Page 97: ...econd key the new code is required with the message ENTER NEW CODE Once the operation is finished the instrument panel goes back to the SET UP menu DIAGNOSIS Access to this menu diagnosis functions for the technical service only after requesting a service code It will read ENTER THE SERVICE CODE This vehicle code is 10695 The functions in this menu are Exit ECU diagnosis Instrument Panel Errors Er...

Page 98: ...pper Error DC Gnd ECU 62 Not recognised error ECU 00 INSTRUMENT PANEL ERRORS In this mode a chart is displayed showing potential errors in the immobilizer and its sensors This is the error decoding chart Description Immobilizer failure Key code read but not recognised Error code DSB 01 Description Immobilizer failure Key code not read Key not inserted or transponder broken Error code DSB 02 Descri...

Page 99: ...o connect to the Navigator cable KEY CHANGE FUNCTION This function can be used 1 if one key is lost the dealer can disable this key 2 to activate up to 4 keys 3 should a new key lock be necessary and thus program the new set of keys In the first phase the user code must be entered and after confirming the inserted key key I has been programmed the other keys must be entered too The procedure finis...

Page 100: ...measured between pins 3 and 4 250 300 Ohm with fuel level equal to 0 litre 100 Ohm with fuel level equal to 11 25 litres 20 43 pt 10 20 Ohm with fuel level equal to 22 5 litres 40 86 pt The low fuel warning light turns on with values over 230 Ohm In case there is anomaly on the fuel probe the low fuel warning light flashes on the instrument panel The alarm warning light on the instrument panel doe...

Page 101: ...ense plate light 12V 5 W Fuses AUXILIARY FUSES The secondary fuses are located in the front part of the motorcycle below the instrument panel on the left side of the front sub frame A Stop horn coil GPS hazard button lighting coils light relay passing heated grips 15 A B Tail lights license plate lamp 15 A C Live positive ABS control unit power supply 10 A where foreseen Stelvio 1200 NTX MY11 Elec...

Page 102: ...H MAIN FUSES The main fuses are located in the central part of the motorcycle under the rider saddle on the right side 1 Battery recharge 40 A 2 Motion main fuse 30 A 3 High beam fuse 30 A 4 Primary ABS fuse 20 A where foreseen 5 Secondary fuse protection D E F injection system 30 A NOTE THERE ARE FOUR SPARE FUSES 6 Control unit Model Magneti Marelli IAW 5 AM2 Electrical system Stelvio 1200 NTX MY...

Page 103: ... under the fuel tank front position PINS PIN 1 Ground connection white PIN 2 Power supply voltage Output signal white brown NAVIGATOR PARAMETERS Speed sensor Vehicle speed km h FRONT SPEED SENSOR ELECTRICAL ERRORS 5D90 electric malfunction Electrical fault in sensor or cable harness Troubleshooting Check the sensor connector and the ABS control unit connector If it is not OK restore the connectors...

Page 104: ...excessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK ...

Page 105: ...or and pin 11 of the ABS module connector If there is not enough voltage check cable continuity from the ABS module to the speed sensor connector and make sure that the cable is ground insulated Solution restore wiring It is normal that when the speed sensor connector is disconnected no voltage is detected If functioning is correct proceed to the next check Checks check the speed sensor signal 0 5...

Page 106: ...Checks check tyres for wear there should not be much difference between front and rear and for correct pressure Solution use tyres with the specified tyre wear condition and pressure If functioning is correct proceed to the next check Checks make sure that the failure has not been caused by using the vehicle in sport competitions Solution for example avoid prolonged rearing up on the back wheel En...

Page 107: ... A BROWN it they are not OK restore If OK check continuity of the two cables leading to PINS 25 and 35 of the control unit connector if there is not continuity restore the cable harness if there is continuity check the interruption on the sensor and replace it WARNING If the electric circuit is short circuited no error is displayed Check the sensor electrical specifications If they are not correct...

Page 108: ... THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT...

Page 109: ... restored shorted to negative disconnect the sensor connector and check the ground insulation of the red cable from throttle sensor connector or control unit connector if there is continuity to ground restore the cable harness if it is ground insulated the resistance between PIN A and PIN C is below 1 3 kOhm therefore the throttle body should be replaced NAVIGATOR ADJUSTMENT Throttle position auto...

Page 110: ...esistance at 50 C 122 F 1 080 kOhm 11 Resistance at 60 C 140 F 0 750 kOhm 12 Resistance at 70 C 158 F 0 530 kOhm 13 Resistance at 80 C 176 F 0 380 kOhm 14 Resistance at 90 C 194 F 0 280 kOhm 15 Resistance at 100 C 212 F 0 204 kOhm 16 Resistance at 110 C 230 F 0 153 kOhm 17 Resistance at 120 C 257 F 0 102 kOhm Pin out PIN 1 Ground connection PIN 2 0 5 V signal THE CONNECTION DIAGRAMS ARE IN THE ELE...

Page 111: ... vehicle ground connection if there is not continuity restore the cable harness if there is continuity it means that the cause of the error is that the cable is shorted to positive and now the cable harness between the BROWN PIN 5 and PIN 2 of the sensor should be restored If the air temperature sensor error is displayed at the same time this means that the grey cable common for both sensors is sh...

Page 112: ...kOhm 6 Resistance at 40 C 104 F 1 600 kOhm 7 Resistance at 90 C 194 F 0 280 kOhm Pin out PIN 1 Ground connection PIN 2 0 5 V signal NAVIGATOR PARAMETERS Air temperature In case of failure temperature is set at 25 C 77 F NAVIGATOR ERRORS air temperature sensor P0110 open circuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has been...

Page 113: ... detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty then check through Navigator if the temperature indicated is plausible in relation to the ambient temperature Check also that the sensor electrical charac teristics are observed replace the sensor if not OK if it is OK check the sensor connector and the Marelli control unit connector Lambda ...

Page 114: ...the lambda probe signal to keep the combustion as close as possible to the stoichiometric value NAVIGATOR ELECTRICAL ERRORS Left lambda sensor P0130 Shorted to positive Error cause Excessive voltage battery voltage has been detected at PINS 32 and 22 of the BLUE connector Troubleshooting shorted to positive with the key set to ON disconnect the sensor connector and measure voltage at PIN 1 on the ...

Page 115: ...N 11 of the BLUE connector and restore the cable harness LOGIC ERRORS Left lambda sensor P0134 voltage without variation Error cause An abnormal behaviour of the voltage at PIN 22 of the BLUE connector has been detected the voltage that should vary over time keeps a constant value instead Troubleshooting check circuit continuity of the lambda sensor connector PIN 1 PIN2 toward the probe replace th...

Page 116: ...vicino alla bobina VERIFICARE comunque l identificazione del relè con il colore dei cavi se pre senti anche errori bobine e iniettori verificare il relè stesso e la sua linea di eccitazione e potenza se tensione al PIN 4 presente verificare isolamento da massa del cavo rosa mar rone lato cablaggio PIN 3 se non ok ripristinare cablaggio se ok verificare continuità del cavo rosa marrone lato cablagg...

Page 117: ... relè a sinistra vicino alla bobina VERIFICARE comunque l identificazione del relè con il colore dei cavi per 5 secondi e viene chiuso a massa il cavo grigio rosso dell iniettore per 4 ms ogni secondo Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation The continuity of the cable harness is necessary for correct activation no error indications are d...

Page 118: ...dell iniettore per 4 ms ogni secondo Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation The continuity of the wiring is necessary for correct activation no error indications are dis played in case of lack of activation NAVIGATOR ERRORS Right injector P0202 shorted to positive shorted to negative open circuit Error cause If shorted to positive exces...

Page 119: ...und NAVIGATOR PARAMETERS Left coil ignition advance NAVIGATOR ACTIVATION Left coil Viene eccitato il relè iniezione secondario n 37 dello schema elettrico posizione lato sinistro anteriore del motociclo primo relè a sinistra vicino alla bobina VERIFICARE comunque l identificazione del relè con il colore dei cavi per 5 secondi e viene chiuso a massa il cavo verde arancio della bobina per 2 ms ogni ...

Page 120: ...eriore del motociclo primo relè a sinistra vicino alla bobina VERIFICARE comunque l identificazione del relè con il colore dei cavi per 5 secondi e viene chiuso a massa il cavo azzurro verde della bobina per 2 ms ogni secondo Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation The continuity of the wiring is necessary for correct activation no error...

Page 121: ...off it is detected that the sensor circuit is open The test is performed only once when the key is set to ON This error is signalled by the bulb icon and the general warning light turns on as well Troubleshooting Check the sensor connector and the instrument panel connector PIN 17 If not OK restore If OK check the continuity of the purple cable between the sensor connector and the in strument pane...

Page 122: ...ed check the control unit connector and the sensor connector if they are not OK restore the cable harness if OK disconnect the connector and with gear in neutral check continuity to ground of the terminal sensor side if there is not continuity replace the sensor after checking cable harness continuity on the sensor side and the correct mechanical position if there is check cable continuity between...

Page 123: ...oubleshooting Indication on Navigator always No check the correct position of the cable terminals on the sensor and the correct connection of the cables on the terminals If they are not correct restore the cable harness if correct disconnect the two terminals from the sensor and check continuity to ground of PIN 2 cable harness side if there is no continuity restore the cable harness if there is r...

Page 124: ...tion 2 Voltage 12 V brown sensor side NAVIGATOR STATUSES Side stand Example value retracted extended DIAGNOSIS Indication on Navigator always EXTENDED check the side stand sensor connector and the ECU connector se non ok ripristinare se ok scollegare i due terminali dal sensore e verifi care continuità a massa del PIN 1 grigio lato cablaggio if there is not continuity restore the cable harness if ...

Page 125: ...n when the sensor is inverted disconnect the connector and with sensor inverted check if there is continuity between the two PINS of the sensor if there is no continuity replace the sensor if there is check the connector If not OK restore the cable harness if OK check continuity to ground of PIN 2 if there is no continuity restore the cable harness if there is with key set to KEY ON check if there...

Page 126: ... and the instrument panel connector PINS 10 and 18 If they are not OK restore If OK check continuity of the pink cable between the sensor connector and the instrument panel connector PIN 10 if it is not OK restore the cable harness if OK check the correct sensor resistance if it is not OK replace the sensor if it is OK check continuity of the brown cable between the sensor connector and PIN 18 of ...

Page 127: ...ircuit diagram Start up enabling switches Location right light switch connector right side near the coil Electrical characteristics STOP position the circuit is open RUN position closed circuit continuity PIN sky blue orange cable 0V if engine kill in STOP 12V if engine kill in RUN red black cable Voltage 12V NAVIGATOR STATUSES Run stop switch Example value Run Stop DIAGNOSIS Indication on Navigat...

Page 128: ...means that with the key set to KEY ON the sky blue orange cable is shorted to positive restore the cable harness Connectors ECU BROWN connector pin configuration Pin Use 1 Not used 2 Not used 3 Ignition potentiometer signal 4 Not used 5 Engine temperature signal 6 Not used 7 Not used 8 Not used 9 Stepper motor 10 Right cylinder coil control 11 Not used 12 Not used 13 Not used 14 Air temperature si...

Page 129: ...E connector pin configuration Pin Use 1 Pin 85 ignition relay control 2 Not used 3 Not used 4 Power supply protected from instrument panel 5 Not used 6 Pin 86 auxiliary relay control 7 Immobilizer line 8 Not used 9 Not used 10 Not used 11 Oxygen probe negative control 1 left 12 Not used 13 Not used 14 Not used 15 Not used 16 K line diagnosis 17 Power supply from main relay 18 Not used 19 Not used ...

Page 130: ... used 35 Fall sensor signal 36 Not used 37 Not used 38 Side stand sensor signal Dashboard The pin configuration of the GREY bodied con nector is as follows PIN USE 1 KEY 2 RIGHT TURN INDICATOR CONTROL 3 HIGH BEAM LIGHT INPUT 4 5 FOG LIGHTS ON OPT 6 K LINE 7 HEATED HANDGRIP CONTROL 8 CONTROL SET 9 FUEL LEVEL SENSOR 10 AIR TEMPERATURE SENSOR 11 BATTERY 12 LEFT TURN INDICATOR CONTROL 13 14 15 16 GENE...

Page 131: ...ACTIVATION 23 REAR LEFT TURN INDICATOR ACTIVATION 24 AERIAL 1 25 LEFT HEATED HANDGRIPS ACTUATOR OPT 26 CAN H 27 CONTROL RESET 28 LIGHTS RELAY ACTIVATION 29 ANTITHEFT DEVICE LED 12v 30 CONTROL DOWN 31 BATTERY 32 FRONT RIGHT TURN INDICATOR ACTIVATION 33 REAR RIGHT TURN INDICATOR ACTIVATION 34 AERIAL 2 35 RIGHT HEATED HANDGRIPS ACTUATOR OPT 36 CAN L 37 HAZARD CONTROL 38 39 ABS Stelvio 1200 NTX MY11 E...

Page 132: ...d 6 Not used 7 ABS deactivation switch 8 ABS warning light 9 Not used 10 Not used 11 Rear ABS speed sensor supply 12 Rear ABS speed sensor signal ground 13 Front ABS speed sensor signal ground 14 Front ABS speed sensor supply 15 Ground connection 16 Diagnosis 17 Not used 18 ABS pump supply Electrical system Stelvio 1200 NTX MY11 ELE SYS 132 ...

Page 133: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE ...

Page 134: ...ve the exhaust system the fork with cardan shaft the fuel tank and the rear shock absorber See also Exhaust Removing Fuel tank Removing Removing the engine from the vehicle Disconnect the spark plug tubes Unscrew and remove the three screws and remove the clutch control cylinder Lock the cylinder using a clamp to pre vent oil leaks Remove the starter motor cover Unscrew and remove the stud bolt Di...

Page 135: ... the start er motor Disconnect the stand sensor connec tor and release it from the clamps Slide off the gearbox oil breather pipe Disconnect the gear in neutral sensor connector Stelvio 1200 NTX MY11 Engine from vehicle ENG VE 135 ...

Page 136: ... the oil radiator to the chassis Loosen the clamp and slide off the oil pipe from the blow by tank Working on both sides release the clamp and slide off the engine oil breather pipe Working on both sides disconnect the injector connectors Engine from vehicle Stelvio 1200 NTX MY11 ENG VE 136 ...

Page 137: ...th sides undo and re move the three inlet manifold screws Collect the gasket Disconnect the alternator connectors Disconnect the engine temperature sensor connector Stelvio 1200 NTX MY11 Engine from vehicle ENG VE 137 ...

Page 138: ...move the fairing under the oil sump Support the vehicle with the engine service stand Undo and remove the screws fixing the centre stand plates Remove the centre stand Working on both sides unscrew and remove the front screw and collect the washer Engine from vehicle Stelvio 1200 NTX MY11 ENG VE 138 ...

Page 139: ...her Remove the lower bolt and collect the washer Unscrew and remove the upper nut fix ing the engine and collect the washer Remove the upper pin and collect the washer Lower the engine completely Lift the rear part of the vehicle Release the front belts Hold the rear part of the vehicle remove the chassis from the engine Stelvio 1200 NTX MY11 Engine from vehicle ENG VE 139 ...

Page 140: ... the engine placing it in position Connect the oil pressure sensor con nector Working from the left side fit the en gine upper bolt with the washer From the opposite side fit the washer and screw the nut Working on both sides insert the washer and screw the screw without tighten it Working from the left side fit the en gine lower bolt with the washer From the opposite side fit the washer and tight...

Page 141: ...fixing the centre stand plates Remove the engine service stand from under the oil sump Working from both sides place the in let manifold fitting a new gasket be tween the manifold and head Fasten the inlet manifold with the three screws Connect the stand sensor connector and fix it to the chassis with new clamps Stelvio 1200 NTX MY11 Engine from vehicle ENG VE 141 ...

Page 142: ...ther pipe and fasten it with a new clamp Fit the gearbox oil breather pipe Fit the clutch control cylinder Tighten the three screws Connect the starter motor connectors Engine from vehicle Stelvio 1200 NTX MY11 ENG VE 142 ...

Page 143: ...he ground leads and tighten the stud bolt Fit the starter motor cover Tighten the screws Connect the neutral sensor connector Connect the alternator connectors Stelvio 1200 NTX MY11 Engine from vehicle ENG VE 143 ...

Page 144: ... the revolution sensor connec tor Connect the horn connectors Connect the engine temperature sen sor connector Place the oil radiator Tighten the two screws Engine from vehicle Stelvio 1200 NTX MY11 ENG VE 144 ...

Page 145: ...g on both sides connect the in jector connectors Adjust the throttle grip cable clearance Working from both sides connect the spark plug tube Install the fuel tank Fit the saddle Install the complete exhaust Stelvio 1200 NTX MY11 Engine from vehicle ENG VE 145 ...

Page 146: ...INDEX OF TOPICS ENGINE ENG ...

Page 147: ...Gearbox Diagram key 1 Ball bearing Stelvio 1200 NTX MY11 Engine ENG 147 ...

Page 148: ...ge 16 Gear 17 Seal ring 18 Ball bearing 19 Gear 20 Circlip 21 Clutch shaft 22 Ball bearing 23 Oil plug 24 Washer 25 Gearbox 26 Aluminium washer 27 Breather cap 28 Neutral sensor 29 Gasket 30 Seal ring 31 Bushing 32 Gasket 33 Oil drainage plug 34 Seal ring 35 Thrust bearing 36 Roller bearing 37 Spring 38 Complete pre selector 39 Bushing Engine Stelvio 1200 NTX MY11 ENG 148 ...

Page 149: ...ft 52 Transmission gear 53 Fork 5th 1st 54 Fork shaft 55 Fork 3rd 4th 56 Fork 2nd 4th 57 Gear 58 Gear 59 Ball bearing 60 Transmission shaft 61 Gear 62 Spacer Gearbox Removing the gearbox Remove the starter motor Make sure the transmission is in idle Undo and remove the screw and re move the gearbox lever Stelvio 1200 NTX MY11 Engine ENG 149 ...

Page 150: ... filler cap Place a container of suitable capacity under it unscrew and remove the cap and then bleed all gearbox oil Loosen and turn the oil pipe joint on the sump Unscrew and remove the three screws Engine Stelvio 1200 NTX MY11 ENG 150 ...

Page 151: ... Undo and remove the two screws Unscrew and remove the screw Remove the gearbox See also Removing the starter motor Replacement Gearbox shafts Stelvio 1200 NTX MY11 Engine ENG 151 ...

Page 152: ... and slide off the odometer gear and collect the abutment washer that is inside the gearbox From the outside slide off the thrust cylinder and collect the O Ring and the washer Remove the thrust bearing and the washer Engine Stelvio 1200 NTX MY11 ENG 152 ...

Page 153: ...ws Place the gearbox on the specific gearbox support tool and on a vice Specific tooling 05 90 25 30 Gearbox support Undo and remove the nine internal screws Open the gearbox using the specific tool Specific tooling 05 91 25 30 Gearbox opening Stelvio 1200 NTX MY11 Engine ENG 153 ...

Page 154: ...s from the gearbox if necessary Release the spring Pressing the selector slide off the whole transmission lever Use rubber bands to tie down the trans mission shaft unit and extract it Engine Stelvio 1200 NTX MY11 ENG 154 ...

Page 155: ...mission shaft unit is in on a bench remove the rubber bands being careful with the group Detach the shafts and label the forks before removal Remove the forks and collect the shaft Stelvio 1200 NTX MY11 Engine ENG 155 ...

Page 156: ...clutch shaft See also Removing the gearbox Removing the primary shaft Remove the main shaft Operate on the main shaft from the second gear side Remove the gear of the second gear and collect the ball bearing cage Engine Stelvio 1200 NTX MY11 ENG 156 ...

Page 157: ...he gear of the sixth gear and collect the shoulder washer Remove the circlip Remove the gear of the third and fourth gears Remove the circlip and collect the shoulder washer Stelvio 1200 NTX MY11 Engine ENG 157 ...

Page 158: ...bearing cage Heat the shaft with a specific heater and remove the helical transmission gear Removing the secondary shaft Remove the transmission shaft Operate on the shaft from the grooved side Remove the shoulder washer Engine Stelvio 1200 NTX MY11 ENG 158 ...

Page 159: ... of the second gear and collect the ball bearing cage and the shoulder washer Remove the circlip Remove the gear of the sixth gear Remove the circlip and collect the shoulder washer Stelvio 1200 NTX MY11 Engine ENG 159 ...

Page 160: ...ourth gear and collect the ball bearing cage Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer Remove the circlip Remove the gear of the fifth gear Engine Stelvio 1200 NTX MY11 ENG 160 ...

Page 161: ...ng teeth for cracks damage and wear and replace those damaged if necessary Check the transmission gears movement and if it is not regular replace the damaged part Checking the secondary shaft Measure the coaxiality of the transmission shaft with a dial gauge and a centring device and re place it if not complying with specifications Characteristic Shaft coaxiality limit 0 08 mm 0 0031 in Check tran...

Page 162: ... FOR ALL GEARBOX FORKS Check the transmission fork cam roller 1 and the transmission fork tooth 2 for damage deformation and wear Replace the transmission fork if nec essary Check the transmission fork move ment and if it is not regular replace the transmission forks See also Disassembling the gearbox Fitting the primary shaft NOTE TO REFIT FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERS...

Page 163: ...ch control bowl in the gear box Fit the gearbox on the engine block Fit the tool in the gearbox to determine the clutch control rod length Measure rod protrusion using a depth gauge see picture According to the value found select the correct rod based on the following table Specific tooling 020678Y Tool for clutch rod checking CLUTCH CONTROL ROD SELECTION Specification Desc Quantity Protrusion 9 8...

Page 164: ...Disassembling the gearbox Gear selector GEAR INTERNAL CONTROLS pos Description Type Quantity Torque Notes 1 Spring guide pin 1 24 Nm 17 70 lb ft Loctite 243 Engine Stelvio 1200 NTX MY11 ENG 164 ...

Page 165: ...Generator key 1 Alternator 2 Spacer 3 Screw 4 Screw 5 Nut 6 Belt 7 Generator control pulley 8 Nut 9 Washer 10 Magneto flywheel cotter 11 Screw 12 Nut Stelvio 1200 NTX MY11 Engine ENG 165 ...

Page 166: ...73 76 lb ft Loctite 243 2 Generator upper fixing screw M8 1 22 Nm 16 23 lb ft 3 Generator lower fixing screw M10x60 1 30 Nm 22 13 lb ft GENERATOR COVER pos Description Type Quantity Torque Notes 1 Timing system cover cap fixing screw M6x20 2 10 Nm 7 38 lb ft Loctite 243 Engine Stelvio 1200 NTX MY11 ENG 166 ...

Page 167: ...0 9 12 Nm 8 85 lb ft 4 Generator cover fixing screw M6x16 5 12 Nm 8 85 lb ft Removing the generator Remove the fuel tank Remove the control unit from its seat Disconnect the alternator connectors Undo and remove the five screws and collect the bushings Remove the cover Unscrew the nut and collect the screw Stelvio 1200 NTX MY11 Engine ENG 167 ...

Page 168: ...n the screw Loosen the nut and undo the set screw so that the alternator slides down Completely loosen and remove the screw Remove the belt and the alternator with pulley Engine Stelvio 1200 NTX MY11 ENG 168 ...

Page 169: ...sing a compressed air gun unscrew and remove the nut and collect the spacer Remove the lower pulley Unscrew and remove the eight screws Undo and remove the two screws Stelvio 1200 NTX MY11 Engine ENG 169 ...

Page 170: ... fixing screws of the oil radiator Collect the spacers Undo and remove the five screws fixing the alternator belt cover Remove the oil radiator lower support bracket and the alternator belt cover Locking torques N m Alternator belt cover screw radiator bracket retainer TCEI M6x40 2 10 Nm 7 38 lb ft Alterna tor belt cover screw TCEI M6x16 4 10 Nm 7 38 lb ft Engine Stelvio 1200 NTX MY11 ENG 170 ...

Page 171: ...t the alternator slides down Using the belt tensioning tool tension the belt to the prescribed torque Screw the set screw Tighten the lock nut Specific tooling 020677Y Generator belt tensioner lever for belt tensioning Locking torques N m Belt tension 50 Nm 36 88 lb ft See also Engine oil cooler Stelvio 1200 NTX MY11 Engine ENG 171 ...

Page 172: ...tooling 05 92 72 30 Timing system cover sealing ring punch Place the bolt and the pin in the gen erator cover Replace the gasket and place the al ternator frame using the front cover in sertion cone Remove the insertion cone afterwards Specific tooling 05 91 17 30 Front cover insertion cone Tighten the two screws Engine Stelvio 1200 NTX MY11 ENG 172 ...

Page 173: ...he ten fixing screws on the al ternator fitting Tighten the four screws operating di agonally and in stages Position the lower pulley and the spacer Tighten the nut to the prescribed tor que Position the alternator and the timing system belt Stelvio 1200 NTX MY11 Engine ENG 173 ...

Page 174: ...belt tensioning tool tension the belt to the prescribed torque and tighten the set screw Remove the belt tensioning tool Lock the set screw in position by screwing the lock nut Specific tooling 020677Y Generator belt tensioner lever for belt tensioning Engine Stelvio 1200 NTX MY11 ENG 174 ...

Page 175: ... screws Place the alternator belt cover Tighten the five screws operating diag onally and in stages Starter motor Removing the starter motor Undo and remove the two screws and collect the washers Stelvio 1200 NTX MY11 Engine ENG 175 ...

Page 176: ... the starter motor Clutch side Disassembling the clutch key 1 Complete clutch 2 Clutch 3 Clutch bell 4 TCEI screw 5 Clutch plate 6 Sprocket 7 TCEI screw 8 Clutch thrust plate Engine Stelvio 1200 NTX MY11 ENG 176 ...

Page 177: ... CLUTCH pos Description Type Quantity Torque Notes 1 Clutch to crankshaft fixing screw 6 42 Nm 30 98 lb ft Tighten with cross sequence 2 Clutch external flange fixing screw on flywheel M7x16 6 20 Nm 14 75 lb ft Loctite 243 3 Start up crown fixing screw on flywheel 6 10 Nm 7 37 lb ft Loctite 243 4 Clutch control cylinder fixing screw 3 10 Nm 7 37 lb ft Loctite 243 Stelvio 1200 NTX MY11 Engine ENG 1...

Page 178: ...lete gearbox Unscrew and remove the six screws Remove the start up crown gear Remove the clutch housing and the friction disc Remove the retainer ring Remove the clutch pressure cap Engine Stelvio 1200 NTX MY11 ENG 178 ...

Page 179: ...order to use the correct rod Measure as follows Fit the new clutch on the crankshaft Fit the clutch control bowl in the gear box Fit the gearbox on the engine block Fit the tool in the gearbox to determine the clutch control rod length Measure rod protrusion using a depth gauge see picture According to the value found select the correct rod based on the following table Specific tooling Stelvio 120...

Page 180: ...mm 7 323 in Protrusion 5 3 6 7 mm 0 209 0 264 in Clutch control rod length code 976596 187 5 mm 7 382 in Assembling the clutch Lock crankshaft rotation with the crankpin facing upwards Place the clutch plate with the refer ence facing upwards Fasten the clutch plate on the crank shaft with the six screws Loctite 243 and the belleville springs Place the clutch pressure plate Fit the tool to centre ...

Page 181: ...the tool Remove the special tool Place the friction disc centre it Place the clutch bell with the reference facing upwards Place the start up crown gear with the reference facing upwards Tighten the six screws to the prescri bed torque operating diagonally and in stages Stelvio 1200 NTX MY11 Engine ENG 181 ...

Page 182: ...ion Type Quantity Torque Notes 1 Special cylinder head fixing screw 8 8 Nm 5 90 lb ft Locked with cross sequence 2 Spark plug cover fixing screw M5x10 2 8 Nm 5 90 lb ft OPTION 01 TRADITIONAL TIMING SYSTEM Engine Stelvio 1200 NTX MY11 ENG 182 ...

Page 183: ...8 Nm 5 90 lb ft 6 Camshaft support fixing screw 6 18 Nm 13 28 lb ft LEFT CYLINDER HEAD pos Description Type Quantity Torque Notes 1 Movable chain tensioner pad fixing screw 1 20 Nm 14 75 lb ft Loctite 243 2 Head tightening nut M10x1 25 4 15 Nm 11 06 lb ft Engine Oil Pre tightening 2 Head tightening nut M10x1 25 4 42 Nm 30 98 lb ft Final tightening 3 Head tightening screws chain compartment M6x120 ...

Page 184: ... Pre tightening 2 Head tightening nut M10x1 25 4 42 Nm 30 98 lb ft Final tightening 3 Plate locking screw and timing gear 1 30 Nm 22 13 lb ft Loctite 243 4 Timing cover fixing screw on the cylinder head M5x10 2 8 Nm 5 90 lb ft 5 Camshaft support fixing screw 6 18 Nm 13 28 lb ft 6 Cup spring fixing screw 1 18 Nm 13 28 lb ft 7 Ground plate fixing screw 2 Nm lb ft Engine Stelvio 1200 NTX MY11 ENG 184...

Page 185: ...htening nut M10x1 25 4 42 Nm 30 98 lb ft Final tightening 3 Plate locking screw and timing gear 1 30 Nm 22 13 lb ft Loctite 243 4 Timing cover fixing screw on the cylinder head M5x10 2 8 Nm 5 90 lb ft 5 Camshaft support fixing screw 6 18 Nm 13 28 lb ft 6 Cup spring fixing screw 1 18 Nm 13 28 lb ft 7 Ground plate fixing screw 2 Nm lb ft Head and timing OPTION 01 TRADITIONAL TIMING SYSTEM Stelvio 12...

Page 186: ...Pin 7 Nut 8 Right exhaust left intake rocking lever 9 Left exhaust right intake rocking lever 10 Set screw 11 Nut 12 Rocking lever rod 13 Tappet bowl 14 Flanged screw 15 Spacer 16 Camshaft 17 Pin 18 Timing system gear 19 Breather plate 20 TE flanged screw 21 O ring Engine Stelvio 1200 NTX MY11 ENG 186 ...

Page 187: ...xhaust left intake rocking lever 37 Left exhaust right intake rocking lever 38 Set screw 39 Nut 40 Rocking lever rod 41 Tappet bowl 42 Flanged screw 43 Spacer 44 Camshaft 45 Pin 46 Timing system gear 47 Breather plate 48 TE flanged screw 49 O ring 50 Complete breather cover 51 TBEI screw 52 Timing system chain 53 Chain guide slider 54 Chain tensioner pad 55 Chain tensioner screw 56 Left chain tens...

Page 188: ...haft 8 Pin 9 Intake and exhaust com rockers 10 Rocker adjustment nut 11 Adjustment screw 12 Intake and exhaust com rockers 13 5 3x10x0 5 spring washer 14 Complete breather cover 15 Screw 16 Plate 17 TE flanged screw M6x25 18 Cup spring 19 Shim washer 20 Shim washer 21 Roller Engine Stelvio 1200 NTX MY11 ENG 188 ...

Page 189: ...ew M8 Removing the head cover NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS Disconnect the spark plug by leverag ing a screwdriver through the slot CAUTION PAY ATTENTION TO APPLY LEVERAGE ON THE RUBBER OF THE SPARK PLUG CAP ITSELF IN ORDER TO AVOID DAMAGES Unscrew and remove the four head cover fixing screws and collect the sealing O rings Stelvio 1200...

Page 190: ...G THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING Remove the head cover Unscrew and remove the two screws Remove the cap Unscrew and remove the screw Remove the timing system upper gear bulkhead Engine Stelvio 1200 NTX MY11 ENG 190 ...

Page 191: ...p Remove the right chain tensioner For the left head Unscrew and remove the screw and the washer Relief oil pressure from the left chain tensioner Slide off the timing system gear from the chain to remove it from the cam shaft Stelvio 1200 NTX MY11 Engine ENG 191 ...

Page 192: ...the chain Fit the chain tensioner cap temporarily and keep the chain taut on the service shaft Collect the two head dowel pins Collect the gasket between the head and the cylinder OPTION 02 CAUTION WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING Engine Stelvio 1200 NTX MY11 ENG 192 ...

Page 193: ...the two screws in the points indicated in the figure Remove the blow by spout Undo and remove the centrifugal sep arator fixing screw Remove the spacer as shown in the figure Remove the centrifugal separator Stelvio 1200 NTX MY11 Engine ENG 193 ...

Page 194: ...p Remove the right chain tensioner For the left head Unscrew and remove the screw and the washer Relief oil pressure from the left chain tensioner Slide off the timing system gear from the chain to remove it from the cam shaft Engine Stelvio 1200 NTX MY11 ENG 194 ...

Page 195: ...e the head Fit the timing system upper gear back to the chain Fit the chain tensioner cap temporarily and keep the chain taut on the service shaft Collect the two head dowel pins Collect the gasket between the head and the cylinder Cylinder head Removing the overhead camshaft CAUTION Stelvio 1200 NTX MY11 Engine ENG 195 ...

Page 196: ...TION 01 TRADITIONAL TIMING SYSTEM Remove the two rocking levers from the cam cap Remove the two rods Unscrew and remove the four screws Remove the U bolt Remove the camshaft Remove the bowls from the cam cap and mark their position so as not inter change them when refitting OPTION 02 ROLLER TIMING SYSTEM Engine Stelvio 1200 NTX MY11 ENG 196 ...

Page 197: ...rom the cam tower marking the posi tion to not invert when refitting Removing the rocker arms CAUTION WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING OPTION 01 TRADITIONAL TIMING SYSTEM Stelvio 1200 NTX MY11 Engine ENG 197 ...

Page 198: ...lt Remove the two rocking levers from the cam cap OPTION 02 ROLLER TIMING SYSTEM Remove the cam cap from the stud bolts Undo and remove the two screws Remove the U bolt being careful to re cover the plate Remove the two rocking levers from the cam cap Engine Stelvio 1200 NTX MY11 ENG 198 ...

Page 199: ... be slid off the valve seats unscrew the tool and remove it from the head Slide off the upper cap 2 Remove the spring 3 Remove the lower cap 5 and the valve guide oil seal 4 if necessary Remove the valve 6 from inside the head Checking the valve guides Use a punch to extract the valve guides from the heads The valve guides should be replaced only if the clearance between them and the stem cannot b...

Page 200: ...ntity Valve guide inside diameter 5 0 5 012 mm 0 19685 0 19732 in Valve stem diameter 4 960 4 975 mm 0 19527 0 19587 in Fitting clearance 0 025 0 052 mm 0 00098 0 00205 in Checking the cylinder head Check that The planes of contact with the cover and with the cylinder are not scored or damaged so as to compromise a perfect seal Check that the clearance between the valve guide holes and valve stanc...

Page 201: ...e 6 inside the head Place the spring 3 Fit the upper cap 2 Place the two cotters 1 on the seats in the valves By compressing the spring 3 with the special tool fit the valve cotters Specific tooling 10 90 72 00 Tool for valve removal and refitting AP9100838 Tool for valve pressure plate Remove the special tool Installing the rocker arms Fit the camshaft Fit the two rods OPTION 01 TRADITIONAL TIMIN...

Page 202: ...in the cam tower seats Place the U bolt on the rocking levers making sure the two reference pins match the seats on the cam tower Tighten the two screws operating diag onally and in stages OPTION 02 ROLLER TIMING SYSTEM Insert the roller hydraulic tappets Fit the camshaft Engine Stelvio 1200 NTX MY11 ENG 202 ...

Page 203: ...ower seats Position the U bolt on the rockers Position the ground plate and tighten the two screws Installing the overhead camshaft OPTION 01 TRADITIONAL TIMING SYSTEM Place the bowls in the cam tower if those previously removed are refitted be careful not to interchange them Stelvio 1200 NTX MY11 Engine ENG 203 ...

Page 204: ...ft mak ing sure the two reference pins match the seats on the cam tower Tighten the four screws operating di agonally and in stages OPTION 02 ROLLER TIMING SYSTEM Insert the roller hydraulic tappets mak ing sure that the roller 1 in the appro priate milling 2 of the cam tower coincides Engine Stelvio 1200 NTX MY11 ENG 204 ...

Page 205: ... matching up the reference pins Tighten the four fixing screws to the prescribed torque proceeding diago nally Remove the bushing so as to be able to fix the tool Be careful when removing it not to damage it Specific tooling 020953Y Cam shaft lock for fixing Stelvio 1200 NTX MY11 Engine ENG 205 ...

Page 206: ...sarily be centred using the ap propriate tool Specific tooling 020954Y Centring cam shaft cup spring Timing TIMING SYSTEM CONTROL pos Description Type Quantity Torque Notes 1 Control timing system shaft support flange fixing screw M6x14 2 8 Nm 5 90 lb ft 2 Bearing fixing screw M6x16 1 10 Nm 7 37 lb ft Loctite 243 Engine Stelvio 1200 NTX MY11 ENG 206 ...

Page 207: ...g the phonic wheel Remove the generator and the timing system cover Unscrew and remove the nut and col lect the washer Remove the timing system gear on the service shaft Remove the timing sensor and any shim washers Remove the tone wheel Remove the cotter and shim washer from the service shaft See also Removing the generator Service shaft removal Remove the tone wheel Remove both cylinders Undo an...

Page 208: ...g if pre viously removed on the crankcase Fix it to the seat with the lock washer and screw Fit the timing chains according to the references marked at the removal phase Lubricate the service shaft Insert the service shaft in its crankcase seat by sliding it through the two chains Fit each chain to the corresponding service shaft gear Fit the roller cage and a new O ring on the service shaft closi...

Page 209: ... Undo and remove the two M6 flanged screws Tighten the cap with the two original TBEI screws Installing sliders Fit the crankshaft and the service shaft on the crankcase Fit the fixed chain sliders and tighten the fixing screws Tighten the chain caps with O rings The operations related to the movable chain sliders are described in the cyl inder fitting section See also Installing the crankshaft St...

Page 210: ...ead centre TDC Fit the cotter and the shim washer on the service shaft Fit the tone wheel with the chamfered side facing the crankcase on the serv ice shaft Lock crankshaft rotation Unscrew and remove the nut fixing the crankshaft gear Remove the oil pump control gear Specific tooling 12 91 18 01 Tool to lock the flywheel and the starting ring gear Engine Stelvio 1200 NTX MY11 ENG 210 ...

Page 211: ...gn the two gears After shimming the timing sensor prop erly proceed to fit it Fit the washer and tighten the timing system gear fixing nut of the service shaft Place a new gasket between the crank case and the oil pump Fit the oil pump Tighten the three oil pump fixing screws Stelvio 1200 NTX MY11 Engine ENG 211 ...

Page 212: ...e washer on the oil pump shaft Tighten the nut to the specified torque Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear Tighten the nut to the specified torque Engine Stelvio 1200 NTX MY11 ENG 212 ...

Page 213: ...e See also Installing the crankshaft Installing the service shaft Measuring air gap Measuring air gap Undo and remove the two screws and remove the sensor Insert a suitable plain washer on the sensor and note its thickness Stelvio 1200 NTX MY11 Engine ENG 213 ...

Page 214: ... Subtract the plain washer value from this measurement to obtain the clearance between the sensor and the tone wheel Remove the washer and fit the sensor after applying adequate sealing paste on the fixing plate then tighten the screws to the prescribed torque Cylinder piston assembly key 1 Right cylinder 2 Piston 3 Screw 4 Top piston ring Engine Stelvio 1200 NTX MY11 ENG 214 ...

Page 215: ... chain tensioner CONNECTING ROD ASSEMBLY CYLINDERS pos Description Type Quantity Torque Notes 1 Thermal group fixing stud bolt M10x1 25 8 5 Nm 3 69 lb ft Loctite 243 2 Connecting rod screws 4 40 Nm 29 50 lb ft Pre tightening 2 Connecting rod screws 4 80 Nm 59 00 lb ft Final tightening 3 Right hydraulic tensioner cover 1 42 Nm 30 98 lb ft 4 Left hydraulic tensioner cover 1 30 Nm 22 13 lb ft Stelvio...

Page 216: ... 2 Head tightening nut M10x1 25 4 42 Nm 30 98 lb ft Final tightening 3 Head tightening screws chain compartment M6x120 2 10 Nm 7 37 lb ft 4 Plate locking screw and timing gear 1 30 Nm 22 13 lb ft Loctite 243 5 Timing cover fixing screw on the cylinder head M5x10 2 8 Nm 5 90 lb ft 6 Camshaft support fixing screw 6 18 Nm 13 28 lb ft 7 Cup spring fixing screw 1 18 Nm 13 28 lb ft Engine Stelvio 1200 N...

Page 217: ...t 4 Plate locking screw and timing gear 1 30 Nm 22 13 lb ft Loctite 243 5 Timing cover fixing screw on the cylinder head M5x10 2 8 Nm 5 90 lb ft 6 Camshaft support fixing screw 6 18 Nm 13 28 lb ft 7 Cup spring fixing screw 1 18 Nm 13 28 lb ft Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS Remove the head the gasket between the head...

Page 218: ...TIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS Remove the cylinder Cover the crankcase opening with a clean cloth Release the snap ring Remove the pin Mark the piston crown on the exhaust side so as to remember the refitting po sition Remove the piston Fitting the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS Engin...

Page 219: ... 120 one from the other Fit one of the two pin snap rings on the piston Lock crankshaft rotation Specific tooling 12 91 18 01 Tool to lock the flywheel and the starting ring gear Fit the piston NOTE CHECK THE ORIENTATION OF THE PISTON ACCORDING TO THE REFERENCES AT THE TOP DO NOT ASSEMBLE PISTONS AND CYLINDERS OF DIFFERENT SELECTOR TYPES Insert the pin Insert the snap ring Specific tooling 020470Y...

Page 220: ...n the stud bolts Lu bricate the piston and the cylinder Lock connecting rod motion with the fork tool Using the suitable piston ring clamp tool place the cylinder and fit the chain in the timing system plate CAUTION DURING THIS OPERATION PAY ATTENTION NOT TO DAMAGE THE PISTON Specific tooling 020674Y Piston ring clamp 020716Y Connecting rod locking Remove the piston ring clamp tool and finish posi...

Page 221: ... cylinder Place the two dowel pins on the stud bolts Undo the screw which will be used to time the upper gear Check that the oil in the left cylinder chain tensioner has been drained off by compressing it If the operation is difficult use a pin drive to push the central hole so that the oil is drained off from the circuit Fit the chain tensioner in the cylinder Lubricate the piston and the cylinde...

Page 222: ...ice shaft Installing the cylinder head OPTION 01 Fit the valves in the head if previously removed Take the left cylinder piston to TDC and lock crankshaft rotation Determine the thickness of the gasket to be fitted between the head and the cylinder as described in the section Shimming system Place the two dowel pins Fit the gasket with the correct thick ness between the head and the cylin der Fit ...

Page 223: ...ur nuts on the stud bolts Fix the head with the two screws Tighten nuts and screws to the prescri bed torque operating diagonally and in stages Loosen the valve set screws Using a thin screwdriver relief oil pres sure from the left cylinder chain ten sioner Stelvio 1200 NTX MY11 Engine ENG 223 ...

Page 224: ...and washer Rotate the crankshaft clockwise by 270 from the timing system side so that the right cylinder piston reaches the TDC lock crankshaft rotation Also determine the thickness of the gasket for the right cylinder to be fitted between the head and the cylinder as described in the section Shimming system Place the two dowel pins Fit the gasket with the correct thick ness between the head and t...

Page 225: ...sioner Undo and remove the screws used to place the gear on the camshaft Place the bulkhead and align the holes with the timing system gear Fix the bulkhead on the timing system gear using a screw with Loctite on the thread Tighten the screw to the prescribed tor que Also place the bulkhead of the other head Place the cap Tighten the two screws to the prescri bed torque Also place the cap of the o...

Page 226: ...ed between the head and the cylinder as described in the section Shimming system Place the two dowel pins Fit the gasket with the correct thick ness between the head and the cylin der Fit the left cylinder head Fit a new O ring in the spark plug hole Fit the complete cam cap Fix the cam cap with the four nuts on the stud bolts Engine Stelvio 1200 NTX MY11 ENG 226 ...

Page 227: ...le in the timing system chain Place the gear in the chain On the left camshaft pin fit the hole marked with the letter L of the timing system gear Block the left chain tensioner hole with screw and washer Rotate the crankshaft clockwise by 270 from the timing system side so that the right cylinder piston reaches the TDC lock crankshaft rotation Also determine the thickness of the gasket for the ri...

Page 228: ...n fit the hole marked with the letter R of the timing system gear Screw the cap of the right chain ten sioner Undo and remove the screws used to place the gear on the camshaft Place the centrifugal separator align ing the reference pins with timing sys tem gear and so as to show the two reference letters L R parallel to the direction of the chain L left side R right side Insert the spacer Fix the ...

Page 229: ...e Also place the cap of the other head Adjust valve clearance See also Checking the valve clearance Installing the head cover Replace the gaskets and install the head cover Place the plastic half cover Replace the four rubber rings Tighten the four screws to the prescri bed torque Stelvio 1200 NTX MY11 Engine ENG 229 ...

Page 230: ...ft Remove the clutch Remove the tone wheel and the oil pump gear Working from the generator side un screw and remove the nut Remove both gears Remove the connecting rods Undo and remove the eight fixing screws and collect the washers Engine Stelvio 1200 NTX MY11 ENG 230 ...

Page 231: ... removal of the crank shaft flange by further tightening the central screw of the special tool If there are still difficulties removing it heat the area Remove the sealing ring from the flange if necessary Specific tooling 12 91 36 00 Tool to remove the flywheel side flange Remove the crankshaft afterwards Collect the shim washer from inside the crankcase See also Disassembling the clutch Removing...

Page 232: ... TIMING SYSTEM SIDE Specification Desc Quantity Diameter of crankshaft main journal timing system side 37 975 37 959 mm 1 49507 1 49444 in Inside diameter of crankshaft bushing timing system side 38 016 38 0 mm 1 49669 1 49606 in Clearance between bushing and main journal timing system side 0 025 0 057 mm 0 00098 0 00224 in CRANKSHAFT SEAT CLUTCH SIDE Specification Desc Quantity Diameter of cranks...

Page 233: ...connecting rods check that Bushing conditions and bushings pins clearance Shaft parallelism Connecting rod bearings These are thin shell bearings anti friction alloy that does not allow for any adaptation replace them immediately if seizing or wear marks are found Upon replacing the bearings it may be necessary to ream the crankshaft pin Before reaming the crankpin measure the pin diameter B compa...

Page 234: ...SHING COUPLING DATA Specification Desc Quantity Fitted and machined bushing inside Ø 22 003 22 020 mm 0 86626 0 86692 in Pin diameter 21 998 21 994 mm 0 86606 0 86590 in Clearance between pin and bushing 0 005 0 026 mm 0 000197 0 001024 in The connecting rods have a marked area for weight selection The weight indicated in the chart includes screws dowels and the bushing CONNECTING ROD WEIGHT SELEC...

Page 235: ...ng rods to the crankshaft must be replaced with new ones at the following refitting as they are subject to high loads and stress The fitting clearance between bearing and connecting rod pin is 0 028 mm 0 0011 inch minimum and 0 052 mm 0 0020 inch maximum The clearance between the shim washers of the connecting rod and those of the crankshaft is comprised between 0 30 mm 0 01181 in and 0 50 mm 0 01...

Page 236: ...ooling 19 92 71 00 Tool to fit the seal ring on the flywheel side flange Prepare loctite 510 between the crankcase and the crankshaft flange on the flywheel side Fit the crankshaft on the crankcase flywheel side Mark the crankshaft on the flywheel side with the crankpin facing upwards Place the suitable sealing ring centring tool on the crankshaft Specific tooling 12 91 20 00 Tool to fit the flywh...

Page 237: ...side proceeding diagonally Remove the sealing ring centring tool from the crankshaft Specific tooling 12 91 20 00 Tool to fit the flywheel side flange together with seal ring on the crankshaft To avoid that shim inside the crank case moves from its seat fit on the crankshaft on the alternator side the two gears and the nut Stelvio 1200 NTX MY11 Engine ENG 237 ...

Page 238: ...otes 1 Pump outlet oil pipe nipple M14x1 5 1 40 Nm 29 50 lb ft 2 Slot screw for oil pipe on the cylinder head M14x1 5 2 20 Nm 14 75 lb ft 3 Nipple on the radiator and the oil pipe M16x1 5 2 20 Nm 14 75 lb ft Apply Vaseline oil 4 Oil delivery pipe to radiator slot screw M14x1 5 1 35 Nm 25 81 lb ft 5 Jets fixing screw 3 Using a T spanner close by hand Loctite 243 6 Minimum oil pressure sensor M12 1 ...

Page 239: ...ixing radiator to chassis M6x30 3 10 Nm 7 38 lb ft OIL PUMP pos Description Type Quantity Torque Notes 1 Oil pump fixing screw M6x45 3 10 Nm 7 37 lb ft Loctite 243 2 Oil pump driven gear locking nut M6 1 8 Nm 5 90 lb ft Loctite 243 Stelvio 1200 NTX MY11 Engine ENG 239 ...

Page 240: ...ase 2 25 Nm 18 44 lb ft 5 Flange fixing screw under the crankcase M6x60 2 10 Nm 7 37 lb ft 6 Flange fixing screw under the crankcase 2 10 Nm 7 37 lb ft 7 Oil sump fixing screw filter contour M6x35 4 10 Nm 7 37 lb ft 8 Oil sump fixing screw M6 14 10 Nm 7 37 lb ft 9 Cover on the flange under the crankcase 2 20 Nm 14 75 lb ft 10 Magnetic oil drainage cap 1 20 Nm 14 75 lb ft 11 Gear to engine fixing n...

Page 241: ...ase 1 40 Nm 29 50 lb ft 2 Oil filter joint 1 10 Nm 7 37 lb ft Loctite 243 3 Oil sump pipe 1 20 Nm 14 75 lb ft Loctite 648 4 Oil filter 1 15 Nm 11 06 lb ft Engine oil 5 Rose pipe fixing screw M6 10 Nm 7 37 lb ft 6 Maximum pressure valve cover M18 1 40 Nm 29 50 lb ft Stelvio 1200 NTX MY11 Engine ENG 241 ...

Page 242: ... Oil delivery pipe to radiator 4 Oil pump body 5 Oil pump gasket 6 Rotor for lubrication 7 Rotor for cooling 8 Rotor control shaft 9 Oil pump cover 10 Oil pump control gear 11 Lubrication oil intake filter 12 Cooling oil intake filter Engine Stelvio 1200 NTX MY11 ENG 242 ...

Page 243: ...dispersing part of the heat and reaches the heads through the hoses 2 Oil goes down to the sump again and joins the oil used for lubrication Lubrication The rotor 6 takes in oil from the sump through the filter 11 the oil is sent through special ducts in the crankcase to all the parts to be lubricated Oil goes down to the sump again and joins the oil used for cooling Oil pump Removing Drain the en...

Page 244: ...itting Unscrew and remove the nut on the crankshaft Remove the oil pump control gear Screw the nut again so that the internal shim washer does not fall in the crank shaft crankcase Unscrew and remove the driven gear nut Collect the washer Remove the oil pump driven gear Remove the driving pin Unscrew and remove the three screws Remove the oil pump Engine Stelvio 1200 NTX MY11 ENG 244 ...

Page 245: ... oil pump See also Removing the generator Installing Place a new gasket between the crank case and the oil pump Fit the oil pump Tighten the three oil pump fixing screws Place the driving pin on the oil pump shaft Stelvio 1200 NTX MY11 Engine ENG 245 ...

Page 246: ... the nut to the specified torque Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear Tighten the nut to the specified torque Insert the joint in the oil pump Engine Stelvio 1200 NTX MY11 ENG 246 ...

Page 247: ... crankcase 2 25 Nm 18 44 lb ft 5 Flange fixing screw under the crankcase M6x60 2 10 Nm 7 37 lb ft 6 Flange fixing screw under the crankcase 2 10 Nm 7 37 lb ft 7 Oil sump fixing screw filter contour M6x35 4 10 Nm 7 37 lb ft 8 Oil sump fixing screw M6 14 10 Nm 7 37 lb ft 9 Cover on the flange under the crankcase 2 20 Nm 14 75 lb ft 10 Magnetic oil drainage cap 1 20 Nm 14 75 lb ft 11 Gear to engine f...

Page 248: ...se pipe fixing screw M6 10 Nm 7 37 lb ft 6 Maximum pressure valve cover M18 1 40 Nm 29 50 lb ft Removing the oil sump NOTE TO REMOVE THE OIL SUMP PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL If necessary the filter can be removed with the suitable special tool Specific tooling 01 92 91 00 Wrench for removing the cover on sump and filter Unscrew and remove the o...

Page 249: ... Undo and remove the fourteen screws fixing the oil sump to the engine crank case Unscrew and remove the four screws Remove the flange Stelvio 1200 NTX MY11 Engine ENG 249 ...

Page 250: ... the two screws Remove both side filters Unscrew and remove the cap Remove the thermostatic valve Unscrew and remove the overpressure valve plug Remove the overpressure valve ele ments Engine Stelvio 1200 NTX MY11 ENG 250 ...

Page 251: ...e oil sump Place the overpressure valve elements correctly Tighten the overpressure valve plug Place the thermostatic valve CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED Stelvio 1200 NTX MY11 Engine ENG 251 ...

Page 252: ... thermostatic valve plug Place a new gasket between the crank case and the flange Insert the flange Fix the flange with the four screws Insert the lubrication oil intake filter Engine Stelvio 1200 NTX MY11 ENG 252 ...

Page 253: ... the cooling oil intake filter Fix both filters by tightening the two screws to the prescribed torque Fit a new oil filter by tightening it to the prescribed torque Place a new gasket between the flange and the sump Stelvio 1200 NTX MY11 Engine ENG 253 ...

Page 254: ... Place the oil sump Tighten the fourteen screws to the pre scribed torque Add engine oil up to the correct level Engine Stelvio 1200 NTX MY11 ENG 254 ...

Page 255: ...INDEX OF TOPICS POWER SUPPLY P SUPP ...

Page 256: ...saggio protezioni corpo farfallato M6 2 10 Nm 7 38 lbf ft THROTTLE BODY pos Description Type Quantity Torque Notes 1 Intake pipe fixing screw 6 10 Nm 7 37 lb ft 2 Flange fixing screw on the throttle body M5x12 2 6 Nm 4 42 lb ft Power supply Stelvio 1200 NTX MY11 P SUPP 256 ...

Page 257: ...Circuit diagram Key 1 Complete fuel pump unit 2 Nut 3 Fuel pipe 4 Pipe 5 Screw Removing Rimuovere l anello di fermo della pom pa carburante Stelvio 1200 NTX MY11 Power supply P SUPP 257 ...

Page 258: ... il basso Terminare l estrazione della pompa carburante ruotandola progressiva mente verso l alto in modo da non dan neggiare il galleggiante CAUTION ESEGUIRE LA PROCEDURA INVERSA DURANTE LA FASE DI RIMONTAGGIO Injection Power supply Stelvio 1200 NTX MY11 P SUPP 258 ...

Page 259: ...itch 3 Battery 4 Fuel pump 5 Coils 6 Instrument panel 7 Air temperature sensor 8 Throttle valve position sensor 9 Injectors 10 Engine temperature sensor 11 Crankshaft position sensor 12 Side stand Stelvio 1200 NTX MY11 Power supply P SUPP 259 ...

Page 260: ... fuel pipe connected to the throttle bodies should be placed on the right Cylinders synchronisation With engine off connect the Navigator tool to the diagnosis connector and to the vehicle battery Turn on the scanner Screw the joints connecting the vacu ometer pipes on the inlet pipe holes Connect the vacuometer pipes to the relative joints Set the key to ON Power supply Stelvio 1200 NTX MY11 P SU...

Page 261: ...hat the Throttle value reading is 4 7 0 2 If the value is incorrect replace the control unit and repeat the procedure from the start Completely close the two by pass screws on the throttle bodies Start the engine Take the engine to the prescribed tem perature 60 C 140 F Make the engine rev at 2000 3000 rpm and with the vacuometer check that the difference between the two pressures is 1 cm Hg 1 33 ...

Page 262: ...n If the signal of the following sensors is interrupted the control unit determines some values to keep the engine running or it uses a different parameter The instrument panel and the Navigator also signal the problem RECOVERY FUNCTION Specification Desc Quantity air temperature 25 C 77 F engine temperature 30 C 86 F with linear increase from the air temperature at ignition barometric pressure 10...

Page 263: ...sensor in the filter casing This is not the temperature indicated by the instrument panel Engine temperature C Battery voltage V Throttle Value corresponding to the throttle when closed approximate value between 4 5 and 4 9 left throttle supported by the end of stroke screw If a different value is read it is necessary to activate the parameter Throttle positioner autodetection and obtain this valu...

Page 264: ...eration con dition of some vehicle systems for example lamb da probe functioning status STATUSES Specification Desc Quantity Engine status ON run power latch stopped operation conditions Throttle position Released pressed indicates if the throttle potentiometer is open or closed Stand Retracted extended indicates the position of the side stand only with gear engaged Ignition Enabled disabled indic...

Page 265: ...so bidi lan guage AR SA For 4 advancement command of 32 steps for the next 4 retrocession command of 32 steps and so on for 30 ERRORS screen page This screen page displays any errors detected in the vehicle ATT or stored in the control unit MEM and you can check that the cancellation of error STO has taken place ERRORS Specification Desc Quantity Pressure sensor Possible short circuit in the earth...

Page 266: ...tarter diagnosis Possible short circuit in the earth lead battery or open circuit Engine revolution sensor Possible open circuit Lambda heater Possible short circuit in the earth lead battery or lambda probe heating circuit open SPEED SENSOR CAN line diagnosis span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT ...

Page 267: ...INDEX OF TOPICS SUSPENSIONS SUSP ...

Page 268: ...g wheel pin 1 80 Nm 59 00 lbf ft 3 Vite flang fissaggio sensore 1 6 Nm 4 42 lbf ft Loct 243 4 Vite TCB fissaggio passacavo M4x6 1 3 Nm 2 21 lbf ft Removing the front wheel Working from both sides undo and re move the two fixing screws from the front brake callipers and remove them from their seats Suspensions Stelvio 1200 NTX MY11 SUSP 268 ...

Page 269: ...ws on the wheel bolt clamps Tap the wheel axle slightly with a rubber mallet so that the hole on the opposite side is exposed Remove the wheel axle by inserting a screwdriver in the holes on the pin During extraction support the wheel and then remove it Collect the spacer from the front wheel right side Stelvio 1200 NTX MY11 Suspensions SUSP 269 ...

Page 270: ... 1 5 Nm 1 11 lb ft 4 Anti vibration counterweight fastener connec tion M18x15 2 Nm lb ft 5 TCEI anti vibration counterweight fastener screws 2 10 Nm 7 38 lb ft Loct 243 6 Rear view mirror fixing connections M10 2 30 Nm 22 13 lb ft Installing To fix the handlebar on the steering yoke use a torque wrench with a bush ing of 13 socket 3 8 with a maximum external diameter 18 mm 0 71 in as shown in the ...

Page 271: ...thogonally inserted re garding its head CAUTION A WRONG DIAMETER OF THE BUSHING COULD REDUCE THE EFFECTIVE CLOSING TORQUE DUE TO THE FRIC TION EFFECT BETWEEN BUSHING AND THE SEAT ON THE PLATE Tighten the two M10 fixing screws of the steering wheel with a torque of 50 Nm 36 88 lbf ft applying Loctite 243 Front fork Stelvio 1200 NTX MY11 Suspensions SUSP 271 ...

Page 272: ... ft 3 Fork cap 1 1 Nm lbf ft Diagram Key 1 Complete front fork 2 TCE screw 3 Washer 4 TE flanged screw 5 Stem right wheel holder 6 Bushing 7 Stem left wheel holder 8 Complete right pumping member 9 Nut 10 Complete left pumping member 11 Fork upper plate 12 TCE screw 13 Base with headstock 14 Right sleeve cap Suspensions Stelvio 1200 NTX MY11 SUSP 272 ...

Page 273: ...dstock by means of two plates For adjusting the suspension set up each stan chion has an upper nut 1 for adjusting spring preloading and an upper set screw 2 act on the right stem set screw to adjust hydraulic rebound damping act on the left stem set screw to adjust hydraulic compression damping ADJUSTMENTS Regular adjustment standard rider only Medium load setting for example rider with passenger...

Page 274: ... 2 maximum load conditions unscrew anticlockwise 1 turn from fully closed Compression damping left stem set screw 2 regular load conditions unscrew anticlockwise 1 turn from fully closed Compression damping left stem set screw 2 half load con ditions unscrew anticlockwise 1 turn from fully closed Compression damping left stem set screw 2 maximum load conditions unscrew anticlockwise 1 turn from fu...

Page 275: ...ng the front wheel Draining oil Lock the sleeve in a vice with the spe cific tool code AP8140149 Set the minimum spring preloading Specific tooling AP8140149 Protection for fitting operations Unscrew the sleeve top cap Stelvio 1200 NTX MY11 Suspensions SUSP 275 ...

Page 276: ... spring Let the oil depos ited on the spring turns fully drip into the sleeve Pour the oil into the container Remove in order upper spring guide preload pipe lower spring guide spring holder cap Suspensions Stelvio 1200 NTX MY11 SUSP 276 ...

Page 277: ...mbling the fork Drain all the oil from the stem Tighten the wheel holder sleeve in a vice Undo the fork end bottom screw and remove it with the corresponding gas ket Stelvio 1200 NTX MY11 Suspensions SUSP 277 ...

Page 278: ...raper from the sleeve using a screwdriver as a lever During this operation pay attention not to damage the sleeve rim Remove the retainer ring Take out the sleeve from the stem us ing the stem as a hammer puller Suspensions Stelvio 1200 NTX MY11 SUSP 278 ...

Page 279: ...stem remove the fixed fitted bushing the movable bushing the ring and the oil seal Remove the ring and the dust guard See also Draining oil Checking the components Stem Stelvio 1200 NTX MY11 Suspensions SUSP 279 ...

Page 280: ...TS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic Bending limit 0 2 mm 0 00787 in Sleeve Check that there are no damages and or cracks otherwise replace it Spring Check the spring is in good conditions Check that the following components are in good conditions upper bushing lower bushing piston If there are signs of excessive wear or damage replace the affect...

Page 281: ...embling the fork Lock the stem in a vice without dam aging the surface Protect the bearing tube end with ad hesive tape Lubricate the sliding edges with fork oil or sealing grease Fit on the slider the dust scraper the retainer ring and the seal ring Stelvio 1200 NTX MY11 Suspensions SUSP 281 ...

Page 282: ...The sealing ring must be placed with the stamped part facing the dust gaiter Fit the ring the movable bushing and after removing the tape fit the fixed bushing Suspensions Stelvio 1200 NTX MY11 SUSP 282 ...

Page 283: ...with the specific tool Specific tooling 9100903 Marzocchi fork oil seal ø 45 mm 1 77 in Fit the pumping member pin with the cap in the spring holder sleeve and in the preload pipe Stelvio 1200 NTX MY11 Suspensions SUSP 283 ...

Page 284: ...k oil seal ø 45 mm 1 77 in Insert the retainer ring in its position Filling oil Place the sleeve upright in a vice fitted with protection shoes Compress the sleeve in the stem Place a support under the stem in order to leave it compressed Pour part of the fork oil into the sleeve Wait some minutes until the oil fills all the ducts Pour the remaining oil Pump out oil a few times Suspensions Stelvio...

Page 285: ...TANCHIONS Specific tooling AP8140149 Protection for fitting operations Characteristic Oil level from sleeve rim without the spring and preloading pipe 110 mm 4 33 in Fork oil 650 cm 39 66 cu in for each stem Insert the spring holder cap in the sleeve Insert the preloading pipe with the two spring guides in the sleeve Fit the spring Stelvio 1200 NTX MY11 Suspensions SUSP 285 ...

Page 286: ...he sleeve in the vice using the specified tool Screw the upper cover tightening it to the prescribed torque Specific tooling AP8140149 Protection for fitting operations Once the operations are completed restore the spring preloading correct value Installing the fork legs Insert the fork stem in position Suspensions Stelvio 1200 NTX MY11 SUSP 286 ...

Page 287: ... Insert the wheel pin so that the stems are aligned Tighten the screws on the fork plates to the prescribed torque Stelvio 1200 NTX MY11 Suspensions SUSP 287 ...

Page 288: ...3 Headstock ring nut 1 40 Nm 29 50 lbf ft 4 Headstock counter lock ring 1 manual 90 degrees 5 Upper yoke fixing cap 1 100 Nm 73 76 lbf ft Adjusting play Unscrew and remove the U bolt four fixing screws Remove the U bolt Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out Suspensions Stelvio 1200 NTX MY11 SUSP 288 ...

Page 289: ... the fork stems Unscrew and remove the fork upper plate cover collect the shim Lift the fork upper plate sliding it off from the stems Rivet the safety washer on the head stock UPON REFITTING REPLACE THE SAFETY WASHER WITH A NEW ONE Stelvio 1200 NTX MY11 Suspensions SUSP 289 ...

Page 290: ...uitable special tool set the preloading of the steering bearings Specific tooling AP8140190 Tool for steering tightening Fit a new safety washer Screw the upper ring nut manually and then slightly tighten the clamps on the plate so as to align notches on the ring nut Specific tooling AP8140190 Tool for steering tightening Suspensions Stelvio 1200 NTX MY11 SUSP 290 ...

Page 291: ...late on the stems Rear Removing the rear wheel Support the vehicle rear part using a suitable stand Engage the first gear Undo and remove the four screws col lect the spacers and the dust protec tion ring Remove rear wheel Stelvio 1200 NTX MY11 Suspensions SUSP 291 ...

Page 292: ...f ft 4 Vite TE flang fissaggio biella singola biella doppia M10x95 1 50 Nm 36 88 lbf ft 5 Vite TE flang fissaggio biella singola al telaio M10x85 1 50 Nm 36 88 lbf ft Adjusting The rear suspension consists of a spring shock absorber unit linked to the frame via Silent block and to the rear fork via a linkage system To set vehicle suspension the shock absorber has a set screw 1 to adjust the hydrau...

Page 293: ...SSARY CONTACT AN Official Moto Guzzi Dealer TRY RIDING THE VEHICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED SHOCK ABSORBER SETTING TABLE Regular load adjustments are the standard settings by manufacturer REAR SHOCK ABSORBER ADJUSTMENT Specification Desc Quantity Preload regular load conditions 15 clicks starting from knob 2 fully loosened Preload half load conditions 28 clicks starti...

Page 294: ...cle on its centre stand Lock the vehicle handlebar so that the rear wheel is off the ground Remove the fork Undo and remove the shock absorber upper screw Remove the shock absorber Suspensions Stelvio 1200 NTX MY11 SUSP 294 ...

Page 295: ...INDEX OF TOPICS CHASSIS CHAS ...

Page 296: ...garm pin on the swingarm M12 1 60 Nm 44 25 lbf ft 4 Preloading bushing to the swingarm pin M25 1 10 Nm 7 37 lbf ft Removing To remove the fork first remove the footrest holding plate and the exhaust silencer Slide off the rear brake calliper from the disc and release the brake pipe Engage the first gear Unscrew and remove the four screws collecting the spacers and the dust pro tection ring Chassis...

Page 297: ... two screws Remove the speed sensor from the fork Unscrew and remove the nut fixing the reaction rod Remove the screw Fix the reaction rod to the chassis with a clamp Remove the clamp from the dust guard cap Stelvio 1200 NTX MY11 Chassis CHAS 297 ...

Page 298: ...ng rod assembly and col lect the screw Loosen the ring nut Specific tooling GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body Helped by a second operator remove the pin and remove the swingarm to gether with the cardan shaft Chassis Stelvio 1200 NTX MY11 CHAS 298 ...

Page 299: ...rooves are not damaged deformed or deteriorated otherwise replace the sleeve Check that the sleeve outer toothing and grooves are not damaged Installing Spread a thin layer of lubricating grease all along the swingarm pin Fit the ring nut in the swingarm pin and screw it manually Working from both sides grease the cardan shaft cables with the recom mended product from the recommen ded products tab...

Page 300: ...xing ring nut of the clutch shaft internal body Tighten the two screws of the swing arm clamp Fit the dust guard cap in the gearbox Lock the dust guard cap with a new clamp Place the reaction rod into its seat Insert the screw Screw the nut fixing the reaction rod Chassis Stelvio 1200 NTX MY11 CHAS 300 ...

Page 301: ... speed sensor on the fork and screw the two screws Fit the rear wheel Place the rear brake calliper on the disc and the brake pipe on the fork See also Recommended products chart Bevel gears Removing Remove the rear wheel Unscrew and remove the two screws Remove the speed sensor from the fork Stelvio 1200 NTX MY11 Chassis CHAS 301 ...

Page 302: ...action rod Remove the screw Fasten the reaction rod to the chassis with a clamp Undo and remove the four screws Remove the transmission casing slid ing off the universal joint Checking Casing unit removal Chassis Stelvio 1200 NTX MY11 CHAS 302 ...

Page 303: ...Casing unit removal Remove the cover 20 Remove the plug 3 to drain out the oil Lift the cap 10 Stelvio 1200 NTX MY11 Chassis CHAS 303 ...

Page 304: ...Remove the clamps 9 and 11 Remove the cap 14 Remove the screws 16 Collect the ring 15 Remove the screws 7 Remove the casing 4 Chassis Stelvio 1200 NTX MY11 CHAS 304 ...

Page 305: ...Remove the clamp 12 Remove the cap 14 Collect the ring 13 Remove the support unit 8 Casing unit fitting Stelvio 1200 NTX MY11 Chassis CHAS 305 ...

Page 306: ...el pins to the casing with the buffer and a hammer Assemble the casing to the special fastening tool Clean the casing faying surfaces carefully Heat the casing Insert the support group in the casing Chassis Stelvio 1200 NTX MY11 CHAS 306 ...

Page 307: ...Assemble the cap and the ring Fit the cap on the support Fit the clamp Screw the clamp with the specific pliers Apply the prescribed sealant to the casing Stelvio 1200 NTX MY11 Chassis CHAS 307 ...

Page 308: ...two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture Fit the casing Remove the two dowel pins Assemble the fixing screws 7 Tighten the screws 7 to the prescribed torque Remove excessive sealant Chassis Stelvio 1200 NTX MY11 CHAS 308 ...

Page 309: ...Tighten the fixing screws to the prescribed torque Fit the cap with the washer Screw the cap to the prescribed torque Fit the breather with the washer Screw the breather to the prescribed torque Stelvio 1200 NTX MY11 Chassis CHAS 309 ...

Page 310: ... with the washer Screw the cap to the prescribed torque Assemble the cap with the clamps Fit the cap in its seat Wheel axle unit Gruppo asse ruota Removal Remove the bearing from the wheel axle with a suitable extractor Chassis Stelvio 1200 NTX MY11 CHAS 310 ...

Page 311: ...g from the wheel axle with a suitable extractor FITTING Heat the bearings to 100 C 212 F Assemble the bearings to the wheel axle Turn the unit over Assemble the bearings to the wheel axle Pinion unit Stelvio 1200 NTX MY11 Chassis CHAS 311 ...

Page 312: ...ut 2 with the special spanner s4 Remove the ring nut 2 and remove the sealing ring from the ring nut NOTE THIS OPERATION DESTROYS THE SEALING RING Assemble the sealing ring 3 to the ring nut 2 with the buffer CA715855 see Fig 1 and a ham mer Chassis Stelvio 1200 NTX MY11 CHAS 312 ...

Page 313: ...ling ring 3 Assemble the ring nut 2 Tighten the ring nut 2 with the special spanner s4 to the prescribe torque Insert the stop ring 1 in the ring nut 2 in the in dicated direction Stelvio 1200 NTX MY11 Chassis CHAS 313 ...

Page 314: ...Assembly position of the stop ring 1 CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT Support unit Chassis Stelvio 1200 NTX MY11 CHAS 314 ...

Page 315: ...ling rings 2 and 7 with a screw driver Remove the stop rings 3 and 6 from the support 5 with suitable pliers NOTE THIS OPERATION DESTROYS THE SEALING RING Remove the ball joint 4 with a suitable buffer and a rubber hammer FITTING Fit the stop ring 6 in the support 5 with suitable pliers Stelvio 1200 NTX MY11 Chassis CHAS 315 ...

Page 316: ...the bushing 1 Drive the bushing 1 in with a plastic hammer Turn the support 5 over and assemble the other bushing 8 TROUBLESHOOTING Possible Cause Operation 1 Fitting error of the radial seal or seal damaged 2 Sliding surface of the wheel axle seal spoiled or damaged 1 Replace the sealing ring and fit it correctly with the suitable tool 2 Replace the wheel axle Chassis Stelvio 1200 NTX MY11 CHAS 3...

Page 317: ...he wheel spacer spoiled or damaged 1 Replace the cap 2 Screw the clamp with suitable pliers 3 Replace the sealing ring and fit it correctly with the suitable tool 4 Replace the spacer 1 Cap damaged 2 Internal retaining clamp or external closing clamp loose 1 Replace the cap 2 Screw the internal or external clamp with suitable pliers 1 Bevel gear pair fitting error 2 Bevel gear pair toothing spoile...

Page 318: ...acing the transmission unit Place the speed sensor and fasten the cable harness with the clamps Place the rear wheel on the fork Tighten the four screws with their spacers and the dust protection ring Place the rear brake calliper on the disc and the brake pipe on the fork Chassis Stelvio 1200 NTX MY11 CHAS 318 ...

Page 319: ...ri M8 4 25 Nm 18 44 lbf ft 2 Oxygen sensor fastener 2 38 Nm 28 03 lbf ft 3 Vite TE Flang fissaggio parte centrale M10x55 1 25 Nm 18 44 lbf ft 4 Viti fissaggio protezione 2 10 Nm 7 38 lbf ft 5 Vite TCEI fissaggio silenziatore a telaio M8x60 1 25 Nm 18 44 lbf ft Stelvio 1200 NTX MY11 Chassis CHAS 319 ...

Page 320: ...anged screw 10 Silent block 11 Flanged self locking nut 12 Lambda probe 13 Gasket 14 Clamp 15 Silencer 16 TCEI screw 17 Silencer fixing bushing 18 Muffler rubber ring 19 Spacer 20 Washer 21 Nut Removing the tail pipe Loosen the sealing clamp between the exhaust and the central manifold Chassis Stelvio 1200 NTX MY11 CHAS 320 ...

Page 321: ...exhaust end and the ex haust manifolds Remove the starter motor protection in order to disconnect the lambda probe connector Unscrew and remove the nut and re move the fixing screw Remove the manifold exhaust end coupling together with the lambda probe See also Removing the exhaust manifold Stelvio 1200 NTX MY11 Chassis CHAS 321 ...

Page 322: ...nterval after the engine has been switched off Before handling these components make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down Unscrew and remove the two nuts on the head exhaust stud bolts Retrieve the washers Loosen the clamp Remove the exhaust manifold Chassis Stelvio 1200 NTX MY11 CHAS 322 ...

Page 323: ...Engine oil cooler OIL RADIATOR pos Description Type Quantity Torque Notes 1 Screws fixing radiator to chassis M6x30 3 10 Nm 7 38 lb ft Key 1 Complete oil radiator Stelvio 1200 NTX MY11 Chassis CHAS 323 ...

Page 324: ...e e del filtro olio è necessario rimuovere il paramotore in metallo svitando le quattro viti 1 che lo fissano al motore Place a collecting container and empty the lubrication system Unscrew and remove the two oil pipes on the radiator Undo and remove the radiator lower screw and collect the washer Chassis Stelvio 1200 NTX MY11 CHAS 324 ...

Page 325: ...everse order Pull out the oil filler plug oil level dip stick 1 Pour new oil until it goes over the min imum level marked MIN on the dip stick 1 Insert the oil filler plug oil level dipstick 1 Start the vehicle and let the engine run for a few minutes so that the oil circu lates and fills the radiator internal ducts Stop the engine and check the oil level with the dipstick 1 Fill with engine oil a...

Page 326: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS ...

Page 327: ...t with brake pipes retainer bleeding on the calliper M10 3 25 Nm 18 44 lbf ft 3 Brake pipes joint on the ABS hydraulic unit 4 25 Nm 18 44 lbf ft Interventions rules CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM Stelvio 1200 NTX MY11 Braking system BRAK SYS 327 ...

Page 328: ...ABS key 1 ABS ECU control unit 2 Front ABS sensor 3 Rear ABS sensor 4 Battery 5 Main relay 6 ECU 7 Instrument panel 8 K line diagnosis 9 Key 10 Fuses Braking system Stelvio 1200 NTX MY11 BRAK SYS 328 ...

Page 329: ...Operating diagram ABS functional diagram key 1 Front system circuit 2 Front brake pump 3 Front brake lever 4 Rear system circuit Stelvio 1200 NTX MY11 Braking system BRAK SYS 329 ...

Page 330: ...of the wheels in order to assess potential wheel slippage When in standby the system does not intervene at all when the rider brakes the braking system is the same as the one without ABS Stages in ABS cycle the following operations refer to the front circuit but are also applicable to the rear one A Brake activation the rider starts braking as he would usually do B Pressure reduction it coincides ...

Page 331: ...als this out and adjusts the pressure in the braking circuit accordingly NOTE WHEN THE ABS SYSTEM STARTS WORKING A VIBRATION IS FELT ON THE BRAKE LEVER THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED HANDLE BAR TURNED ON UN EVEN OR SLIPPERY ROADS OR WITH POOR GRIP CREATES LACK OF STABILITY DIFFICULT TO HANDLE THEREFORE RIDE CA...

Page 332: ...engine With the vehicle at a standstill press and hold the button After roughly three seconds the indicator light ABS 5 on the instrument panel 4 becomes steadily on Release the button immediately Now the ABS warning light 5 on the instrument panel 4 continues to be on the ABS system is then completely deactivated ABS system reactivation With the vehicle at a standstill press and hold the button A...

Page 333: ...y just as any other braking system without ABS The diagnosis requires exceeding the 5 km h 3 1 mph Each time the key is ON if at least one current or stored error of the ABS system is not detected the abs warning light flashes When the 5 km h 3 1 mph are exceeded if errors are not detected the ABS warning light turns off if at least one malfunction is detected the ABS warning light turns on perman...

Page 334: ...4 3 PERFORM THESE CHECKS A PIN 1 Ground connection B 12V at PIN 18 C 12V at PIN 4 with key ON 4 ARE THERE ANY ERRORS YES go to point 5 NO go to 6 5 CONSULT THE ERRORS TABLE 6 ABS WARNING LIGHT ACTIVATION IS IT ACTIVATED YES point 7 NO point 8 7 CONTACT TECHNICAL SERVICE 8 CHECK A Cable continuity between PIN 8 of the ABS control unit connector and PIN 39 of the instrument panel B Check connectors ...

Page 335: ...N 15 of the ABS control unit connector cor responds to a different type of vehicle see the following table NOTE the X in the table identifies the connector pin is grounded ABS CONNECTOR IS GROUNDED Vehicle PIN 2 PIN 15 Stelvio 1200 4V ABS X Norge 1200 4V ABS X PARAMETERS screen page This screen page shows the parameters meas ured by the several sensors engine revs engine temperature etc or values ...

Page 336: ...or has been detected by the control unit Ambient parameter error reading 3 for example if it indicates 2 it means that the error has been detected ATT then it has not been de tected for a while sent to the MEM and then it has been detected again Ambient parameter error reading 4 Operation cycles from the last reading a cycle is counted if the following occurs key ON and speed over 20 km h Ambient ...

Page 337: ...ensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Rear speed sensor 5DA4 no accel eration after pressure reduction Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel Rear speed sensor excessive meas ured speed 5DA5 Faulty sensor or tone wheel with wrong number...

Page 338: ...con nection of PINS 2 and 15 of the ABS control unit connector and is stored in the control unit memory Coding 3 The identification can be read in the INFO ECU screen page in the line Vehicle code NOTE the X in the table identifies the connector pin is grounded ABS CONNECTOR IS GROUNDED Vehicle PIN 2 PIN 15 Stelvio 1200 4V ABS X Norge 1200 4V ABS X Abs screen pages Modulator Remove the fuel tank C...

Page 339: ...trol unit Loosen the nuts and remove the pipes Cover the pipes to prevent brake fluid spilling See also Fuel tank Unscrew and remove the two screws Disconnect the ABS control unit con nector Remove the ABS control unit INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR Check the initial position of the lever that couples the connector Stelvio 1200 NTX MY11 Braking system BRAK SYS 339 ...

Page 340: ...revious points IT IS ADVISABLE TO CREATE A TEMPLATE TO CHECK THE CORRECT CONNECTOR IN SERTION Fit the protection casing Component maintenance The vehicle is fitted with a two channel ABS sys tem i e it works on both the front and the rear wheel Check periodically and each time the wheels are refitted the tone wheel 2 or the sensor 1 re placed that the wheel distance is constant at each 360 Use a t...

Page 341: ...ove any possible dirt deposits with a cloth or metal brush Avoid using solvents abrasives and air or water jets directly on the tone wheel 2 TONE WHEEL SENSOR REPLACEMENT Disconnect the tone wheel sensor connector 1 from the main wire Unscrew and remove the screw and remove the tone wheel sensor 1 CAUTION BEFORE REFITTING MAKE SURE THAT THE FAYING SURFACES BETWEEN THE SENSOR 1 AND THE SEAT ITSELF ...

Page 342: ...2 50 Nm 36 87 lbf ft 2 Vite fissaggio tubo olio 1 Nm lbf ft 3 Vite fissaggio tubo olio 1 Nm lbf ft Key 1 Rear brake calliper 2 Screw 3 Pads 4 Pin calliper split pin 5 Spring 6 Gasket 7 Screw 8 Air bleed 9 Air bleed cap 10 Rear brake pipe 11 Oil pipe screw Braking system Stelvio 1200 NTX MY11 BRAK SYS 342 ...

Page 343: ...Front brake calliper FRONT BRAKE CALLIPERS pos Description Type Quantity Torque Notes 1 Viti TE Flang fissaggio pinze M10x55 4 50 Nm 36 88 lbf ft Key Stelvio 1200 NTX MY11 Braking system BRAK SYS 343 ...

Page 344: ... The following operations are to be car ried out with brake disc fitted on the wheel Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the mini mum thickness even in a single point of the disc is less than the minimum value replace the disc Disc thickness minimum value 4 5 mm 0 18 in CAUTION THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND M...

Page 345: ...CE SPECIFICATIONS OF THE SYSTEM The following operations must be car ried out with the brake discs fitted on the wheel they refer to a single disc but are valid for both Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the mini mum thickness even in a single point of the disc is less than the minimum value replace the disc Disc thickness minimum ...

Page 346: ... and remove the two screws Slide off the brake calliper from the disc Turn the pins and remove both cotter pins Remove both pins Remove the vibration damping plate Braking system Stelvio 1200 NTX MY11 BRAK SYS 346 ...

Page 347: ...ng them so that the holes are aligned with the cal liper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Position the anti vibration plate Insert both pins Position both split pins Abut the plungers against the pads acting on the brake pump lever several times Check the brake fluid level in the res ervoir Stelvio 1200 NTX MY11 Braking system B...

Page 348: ... pads Removal Undo and remove the two screws Remove the brake calliper from the disc Turn the pin and pull out the cotter pin Remove the cotter pin Remove the pin Braking system Stelvio 1200 NTX MY11 BRAK SYS 348 ...

Page 349: ...the holes are aligned with the cal liper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Insert the pin Position the split pin Insert the brake calliper into the disc by screwing in the two screws Abut the plungers against the pads acting on the brake pump pedal sever al times Check the brake fluid level in the res ervoir Stelvio 1200 NTX MY11...

Page 350: ...a new one Connect the brake pipe to the new brake pump Fill the reservoir with new brake fluid CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEEDING AS DESCRIBED AT THE END OF THE CHAPTER Always fill the reservoir up to the reference MAX and refit the cap Check the stroke and the sensitivity of both the lever and the brake pedal If after bleeding the pedal or the lever stroke is too long check that ...

Page 351: ...om the ABS control unit to the brakes and also seal these unions with protective caps Install the new ABS control unit previ ously filled up So that the brake fluid remains in the ABS control unit first remove the pro tective caps of the braking circuit un ions and connect the respective pipes Once all the braking circuits have been con nected remove the protective caps from the braking pump union...

Page 352: ...ng de vice so as to avoid fluid flowing out from the open system Close the bleed screws of the front cal liper and remove the bleed bottle Replace the damaged calliper with a new one Unlock the brake lever Remove the reservoir cap and fill it with new brake fluid up to the reference MAX CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEEDING AS DESCRIBED AT THE END OF THE CHAPTER Always fill the reser...

Page 353: ...EEDING AS DESCRIBED AT THE END OF THE CHAPTER See also Front Rear Front Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper The presence of air is signalled by the sponginess of the brake control and by poor braking efficiency CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS S...

Page 354: ... brake oil reservoir cap Refit the rubber protection cover Rear Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper The presence of air is signalled by the sponginess of the brake control and by poor braking efficiency CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY ...

Page 355: ...e the brake lever and then open the bleed valve on the calliper 1 4 of a turn to let the air out Close the bleed again before reaching the lever end of the stroke and repeat the operation until there is no air Screw the bleeding valve and remove the pipe Top up the reservoir until the correct brake fluid level is obtained Refit and lock the rear brake oil reservoir cap Refit the rubber protection ...

Page 356: ...INDEX OF TOPICS BODYWORK BODYW ...

Page 357: ...f ft 2 Viti fissaggio freccie anteriori M4 2 3 Nm 2 21 lbf ft 3 Vite fissaggio superiore fanale a carozzeria M4 1 3 Nm 2 21 lbf ft 4 Viti fissaggio fanale a carozzeria M4x25 2 3 Nm 2 21 lbf ft 5 Viti TCEI fissaggio fanale a telaietto M5x25 5 6 Nm 4 42 lbf ft Stelvio 1200 NTX MY11 Bodywork BODYW 357 ...

Page 358: ... Viti TCE M5 2 6 Nm 4 42 lbf ft CARROZZERIA ANTERIORE CUPOLINO pos Description Type Quantity Torque Notes 1 Viti fissaggio parabrezza M6 4 10 Nm 7 38 lbf ft 2 Viti TBEI Flang fissaggio cupolino M5x12 4 6 Nm 4 42 lbf ft 3 Viti fissaggio deflettori superiori M5 4 6 Nm 4 42 lbf ft 4 Colonnette fissaggio deflettori M5 2 6 Nm 4 42 lbf ft 5 Viti TE Flang fissaggio staffa parabrezza M6x16 4 10 Nm 7 38 lb...

Page 359: ...e Quantity Torque Notes 1 Viti TBEI Flang fissaggio convogliatori M5x9 2 6 Nm 4 42 lbf ft 2 Viti TBEI Flang fissaggio convogliatori M5 2 6 Nm 4 42 lbf ft 3 Viti SWP Autofil fissaggio telaietto griglie 2 9x12 4 Manual Stelvio 1200 NTX MY11 Bodywork BODYW 359 ...

Page 360: ...e Notes 1 Viti TBEI Flang fissaggio parafango anteriore M5x12 6 6 Nm 4 42 lbf ft COPERTURA SERBATOIO CARBURANTE pos Description Type Quantity Torque Notes 1 Vite TBEI Flang fissaggio copertura 4 5 Nm 3 69 lbf ft Bodywork Stelvio 1200 NTX MY11 BODYW 360 ...

Page 361: ... TE Flang fissaggio supporti valigie M6 4 10 Nm 7 38 lbf ft 4 Viti TBEI Flang fissaggio paraspruzzi M5x12 2 6 Nm 4 43 lbf ft LICENSE PLATE HOLDER pos Description Type Quantity Torque Notes 1 Viti TBEI Flang fissaggio portatarga M5 2 6 Nm 4 43 lbf ft 2 Viti TBEI speciali 2 6 Nm 4 43 lbf ft 3 Dado autobloc flang fissaggio catadiottro M5 1 6 Nm 4 43 lbf ft Stelvio 1200 NTX MY11 Bodywork BODYW 361 ...

Page 362: ... M8x20 2 25 Nm 18 44 lbf ft 5 Vite TBEI fissaggio supporti portapacchi M8x30 2 25 Nm 18 44 lbf ft 6 Vite TSPEI fissaggio coperchio portapacchi M6x35 2 10 Nm 7 38 lbf ft 7 Vite autofil fissaggio coperchio portapacchi 5 4 Manual Engine guard ENSURE THAT THE ENGINE AND THE THERMAL PARTS OF THE VEHICLE ARE COLD BEFORE OPERATING ACCORDING TO THE FOLLOWING INSTRUCTIONS PARK THE VEHICLE ON STAND ON FIRM ...

Page 363: ...vimaneto Undo the screw and remove the rear brake oil reservoir From the left side of the vehicle re move the nut 1 and the correspond ing washer Slide off the frame pin 2 from the right side with the corresponding washer Stelvio 1200 NTX MY11 Bodywork BODYW 363 ...

Page 364: ...el mo tociclo Rimuovere le viti di fissaggio 4 del paramotore da entrambi i lati del mo tociclo Rimuovere le viti di fissaggio 5 del paramotore da entrambi i lati del mo tociclo prestando attenzione a recu perare la guida in gomma Bodywork Stelvio 1200 NTX MY11 BODYW 364 ...

Page 365: ... le fascette 6 e scol legare i connettori 7 per rimuovere completamente i paramotori Instrument panel Rimuovere i deflettori laterali traspar enti Remove the screws 1 Sganciare le estremità della plancia e sollevarla Stelvio 1200 NTX MY11 Bodywork BODYW 365 ...

Page 366: ...TE FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER Additional lights Liberare i cablaggi dei fari supplemen tari rimuovendo le fascette 1 sul telaio e scollegare i connettori 2 Rimuovere le fascette 3 per liberare completamente il cablaggio dei fari supplementari Bodywork Stelvio 1200 NTX MY11 BODYW 366 ...

Page 367: ...luminosi Ora è possibile rimuovere i fari supple mentari NOTE FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER Headlight fairing Remove the windshield Remove the control panel Rimuovere le quattro viti inferiori Rimuovere le due viti di fissaggio del cupolino al telaietto in corrispondenza delle freccie anteriori Stelvio 1200 NTX MY11 Bodywork BODYW 367 ...

Page 368: ...i dei fari e rimuovere il cupolino Rider footrest plate LEFT SIDE Undo and remove the upper screw and collect the washer and the nut Undo and remove the lower screw and collect the two washers and the spacer Undo and remove the lower screw and collect the washer and the spacer Bodywork Stelvio 1200 NTX MY11 BODYW 368 ...

Page 369: ...e the left footrest holding plate RIGHT SIDE Undo and remove the upper screw and collect the washer and the nut Undo and remove the front lower screw Undo and remove the three screws Remove the right under seat fairing Stelvio 1200 NTX MY11 Bodywork BODYW 369 ...

Page 370: ...ws collect the washers and the spacer Unscrew and remove the screw Detach the rear brake fluid reservoir but keep it connected to the pipe Remove the right footrest plate keeping the brake fluid reservoir in vertical position Side fairings Rimuovere la vite interna prestando at tenzione a recuperare la relativa ron della Bodywork Stelvio 1200 NTX MY11 BODYW 370 ...

Page 371: ... esterna Scollegare il connettore della freccia anteriore e rimuovere il fianchetto lat erale CAUTION ESEGUIRE LA MEDESIMA OPERAZIONE DI SMONTAGGIO ANCHE PER IL FIANCHETTO OP POSTO Air box Stelvio 1200 NTX MY11 Bodywork BODYW 371 ...

Page 372: ...er fastening screw SWP 5x20 6 3 Nm 2 21 lb ft Remove the saddle Remove the passenger grab handle Undo and remove the two screws and collect the cable guide Disconnect the air temperature sensor connector Slide off and remove the main fuse box from its holder Disconnect the rear light connectors Bodywork Stelvio 1200 NTX MY11 BODYW 372 ...

Page 373: ...de Operating from both sides undo and remove the three screws Remove the mudflap Release from its and remove the breather pipe placed on the right side of the filter casing Operating on both sides loosen the clamp Stelvio 1200 NTX MY11 Bodywork BODYW 373 ...

Page 374: ...THERMAL PARTS OF THE VEHICLE ARE COLD BEFORE OPERATING ACCORDING TO THE FOLLOWING INSTRUCTIONS PARK THE VEHICLE ON STAND ON FIRM AND LEVEL GROUND Rimuovere le quattro viti di fissaggio del paramotore prestando attenzione a recuperare i gommini Rimuovere il paramotore NOTE FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER Bodywork Stelvio 1200 NTX MY11 BODYW 374 ...

Page 375: ...ngs Remove the control panel Rimuovere la vite anteriore del serba toio Rimuovere le viti posteriori del serba toio See also Side fairings Scollegare il tubo carburante 1 Scollegare i tubi sfiato 2 Scollegare il connettore della pompa carburante 3 Remove the fuel tank NOTE FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER Stelvio 1200 NTX MY11 Bodywork BODYW 375 ...

Page 376: ... nuts 16 Remove the cross member 9 Remove the hexagonal head screw 3 and collect the washers 4 Remove the Allen screws 5 and 7 Remove the support for the left top box 2 Remove the spacers 6 and 8 Remove the components 11 to 16 from both supports Bodywork Stelvio 1200 NTX MY11 BODYW 376 ...

Page 377: ... remove the knob Working from both sides unscrew and remove the lower screw Working from both sides remove the windscreen support from the bracket Remove the four bushings from the brackets If replacing the bushings remember to place them with the larger diameter inside the brackets Stelvio 1200 NTX MY11 Bodywork BODYW 377 ...

Page 378: ...INDEX OF TOPICS PRE DELIVERY PRE DE ...

Page 379: ...ng screws Electrical system Main switch Headlamps high beam lights low beam lights tail lights front and rear and their warning lights Headlight adjustment according to regulations in force Front and rear stop light switches and their bulbs Turn indicators and their warning lights Instrument panel lights Instrument panel fuel and temperature indicator if present Instrument panel warning lights Hor...

Page 380: ...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 GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN ...

Page 381: ...t Functional inspection Hydraulic braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EX...

Page 382: ...e seat Remove the existing connector from bridge C and retain it Connect the connector cable with that of the antitheft device Make the holes where indicated on plastic with a 5 mm drill bit In the event that the drilling points are not indicated for securing the antitheft device drill the holes as indicated in the drawing positioning the antitheft device in its seat and etch the points indicated ...

Page 383: ...ice in the seat of the plastic and move the clamps into the holes made Tighten the clamps at the points indi cated to lock the antitheft device NOTE IT IS RECOMMENDED TO APPLY SILICON TO THE HOLES MADE FROM THE OUTSIDE OF THE PLASTIC TIGHTEN THE SCREWS TO THE PRESCRIBED TORQUE Stelvio 1200 NTX MY11 Pre delivery PRE DE 383 ...

Page 384: ... 51 230 238 Crankshaft 51 209 213 230 232 236 Cylinder 50 190 195 200 217 218 220 222 232 D Desmodromic drum 162 Diagnostics 262 334 E ECU 128 263 335 Electrical system 12 73 75 379 Engine oil 64 171 323 Engine temperature sensor 110 Exhaust 134 319 321 322 Exhaust manifold 321 322 F Fairings 370 375 Fork 271 274 277 281 286 Forks 162 Front headlamp Front wheel 268 275 Fuel 134 170 339 375 Fuses 1...

Page 385: ... 156 161 163 R Radiator Rear light Rear wheel 291 Recommended products 53 301 Run Stop switch 127 S Saddle Scheduled maintenance 62 Secondary shaft 158 161 163 Shock absorber Shock absorbers 292 Side fairings 370 Side stand 124 Side stand sensor 124 Speed sensor 103 Stand 124 Start up 100 Starter motor 151 175 T Tank 134 170 339 375 Throttle body Transmission 12 63 Tyres 14 U Use 262 334 W Wiring ...