MOTO GUZZI Stelvio 1200 4V Service Station Manual Download

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2. Circlip

3. Thickness

4. Pin

5. Complete desmodromic

6. Ball bearing

7. Spring

8. Spacer

9. Circlip

10.Fifth wheel

11.Linking pin

12.Gear

13.Circlip

14.Thrust washer

15.Ball bearing cage

16.Gear

17.Sealing 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.Sealing ring

31.Bushing

32.Gasket

33.Oil drainage plug

34.Sealing ring

35.Thrust bearing

36.Roller bearing

37.Spring

38.Complete pre-selector

39.Bushing

STELVIO 4V - 1200

Engine

ENG - 3

Summary of Contents for Stelvio 1200 4V

Page 1: ...SERVICE STATION MANUAL 981063 STELVIO 4V 1200...

Page 2: ...product designed and tested 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...

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 o...

Page 4: ......

Page 5: ...INDEX OF TOPICS CHARACTERISTICS CHAR MAINTENANCE MAIN ELECTRICAL SYSTEM ELE SYS ENGINE ENG POWER SUPPLY P SUPP CHASSIS CHAS...

Page 6: ......

Page 7: ...INDEX OF TOPICS CHARACTERISTICS CHAR...

Page 8: ...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...

Page 9: ...LARGE QUANTITIES OF WATER OR MILK FOLLOWED BY MILK OF MAGNESIA OR VEGETABLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY THE BATTERY RELEASES EX PLOSIVE GASES KEEP IT AWAY FROM FLAMES SPARKS CIGARETTES OR...

Page 10: ...he ve hicle on private grounds or in an area with low traffic density Clean all junction surfaces oil guard rims and washers before refitting them Smear a light layer of lithium based grease on the oi...

Page 11: ...LD BE CONSIDERED NORMAL AND WILL DISAPPEAR 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 ONLY AFTER TH...

Page 12: ...the same selection types D E F Check clearance 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 o...

Page 13: ...0 00118 0 00256 in Middle ring 0 020 0 055 mm 0 00079 0 00216 in Oil scraper ring 0 010 0 045 mm 0 00039 0 00177 in Gap between the end of the piston rings inserted in the cylinder Top and middle pis...

Page 14: ...ndri Portare il pistone del cilindro sinistro al PMS e bloccare la rotazione dell albero motore Specific tooling 020675Y Fermo ingranaggio albero di servizio Fit both pistons on the connecting rods Wo...

Page 15: ...mm 0 0075 0 in gasket thickness 1 05 mm 0 0413 in Recommended products chart RECOMMENDED PRODUCTS Product Description Specifications AGIP RACING 4T 10W 60 Engine oil SAE 10W 60 As an alternative for...

Page 16: ...Characteristics STELVIO 4V 1200 CHAR 10...

Page 17: ...INDEX OF TOPICS MAINTENANCE MAIN...

Page 18: ...d 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 the set screw 2 until the followi...

Page 19: ...RECTLY WHICH CAN LEAD TO PROBLEMS SUCH AS PRESSURE DROP ENGINE OVERHEAT VALVE BURNOUT ETC STELVIO 4V 1200 Maintenance MAIN 3...

Page 20: ...Maintenance STELVIO 4V 1200 MAIN 4...

Page 21: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS...

Page 22: ...Checking the stator Single phase generator with regulated voltage Maximum load 40A 550W Charging voltage 14 2 14 8 V 5000 rpm Start up system check pick up input about 100 A Battery 12 V 18 Ampere ho...

Page 23: ...wered features NTC specifications and sends the control unit a signal which varies depending on temperature to help manage the stoichiometric ratios during engine speed adjustment ENGINE TEMPERATURE S...

Page 24: ...102 kOhm Air temperature sensor NTC type sensor AIR TEMPERATURE SENSOR RESISTANCE Specification Desc Quantity 1 Resistance at 40 C 104 F 100 950 kOhm 2 Resistance at 0 C 32 F 9 750 kOhm 3 Resistance a...

Page 25: ...pins 1 and 2 Heater resistance 12 8 Ohm to be measured be tween pins 3 and 4 at 20 C 68 F Injector Resistance 14 Ohm 2 Ohm measured at 20 C 68 F Coil Characteristic Primary resistance 0 9 1 1 measure...

Page 26: ...hen the sensor remains closed for at least 300 seconds The opening of the sensor and therefore the alarm triggering is detected if the contact is open for at least one second Bank angle sensor Normall...

Page 27: ...INDEX OF TOPICS ENGINE ENG...

Page 28: ...Gearbox Diagram Key 1 Ball bearing Engine STELVIO 4V 1200 ENG 2...

Page 29: ...age 16 Gear 17 Sealing 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 Seali...

Page 30: ...n shaft 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 t...

Page 31: ...oil 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 fitting on the sump Undo and remove the three scre...

Page 32: ...Undo and remove the two screws Undo and remove the screw Remove the gearbox See also Removing the starter motor Replacement Gearbox shafts Engine STELVIO 4V 1200 ENG 6...

Page 33: ...rew 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 be...

Page 34: ...and remove the five external screws 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 Aprire l...

Page 35: ...ide off the whole transmission lever Use rubber bands to tie down the trans mission shaft unit and extract it Once the transmission shaft unit is in on a bench remove the rubber bands being careful wi...

Page 36: ...Remove the forks and collect the shaft Engine STELVIO 4V 1200 ENG 10...

Page 37: ...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 Remove the gear of...

Page 38: ...the circlip Remove the gear of the third and fourth gears Remove the circlip and collect the shoulder washer Remove the gear of the fifth gear and collect the ball bearing cage Engine STELVIO 4V 1200...

Page 39: ...smission gear Removing the secondary shaft Remove the transmission shaft Operate on the shaft from the grooved side Remove the shoulder washer Remove the gear of the second gear and collect the ball b...

Page 40: ...emove the circlip Remove the gear of the sixth gear Remove the circlip and collect the shoulder washer Remove the gear of the fourth gear and collect the ball bearing cage Engine STELVIO 4V 1200 ENG 1...

Page 41: ...e shoulder washer Remove the circlip Remove the gear of the fifth gear Remove the circlip the shoulder wash er and remove the gear of the first gear collect the ball bearing cage Remove the bearing if...

Page 42: ...nsmission 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 transmission gears for signs...

Page 43: ...Disassembling the gearbox Fitting the primary shaft NOTE TO REFIT FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER REMEMBER TO REPLACE ALL SEALING RINGS CIRCLIPS AND SAFETY RINGS PREV...

Page 44: ...Fit the gearbox on the engine block Fit the tool in the gearbox to determine the clutch control rod length According to the value found select the correct rod based on the following table Specific to...

Page 45: ...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 4V 1200 Engine ENG 19...

Page 46: ...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 Loosen t...

Page 47: ...t the alternator slides down Completely loosen and remove the screw Remove the belt and the alternator with pulley Using a compressed air gun unscrew and remove the nut and collect the spacer Remove t...

Page 48: ...Undo and remove the eight screws Undo and remove the two screws Undo and remove the two screws Engine STELVIO 4V 1200 ENG 22...

Page 49: ...ide fairings Remove the right exhaust manifold Remove the control unit Undo and remove the fixing screw of the engine oil scavenge reservoir Unscrew and remove the spacer Undo and remove the five fixi...

Page 50: ...tro Serrare il controdado Specific tooling 020677Y Tenditore cinghia alternatore Installing the generator If the sealing ring has been previously removed replace it using the punch of the timing syste...

Page 51: ...ing 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 Tighten the eight lower screws Operating diagona...

Page 52: ...ing 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 Position the screw and pre tighten i...

Page 53: ...ionare la cinghia alla coppia prestabilita e avvitare il registro Rimuovere l attrezzo di tensionamento della cinghia Bloccare il registro in posizione serran do il controdado Specific tooling 020677Y...

Page 54: ...cover Tighten the five screws operating in oblique direction and in stages Starter motor Removing the starter motor Undo and remove the two screws and collect the washers Slide off the starter motor E...

Page 55: ...Clutch 3 Clutch bell 4 TCEI screw 5 Clutch disc 6 Crown 7 TCEI screw 8 Clutch pressure plate 9 Ring 10 TE flanged screw 11 Conical washer 12 Bushing 13 Rod 14 Bushing 15 Intermediate body 16 Thrust b...

Page 56: ...er 20 TE flanged screw Remove the complete gearbox Undo and remove the six screws Remove the start up crown gear Remove the clutch bell and the friction disc Remove the Seeger ring Remove the clutch p...

Page 57: ...ol rod in 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 gearb...

Page 58: ...utch control rod code 976596 187 5 mm 7 382 in Assembling the clutch Lock crankshaft rotation with the crankpin facing upwards Place the clutch disc with the reference facing upwards Fasten the clutch...

Page 59: ...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 operat...

Page 60: ...g lever support 5 Screw 6 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 Spac...

Page 61: ...33 Screw 34 Pin 35 Nut 36 Right exhaust 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 Camsh...

Page 62: ...ad cover fixing screws and collect the sealing O rings Remove the head cover together with the gasket Removing the cylinder head CAUTION WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VER...

Page 63: ...pper gear bulkhead For the right head Unscrew and remove the chain ten sioner cap Remove the right chain tensioner For the left head Undo and remove the screw and the washer Relief oil pressure from t...

Page 64: ...ew and remove the four nuts on the stud bolts Remove the complete cam cap Undo and remove the two screws Remove the head Fit the timing system upper gear back to the chain Fit the chain tensioner cap...

Page 65: ...ead Removing the overhead camshaft 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 Remove the two roc...

Page 66: ...ee also Removing the rocker arms 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 FIT...

Page 67: ...ol for valve pressure plate Tighten the tool screw until fitted and then hit the tool head where the upper cap works with a mallet so that the two cotters 1 get detached from the upper cap 2 Once the...

Page 68: ...m 0 0018 0 0030 in VALVE GUIDE COUPLING VALVES INLET Specification Desc Quantity Valve guide inside diameter 5 0 5 012 mm 0 19685 0 19732 in Valve stem diameter 4 972 4 987 mm 0 19574 0 19633 in Fitti...

Page 69: ...OLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS Place the valve guide oil seal 4 in the head Place the lower cap 5 Place the valve 6 inside the head Place the spring 3 Fit...

Page 70: ...Place the two rocking levers in the cam cap seats Place the U bolt on the rocking levers making sure the two reference pins match the seats on the cam cap Tighten the two screws operating diag onally...

Page 71: ...refitted be careful not to interchange them Place the camshaft with the gear seat on the dowel side Place the U bolt on the camshaft mak ing sure the two reference pins match the seats on the cam cap...

Page 72: ...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 Removing the serv...

Page 73: ...ring 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...

Page 74: ...move 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 th...

Page 75: ...it 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 Spe...

Page 76: ...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 Place the oil pump Tighten the three screws fixing the oil pump Pla...

Page 77: ...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 Tighten the screw with the washer t...

Page 78: ...tact with the tone wheel Measure the clearance between the fixing plate and the crankcase with a thickness gauge Subtract the plain washer value from this measurement to obtain the clearance between t...

Page 79: ...ring 5 Middle piston ring 6 Oil scraper piston ring 7 Pin 8 Snap ring 9 Cylinder base gasket 10 Stud bolt 11 Pin 12 Cylinder head gasket 13 Left cylinder 14 Washer 15 Chain tensioner cap 16 Washer 17...

Page 80: ...the stud bolts Remove the two dowel pins on the stud bolts Remove the two gaskets between the crankcase and the cylinder Cover the crankcase opening with a clean cloth See also Removing the cylinder...

Page 81: ...raper in the lower slot the thicker smooth ring in the intermediate slot the less thick smooth ring in the upper slot The piston rings must be offset at 120 one from the other Fit one of the two pin s...

Page 82: ...e coupling ends are 120 degrees from each other Place a new metal gasket between the crankcase and the cylinder Place the two dowel pins on the stud bolts Lu bricate the piston and the cylinder Lock c...

Page 83: ...in tensioner cap temporarily and keep the chain taut on the service shaft LEFT CYLINDER Fit the piston Remove the cloth used to prevent for eign bodies from getting into the crank case Turn the rings...

Page 84: ...on 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 OPERATIO...

Page 85: ...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...

Page 86: ...r gear 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 cranksh...

Page 87: ...right camshaft pin 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...

Page 88: ...d Adjust valve clearance See also Checking the valve clearance Installing the head cover Replace the gasket and install the head cover Place the plastic half cover Replace the four rubber rings Tighte...

Page 89: ...Remove both gears Remove the connecting rods Undo and remove the eight fixing screws and collect the washers Hold the crankshaft during flange re moval Using the suitable special tool remove the cran...

Page 90: ...nic wheel Disassembling the connecting rod Remove both heads Remove the cylinders and the pistons Remove the oil sump Undo the coupling screws A inside the crankcase and remove the con necting rods B...

Page 91: ...of crankshaft bushing on clutch side flange 54 019 54 0 mm 2 12673 2 12598 in Clearance between bushing and main journal clutch side 0 030 0 058 mm 0 00118 0 00228 in CRANKPIN DIAMETER B Specification...

Page 92: ...icated in the figure this defines what kind of undersizing the bearing should have and to which diameter the pin B should be reamed Checking shaft parallelism Check shafts for squaring before fitting...

Page 93: ...a marked area for weight selection The weight indicated in the chart includes screws dowels and the bushing CONNECTING ROD WEIGHT SELECTION Specification Desc Quantity Connecting rod brown 0 588 0 598...

Page 94: ...ch 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 01968 in Lock the screws A on the caps B with...

Page 95: ...20 00 Tool to fit the flywheel side flange together with sealing ring on the crankshaft Place the flywheel side flange on the crankshaft and check if the dowel pin with the O ring is correctly placed...

Page 96: ...crank shaft on the generator side Refitting the crankcase halves In case the lubrication jets are removed replace them with two new of the same type Check that the O ring is fitted on the jets Do not...

Page 97: ...3 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...

Page 98: ...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...

Page 99: ...refitting 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 rem...

Page 100: ...mp See also Replacement Removing the generator Installing Place a new gasket between the crank case and the oil pump Place the oil pump Tighten the three screws fixing the oil pump Place the driving p...

Page 101: ...en 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 th...

Page 102: ...DER 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...

Page 103: ...Undo and remove the four screws Remove the flange Undo and remove the two screws Remove both filters STELVIO 4V 1200 Engine ENG 77...

Page 104: ...Unscrew and remove the plug Remove the thermostatic valve Unscrew and remove the pressure re lief valve plug Remove the pressure relief valve com ponents Engine STELVIO 4V 1200 ENG 78...

Page 105: ...e pressure relief valve compo nents correctly Screw the pressure relief valve plug Place the thermostatic valve CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED Tighten the thermostatic valve plu...

Page 106: ...e crank case and the flange Fit the flange Fix the flange with the four screws Fit the lubrication oil intake filter Check that the O rings are fitted on the oil pump Fit the cooling oil intake filter...

Page 107: ...torque Fit a new oil filter and tighten it to the prescribed torque Place a new gasket between the flange and the sump Place the oil sump Tighten the fourteen screws to the pre scribed torque Add eng...

Page 108: ...Engine STELVIO 4V 1200 ENG 82...

Page 109: ...INDEX OF TOPICS POWER SUPPLY P SUPP...

Page 110: ...y 1 Control unit 2 Ignition switch 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 Power supply STEL...

Page 111: ...minimo deve essere installata in modo che la parte sagomata sia inserita nella cassa filtro aria La parte pi corta della tubazione carburante col legata ai corpi farfallati deve essere posizionata a...

Page 112: ...adjustable parameters screen Autodetect the throttle position Turn the key to OFF and leave it for at least 30 seconds Turn the key back to ON and restore the Axone session Check that the Throttle val...

Page 113: ...cylinders Otherwise open only the screw with higher depression using the by pass screws to compensate Recovery function If the signal of the following sensors is interrupted the control unit determin...

Page 114: ...m Engine revolutions per minute the minimum value is set by the control unit cannot be adjusted Injection time ms Ignition advance Air temperature C Temperature of the air taken in by the engine measu...

Page 115: ...50 approximate values Steps set by the control unit for the Stepper motor At idle steps so that the engine keeps the target engine revs set by the control unit Stepper regulator Difference between cur...

Page 116: ...ontrol unit detects the revolution sensor signal correctly Devices activation screen page DEVICES ACTIVATION This displays is used to delete errors in the control unit memory and activate some systems...

Page 117: ...covery function hardly noticeable for customer Left injector Possible short circuit in the earth lead battery or open circuit If both injectors do not work the en gine does not work Right injector Pos...

Page 118: ...d earth connections ROM memory Possible internal control unit error Also check the control unit supply and earth connections Microprocessor Possible internal control unit error Also check the control...

Page 119: ...INDEX OF TOPICS CHASSIS CHAS...

Page 120: ...Bevel gears Checking Smontaggio gruppo scatola Remove the cover 20 Remove the plug 3 to drain out the oil Lift the cap 10 Chassis STELVIO 4V 1200 CHAS 2...

Page 121: ...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 STELVIO 4V 1200 Chassis CHAS 3...

Page 122: ...Remove the clamp 12 Remove the cap 14 Collect the ring 13 Remove the support unit 8 Montaggio gruppo scatola Chassis STELVIO 4V 1200 CHAS 4...

Page 123: ...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 STELVIO...

Page 124: ...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 Chassis STELVIO 4V 1200 CHAS 6...

Page 125: ...le 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...

Page 126: ...ng 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 Ch...

Page 127: ...Fit the cap with the washer Screw the cap to the prescribed torque Assemble the cap with the clamps Fit the cap in its seat Gruppo asse ruota REMOVAL Remove the bearing from the wheel axle with a suit...

Page 128: ...ng 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 Gruppo pign...

Page 129: ...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 b...

Page 130: ...sealing 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 Chassis STELVIO 4...

Page 131: ...Assembly position of the stop ring 1 CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT Gruppo supporto STELVIO 4V 1200 Chassis CHAS 13...

Page 132: ...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 an...

Page 133: ...bber hammer Fit the stop ring 3 in the support 5 with suitable pliers Manually assemble the new sealing rings 2 and 7 Assemble the bushing 1 Drive the bushing 1 in with a plastic hammer Turn the suppo...

Page 134: ...four screws to the prescri bed torque operating diagonally Place the reaction rod into its seat Insert the screw Screw the nut fixing the reaction rod Place the dust protection ring between the rim a...

Page 135: ...ggio tramite fascette Posizionare sul forcellone la ruota pos teriore Serrare le quattro viti complete di dis tanziali e anello antipolvere Posizionare sul disco la pinza freno posteriore e il tubo fr...

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MOTO GUZZI Stelvio 1200 4V, Service Station Manual

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