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MOTO GUZZI Stelvio 1200 NTX, Service Manual

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MOTO GUZZI Stelvio 1200 NTX Service Manual Download Page 22

•

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 crankshaft by 90°until the right cylinder piston reaches the TDC.

•

Lock crankshaft rotation.

•

Place the tool on the right cylinder stud bolts to determine the "squish" (X).

Specific tooling

020676Y

 

Comparator support for piston position checking

•

Repeat the same operations to determine the thickness of the left cylinder gasket between

cylinder and head also for the right cylinder.

CYLINDER GASKET THICKNESS - HEAD

Specification

Desc./Quantity

Value (X) -0.56 / -0.37 mm (-0.022 / -0.0146 in)

gasket thickness: 0.65 mm (0.0256 in)

Value (X) -0.37 / -0.19 mm (-0.0146 / -0.0075 in)

gasket thickness: 0.85 mm (0.0335 in)

Value (X) -0.19 / 0 mm (-0.0075 / 0 in)

gasket thickness: 1.05 mm (0.0413 in)

Recommended products chart

R

ECOMMENDED

 

PRODUCTS

Product

Description

Specifications

AGIP RACING 4T 10W-60

Engine oil

SAE 10W - 60. As an alternative to rec-

ommended fluids, use top branded oils

with performances that meet or exceed

the requirements of CCMC G-4 API. SG

specifications.

AGIP GEAR SAE 80 W 90

Transmission oil

-

AGIP GEAR MG/S SAE 85 W 90

Gearbox oil

-

AGIP FORK 7.5W

Fork oil

SAE 5W / SAE 20W

AGIP GREASE SM2

Lithium grease with molybdenum for

bearings and other points needing lubri-

cation

NLGI 2

Neutral grease or petroleum jelly.

BATTERY POLES

AGIP BRAKE 4 / BRAKE 5.1

Brake fluid

As an alternative for recommended flu-
ids, use top branded fluids that meet or

exceed the requirements of SAE J1703,

NHTSA 116 DOT 4, ISO 4925 synthetic

fluid specifications.

AGIP BRAKE 4 / BRAKE 5.1

Clutch fluid

As an alternative for recommended flu-
ids, use top branded fluids that meet or

exceed the requirements of SAE J1703,

NHTSA 116 DOT 4, ISO 4925 synthetic

fluid specifications.

Characteristics

STELVIO 1200 NTX

CHAR - 22

Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Summary of Contents for Stelvio 1200 NTX

Page 1: ...SERVICE STATION MANUAL 981127 STELVIO 1200 NTX ...

Page 2: ...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 manual remain unchanged Moto Guzzi reserves the right at any time and without being required to update this pu...

Page 3: ... 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 updates and technical changes related to ...

Page 4: ...Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 5: ...NTENANCE 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 6: ...INDEX OF TOPICS CHARACTERISTICS CHAR Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 7: ... WHICH MAY CAUSE IGNITION OR EXPLOSION DO NOT ALLOW FUEL TO DISPERSE INTO 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 system have cooled down Used engine o...

Page 8: ...OLLOWED 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 ANY OTHER HEAT SOURCES ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY KEEP OUT OF THE REACH OF CHILDREN BATTERY LIQUID IS CORROSIVE DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN PARTICULAR ENSURE THAT THE ELECTROL...

Page 9: ...uard rims and gaskets before 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 wiring harness Press the...

Page 10: ...PORTANT 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 RUN IN PERIOD Follow the guidelines detailed below Do not twist the throttle grip abruptly and completely when the engine is working at a low revs either during or after run in During the first 100 Km 62 miles use t...

Page 11: ...T AND DIMENSIONS Specification Desc Quantity Maximum width without accessories 2305 mm 90 75 in Maximum width at handlebar 910 mm 35 83 in Maximum width of vehicle with accessories 1080 mm 42 52 in Minimum maximum height adjustable windshield 1395 1440 mm 54 92 56 69 in Saddle height 800 mm 31 5 in Minimum ground clearance 185 mm 7 3 in Wheelbase 1535 mm 60 43 in Kerb weight 251 kg 553 lb Kerb wei...

Page 12: ...cal gearbox with foot gearshift lever on left hand side of engine 1st gear ratio 17 38 1 2 2353 2nd gear ratio 20 34 1 1 7 3rd gear ratio 23 31 1 1 3478 4th gear ratio 26 29 1 1 1154 5th gear ratio 31 30 1 0 9677 6th gear ratio 29 25 1 0 8621 Final drive cardan shaft Ratio 12 44 1 3 6667 Capacities CAPACITIES Specification Desc Quantity Engine oil Oil change and oil filter replacement 3 500 cm 214...

Page 13: ...ic fork with 50 mm 1 97 in di am stanchions and radial calliper mounting with adjustable spring preload and hydraulic compression and rebound damp ing Front wheel travel 170 mm 6 69 in Rear single sided swingarm with progressive linkage and mono shock with adjustable hydraulic rebound and compression damping and spring preload Unloaded shock absorber spring length 180 mm 7 09 in Rear wheel travel ...

Page 14: ...with ABS WHEN FITTING Metzeler Karoo 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 TYRES AS THESE TYRES OFFER POOR GRIP AND STABILITY ON TARMAC DO NOT INSTALL M S TYPE TYRES ON VEHICLES EQUIPPED WITH ABS Supply FUEL SYSTEM Specification Desc Quantity Fuel system Electronic injectio...

Page 15: ... 29 5 lbf ft Loctite 243 Oil pipe in sump 20 Nm 14 75 lbf ft Loctite 648 Pressure relief plug 40 Nm 29 5 lbf ft Cap on oil sump flange 2 20 Nm 14 75 lbf ft Cap 1 40 Nm 29 5 lbf ft CRANKSHAFT FLYWHEEL Name Torque in Nm Connecting rod screw 4 pre tightening 40 Nm 29 5 lbf ft Connecting rod screw 4 final tightening 80 Nm 59 lbf ft Screw fixing clutch disc on crankshaft M8x25 6 42 Nm 30 98 lbf ft Loct...

Page 16: ...20 Nm FUEL SUPPLY CONTROL UNIT Name Torque in Nm M5x12 TCEI screw 6 7 Nm Stainless M5x16 TBEI flanged screw 6 7 Nm M6x25 TCEI DA screw 8 12 Nm CHASSIS Name Torque in Nm Front engine to chassis retainer 80 Nm Transmission to chassis retainer M12x250 M12x230 50 Nm Right fixing plate transmission retainer 25 Nm Plate clamp Blow by retainer 10 Nm Coil plate retainer 10 Nm Electronic control unit retai...

Page 17: ...loading bushing to swingarm bolt retainer 10 Nm FRONT SUSPENSION Name Torque in Nm Tube lock plate to steering base retainer 6 Nm Fork stem on upper plate retainer M8x30 2 20 Nm 14 75 lbf ft Fork stem on lower plate retainer M8x30 4 20 Nm 14 75 lbf ft Headstock ring nut 40 Nm Headstock counter ring nut manual 90 degrees Upper yoke fixing cap 100 Nm Fork hub closing M6x30 2 2 10 Nm 7 38 lbf ft REAR...

Page 18: ...weight fastener 10 Nm Brake pump and clutch U bolts retainer 10 Nm Right and left light switch retainer 1 5 Nm Clutch control cylinder to gear retainer 10 Nm Rear view mirror Manual ELECTRICAL SYSTEM Name Torque in Nm Coil retainer 2 Nm Horn retainer 15 Nm Odometer sensor on bevel gear pair retainer 3 Nm INSTRUMENT PANEL AND LIGHTS Name Torque in Nm Instrument panel retainer 3 Nm Front arrows reta...

Page 19: ... M8 2 25 Nm 18 44 lbf ft Passenger grab handle to chassis retainer M6 4 10 Nm 7 38 lbf ft License plate holder to chassis retainer M5 4 4 Nm 2 95 lbf ft Luggage carrier brackets retainer M8 2 2 25 Nm 18 44 lbf ft FINISHINGS Name Torque in Nm Ignition lock retainer shear head screw Nm Overhaul data Assembly clearances Cylinder piston assy Measurement of the cylinder diameter must be done at three h...

Page 20: ...on ring 1 middle piston ring 1 oil scraper piston ring Turn the rings so that the coupling ends are 120 degrees from each other CLEARANCE BETWEEN PISTON RINGS AND SEATS ON PISTON Specification Desc Quantity Top ring 0 030 0 065 mm 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 t...

Page 21: ...ange 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 Slot packing system Fit both pistons on the connecting rods Working from both sides fit the gasket between the crankcase and the cylin der on the crankcase Fit both cylinders Take the left cylinder piston to TDC and lock crankshaft rotation Specific tooling 020675Y Servic...

Page 22: ... 0 19 0 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 to rec ommended fluids use top branded oils with performances that meet or exceed the requirements of CCMC G 4 API SG specifications AGIP GEAR SAE 80 W 90 Transmission oil AGIP GEAR MG S SAE 85 W 9...

Page 23: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 24: ... 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 Special tools STELVIO 1200 NTX S TOOLS 24 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 25: ... ignition timing 12 91 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 STELVIO 1200 NTX Special tools S TOOLS 25 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 26: ...er with sealing ring on the crankshaft 19 92 71 00 Tool to fit the sealing 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 Special tools STELVIO 1200 NTX S TOOLS 26 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 27: ...ch rod checking 05 91 25 30 Gearbox opening CHASSIS Stores code Description 05 91 26 30 Tool for tightening the swingarm pin ring nut clutch hub AP8140190 Tool for steering tightening STELVIO 1200 NTX Special tools S TOOLS 27 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 28: ...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 Special tools STELVIO 1200 NTX S TOOLS 28 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 29: ...ores code Description AP8140146 Weight AP8140149 Protection for fitting operations AP8140758 tool to fit oil seals and dust guards for ø 50 mm 1 97 in stems STELVIO 1200 NTX Special tools S TOOLS 29 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 30: ...INDEX OF TOPICS MAINTENANCE MAIN Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 31: ... I I I I I I Wheel bearings 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 Engine oil filter R R R R R R R R R Fork I I I I I Vehicle general operation I I I I I I I I I Braking systems I I I I I I I I I Light circuit I I I I I I I I I Safety switches I I I I I Brake fluid I I R I R I R I R Clutch fluid I I I I I I I I I Gearbox oil R R R R R R R R R Engine oil R R R R R ...

Page 32: ...IL Place a container with 400 cm 25 cu in capacity under the drainage plug 3 Unscrew and remove the drainage plug 3 Unscrew and remove the breather cap 2 Drain the oil into the container allow several minutes for oil to drain out completely Check and if necessary replace the sealing washer of drainage plug 3 Remove any metal scrap attached to the drainage plug 3 magnet Screw and tighten the draina...

Page 33: ...ut 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 OIL WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN Replacement NOTE HOT OIL IS LESS VISCOUS AND WILL DRAIN OUT MORE EASILY AND COMPLETELY It is necessary to remove the metal oil sump guard in or...

Page 34: ...nd tighten the drainage plug 3 DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL STORED IN A SEALED CON TAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL RECLAMATION FIRM Engine oil filter Replace the engine oil filter each time you change the engine oil Drain the engine oil completely Unscrew and remove the engine oil fil ter from its seat NOTE NEVER REUSE AN OLD FILTE...

Page 35: ...hes the dip stick opening 1 CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER EL EMENT MAKE SURE IT IS PERFECTLY CLEAN Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY Place a container with suitable capacity under the drainage plug 2 Unscrew and remove the drainage plug 2 Unscrew and remove the filler cap 1 Drain ...

Page 36: ...ith a clean cloth so that no foreign bodies get into the inlet ducts DO NOT START THE ENGINE WITHOUT THE AIR FILTER TO CLEAN THE FILTERING ELEMENT USE A PRESSURE AIR JET FROM THE INSIDE TO THE OUTSIDE Checking the valve clearance If the timing system is very noisy check the clearance between the valves and the rocking levers NOTE ADJUST WITH COLD ENGINE WITH PISTON AT TOP DEAD CENTRE TDC IN COMPRE...

Page 37: ... 0059 in The measurement must be taken using a special thickness gauge CAUTION IF CLEARANCE IS LARGER THAN RECOMMENDED THE TAPPETS WILL BE NOISY OTHERWISE THE VALVES DO NOT CLOSE CORRECTLY WHICH CAN LEAD TO PROB LEMS SUCH AS PRESSURE DROP ENGINE OVERHEAT VALVE BURN OUT ETC Braking system Level check Brake fluid check Rest the vehicle on its stand For the front brake turn the handlebar fully to the...

Page 38: ...rew and remove the cap 5 Remove the gasket 6 Top up the reservoir with brake fluid to the correct level which is between the two MIN and MAX reference marks RISK OF BRAKE FLUID SPILLING DO NOT OPERATE THE BRAKE LEVER IF THE BRAKE FLUID RESERVOIR CAP IS LOOSE OR HAS BEEN REMOVED CAUTION AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT W...

Page 39: ... MARK WHEN BRAKE PADS ARE WORN AS YOU RISK SPILLING FLUID WHEN CHANGING THE BRAKE PADS CHECK BRAKING EFFICIENCY IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFORM ANCE OF THE BRAKING SYSTEM TAKE YOUR VEHICLE TO AN Official Moto Guzzi Dealer AS IT MAY BE NECES SARY TO PURGE THE AIR IN THE SYSTEM STELVIO 1200 NTX Maintenance MAIN 39 Revente Interdite Revendita Vietata Resaling Forbiden W...

Page 40: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 41: ...Components arrangement key 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector STELVIO 1200 NTX Electrical system ELE SYS 41 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 42: ...Relay 23 Additional headlamps Electrical system installation Front side CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED CARRY OUT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION FRONT SECTION TABLE A Clamp the brake pipes with the throttle grip trans...

Page 43: ...and the clamp gets unhooked FRONT SECTION TABLE B Pay attention to the longer cable 1 which is to be placed to the left while the shorter cable 2 is to be placed to the right TABLE C HEADLIGHT AND TURN INDICATOR SYSTEM CLAMPS Clamp the right headlight cable 1 and the right turn indicator 2 STELVIO 1200 NTX Electrical system ELE SYS 43 Revente Interdite Revendita Vietata Resaling Forbiden Wiederver...

Page 44: ...ICAL SYSTEM IS REFITTED THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED CARRY OUT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION Electrical system STELVIO 1200 NTX ELE SYS 44 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 45: ...RED CLAMP STARTING POINT IN THE ELECTRICAL SYSTEM The red clamp must start from the point indicated The cable of heated handgrips must come out under the beam and be clam ped Pass the cable harness under the beam STELVIO 1200 NTX Electrical system ELE SYS 45 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 46: ... the air filter TABLE D LAMBDA PROBE SYSTEM CLAMP ING Clamp the stand system with the return pipes in sump and leave the lambda probe system free The ground lead must be towards the bottom tighten the stud bolt nut to 10Nm 7 37 lbf ft Electrical system STELVIO 1200 NTX ELE SYS 46 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 47: ...OF THE ODOM ETER CLAMP The clamp fixing the odometer cable must be placed ahead of the brake pipe guide clamp REAR SECTION TABLE B FITTING THE FAIRING COMPART MENT LID SAFETY RELAY Lay down the main system and clamp the stop switch system odometer sen sor and fall sensor to the system Be careful that the latter does not come into contact with clips Attach the relay to the support plate and fix it ...

Page 48: ...AR SYSTEM RETAINER Pay attention to the position of the U bolt adhesive cable grommets for the system Electrical system STELVIO 1200 NTX ELE SYS 48 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 49: ...iagram Key 1 Multiple connectors 2 Clutch switch 3 Start up relay 4 Start up maintenance relay STELVIO 1200 NTX Electrical system ELE SYS 49 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 50: ...switch 22 Front stop switch 23 ECU Diagnosis connector 24 Auxiliary fuses 25 Starter motor 26 Battery 27 12V socket 28 Main fuses 29 Alternator 30 Main injection relay 31 Secondary injection relay 32 Oil pressure bulb 33 Gear in neutral switch 34 Lambda Probe 35 Side stand switch 36 Fuel reserve sensor 37 Fuel pump 38 Intake air temperature thermistor 39 Head temperature thermistor 40 Automatic ai...

Page 51: ...bulb 56 Low beam bulb 57 High beam bulb 58 Front right turn indicator 59 Instrument panel diagnosis 60 Antitheft control unit optional equipment 61 Under saddle switch 62 Glove box compartment opening relay 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 Checks and inspections STELVIO 1200 NTX Electrical system ELE SYS 51 Revente ...

Page 52: ...eration 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 Error Clearing Reset Service Update Change Keys km Miles ECU ERRORS The instrume...

Page 53: ...ng 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 Description Immobilizer failure Aerial not working Open or short circuited Error code DSB 03 Description Immobilizer failu...

Page 54: ...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 finishes once the 4 keys have been programmed or after 20 seconds Should a new key lock be necessary the procedure is once the key is set to ON but the instr...

Page 55: ... 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 does not light up and the word Service is not displayed Lights list FRONT HEADLAMP Specification Desc Quantity Front daylight running light 12V 5W Low high beam headlight h...

Page 56: ...stop light LED License plate light 12V 5 W ADDITIONAL HEADLAMPS Specification Desc Quantity Additional headlamp bulbs 12V 55W H3 Electrical system STELVIO 1200 NTX ELE SYS 56 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 57: ...Permanent positive ECU power supply 3A NOTE THERE ARE TWO SPARE FUSES MAIN FUSES 1 Battery recharge 40 A 2 Motion main fuse 30 A NOTE THERE IS ONE SPARE FUSE Control unit Model Magneti Marelli IAW 5 AM2 BROWN connector pin configuration Pin Use 1 Not used 2 Not used 3 Ignition potentiometer signal 4 Not used 5 Engine temperature signal STELVIO 1200 NTX Electrical system ELE SYS 57 Revente Interdit...

Page 58: ...nal 26 Not used 27 Not used 28 Left cylinder injector control 29 Ignition potentiometer power supply 30 Not used 31 Not used 32 Ignition potentiometer negative 33 Not used 34 Revolution sensor anti jamming cable 35 Engine revolution sensor signal 36 Not used 37 Right cylinder injector control 38 Left cylinder coil control BLUE connector pin configuration Pin Use 1 Pin 85 ignition relay control 2 N...

Page 59: ...t used 20 CAN H line ccm instrument panel 21 Not used 22 Oxygen probe signal 23 Not used 24 Vehicle speed signal input 25 Not used 26 Not used 27 Engine stop signal input 28 Ignition signal input 29 CAN L line ccm instrument panel 30 Not used 31 Not used 32 Oxygen probe power supply 33 Clutch sensor signal 34 Not used 35 Fall sensor signal 36 Not used 37 Not used 38 Side stand sensor signal STELVI...

Page 60: ...Location Sensor on swingarm right side near the rear brake calliper Connector near the upper retainer of the rear shock absorber Pin out 1 Supply voltage green 2 Output signal grey white 3 Ground blue orange PIN PINS 1 3 Voltage approx 12 V PINS 2 3 Voltage variable 0 4V 12V by turning the rear wheel AXONE ELECTRICAL ERRORS Speed sensor invalid signal Error cause Electrical system STELVIO 1200 NTX...

Page 61: ... harness from PIN 24 of the ECU BLUE connector Check PIN 24 of the BLUE connector If after all these checks the failure is not found replace the sensor Speed sensor over the maximum limit Error cause Error signal if a speed above the default value set by the manufacturer for the running vehicle is detected Troubleshooting above the maximum threshold replace the sensor Engine rpm sensor Function In...

Page 62: ...l unit connector 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...

Page 63: ...ONS 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 THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELEC...

Page 64: ... 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 AXONE ADJUSTABLE PARAMETERS Throttle position autodetection It allows the control unit to detect the closed throttle position just press the Enter key Self adjustable parameters reset Lambda probe self adaptability parameters reset oper...

Page 65: ...ON 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 THE BEGINNIN...

Page 66: ...ance is null replace the sen sor if resistance is correct it means that the orange cable has ground connection restore the cable harness NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty then check through Axone if the temperature indicated is plausible in relation to the engine temperature Check also that the sensor electr...

Page 67: ...y if it is OK reconnect the control unit connector and with key set to key ON check the continuity between the sensor connector PIN 1 and the 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 14 and PIN 2 of the sensor sho...

Page 68: ... Heater ground connection white 4 Heater power supply white AXONE PARAMETERS Lambda probe Example value 0 1000 mV If there is a short circuit at 5 V or above the value read is approx 5 000 mV If there is a short circuit to ground instead the value read is equal to 0 mV and the Lambda Sensor Correction parameter shows 25 no error is displayed though Lambda sensor correction example value 1 00 In cl...

Page 69: ...r correct resist ance replace the sensor if not OK if it is OK restore the cable harness if the circuit is open shorted to negative check the continuity from probe connector PIN 3 and 4 towards the probe if not OK replace the probe if it is correct check the sensor connector and the Marelli control unit connector If not OK restore If OK and with key set to ON and sensor connector disconnected chec...

Page 70: ...owever the identification of the relay with the colour of the cables is energised for 5 seconds and the grey red cable of the injector is closed to ground for 4 ms per second 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 displayed in case of lack of activ...

Page 71: ...or 4 ms per second 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 displayed in case of lack of activation AXONE ELECTRICAL ERRORS Right injector P0202 shorted to positive shorted to negative open circuit Error cause If shorted to positive excessive voltage...

Page 72: ...eft coil The auxiliary injection relay No 31 in the wiring diagram placed on the front right side of the motorcycle in the auxiliary fuses relays box first relay to the left starting from the front CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the green orange cable of the coil is closed to ground for 2 ms per second Disconnect the 4 way...

Page 73: ...ng from the front CHECK however the identification of the relay with the colour of the cables is energised for 5 seconds and the sky blue green cable of the coil is closed to ground for 2 ms per second 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 display...

Page 74: ...ircuit 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 panel connector PIN 17 if not OK restore...

Page 75: ...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 the sensor connector and PIN 23 of the BROW...

Page 76: ...s 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 replace the sensor Check continuity of the b...

Page 77: ...sensor side AXONE STATUSES Side stand Example value retracted extended DIAGNOSIS Indication on Axone always EXTENDED check the side stand sensor connector and the ECU connector if they are not OK restore if OK disconnect both terminals from the sensor and check continuity to ground of PIN 1 blue green cable harness side if there is not continuity restore the cable harness if there is check continu...

Page 78: ...nect the con nector 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 is 12V voltage at PIN 1 If there i...

Page 79: ...r 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 the instrument panel connector If not OK restore the cable harness if OK with key set to ON check if there is voltage at the sensor conn...

Page 80: ...ition 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 AXONE STATUSES Run stop switch Example value Run Stop DIAGNOSIS Indication on Axone always STOP disconnect the connector and with the switch set to RUN check if there is continuity towards the switch of both the sky blue green and the grey sky blue cables sensor...

Page 81: ...blue orange cable is shorted to positive restore the cable harness Connectors Dashboard The pin configuration of the GREY bodied connector 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 8 CONTROL SET 9 FUEL LEVEL SENSOR 10 AIR TEMPERATURE SENSOR 11 BATTERY 12 LEFT TURN INDICATOR CONTROL 13 14 15 16 GENERAL EARTH CONNECTION 17 OIL...

Page 82: ...ED HANDGRIPS ACTUATOR OPT 26 CAN H 27 CONTROL RESET 28 LIGHTS RELAY ACTIVATION 29 ANTI THEFT 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 OPT 40 CONTROL UP Electrical system STELVIO 1200 NTX ELE SYS 82 Revente Interdite Revendita Viet...

Page 83: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 84: ...ber the sump guard the engine guard the additional headlamp supports and the corresponding headlamps See also Exhaust Removing Fuel tank Removing Additional lights Supplementary light mount Sump guard Pannier mounting Engine guard Engine guard 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 cyl...

Page 85: ...und leads Disconnect the starter motor connec tors Disconnect the stand sensor connec tor and release it from the clamps Slide off the gearbox oil breather pipe STELVIO 1200 NTX Engine from vehicle ENG VE 85 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 86: ...e screw fixing 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 Engine from vehicle STELVIO 1200 NTX ENG VE 86 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 87: ...ors Working from both sides undo and re move the three inlet manifold screws Collect the gasket Disconnect the alternator connectors STELVIO 1200 NTX Engine from vehicle ENG VE 87 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 88: ...evolution sensor con nector Remove 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 Engine from vehicle STELVIO 1200 NTX ENG VE 88 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 89: ... washer 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 Engine from vehicle ENG VE 89 Revente Interdite Revendit...

Page 90: ...onnect 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 tighten the nut Engine from vehicle STELV...

Page 91: ...ve 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 Engine from vehicle ENG VE 91 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbot...

Page 92: ...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 ENG VE 92 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 93: ... bolt Fit the starter motor cover Tighten the screws Connect the neutral sensor connector Connect the alternator connectors STELVIO 1200 NTX Engine from vehicle ENG VE 93 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 94: ...onnect the horn connectors Connect the engine temperature sen sor connector Place the oil radiator Tighten the two screws Engine from vehicle STELVIO 1200 NTX ENG VE 94 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 95: ...or 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 Engine from vehicle ENG VE 95 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 96: ...INDEX OF TOPICS ENGINE ENG Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 97: ...Gearbox Diagram Key 1 Ball bearing STELVIO 1200 NTX Engine ENG 97 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 98: ...aring 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 Engine STELVIO 1200 NTX ENG 98 Revente Interdite Revendita Vietata Resaling Forbiden Wiede...

Page 99: ...h 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 Engine ENG 99 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 100: ...table 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 screws Engine STELVIO 1200 NTX ENG 100 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 101: ...o screws Undo and remove the screw Remove the gearbox See also Removing the starter motor Replacement Gearbox shafts STELVIO 1200 NTX Engine ENG 101 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 102: ... 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 ENG 102 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 103: ... 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 Engine ENG 103 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 104: ...ase 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 ENG 104 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 105: ...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 Engine ENG 105 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 106: ...earbox 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 ENG 106 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 107: ...t 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 Engine ENG 107 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 108: ...pecific 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 ENG 108 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 109: ...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 Engine ENG 109 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 110: ...ing 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 ENG 110 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 111: ...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 transmission gears for signs of pitting ...

Page 112: ...nsmission 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 REVERSE ORDER REMEMBER TO REPLACE ALL SEAL...

Page 113: ...rbox 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 11 2 mm 0 386 0 441 in Clutch control rod ...

Page 114: ... 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 Engine STELVIO 1200 NTX ENG 114 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 115: ...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 the screw STELVIO 1200 NTX Engine ENG 115 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 116: ... 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 the lower pulley Engine STELVIO 1200 NTX ENG 116 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 117: ...Undo and remove the eight screws Undo and remove the two screws Undo and remove the two screws STELVIO 1200 NTX Engine ENG 117 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 118: ...lt Operating from both sides undo and remove the screw fixing the oil radiator to the chassis Undo and remove the radiator lower screw and collect the washer Undo and remove the horn fixing screw Engine STELVIO 1200 NTX ENG 118 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 119: ...ew TCEI M6x16 4 10 Nm 7 38 lbf ft Loosen the screw Loosen the nut and undo the set screw so that the alternator slides down Using the belt tensioning tool tension the belt to the prescribed torque Tighten the set screw Tighten the lock nut Specific tooling 020677Y Alternator belt tensioner Belt ten sioning lever Locking torques N m Belt tension 50 Nm 36 88 lbf ft STELVIO 1200 NTX Engine ENG 119 Re...

Page 120: ...ver 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 ENG 120 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 121: ...tor 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 Engine ENG 121 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 122: ...lt 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 Alternator belt tensioner Belt ten sioning lever Engine STELVIO 1200 NTX ENG 122 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 123: ...ver 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 Engine ENG 123 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 124: ...ssembling the clutch Key 1 Complete clutch 2 Clutch 3 Clutch bell 4 TCEI screw 5 Clutch disc 6 Crown 7 TCEI screw 8 Clutch pressure plate Engine STELVIO 1200 NTX ENG 124 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 125: ... control bowl 18 Thrust cylinder 19 Clutch control cylinder 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 STELVIO 1200 NTX Engine ENG 125 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 126: ...moving the gearbox Checking the clutch actuator If the clutch is replaced measure the length of the clutch control 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 Engine STELVIO 1200 NTX ENG 126 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 127: ...84 5 mm 7 264 in Protrusion 6 8 8 2 mm 0 268 0 323 in Clutch control rod length code 976595 186 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 disc with the reference facing upwards Fasten the clutch disc on the crank shaft with the six screws L...

Page 128: ...Undo and remove the two screws fixing the tool Remove the special tool Place the friction disc centre it Place the clutch bell with the reference facing upwards Engine STELVIO 1200 NTX ENG 128 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 129: ...n stages Head and timing Key 1 Right cylinder head 2 Stud bolt 3 Cylinder head gasket 4 Right rocking 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 STELVIO 1200 NTX Engine ENG 129 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 130: ... 28 Right chain tensioner 29 Left cylinder head 30 Stud bolt 31 Cylinder head gasket 32 Left rocking lever support 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 Camshaft 45 Pin 46 Timing system gear 47 Breather plate 48 TE flanged screw Engine STELVIO...

Page 131: ... BUT APPLY TO BOTH HEADS Disconnect the spark plug tube Unscrew and remove the four head 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 VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING STELVIO 1200 NTX Engine ENG 131 Revent...

Page 132: ...r gear bulkhead For the right head Unscrew and remove the chain ten sioner cap 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 Engine STELVIO 1200 NTX ENG 132 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 133: ... it from the cam shaft Unscrew and remove the four nuts on the stud bolts Remove the complete cam cap Unscrew and remove the two screws Remove the head STELVIO 1200 NTX Engine ENG 133 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 134: ...he cylinder See also Removing the head cover Cylinder head 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 rocking levers from the cam cap Remove the two rods Engine STELVIO 1200 NTX ENG 134 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverk...

Page 135: ...er change them when refitting See 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 FITTING STELVIO 1200 NTX Engine ENG 135 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 136: ...c tooling 10 90 72 00 Tool for valve removal and refitting AP9100838 Tool 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 two cotters 1 are detached screw these cotters until they can be slid off the valve seats unscrew the tool and remove it from the...

Page 137: ... the valve guide must be 0 046 0 075 mm 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 Fitting clearance 0 013 0 040 mm 0 00051 0 00157 in VALVE GUIDE COUPLING VALVES OUTLET Specification Desc Quantity Valve guide inside diameter 5 0 5 012 mm 0 19685 0 1...

Page 138: ...VING 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 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 pre...

Page 139: ...amshaft Fit the two rods WARNING MAKE SURE THAT THE NOTCH ON THE DIPSTICK BODY FACES THE ROCKING LEVER Place the two rocking levers in the cam tower seats STELVIO 1200 NTX Engine ENG 139 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 140: ...aft Place the bowls in the cam tower if those previously removed are 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 tower Tighten the four screws operating di agonally and in stages Engine STELVIO 1200 NTX ENG 140 Revente Interdite Revendita Vietata R...

Page 141: ...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 and remove the two screws Remove the service shaft closing cap STELVIO 1200 NTX Engine ENG 141 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 142: ...kcase 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 closing cap Engine STELVIO 1200 NTX ENG 1...

Page 143: ...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 Installing the service shaft STELVIO 1200 NTX Engine ...

Page 144: ...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 Fit the timing system gear and align the reference with that on the crankshaft gear Turn the crankshaft to align the two gears Engine STELVIO 1200 NTX ENG 144 Reve...

Page 145: ...ar 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 Place the driving pin on the oil pump shaft STELVIO 1200 NTX Engine ENG 145 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 146: ...gn 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 to the prescribed torque See also Installing the crankshaft Installing the service shaft Measuring air gap Engine STELVIO 1200 NTX ENG 146 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 147: ...learance between the fixing plate and the crankcase with a thickness gauge 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 STELVIO 1200 NTX Engine ENG 147 Revente Interdite Revendita Vieta...

Page 148: ...r 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 Left chain tensioner 18 Right chain tensioner Engine STELVIO 1200 NTX ENG 148 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 149: ...ins 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 head Disassembling the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS Remove the cylinder Cover the crankcase opening with a clean cloth Disengage the pin clip Remove the pin STELVIO 120...

Page 150: ...h 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 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 PISTON DIRECTION ACCORDING TO THE REFERENCES MARKED ON THE PISTON CROWN DO NOT A...

Page 151: ...ew 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 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...

Page 152: ...t 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 so that the 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 Undo the screw which will be used to time the upper gear Engine STELVIO 1200 NTX ENG 1...

Page 153: ...otion 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 Fit the movable chain slider Fit the upper gear Fit the chain tensioner cap temporarily and keep the chain taut on the service...

Page 154: ...d 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 ENG 154 Revente Interdite Revendita Vietata Resaling Forbiden Wiederv...

Page 155: ...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 by 90 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 cylin...

Page 156: ...On the 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 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 ...

Page 157: ...ing 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 Tighten the four screws to the prescri bed torque Place the spark plug tube STELVIO 1200 NTX Engine ENG 157 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 158: ...ng 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 crankshaft flange Remove the sealing ring from the flange if necessary Specific tooling 12 91 36 00 Tool to remove the flywheel side flange Engine STELVIO 1200 NTX ENG 158 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Ve...

Page 159: ...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 See also Removing the flywheel Disassembling the piston Removing the cylinder Removing the cylinder head STELVIO 1200 NTX Engine ENG 159 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 160: ...ation Desc Quantity Blue bushing half shell regular production 44 008 44 014 mm 1 73259 1 73283 in Red bushing half shell regular production 44 014 44 020 mm 1 73283 1 73307 in BALANCING SELECTION COLOURS 2 Specification Desc Quantity Crankshaft selection colour 2 brown Type 1 to be used with brown connecting rods Balance with a 1558 g 54 96 oz 0 25 weight fitted on the crankpin B Maximum imbalanc...

Page 161: ... 10 mm 0 00393 inch CONNECTING ROD BEARING THICKNESS Specification Desc Quantity Regular Blue connecting rod bearing production 1 539 1 544 mm 0 06059 0 06079 in Regular Red connecting rod bearing production 1 535 1 540 mm 0 06043 0 06063 in CRANKPIN DIAMETER B Specification Desc Quantity Blue bushing half shell regular production 44 008 44 014 mm 1 73259 1 73283 in Red bushing half shell regular ...

Page 162: ... rods the two pins must be facing the crankcase internal side Place the connecting rods and the caps B on the crankshaft and fasten them with new screws A Remember these recommendations The screws fixing the connecting 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 ro...

Page 163: ...e sealing ring on the flange Specific tooling 19 92 71 00 Tool to fit the sealing ring on the flywheel side flange Fit a new gasket between the crankcase and the crankshaft flange 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 1...

Page 164: ...t oil leaks Screw the eight flange screws on the flywheel 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 sealing ring on the crankshaft To avoid that the shim washer inside the crankcase moves out of its seat fit the two gears and the nut on the crank shaft on the generator side En...

Page 165: ... two new of the same type Check that the O ring is fitted on the jets Do not interchange them upon refitting because they have a different length Lubrication Conceptual diagrams Key STELVIO 1200 NTX Engine ENG 165 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 166: ...rom the sump through the filter 12 the oil is sent to the radiator 1 through the hoses 3 Oil passes through the radiator 1 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 t...

Page 167: ...n upon 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 remove the driven gear nut Collect the washer Remove the oil pump driven gear Remove the driving pin STELVIO 1200 NTX Engine ENG 167 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverk...

Page 168: ...the oil pump 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 Engine STELVIO 1200 NTX ENG 168 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 169: ...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 the specified torque STELVIO 1200 NTX Engine ENG 169 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 170: ...TABLE 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 oil level plug and collect the O Ring Engine STELVIO 1200 NTX ENG 170 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 171: ...e fourteen screws fixing the oil sump to the engine crank case Undo and remove the four screws Remove the flange STELVIO 1200 NTX Engine ENG 171 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 172: ...rew 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 1200 NTX ENG 172 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 173: ...ve compo nents correctly Screw the pressure relief valve plug Place the thermostatic valve CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED STELVIO 1200 NTX Engine ENG 173 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 174: ...new gasket between the crank case and the flange Fit the flange Fix the flange with the four screws Fit the lubrication oil intake filter Engine STELVIO 1200 NTX ENG 174 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 175: ...ix both filters and tighten the two screws to the prescribed torque Fit a new oil filter and tighten it to the prescribed torque Place a new gasket between the flange and the sump STELVIO 1200 NTX Engine ENG 175 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 176: ... oil sump Tighten the fourteen screws to the pre scribed torque Add engine oil up to the correct level Engine STELVIO 1200 NTX ENG 176 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 177: ...INDEX OF TOPICS POWER SUPPLY P SUPP Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 178: ...rcuit diagram Key 1 Complete fuel pump unit 2 Nut 3 Fuel pipe 4 Pipe 5 Screw Injection Power supply STELVIO 1200 NTX P SUPP 178 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 179: ... 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 Power supply P SUPP 179 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 180: ... bodies should be placed on the right Cylinders synchronisation With engine off connect the Axone 2000 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 P SUPP 180 Revente Interdite Revendita Vieta...

Page 181: ... 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 prescribe 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 kPa maximum If this condition is detected ...

Page 182: ... 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 Axone 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 1010 hPa throttle valve pote...

Page 183: ...ilter 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 value Atmospheric p...

Page 184: ...ehicle systems for example lamb da probe functioning status DEVICE STATUS 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 expanded indicates the position of the side stand only with gear engaged IGNITION Enabled disabled indicates if the control uni...

Page 185: ...ed in the control unit MEM and it allows to check error clearing STO ERRORS DISPLAY Specification Desc Quantity Pressure sensor Possible short circuit in the earth lead battery or open circuit recovery function noticeable for customer Careful with the air pressure sensor in the instrument panel Air temperature Possible short circuit in the earth lead battery or open circuit recovery function hardl...

Page 186: ...d battery or lambda probe heating circuit open SPEED SENSOR Possible short circuit in the earth lead battery or speed sensor circuit open also possible lack of supply from the control unit CAN line diagnosis Possible error on the CAN line short circuit or line break or no signal or plausibility error detected RAM memory Possible internal control unit error Also check the control unit supply and ea...

Page 187: ...INDEX OF TOPICS SUSPENSIONS SUSP Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 188: ...part of the vehicle Unscrew and remove the nut fixing the wheel bolt and collect the sealing ring Working from both sides loosen the screws on the wheel bolt clamps Hit the wheel pin slightly with a rubber hammer so that the hole on the oppo site side is exposed Suspensions STELVIO 1200 NTX SUSP 188 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 189: ...the bolt holes Upon extracting the wheel hold it and then remove it Collect the spacer from the front wheel right side Front fork Diagram Key STELVIO 1200 NTX Suspensions SUSP 189 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 190: ...12 TCE screw 13 Base with headstock 14 Right sleeve cap 15 Left sleeve cap 16 O ring 17 O ring 18 Washer 19 Snap ring 20 O ring 21 Complete sleeve 22 Spring holder cap 23 Spring guide 24 Preloading pipe 25 Spring guide 26 Spring 27 Bushing 28 Dust guard 29 Snap ring 30 Sealing ring 31 Cap 32 Bushing Suspensions STELVIO 1200 NTX SUSP 190 Revente Interdite Revendita Vietata Resaling Forbiden Wiederv...

Page 191: ...ghten clockwise 7 turns from fully open Spring preloading nut 1 maximum load conditions tighten clockwise 7 turns from fully open Rebound damping right stem set screw 2 regular load con ditions unscrew anticlockwise 2 turns from fully closed Rebound damping right stem set screw 2 half load condi tions unscrew anticlockwise 2 turns from fully closed Rebound damping right stem set screw 2 maximum lo...

Page 192: ...tem and loosen the screws on the upper and then the lower plate Remove the fork stem See also Removing 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 Suspensions STELVIO 1200 NTX SUSP 192 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Ve...

Page 193: ...ool under the pumping member lock nut and on the bushing to keep the spring compressed Remove the whole cap Press down and force the spring to compress Remove the tool Remove the bushing STELVIO 1200 NTX Suspensions SUSP 193 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 194: ...ns 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 SUSP 194 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 195: ... stem Block the wheel holder sleeve with a vice Unscrew the bottom screw and remove it together with its gasket Remove the pumping member STELVIO 1200 NTX Suspensions SUSP 195 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 196: ...le doing this Remove the snap ring Take out the sleeve from the stem us ing the stem as a hammer puller From the stem remove the fixed fitted bushing the movable bushing the ring and the oil seal Suspensions STELVIO 1200 NTX SUSP 196 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 197: ...in 1 If the scorings are deep replace the stem Use a dial gauge to check that the stem bending is below the limit value If over the value replace the stem CAUTION A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic STELVIO 1200 NTX Suspensions SUSP 197 Revente Interdite Revendita Vietata Resaling Forbiden Wieder...

Page 198: ...od conditions upper bushing lower bushing pumping member pin If there are signs of excessive wear or damage replace the affected component CAUTION REMOVE ANY IMPURITY IN THE BUSHINGS TAKING CARE NOT TO SCRATCH THEIR SUR FACE Replace the following components with new ones sealing ring Suspensions STELVIO 1200 NTX SUSP 198 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 199: ...urface 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 Suspensions SUSP 199 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 200: ... 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 SUSP 200 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 201: ...ems Fit the sleeve on the stem and with the specified tool fit the oil seal into posi tion Specific tooling AP8140758 tool to fit oil seals and dust guards for ø 50 mm 1 97 in stems AP8140146 Weight Insert the retainer ring in its position STELVIO 1200 NTX Suspensions SUSP 201 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 202: ...to the prescri bed torque 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 1200 NTX SUSP 202 Revente Interdite Reven...

Page 203: ... tooling AP8140149 Protection for fitting operations Characteristic Oil level from sleeve rim without the spring and preloading pipe 110 mm 4 33 in 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 Suspensions SUSP 203 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 204: ...Screw the upper cap on the pumping member stem Remove the tool to compress the spring Place the 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 Suspensions STELVIO 1200 NTX SUSP 204 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 205: ...talling the fork legs Insert the fork stem in position Insert the wheel pin so that the stems are aligned Tighten the screws on the fork plates to the prescribed torque STELVIO 1200 NTX Suspensions SUSP 205 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 206: ...lutch and front brake tanks does not spill out Working on both sides unscrew and remove the upper plate fixing screw on 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 Suspensions STELVIO 1200 NTX SUSP 206 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 207: ...ve the upper ring nut Specific tooling AP8140190 Tool for steering tightening Remove the safety washer Using the suitable special tool set the preloading of the steering bearings Specific tooling AP8140190 Tool for steering tightening STELVIO 1200 NTX Suspensions SUSP 207 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 208: ...ng Rivet the tongues of the new safety washer Fit the fork upper plate 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 Suspensions STELVIO 1200 NTX SUSP 208 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbo...

Page 209: ...senger and luggage CAUTION SET SPRING PRELOADING AND SHOCK ABSORBER REBOUND DAMPING ACCORDING TO THE VEHICLE USE CONDITIONS IF THE SPRING PRELOADING IS INCREASED IT IS NECES SARY TO INCREASE THE REBOUND DAMPING ACCORDINGLY TO AVOID SUDDEN JERKS WHEN RIDING IF NECESSARY CONTACT AN Official Moto Guzzi Dealer TRY RIDING THE VE HICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED SHOCK ABSORBE...

Page 210: ...IN THE TABLE MAY NEED TO BE MODIFIED ACCORDING TO THE TYRE AND ROAD TYPE NOTE 2 IF FITTED Removing Park the vehicle 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 SUSP 210 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf V...

Page 211: ...INDEX OF TOPICS CHASSIS CHAS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 212: ...e 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 Remove the rear wheel Unscrew and remove the two screws Remove the speed sensor from the fork Chassis STELVIO 1200 NTX CHAS 212 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 213: ...hassis with a clamp Remove the clamp from the dust guard cap Loosen the two swingarm terminal screws Unscrew and remove the fixing nut of the connecting rod assembly and col lect the screw STELVIO 1200 NTX Chassis CHAS 213 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 214: ... joint are not deformed or damaged otherwise replace the joint Check that the rubber bellows are not cut or pierced otherwise replace it Check that the fork pin threads and the fork fixing nuts are not damaged de formed or flattened otherwise replace them Check that the sleeve grooves are not damaged deformed or deteriorated otherwise replace the sleeve Check that the sleeve outer toothing and gro...

Page 215: ...ble Block the swingarm insert the univer sal joint align the holes and at the same time helped by a second opera tor insert the pin completely Tighten the swingarm pin Use the suitable box spanner to tight en the ring nut Specific tooling 05 91 26 30 Tool for tightening the swingarm pin ring nut clutch hub Tighten the two swingarm terminal screws STELVIO 1200 NTX Chassis CHAS 215 Revente Interdite...

Page 216: ...d assembly on the swingarm Insert the screw Tighten the fixing nut of the connecting rod assembly Place the 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 Chassis STELVIO 1200 NTX CHAS 216 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 217: ...speed sensor from the fork Unscrew and remove the nut fixing the reaction rod Remove the screw Fasten the reaction rod to the chassis with a clamp Undo and remove the four screws STELVIO 1200 NTX Chassis CHAS 217 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 218: ... slid ing off the universal joint Checking Casing unit removal Remove the cover 20 Remove the plug 3 to drain out the oil Chassis STELVIO 1200 NTX CHAS 218 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 219: ...the cap 10 Remove the clamps 9 and 11 Remove the cap 14 Remove the screws 16 Collect the ring 15 STELVIO 1200 NTX Chassis CHAS 219 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 220: ...ove the screws 7 Remove the casing 4 Remove the clamp 12 Remove the cap 14 Collect the ring 13 Chassis STELVIO 1200 NTX CHAS 220 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 221: ...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 STELVIO 1200 NTX Chassis CHAS 221 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 222: ...e casing Assemble the cap and the ring Fit the cap on the support Fit the clamp Screw the clamp with the specific pliers Chassis STELVIO 1200 NTX CHAS 222 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 223: ...ubricate the sealing ring Assemble 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 STELVIO 1200 NTX Chassis CHAS 223 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 224: ...ve excessive sealant Assemble the ring to the casing Tighten the fixing screws to the prescribed torque Fit the cap with the washer Screw the cap to the prescribed torque Chassis STELVIO 1200 NTX CHAS 224 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 225: ...transmission with the prescribed oil 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 Wheel axle unit STELVIO 1200 NTX Chassis CHAS 225 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 226: ...Turn the unit over Remove the bearing from the wheel axle with a suitable extractor FITTING Heat the bearings to 100 C 212 F Assemble the bearings to the wheel axle Chassis STELVIO 1200 NTX CHAS 226 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 227: ...ng 1 from the ring nut Unscrew the ring nut 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 STELVIO 1200 NTX Chassis CHAS 227 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 228: ...5855 see Fig 1 and a ham mer Lubricate the sealing ring 3 Assemble the ring nut 2 Tighten the ring nut 2 with the special spanner s4 to the prescribe torque Chassis STELVIO 1200 NTX CHAS 228 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 229: ...t 2 in the in dicated direction Assembly position of the stop ring 1 CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT Support unit STELVIO 1200 NTX Chassis CHAS 229 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 230: ...bushing 8 Remove the sealing 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 Chassis STELVIO 1200 NTX CHAS 230 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 231: ...6 in the support 5 with suitable pliers Turn the support 5 over Assemble the ball joint 4 with the buffer and a rubber hammer Fit the stop ring 3 in the support 5 with suitable pliers STELVIO 1200 NTX Chassis CHAS 231 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 232: ...as been fitted 3 Plug not tightened to the prescribed torque 1 Clean and tighten to the correct torque 2 Replace the sealing ring 3 Tighten the plug to the correct torque 1 Cap damaged 2 Retaining clamp or closing cover loose 3 Fitting error of the radial seal or seal damaged 4 Sliding sur face of the wheel spacer spoiled or damaged 1 Replace the cap 2 Screw the clamp with suitable pliers 3 Replac...

Page 233: ...ue 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 and the cardan shaft taking care to mount it with the collar facing the transmission unit STELVIO 1200 NTX Chassis CHAS 233 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 234: ...ghten 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 Exhaust key 1 Right exhaust pipe 2 Left exhaust pipe Chassis STELVIO 1200 NTX CHAS 234 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 235: ...p 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 Undo and remove the screw and col lect the nut and the washer STELVIO 1200 NTX Chassis CHAS 235 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 236: ...da probe See also Removing the exhaust manifold Removing the tail pipe Removing the exhaust manifold The engine and the exhaust system components get very hot and remain in this condition for a certain time interval 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 dow...

Page 237: ... stud bolts Retrieve the washers Loosen the clamp Remove the exhaust manifold Engine oil cooler Key 1 Complete oil radiator 2 TE flanged screw STELVIO 1200 NTX Chassis CHAS 237 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 238: ...il filter Operating from both sides unscrew and remove both screws 1 Remove the oil sump guard 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 CHAS 238 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 239: ...evel 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 as required STELVIO 1200 NTX Chassis CHAS 239 Re...

Page 240: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 241: ...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 STELVIO 1200 NTX Braking system BRAK SYS 241 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 242: ...ront left brake calliper 3 Pads 4 Air bleed 5 Air bleed cap 6 Pins Calliper springs 7 Spring 8 Aluminium gasket 9 Screw Front brake pads Braking system STELVIO 1200 NTX BRAK SYS 242 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 243: ...ff the brake calliper from the disc Turn the pins and remove both split pins Remove both pins Remove the vibration damping plate STELVIO 1200 NTX Braking system BRAK SYS 243 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 244: ...igned 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 Braking system STELVIO 1200 NTX BRAK SYS 244 Revente Interdite Revendi...

Page 245: ...wo screws Remove the brake calliper from the disc Turn the pin and pull out the split pin Remove the split pin Remove the pin STELVIO 1200 NTX Braking system BRAK SYS 245 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 246: ...at 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 Abut the plungers against the pads acting on the brake pump pedal sever al times Check the brake fluid level in the res ervoir Braking system STELVIO 1200 NTX BRAK SYS 246 Revente Interdite Revendita Vietata Resalin...

Page 247: ...BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Remove the rubber protection cover from the bleed valve Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con tainer to collec...

Page 248: ...LAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED NOTE THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAUL IC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESER VOIR Remove the rubber protection cover from the bleed valve Insert the transparent plastic pipe in the rear brake...

Page 249: ...move the pipe Top up the reservoir until the right brake fluid level is obtained Refit and lock the rear brake fluid reservoir cap Refit the protective rubber cap STELVIO 1200 NTX Braking system BRAK SYS 249 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 250: ...INDEX OF TOPICS BODYWORK BODYW Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 251: ... KEY HAS NOT BEEN LEFT INSIDE THE GLOVE BOX TOOLKIT COMPARTMENT 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 AND LEVEL GROUND 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...

Page 252: ...d Remove the TCEI screw 5 M8x60 in the engine guard front section with the corresponding washer Remove the screw 6 Remove the hexagonal stud bolt 7 with the corresponding washer Remove the left engine guard Bodywork STELVIO 1200 NTX BODYW 252 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 253: ...the corresponding washer Remove the TCEI screws 10 M8x40 in the lower part of the engine guard Remove the right engine guard Instrument panel Undo and remove the four screws STELVIO 1200 NTX Bodywork BODYW 253 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 254: ...E OPERATING ACCORDING TO THE FOLLOWING INSTRUCTIONS PARK THE VEHICLE ON STAND ON FIRM AND LEVEL GROUND Remove the screws 1 Remove the screws 2 Remove the complete support 3 NOTE FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER Bodywork STELVIO 1200 NTX BODYW 254 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 255: ...fairings Remove the screw M8x20 and be careful to collect the washer and the nut NOTE FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER Rider footrest plate LEFT SIDE Undo and remove the upper screw and collect the washer and the nut STELVIO 1200 NTX Bodywork BODYW 255 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 256: ...collect the washer and the spacer Disconnect the gearbox rod and re lease the spring Remove the left footrest holding plate RIGHT SIDE Undo and remove the upper screw and collect the washer and the nut Bodywork STELVIO 1200 NTX BODYW 256 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 257: ...Disconnect the connectors of the rear brake lever switch and the speed sen sor Release the cable harness from the clamps Undo and remove the two rear lower screws collect the washers and the spacer STELVIO 1200 NTX Bodywork BODYW 257 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 258: ...the brake fluid reservoir in vertical position Side fairings Remove the fuel tank upper fairing Unscrew and remove the two screws Working from both sides undo and re move the screw Working from both sides undo and re move the screw Bodywork STELVIO 1200 NTX BODYW 258 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 259: ...o and remove the two front screws Operating from both sides undo and remove the internal screw and collect the washer and the nut Unscrew and remove the two screws STELVIO 1200 NTX Bodywork BODYW 259 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 260: ...des disconnect the turn indicator connector Slightly detach the fairing Disconnect the front headlight connec tors releasing the cable harness from the clamps Remove the fairing together with the front headlight Bodywork STELVIO 1200 NTX BODYW 260 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 261: ...d 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 STELVIO 1200 NTX Bodywork BODYW 261 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 262: ...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 Bodywork STELVIO 1200 NTX BODYW 262 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 263: ...ee also Seat Sump guard ENSURE THAT THE ENGINE AND THE THERMAL PARTS OF THE VEHICLE ARE COLD BEFORE OPERATING AC CORDING TO THE FOLLOWING INSTRUCTIONS PARK THE VEHICLE ON STAND ON FIRM AND LEVEL GROUND STELVIO 1200 NTX Bodywork BODYW 263 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 264: ...k cap Cover the tank fill opening with a clean cloth so that no foreign bodies can come in Undo and remove the four screws Remove the cap FUEL TANK COVER Remove the rider saddle Operating from both sides undo and remove the three screws Collect the rubber rings of the rear screws Remove the fuel tank cover See also Seat Bodywork STELVIO 1200 NTX BODYW 264 Revente Interdite Revendita Vietata Resali...

Page 265: ...he fuel tank cover Working from both sides undo and re move the screw Unscrew and remove the front screw fixing the tank Operating from both sides undo and remove the two screws STELVIO 1200 NTX Bodywork BODYW 265 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 266: ...Seat FUEL TANK Remove the tank side fairings Disconnect the glove box opening control connector Undo and remove the two rear screws and collect the washers Undo and remove the two front screws Bodywork STELVIO 1200 NTX BODYW 266 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 267: ...ve the countersunk head screw 14 and collect the bushings 11 and 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 STELVIO 1200 NTX Bodywork BODYW 267 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 268: ... Remove the spacers 6 and 8 Remove the components 11 to 16 from both supports Bodywork STELVIO 1200 NTX BODYW 268 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 269: ...INDEX OF TOPICS PRE DELIVERY PRE DE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 270: ...n 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 Horn Electric start up Engine stop...

Page 271: ...ITH ABUNDANT WATER FOR AP PROX 15 MIN AND SEEK MEDICAL ATTENTION IMMEDIATELY IF ACCIDENTALLY SWALLOWED IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR VEGETABLE OIL SEEK MEDICAL ATTENTION IMMEDIATELY BATTERIES PRODUCE EXPLOSIVE GASES KEEP CLEAR OF NAKED FLAMES SPARKS OR CIGARETTES VENTILATE THE AREA WHEN RECHARGING INDOORS ALWAYS WEAR EYE PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES KEEP O...

Page 272: ...aking 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 EXCEED THE RECOMMENDED INFLATION PRESS...

Page 273: ... 237 F Fork 189 192 195 199 205 Forks 112 Fuel 84 118 264 Fuses 57 G Gearbox oil 35 I Identification 10 Instrument panel 79 253 M Maintenance 8 31 O Oil filter 34 R Recommended products 22 216 S Shock absorber Shock absorbers 209 Stand 77 Start up 55 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 274: ...T Tank 84 118 264 Transmission 12 31 Tyres 14 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

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