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MOTO GUZZI Stelvio 1200 NTX, Service Station Manual

The MOTO GUZZI Stelvio 1200 NTX is a powerful and reliable adventure bike designed to tackle any terrain. To maintain its optimal performance, it's essential to have the Service Station Manual at hand for routine maintenance. Download this comprehensive manual for free from manualshive.com, ensuring you have all the information you need at your fingertips.

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Key:

1. Complete clutch

2. Clutch

3. Clutch bell

4. TCEI screw

5. Clutch disc

6. Crown

7. TCEI screw

8. Clutch pressure plate

9. Ring

10.TE flanged screw

11.Conical washer

12.Bushing

13.Rod

14.Bushing

15.Intermediate body

16.Thrust bearing

17.Clutch control bowl

18.Thrust cylinder

19.Clutch control cylinder

20.TE flanged screw

Engine

Stelvio 1200 NTX ABS

ENG - 128

Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Summary of Contents for Stelvio 1200 NTX

Page 1: ...SERVICE STATION MANUAL 981138 Stelvio 1200 NTX ABS ...

Page 2: ...e 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 ...

Page 3: ...e 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: ...HICH 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 oil...

Page 8: ...LOWED 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 ELECTROLYT...

Page 9: ...rd 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 r...

Page 10: ...RTANT 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 the...

Page 11: ...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 weigh...

Page 12: ...l 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 c...

Page 13: ...n 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 155 mm 6 10 in SIZES A AN...

Page 14: ...th 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 injection ...

Page 15: ...9 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 Loctit...

Page 16: ... 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 retaine...

Page 17: ...0 Nm Swingarm on bevel gear pair retainer 50 Nm Reaction rod to bevel gear pair retainer 50 Nm Reaction rod to chassis retainer 50 Nm Swingarm bolt to swingarm retainer 60 Nm Preloading 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 retain...

Page 18: ...r U bolts on steering upper plate 50 Nm Retainer for handlebar upper U bolts 25 Nm Anti vibration counterweight 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 ret...

Page 19: ...Cases support retainer M8 2 2 25 Nm 18 44 lbf ft Passenger grab handle to chassis retainer 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 cl...

Page 20: ...051 0 00087 in Piston rings On each piston there are 1 top piston 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...

Page 21: ...ge 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 Service ...

Page 22: ...e 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 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 ...

Page 23: ... 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 Stelvio 1200 NTX ABS Characteristics CHAR 23 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 24: ...INDEX OF TOPICS SPECIAL TOOLS S TOOLS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 25: ...nsertion cone 020716Y Connecting rod locking 020470Y Pin snap ring fitting tool 05 92 72 30 Timing system cover sealing ring punch 01 92 91 00 Wrench for removing the cover on sump and filter Stelvio 1200 NTX ABS Special tools S TOOLS 25 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 26: ...gnition 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 Special tools Stelvio 1200 NTX ABS S TOOLS 26 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 27: ... 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 Stelvio 1200 NTX ABS Special tools S TOOLS 27 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

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

Page 29: ...arbox oil seal buffer 05 90 27 32 Buffer handgrip 05 90 27 33 Ball joint sealing buffer 05 90 27 34 Wrench for pinion ring nut 05 90 27 35 Pinion oil seal buffer Stelvio 1200 NTX ABS Special tools S TOOLS 29 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 30: ...es 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 Special tools Stelvio 1200 NTX ABS S TOOLS 30 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 31: ...INDEX OF TOPICS MAINTENANCE MAIN Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 32: ... 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 R ...

Page 33: ... 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 drainage...

Page 34: ... 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 orde...

Page 35: ... 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 FILTER ...

Page 36: ...s 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 th...

Page 37: ...h 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 COMPRESS...

Page 38: ...059 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 r...

Page 39: ...w 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 WIT...

Page 40: ...ARK 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 Maintenance Stelvio 1200 NTX ABS MAIN 40 Revente Interdite Revendita Vietata Resaling Forbiden...

Page 41: ...INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 42: ...Components arrangement key 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector Electrical system Stelvio 1200 NTX ABS ELE SYS 42 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 43: ...nsor 21 Auxiliary fuses 22 Relay 23 Additional headlamps 24 ABS Control unit 25 Rear speed sensor 26 ABS Fuses 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...

Page 44: ... turning the steering the instrument panel is damaged 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 Electrical system Stelvio 1200 NTX ABS ELE SYS 44 Reven...

Page 45: ...ight cable 3 the left turn indicator 4 and the TOM TOM cable 5 Clamp the heated handgrips cable Stelvio 1200 NTX ABS Electrical system ELE SYS 45 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 46: ...UT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION CENTRAL SECTION TABLE A CORRECT FITTING OF THE ALTER NATOR CABLE The red cable of the alternator must be in upright position Electrical system Stelvio 1200 NTX ABS ELE SYS 46 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 47: ... handgrips must come out under the beam and be clam ped Pass the cable harness under the beam TABLE C POSITION OF THE FUEL PUMP CA BLE HARNESS Clamp the cable at the front to obtain the correct position Stelvio 1200 NTX ABS Electrical system ELE SYS 47 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 48: ...tud bolt nut to 10Nm 7 37 lbf ft TABLE E BATTERY COMPARTMENT HOUS ING The battery housing must be free of any connections or pipes in order to allow perfect fitting Back side CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED CARRY OUT THE CHECKS INDICATED UNDER SPE Electrical system Stelvio 1200 NTX ABS ELE SYS 48 Revente Interdite Revendit...

Page 49: ...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 keeping the main system be tween the plate and the mudflap Connect the recharge cable and place it as in the photo REAR SECTION TABLE C REAR SYSTEM RETAINER Pay attention to the position of the U bolt adhesive ...

Page 50: ...Electrical system Stelvio 1200 NTX ABS ELE SYS 50 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 51: ...gram key 1 Multiple connectors 2 Clutch switch 3 Start up relay 4 Start up maintenance relay Stelvio 1200 NTX ABS Electrical system ELE SYS 51 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 52: ...tch 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 Oxygen sensor 35 Side stand switch 36 Fuel reserve sensor 37 Fuel pump 38 Intake air temperature thermistor 39 Head temperature thermistor 40 Automatic air ...

Page 53: ...lb 2 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 63 ABS CONTROL UNIT 64 ABS diagnosis connector 65 Front speed sensor 66 Rear speed sensor 67 ABS main fuses 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 Stelvio 1200 N...

Page 54: ...the second key the new code is required with the message ENTER NEW CODE Once the operation is finished the instrument panel goes back to the SET UP menu DIAGNOSIS Access to this menu diagnosis functions for the technical service only after requesting a service code It will read ENTER THE SERVICE CODE This vehicle code is 10695 The functions in this menu are Exit ECU diagnosis Instrument Panel Erro...

Page 55: ...56 Stepper Error AC ECU 60 Stepper Error DC V DC ECU 61 Stepper Error DC Gnd ECU 62 Not recognised error ECU 00 INSTRUMENT PANEL ERRORS In this mode a chart is displayed showing potential errors in the immobilizer and its sensors This is the error decoding chart Description Immobilizer failure Key code read but not recognised Error code DSB 01 Description Immobilizer failure Key code not read Key ...

Page 56: ...a Moto Guzzi package to connect to the Axone cable KEY CHANGE FUNCTION This function can be used 1 if one key is lost the dealer can disable this key 2 to activate up to 4 keys 3 should a new key lock be necessary and thus program the new set of keys In the first phase the user code must be entered and after confirming the inserted key key I has been programmed the other keys must be entered too T...

Page 57: ... Ohm with fuel level equal to 0 litre 100 Ohm with fuel level equal to 11 25 litres 20 43 pt 10 20 Ohm with fuel level equal to 22 5 litres 40 86 pt The low fuel warning light turns on with values over 230 Ohm In case there is anomaly on the fuel probe the low fuel warning light flashes on the instrument panel The alarm warning light on the instrument panel does not light up and the word Service i...

Page 58: ... 12 V 55 W 60 W H4 REAR LIGHT Specification Desc Quantity Tail light 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 ABS ELE SYS 58 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 59: ...on lighting coils light relay passing 15 A B Tail lights starter motor 15 A C Live positive ABS power supply 10A D Fuel pump coils injectors 15 A D Lambda burner speed sensor auxiliary injec tion relay coil start up relay coil 15 A F Permanent positive ECU power supply 3A NOTE THERE ARE TWO SPARE FUSES Stelvio 1200 NTX ABS Electrical system ELE SYS 59 Revente Interdite Revendita Vietata Resaling F...

Page 60: ...0 Right cylinder coil control 11 Not used 12 Not used 13 Not used 14 Air temperature signal 15 Not used 16 Not used 17 Stepper motor 18 Stepper motor 19 Stepper motor 20 5V power supply NTC sensors 21 Not used 22 Not used 23 Neutral sensor signal 24 Not used 25 Engine revolution sensor signal 26 Not used Electrical system Stelvio 1200 NTX ABS ELE SYS 60 Revente Interdite Revendita Vietata Resaling...

Page 61: ...2 Not used 3 Not used 4 Power supply protected from instrument panel 5 Not used 6 Pin 86 auxiliary relay control 7 Immobilizer line 8 Pin 85 ignition relay control 9 Not used 10 Not used 11 Oxygen probe negative control 12 Not used 13 Not used 14 Not used 15 Not used 16 K line diagnosis 17 Power supply from main relay 18 Not used 19 Not used 20 CAN H line ccm instrument panel 21 Not used 22 Oxygen...

Page 62: ...mp supply 2 Not used 3 Not used 4 ABS warning light check 5 Not used 6 Not used 7 Not used 8 Not used 9 Not used 10 Not used 11 Not used 12 Not used 13 Ground connection 14 Not used 15 Not used 16 Speed signal for injection ECU 17 Axone 18 Not used 19 Not used 20 Rear ABS speed sensor supply 21 Front ABS speed sensor supply 22 Front ABS speed sensor signal ground Electrical system Stelvio 1200 NTX...

Page 63: ...ction Battery 12 V 18 Ampere hour Engine rpm sensor Function Informs crankshaft position and speed to the Mar elli control unit Operation Operating principle Inductive sensor sinusoidal type generated volt age two teeth are missing on the flywheel for the reference position Level in wiring diagram Revolution sensor Stelvio 1200 NTX ABS Electrical system ELE SYS 63 Revente Interdite Revendita Vieta...

Page 64: ...A BROWN Check the sensor connector and the injection control 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 d...

Page 65: ...S 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 ELECTR...

Page 66: ...round 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 operat...

Page 67: ... 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 BEGINNING ...

Page 68: ...ce 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 electric...

Page 69: ...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 shoul...

Page 70: ...eater 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 clos...

Page 71: ...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 check ...

Page 72: ...ever 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 activat...

Page 73: ... 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 h...

Page 74: ...t 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 c...

Page 75: ... 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 displayed...

Page 76: ...cuit 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 t...

Page 77: ...nsor 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 BROWN ...

Page 78: ...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 bro...

Page 79: ...nsor 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 continuit...

Page 80: ...ct 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 is ...

Page 81: ...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 connec...

Page 82: ...ion 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 s...

Page 83: ...ue 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 P...

Page 84: ... 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 ABS ELE SYS 84 Revente Interdite Revendita Vi...

Page 85: ...INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 86: ...r 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 cylin...

Page 87: ...d 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 ABS Engine from vehicle ENG VE 87 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 88: ...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 ABS ENG VE 88 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 89: ...s Working from both sides undo and re move the three inlet manifold screws Collect the gasket Disconnect the alternator connectors Stelvio 1200 NTX ABS Engine from vehicle ENG VE 89 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 90: ...olution 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 ABS ENG VE 90 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 91: ...asher 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 ABS Engine from vehicle ENG VE 91 Revente Interdite Revend...

Page 92: ...nect 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 Stelvio...

Page 93: ... 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 ABS Engine from vehicle ENG VE 93 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verb...

Page 94: ...amp 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 ABS ENG VE 94 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 95: ...olt Fit the starter motor cover Tighten the screws Connect the neutral sensor connector Connect the alternator connectors Stelvio 1200 NTX ABS Engine from vehicle ENG VE 95 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 96: ...nect the horn connectors Connect the engine temperature sen sor connector Place the oil radiator Tighten the two screws Engine from vehicle Stelvio 1200 NTX ABS ENG VE 96 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 97: ... 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 ABS Engine from vehicle ENG VE 97 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 98: ...INDEX OF TOPICS ENGINE ENG Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 99: ...Gearbox Diagram Key 1 Ball bearing Stelvio 1200 NTX ABS Engine ENG 99 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 100: ...ng 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 ABS ENG 100 Revente Interdite Revendita Vietata Resaling Forbiden Wie...

Page 101: ...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 ABS Engine ENG 101 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

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

Page 103: ...screws Undo and remove the screw Remove the gearbox See also Removing the starter motor Replacement Gearbox shafts Stelvio 1200 NTX ABS Engine ENG 103 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

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

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

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

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

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

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

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

Page 111: ...ll 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 ABS Engine ENG 111 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 112: ...g 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 ABS ENG 112 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 113: ...d 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 an...

Page 114: ...mission 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 SEALIN...

Page 115: ...ox 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 le...

Page 116: ...pacer 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 ABS ENG 116 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 117: ...at 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 ABS Engine ENG 117 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 118: ...oosen 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 ABS ENG 118 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 119: ...do and remove the eight screws Undo and remove the two screws Undo and remove the two screws Stelvio 1200 NTX ABS Engine ENG 119 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

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

Page 121: ... 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 ABS Engine ENG 121 ...

Page 122: ...r 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 ABS ENG 122 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

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

Page 124: ... 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 ABS ENG 124 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 125: ...r 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 ABS Engine ENG 125 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 126: ...he clutch Remove the complete gearbox Undo and remove the six screws Remove the start up crown gear Remove the clutch bell and the friction disc Engine Stelvio 1200 NTX ABS ENG 126 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 127: ...ressure plate Undo and remove the six screws and collect the belleville springs Remove the clutch disc See also Removing the gearbox Stelvio 1200 NTX ABS Engine ENG 127 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 128: ...e 9 Ring 10 TE flanged screw 11 Conical washer 12 Bushing 13 Rod 14 Bushing 15 Intermediate body 16 Thrust bearing 17 Clutch control bowl 18 Thrust cylinder 19 Clutch control cylinder 20 TE flanged screw Engine Stelvio 1200 NTX ABS ENG 128 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 129: ...ECTION Specification Desc Quantity Protrusion 9 8 11 2 mm 0 386 0 441 in Clutch control rod length code 976593 183 mm 7 205 in Protrusion 8 3 9 7 mm 0 327 0 382 in Clutch control rod length code 976594 184 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...

Page 130: ...tooling 020672Y Clutch spring centre and pusher Once the centring tool is fitted lock the plate with the snap ring Undo and remove the two screws fixing the tool Remove the special tool Place the friction disc centre it Engine Stelvio 1200 NTX ABS ENG 130 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 131: ...wn gear with the reference facing upwards Tighten the six screws to the prescri bed torque operating diagonally and in stages Head and timing Key 1 Right cylinder head Stelvio 1200 NTX ABS Engine ENG 131 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 132: ...TE flanged screw 21 O ring 22 Complete breather cover 23 TBEI screw 24 Timing system chain 25 Chain guide slider 26 Chain tensioner pad 27 Chain tensioner screw 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 ...

Page 133: ...rew 52 Timing system chain 53 Chain guide slider 54 Chain tensioner pad 55 Chain tensioner screw 56 Left chain tensioner 57 Spacer Removing the head cover NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS Disconnect the spark plug tube Stelvio 1200 NTX ABS Engine ENG 133 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 134: ...ERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING Remove the head cover Unscrew and remove the two screws Remove the cap Unscrew and remove the screw Remove the timing system upper gear bulkhead For the right head Unscrew and remove the chain ten sioner cap Remove the right chain tensioner Engine Stelvio 1200 NTX ABS ENG 134 Revente Interdite Revendita Vietata Resaling ...

Page 135: ...left chain tensioner Slide off the timing system gear from the chain to remove it from the cam shaft Unscrew and remove the four nuts on the stud bolts Remove the complete cam cap Stelvio 1200 NTX ABS Engine ENG 135 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 136: ...ead dowel pins Collect the gasket between the head and the 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 Engine Stelvio 1200 NTX ABS ENG 136 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Ver...

Page 137: ...he U bolt Remove the camshaft Remove the bowls from the cam cap and mark their position so as not inter change them when refitting See also Removing the rocker arms Removing the rocker arms CAUTION Stelvio 1200 NTX ABS Engine ENG 137 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 138: ...ove the two rocking levers from the cam cap See also Removing the cylinder head Removing the valves Remove the head Place the special tool on the upper cap and at the centre of the head of the valve to be removed Specific tooling 10 90 72 00 Tool for valve removal and refitting AP9100838 Tool for valve pressure plate Engine Stelvio 1200 NTX ABS ENG 138 Revente Interdite Revendita Vietata Resaling ...

Page 139: ...is procedure Heat the head in an oven at about 60 C 140 F Lubricate the valve guide Fit the circlips Press the valve guide with a punch Use a reamer to bore the holes the valve stems slide through so that the inside diameter is at the prescribed value The interference between the seat on the head and the valve guide must be 0 046 0 075 mm 0 0018 0 0030 in VALVE GUIDE COUPLING VALVES INLET Specific...

Page 140: ...od conditions INLET VALVE SEAT DETAIL DRAWING OUTLET VALVE SEAT DETAIL DRAWING If the width of the mark on the valve seat is larger than the prescribed limits true the seats with a 45 milling cutter and then grind Replace the head in case of excessive wear or damage Installing the valves NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS Engine Stelvio 1200 NTX A...

Page 141: ...th the special tool fit the valve cotters Specific tooling 10 90 72 00 Tool for valve removal and refitting AP9100838 Tool for valve pressure plate Remove the special tool Installing the rocker arms Fit the camshaft Fit the two rods WARNING MAKE SURE THAT THE NOTCH ON THE DIPSTICK BODY FACES THE ROCKING LEVER Stelvio 1200 NTX ABS Engine ENG 141 Revente Interdite Revendita Vietata Resaling Forbiden...

Page 142: ...er Tighten the two screws operating diag onally and in stages See also Installing the overhead camshaft Installing the overhead camshaft Place the bowls in the cam tower if those previously removed are refitted be careful not to interchange them Engine Stelvio 1200 NTX ABS ENG 142 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 143: ...g Removing the phonic wheel Remove the generator and the timing system cover Unscrew and remove the nut and col lect the washer Remove the timing system gear on the service shaft Remove the timing sensor and any shim washers Remove the tone wheel Remove the cotter and shim washer from the service shaft See also Stelvio 1200 NTX ABS Engine ENG 143 Revente Interdite Revendita Vietata Resaling Forbid...

Page 144: ... the direction of rotation upon fit ting Slide off the service shaft from the chains Remove both chains See also Removing the phonic wheel Installing the service shaft Place the service shaft bearing if pre viously removed on the crankcase Fix it to the seat with the lock washer and screw Engine Stelvio 1200 NTX ABS ENG 144 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbot...

Page 145: ... O ring on the service shaft closing cap Partially fit the service shaft closing cap To screw the cap until it stops use two M6 flanged screws larger than the orig inal screws Tighten the two M6 flanged screws op erating in stages until the cap stops against the crankcase Undo and remove the two M6 flanged screws Tighten the cap with the two original TBEI screws Stelvio 1200 NTX ABS Engine ENG 145...

Page 146: ...Installing the crankshaft Installing the service shaft Cam timing Fit the crankshaft and the service shaft on the crankcase Fit the cylinders Turn the crankshaft until the left cylin der piston reaches the top dead centre TDC Fit the cotter and the shim washer on the service shaft Fit the tone wheel with the chamfered side facing the crankcase on the serv ice shaft Engine Stelvio 1200 NTX ABS ENG ...

Page 147: ...g gear Fit the timing system gear and align the reference with that on the crankshaft gear Turn the crankshaft to align the two gears After shimming the timing sensor prop erly proceed to fit it Fit the washer and tighten the timing system gear fixing nut of the service shaft Stelvio 1200 NTX ABS Engine ENG 147 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 148: ...p Place the oil pump Tighten the three screws fixing the oil pump Place the driving pin on the oil pump shaft Place the gear on the oil pump shaft Engine Stelvio 1200 NTX ABS ENG 148 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 149: ... 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 Stelvio 1200 NTX ABS Engine ENG 149 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 150: ...arance 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 Engine Stelvio 1200 NTX ABS ENG 150 Revente Interdite Revendita Vie...

Page 151: ...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 Stelvio 1200 NTX ABS Engine ENG 151 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 152: ...s 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 Engine Stelvi...

Page 153: ...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 ASS...

Page 154: ... 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 E...

Page 155: ...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 Stelvio 1200 NTX ABS Engine ENG...

Page 156: ...ion 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 s...

Page 157: ...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 Stelvio 1200 NTX ABS Engine ENG 157 Revente Interdite Revendita Vietata Resaling Forbiden Wiede...

Page 158: ...stem 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 cylinde...

Page 159: ... 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 pl...

Page 160: ...g 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 Engine Stelvio 1200 NTX ABS ENG 160 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 161: ... 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 Stelvio 1200 NTX ABS Engine ENG 161 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf ...

Page 162: ...d 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 Engine Stelvio 1200 NTX ABS ENG 162 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 163: ...ion 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 imbalance ...

Page 164: ...0 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 pr...

Page 165: ...ods 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 rod ...

Page 166: ...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 12 ...

Page 167: ...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 Stel...

Page 168: ...wo 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 Engine Stelvio 1200 NTX ABS ENG 168 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 169: ...m 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 the...

Page 170: ...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 Engine Stelvio 1200 NTX ABS ENG 170 Revente Interdite Revendita Vietata Resaling Forbiden Wiederve...

Page 171: ...e 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 Stelvio 1200 NTX ABS Engine ENG 171 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 172: ... the nut to the specified torque Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear Tighten the nut to the specified torque Engine Stelvio 1200 NTX ABS ENG 172 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 173: ...BLE 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 Stelvio 1200 NTX ABS Engine ENG 173 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 174: ...fourteen screws fixing the oil sump to the engine crank case Undo and remove the four screws Remove the flange Engine Stelvio 1200 NTX ABS ENG 174 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 175: ...w and remove the plug Remove the thermostatic valve Unscrew and remove the pressure re lief valve plug Remove the pressure relief valve com ponents Stelvio 1200 NTX ABS Engine ENG 175 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 176: ... compo nents correctly Screw the pressure relief valve plug Place the thermostatic valve CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED Engine Stelvio 1200 NTX ABS ENG 176 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 177: ...w gasket between the crank case and the flange Fit the flange Fix the flange with the four screws Fit the lubrication oil intake filter Stelvio 1200 NTX ABS Engine ENG 177 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 178: ... 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 Engine Stelvio 1200 NTX ABS ENG 178 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 179: ...il sump Tighten the fourteen screws to the pre scribed torque Add engine oil up to the correct level Stelvio 1200 NTX ABS Engine ENG 179 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 180: ...INDEX OF TOPICS POWER SUPPLY P SUPP Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 181: ...uit diagram Key 1 Complete fuel pump unit 2 Nut 3 Fuel pipe 4 Pipe 5 Screw Injection Stelvio 1200 NTX ABS Power supply P SUPP 181 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 182: ...nstrument panel 7 Air temperature sensor 8 Throttle valve position sensor 9 Injectors 10 Engine temperature sensor 11 Crankshaft position sensor 12 Side stand Power supply Stelvio 1200 NTX ABS P SUPP 182 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 183: ...odies 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 Stelvio 1200 NTX ABS Power supply P SUPP 183 Revente Interdite Revendita Vie...

Page 184: ...f 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 ta...

Page 185: ...ollowing 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 potent...

Page 186: ...ter 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 pre...

Page 187: ...icle 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 unit ...

Page 188: ... 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 hardly ...

Page 189: ...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 eart...

Page 190: ...INDEX OF TOPICS SUSPENSIONS SUSP Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 191: ...rt 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 Stelvio 1200 NTX ABS Suspensions SUSP 191 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 192: ...e 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 Suspensions Stelvio 1200 NTX ABS SUSP 192 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 193: ... 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 Stelvio 1200 NTX ABS Suspensions SUSP 193 Revente Interdite Revendita Vietata Resaling Forbiden Wiede...

Page 194: ...ten 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 load...

Page 195: ...n the screws on the upper and then the lower plate Remove the ABS sensor 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 Stelvio 1200 NTX ABS Suspensions SUSP 195 Revente Interdite Revendita Vietata Resaling Forbiden Wie...

Page 196: ...l 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 Suspensions Stelvio 1200 NTX ABS SUSP 196 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 197: ... 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 Stelvio 1200 NTX ABS Suspensions SUSP 197 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 198: ...tem Block the wheel holder sleeve with a vice Unscrew the bottom screw and remove it together with its gasket Remove the pumping member Suspensions Stelvio 1200 NTX ABS SUSP 198 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 199: ... 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 Stelvio 1200 NTX ABS Suspensions SUSP 199 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 200: ... 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 Suspensions Stelvio 1200 NTX ABS SUSP 200 Revente Interdite Revendita Vietata Resaling Forbiden Wied...

Page 201: ... 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 Stelvio 1200 NTX ABS Suspensions SUSP 201 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbote...

Page 202: ...face 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 Suspensions Stelvio 1200 NTX ABS SUSP 202 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 203: ...he stamped part facing the dust gaiter Fit the ring the movable bushing and after removing the tape fit the fixed bushing Stelvio 1200 NTX ABS Suspensions SUSP 203 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 204: ...s 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 Suspensions Stelvio 1200 NTX ABS SUSP 204 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 205: ... 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 Stelvio 1200 NTX ABS Suspensions SUSP 205 Revente Interdite Rev...

Page 206: ...ooling 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 Suspensions Stelvio 1200 NTX ABS SUSP 206 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 207: ...rew 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 Stelvio 1200 NTX ABS Suspensions SUSP 207 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 208: ...lling 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 Suspensions Stelvio 1200 NTX ABS SUSP 208 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 209: ...tch 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 Stelvio 1200 NTX ABS Suspensions SUSP 209 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 210: ... 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 Suspensions Stelvio 1200 NTX ABS SUSP 210 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 211: ... 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 Stelvio 1200 NTX ABS Suspensions SUSP 211 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Ver...

Page 212: ...nger 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 ABSORBER ...

Page 213: ... 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 Stelvio 1200 NTX ABS Suspensions SUSP 213 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf...

Page 214: ...INDEX OF TOPICS CHASSIS CHAS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 215: ...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 Stelvio 1200 NTX ABS Chassis CHAS 215 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 216: ...ssis 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 Chassis Stelvio 1200 NTX ABS CHAS 216 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 217: ...oint 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 groov...

Page 218: ...e 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 Chassis Stelvio 1200 NTX ABS CHAS 218 Revente Interdi...

Page 219: ...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 Stelvio 1200 NTX ABS Chassis CHAS 219 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 220: ...eed 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 Chassis Stelvio 1200 NTX ABS CHAS 220 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 221: ...lid ing off the universal joint Checking Casing unit removal Remove the cover 20 Remove the plug 3 to drain out the oil Stelvio 1200 NTX ABS Chassis CHAS 221 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 222: ...e cap 10 Remove the clamps 9 and 11 Remove the cap 14 Remove the screws 16 Collect the ring 15 Chassis Stelvio 1200 NTX ABS CHAS 222 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 223: ...e the screws 7 Remove the casing 4 Remove the clamp 12 Remove the cap 14 Collect the ring 13 Stelvio 1200 NTX ABS Chassis CHAS 223 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 224: ...ns 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 Chassis Stelvio 1200 NTX ABS CHAS 224 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 225: ...casing Assemble the cap and the ring Fit the cap on the support Fit the clamp Screw the clamp with the specific pliers Stelvio 1200 NTX ABS Chassis CHAS 225 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 226: ...ricate 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 Chassis Stelvio 1200 NTX ABS CHAS 226 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 227: ... 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 Stelvio 1200 NTX ABS Chassis CHAS 227 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 228: ...ansmission 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 Chassis Stelvio 1200 NTX ABS CHAS 228 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 229: ...rn 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 Stelvio 1200 NTX ABS Chassis CHAS 229 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 230: ... 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 Chassis Stelvio 1200 NTX ABS CHAS 230 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 231: ...55 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 Stelvio 1200 NTX ABS Chassis CHAS 231 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 232: ...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 Chassis Stelvio 1200 NTX ABS CHAS 232 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 233: ...shing 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 Stelvio 1200 NTX ABS Chassis CHAS 233 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 234: ...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 Chassis Stelvio 1200 NTX ABS CHAS 234 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 235: ... 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 Replace ...

Page 236: ... 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 Chassis Stelvio 1200 NTX ABS CHAS 236 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 237: ...ten 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 Stelvio 1200 NTX ABS Chassis CHAS 237 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 238: ...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 Chassis Stelvio 1200 NTX ABS CHAS 238 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 239: ... 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 down ...

Page 240: ...tud bolts Retrieve the washers Loosen the clamp Remove the exhaust manifold Engine oil cooler Key 1 Complete oil radiator 2 TE flanged screw Chassis Stelvio 1200 NTX ABS CHAS 240 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 241: ... 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 Stelvio 1200 NTX ABS Chassis CHAS 241 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 242: ...el 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 Chassis Stelvio 1200 NTX ABS CHAS 242 ...

Page 243: ...INDEX OF TOPICS BRAKING SYSTEM BRAK SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 244: ...t brake pipe 5 Control unit pump 6 Brake pipe 7 Rear brake pipe 8 Screw 9 Bleed valve and cover 10 Cable guide anchor clamp 11 Cable guide 12 Cable guide Braking system Stelvio 1200 NTX ABS BRAK SYS 244 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 245: ...hen the ABS system is working 2 ABS Control unit 4 Front brake calliper 5 Front brake pump 6 Rear brake pump 10 Rear brake calliper 11 ABS pump 12 Front reservoir 13 Rear reservoir 14 Front outlet valve 15 Rear outlet valve Stelvio 1200 NTX ABS Braking system BRAK SYS 245 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 246: ...es the inlet valve 16 and opens the outlet valve 14 temporarily At this stage the rider cannot increase the pressure on the callipers 4 and the system reduces the pressure on the callipers 4 partially The excess fluid temporarily fills the front reservoir 12 until the ABS pump 11 self activates and delivers the fluid back to the reservoir 5 C Pressure maintained the pressure in the callipers 4 rem...

Page 247: ...HEREFORE RIDE CAREFULLY AND SEN SIBLY AND ALWAYS BRAKE GRADUALLY BRAKING WHILE TURNING A CORNER IS SUBJECT TO LAWS OF PHYSICS WHICH NOT EVEN ABS CAN ELIMINATE When sensors 1 detect a significant speed difference between the rear and the front wheels for example when rearing up on the back wheel the ABS system could take this as a dangerous situation In this case 2 things may occurs the ABS system ...

Page 248: ...order to disable the ABS with the engine off and the panel on or with the engine on but the vehicle stopped press the switch 8 release the switch within 3 5 seconds after the warning light 7 starts flashing The warn ing light 7 will continue flashing In order to ena ble the device again stop the vehicle and shut off the engine and to start up again The system gets activated again after the speed g...

Page 249: ...R CORRECT PRESSURE DO NOT RIDE WITH A DIFFERENCE BETWEEN FRONT AND REAR TYRE PRESSURE OTHER THAN THAT SPECIFIED FOR SPORTING APPLICATIONS THE ABS SYSTEM COULD WORK UNPRE DICTABLY IT IS THEREFORE ADVISABLE TO DEACTIVATE THE ABS SYSTEM Using axone for the abs Abs screen pages ISO screen page ISO This screen page shows general data regarding the control unit for example software type map ping control...

Page 250: ...mum value of the signal voltage Rear wheel speed 0 km h 0 mph With wheel stopped 0 km h 0 mph is displayed minimum value of the signal voltage Battery voltage 11 9 V Device status screen page DEVICE STATUS This screen page shows the status usually ON OFF of the vehicle devices or the operation con dition of some vehicle systems for example lamb da probe functioning status DEVICE STATUS Specificati...

Page 251: ...lows to check error clearing STO ERRORS DISPLAY Specification Desc Quantity Front speed sensor open circuit or short circuit see DIAGNOSIS Rear speed sensor open circuit or short circuit see DIAGNOSIS Front speed sensor coherence see DIAGNOSIS Rear speed sensor coherence see DIAGNOSIS ABS motor pump see DIAGNOSIS ABS valve relay see DIAGNOSIS Front inlet valve see DIAGNOSIS Rear inlet valve see DI...

Page 252: ...T COMMUNICATE WITH THE CONTROL UNIT Description of the defect lack of ground connection at pins 13 and 38 of the control unit and or lack of power supply at pin 32 of the control unit Checks Check the ground connection lead to the battery negative pole specific cable for the ABS module different from the ground cable of the ignition system Solution restore the correct cable harness connection If f...

Page 253: ...sure that the cable is grounded insulated Solution if the cable is interrupted or grounded restore wiring If the cable harness is not damaged it means that the speed sensor is defective or the circuit between sensor and connector is interrupted replace the speed sensor FRONT REAR SPEED SENSOR COHERENCE AXONE ERROR Description of the defect the control unit detects an abnormal condition in the sign...

Page 254: ...tected immediately Description of the defect the control unit detects a failure in the ABS valves relay or lack of power supply in pin 25 of the control unit Checks check pin 25 of the ABS control unit connector continuity of the 25 A fuse and relative wiring red white Solution restore the ABS control unit connector or the 25 A fuse or the wiring If functioning is correct proceed to the next check...

Page 255: ...LIED ALREADY FILLED WITH BRAKE FLUID THERE FORE THE CONTROL UNIT HAS TO BE ASSEMBLED ON THE VEHICLE AND THE SYSTEM FILLED AND PURGED AS ANY REGULAR SYSTEM CAUTION FITTING THE PIPES INADEQUATELY CAN CAUSE THE VEHICLE NOT TO BRAKE REPLACE THE SEALING WASHERS IN ALL FILLERS BE FORE TIGHTENING THEM The braking system must be purged every time sponginess is found in the main system i e outside the ABS ...

Page 256: ...BEYOND THE TOLERANCE RANGE IS MEAS URED REPLACE THE SENSOR 1 AND OR THE TONE WHEEL 2 AND REPEAT THE CHECKS MAKE SURE THAT THE VALUES ARE WITHIN THE TOLERANCE LIM ITS TONE WHEELS 2 CLEANING It is important to check that all the tone wheels 2 are always clean Otherwise gently remove any possible dirt deposits with a cloth or metal brush Avoid using solvents abrasives and air or water jets directly o...

Page 257: ...rew 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 ABS Braking system BRAK SYS 257 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 258: ...nt 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 ABS BRAK SYS 258 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 259: ... 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 ABS Braking system BRAK SYS 259 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 260: ...ned 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 ABS BRAK SYS 260 Revente Interdite Reven...

Page 261: ... 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 ABS Braking system BRAK SYS 261 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 262: ... 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 ABS BRAK SYS 262 Revente Interdite Revendita Vietata Resal...

Page 263: ... 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 collect ...

Page 264: ...R 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 c...

Page 265: ...ve 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 ABS Braking system BRAK SYS 265 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 266: ...INDEX OF TOPICS BODYWORK BODYW Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 267: ...EY 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 t...

Page 268: ...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 ABS BODYW 268 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 269: ...e 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 ABS Bodywork BODYW 269 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 270: ...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 ABS BODYW 270 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 271: ...irings 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 ABS Bodywork BODYW 271 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 272: ...llect 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 ABS BODYW 272 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 273: ...sconnect 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 ABS Bodywork BODYW 273 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 274: ...e 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 ABS BODYW 274 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 275: ...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 ABS Bodywork BODYW 275 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 276: ...s 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 ABS BODYW 276 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 277: ...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 ABS Bodywork BODYW 277 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 278: ...th 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 ABS BODYW 278 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 279: ... 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 ABS Bodywork BODYW 279 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 280: ...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 ABS BODYW 280 Revente Interdite Revendita Vietata Resa...

Page 281: ... 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 ABS Bodywork BODYW 281 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 282: ...at 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 ABS BODYW 282 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 283: ... 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 ABS Bodywork BODYW 283 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 284: ... Remove the spacers 6 and 8 Remove the components 11 to 16 from both supports Bodywork Stelvio 1200 NTX ABS BODYW 284 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 285: ...INDEX OF TOPICS PRE DELIVERY PRE DE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 286: ...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 v...

Page 287: ...H 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 OUT...

Page 288: ...ing 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 PRESSUR...

Page 289: ...4 76 240 F Fork 192 195 198 202 208 Forks 114 Fuel 86 120 280 Fuses 59 G Gearbox oil 36 I Identification 10 Instrument panel 81 269 M Maintenance 8 32 256 O Oil filter 35 R Recommended products 22 219 S Shock absorber Shock absorbers 212 Stand 79 Start up 57 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

Page 290: ...T Tank 86 120 280 Transmission 12 32 Tyres 14 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ...

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