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SERVICE STATION

MANUAL

STELVIO 4V - 1200

THE VALUE OF SERVICE

Only the mechanics of the Official Moto Guzzi Service Network know this vehicle well, thanks to constant

technical professional development and Moto Guzzi specific training programmes, and have the tools

needed to carry out maintenance and repair operations correctly.

The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before

setting off, carrying out routine maintenance and using only Moto Guzzi Original Spare parts is

fundamental!

For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or

search directly on the inset map in our Official Website:

www.motoguzzi.it

Only by purchasing Moto Guzzi Original Spare Parts will you get a product designed and tested during

the bike designing phase. Moto Guzzi Original Spare Parts are subject to systematic quality control

procedures so that their reliability and performance over time is guaranteed.

The descriptions and illustrations given in this publication are not binding; While the basic features as

described and illustrated in this booklet remain unchanged, Moto Guzzi reserves the right, at any time

and without being required to update this publication beforehand, to make any changes to components,
parts or accessory supplies, which it deems necessary to improve the product or which are required for

manufacturing or commercial reasons.

Not all versions shown in this publication are available in all Countries. The availability of individual

versions should be checked with the Official Moto Guzzi sales network.

prohibited. Moto Guzzi - After sales service.

Содержание Stelvio 1200 4V

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

Страница 2: ...product designed and tested during the bike designing phase Moto Guzzi Original Spare Parts are subject to systematic quality control procedures so that their reliability and performance over time is...

Страница 3: ...and changes in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case o...

Страница 4: ......

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

Страница 6: ......

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

Страница 8: ...SPARKS OR OTHER SOURCES WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE DO NOT DISPERSE FUEL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system components...

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

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

Страница 11: ...LD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH PLATES GET ADAPTED IT IS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN IN HOWEVER MAKE SURE NOT TO OVERDO THIS CAUTION ONLY AFTER TH...

Страница 12: ...the same selection types D E F Check clearance between cylinders and pistons on the selected diameter if it exceeds the value speci fied it is necessary to replace cylinders and pistons The pistons o...

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

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

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

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

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

Страница 18: ...d remove the four head cover fixing screws and collect the sealing O rings Remove the head cover together with the gasket Loosen the nut 1 Use a screwdriver to act on the set screw 2 until the followi...

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

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

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

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

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

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

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

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

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

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

Страница 29: ...age 16 Gear 17 Sealing ring 18 Ball bearing 19 Gear 20 Circlip 21 Clutch shaft 22 Ball bearing 23 Oil plug 24 Washer 25 Gearbox 26 Aluminium washer 27 Breather cap 28 Neutral sensor 29 Gasket 30 Seali...

Страница 30: ...n shaft 52 Transmission gear 53 Fork 5th 1st 54 Fork shaft 55 Fork 3rd 4th 56 Fork 2nd 4th 57 Gear 58 Gear 59 Ball bearing 60 Transmission shaft 61 Gear 62 Spacer Gearbox Removing the gearbox Remove t...

Страница 31: ...oil filler cap Place a container of suitable capacity under it unscrew and remove the cap and then bleed all gearbox oil Loosen and turn the oil pipe fitting on the sump Undo and remove the three scre...

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

Страница 33: ...rew and slide off the odometer gear and collect the abutment washer that is inside the gearbox From the outside slide off the thrust cylinder and collect the O Ring and the washer Remove the thrust be...

Страница 34: ...and remove the five external screws Place the gearbox on the specific gearbox support tool and on a vice Specific tooling 05 90 25 30 Gearbox support Undo and remove the nine internal screws Aprire l...

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

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

Страница 37: ...the gearbox Removing the primary shaft Remove the main shaft Operate on the main shaft from the second gear side Remove the gear of the second gear and collect the ball bearing cage Remove the gear of...

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

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

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

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

Страница 42: ...nsmission shaft with a dial gauge and a centring device and re place it if not complying with specifications Characteristic Shaft coaxiality limit 0 08 mm 0 0031 in Check transmission gears for signs...

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

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

Страница 45: ...Generator Key 1 Alternator 2 Spacer 3 Screw 4 Screw 5 Nut 6 Belt 7 Generator control pulley 8 Nut 9 Washer 10 Magneto flywheel cotter 11 Screw 12 Nut STELVIO 4V 1200 Engine ENG 19...

Страница 46: ...tank Remove the control unit from its seat Disconnect the alternator connectors Undo and remove the five screws and collect the bushings Remove the cover Unscrew the nut and collect the screw Loosen t...

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

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

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

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

Страница 51: ...ing the front cover in sertion cone Remove the insertion cone afterwards Specific tooling 05 91 17 30 Front cover insertion cone Tighten the two screws Tighten the eight lower screws Operating diagona...

Страница 52: ...ing di agonally and in stages Position the lower pulley and the spacer Tighten the nut to the prescribed tor que Position the alternator and the timing system belt Position the screw and pre tighten i...

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

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

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

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

Страница 57: ...ol rod in order to use the correct rod Measure as follows Fit the new clutch on the crankshaft Fit the clutch control bowl in the gear box Fit the gearbox on the engine block Fit the tool in the gearb...

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

Страница 59: ...friction disc centre it Place the clutch bell with the reference facing upwards Place the start up crown gear with the reference facing upwards Tighten the six screws to the prescri bed torque operat...

Страница 60: ...g lever support 5 Screw 6 Pin 7 Nut 8 Right exhaust left intake rocking lever 9 Left exhaust right intake rocking lever 10 Set screw 11 Nut 12 Rocking lever rod 13 Tappet bowl 14 Flanged screw 15 Spac...

Страница 61: ...33 Screw 34 Pin 35 Nut 36 Right exhaust left intake rocking lever 37 Left exhaust right intake rocking lever 38 Set screw 39 Nut 40 Rocking lever rod 41 Tappet bowl 42 Flanged screw 43 Spacer 44 Camsh...

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

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

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

Страница 65: ...ead Removing the overhead camshaft CAUTION WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING Remove the two roc...

Страница 66: ...ee also Removing the rocker arms Removing the rocker arms CAUTION WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FIT...

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

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

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

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

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

Страница 72: ...gear on the service shaft Remove the timing sensor and any shim washers Remove the tone wheel Remove the cotter and shim washer from the service shaft See also Removing the generator Removing the serv...

Страница 73: ...ring if pre viously removed on the crankcase Fix it to the seat with the lock washer and screw Fit the timing chains according to the references marked at the removal phase Lubricate the service shaft...

Страница 74: ...move the two M6 flanged screws Tighten the cap with the two original TBEI screws Installing sliders Fit the crankshaft and the service shaft on the crankcase Fit the fixed chain sliders and tighten th...

Страница 75: ...it the tone wheel with the chamfered side facing the crankcase on the serv ice shaft Lock crankshaft rotation Unscrew and remove the nut fixing the crankshaft gear Remove the oil pump control gear Spe...

Страница 76: ...washer and tighten the timing system gear fixing nut of the service shaft Place a new gasket between the crank case and the oil pump Place the oil pump Tighten the three screws fixing the oil pump Pla...

Страница 77: ...control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear Tighten the nut to the specified torque Tighten the screw with the washer t...

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

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

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

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

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

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

Страница 84: ...on and the cylinder Lock connecting rod motion with the fork tool Using the suitable piston ring clamp tool place the cylinder and fit the chain in the timing system plate CAUTION DURING THIS OPERATIO...

Страница 85: ...gasket to be fitted between the head and the cylinder as described in the section Shimming system Place the two dowel pins Fit the gasket with the correct thick ness between the head and the cylin der...

Страница 86: ...r gear Place the gear in the chain On the left camshaft pin fit the hole marked with the letter L of the timing system gear Block the left chain tensioner hole with screw and washer Rotate the cranksh...

Страница 87: ...right camshaft pin fit the hole marked with the letter R of the timing system gear Screw the cap of the right chain ten sioner Undo and remove the screws used to place the gear on the camshaft Place...

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

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

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

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

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

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

Страница 94: ...ch maximum The clearance between the shim washers of the connecting rod and those of the crankshaft is comprised between 0 30 mm 0 01181 in and 0 50 mm 0 01968 in Lock the screws A on the caps B with...

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

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

Страница 97: ...3 Oil delivery pipe to radiator 4 Oil pump body 5 Oil pump gasket 6 Rotor for lubrication 7 Rotor for cooling 8 Rotor control shaft 9 Oil pump cover 10 Oil pump control gear 11 Lubrication oil intake...

Страница 98: ...dispersing part of the heat and reaches the heads through the hoses 2 Oil goes down to the sump again and joins the oil used for lubrication Lubrication The rotor 6 takes in oil from the sump through...

Страница 99: ...refitting Unscrew and remove the nut on the crankshaft Remove the oil pump control gear Screw the nut again so that the internal shim washer does not fall in the crank shaft crankcase Unscrew and rem...

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

Страница 101: ...en the nut to the specified torque Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear Tighten the nut to th...

Страница 102: ...DER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL If necessary the filter can be removed with the suitable special tool Specific tooling 01 92 91 00 Wrench for removing the cover on sump and filter...

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

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

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

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

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

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

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

Страница 110: ...y 1 Control unit 2 Ignition switch 3 Battery 4 Fuel pump 5 Coils 6 Instrument panel 7 Air temperature sensor 8 Throttle valve position sensor 9 Injectors 10 Engine temperature sensor Power supply STEL...

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

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

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

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

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

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

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

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

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

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

Страница 121: ...Remove the clamps 9 and 11 Remove the cap 14 Remove the screws 16 Collect the ring 15 Remove the screws 7 Remove the casing 4 STELVIO 4V 1200 Chassis CHAS 3...

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

Страница 123: ...to the casing with the buffer and a hammer Assemble the casing to the special fastening tool Clean the casing faying surfaces carefully Heat the casing Insert the support group in the casing STELVIO...

Страница 124: ...Assemble the cap and the ring Fit the cap on the support Fit the clamp Screw the clamp with the specific pliers Apply the prescribed sealant to the casing Chassis STELVIO 4V 1200 CHAS 6...

Страница 125: ...le two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture Fit the casing Remove the two dowel pins Assemble the fixing screws 7 Tighten the screws 7 to the...

Страница 126: ...ng Tighten the fixing screws to the prescribed torque Fit the cap with the washer Screw the cap to the prescribed torque Fit the breather with the washer Screw the breather to the prescribed torque Ch...

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

Страница 128: ...ng from the wheel axle with a suitable extractor FITTING Heat the bearings to 100 C 212 F Assemble the bearings to the wheel axle Turn the unit over Assemble the bearings to the wheel axle Gruppo pign...

Страница 129: ...2 with the special spanner s4 Remove the ring nut 2 and remove the sealing ring from the ring nut NOTE THIS OPERATION DESTROYS THE SEALING RING Assemble the sealing ring 3 to the ring nut 2 with the b...

Страница 130: ...sealing ring 3 Assemble the ring nut 2 Tighten the ring nut 2 with the special spanner s4 to the prescribe torque Insert the stop ring 1 in the ring nut 2 in the in dicated direction Chassis STELVIO 4...

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

Страница 132: ...rings 2 and 7 with a screw driver Remove the stop rings 3 and 6 from the support 5 with suitable pliers NOTE THIS OPERATION DESTROYS THE SEALING RING Remove the ball joint 4 with a suitable buffer an...

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

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

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

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