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Stelvio 1200 NTX - Workshop manual

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Contents

1. 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 BODYW 260 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Bodywork Air box Remove the saddle Remove the passenger grab handle e Undo and remove the two screws and collect the cable guide Disconnect the air temperature sensor connector e Slide off and remove the main fuse box from its holder Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BODYW 261 Bodywork Disconnect the rear light connectors Release the clutch bleeding pipe from the cable guide Operating from both sides undo and remove the three screws Remove the mudflap Release from its and remove the breather pipe placed on the right side of the filter casing Operating on both sides loosen the clamp STELVIO 1200 NTX BODYW 262 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Bodywork Remove the two breather pipes Operating from both sides undo and remove the stud bolt Remove the filter casing See also Seat Sump guard ENSURE THAT THE ENGINE AND THE THERMAL PARTS OF THE VEHICLE ARE COLD BEFORE OPERATING AC CORDING TO THE FOLLOWING INSTRUCTIO
2. Undo and remove the two screws Undo and remove the two screws Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 117 Engine STELVIO 1200 NTX Remove the alternator frame Remove the sealing ring if necessary See also Fuel tank Tensioning the belt Operating from both sides undo and remove the screw fixing the oil radiator to the chassis 4i 25 NN H V N N vun i a EV e Undo and remove the radiator lower screw and collect the washer Undo and remove the horn fixing Screw ENG 118 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Undo and remove the five screws fixing the alternator belt cover Remove the oil radiator lower support bracket and the alternator belt cover Locking torques N m Alternator belt cover screw radiator bracket retainer TCEI M6x40 2 10 Nm 7 38 Ibf ft Alter nator belt cover screw TCEI M6x16 4 10 Nm 7 38 Ibf ft Loosen the screw e 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 Ibf ft Revente Interdite Reven
3. Make sure the left throttle is fully in DO NOT TOUCH THE THROTTLE ABUTMENT SCREW OR THE THROTTLE BODY MUST BE REPLACED CHECK Fi THAT THE THROTTLE RETURN CABLE IS NOT TAUT 4 J Tol j WW Mr i in Ka 1 i d 1 j bi E i j E i j Jt N Ee i Fd J P j The Axone should display the adjustable parameters screen page 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 value reading is 4 7 0 2 If the value is incorrect replace the control unit and repeat the procedure from the start M Completely close the two by pass screws on the throttle bodies e otart the engine Take the engine to the prescribe tem perature 60 C 140 F Make the engine rev at 2000 3000 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 e take the engine back to idle and check the depression values so that they are aligned between the two cylinders Otherwise open only the screw with higher depression using the by pass screws to compensate Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten P SUPP 181 Power supply STELVIO 1200 NTX If there is a larger difference act on the set screw of th
4. gt gt I gt gt I KKK Transmission fluid Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten MAIN 31 Maintenance STELVIO 1200 NTX Check Keep the vehicle upright with both wheels on the ground e Unscrew and remove the cap dipstick 1 The level is correct if the oil is close to the hole of the cap dipstick 1 If the oil is lower than specified top up until it reaches the cap dipstick hole 1 CAUTION N 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 CAUTION THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS FLUID AND THEREFORE EASY TO DRAIN NOTE RIDE SOME km miles TO WARM UP ENGINE OIL 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 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 dra
5. ENG 144 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine e After shimming the timing sensor prop V d f L d I n 2 E gt e a Ze Es ULT C s erly proceed to fit it Fit the washer and tighten the timing system gear fixing nut of the service shaft Place a new gasket between the crank case and the oil pump Place the oil pump Tighten the three screws fixing the oil pump Place the driving pin on the oil pump shaft Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 145 Engine STELVIO 1200 NTX Place the gear on the oil pump shaft Place the washer on the oil pump shaft Tighten the nut to the specified torque Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear Tighten the nut to the specified torque Tighten the screw with the washer to the prescribed torque See also Installing the crankshaft Installing the service shaft Measuring air gap ENG 146 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Measuring air gap Undo and remove the two screws and remove the sensor Insert a suitable plain washer on the sensor and note its thickness e Place the sen
6. 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine from vehicle ENG VE 89 Engine from vehicle STELVIO 1200 NTX Installing the engine to the vehicle Place the vehicle chassis over the en gine with the gear From the back secure the chassis with belts attached to a hoist From the front secure the vehicle with belts attached to the handlebar and fixed to the work bench Lift the engine placing it in position Connect the oil pressure sensor con nector Working from the left side fit the en gine upper bolt with the washer From the opposite side fit the washer and screw the nut Working on both sides insert the washer and screw the screw without tighten it Working from the left side fit the en gine lower bolt with the washer From the opposite side fit the washer and tighten the nut ENG VE 90 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine from vehicle Operating from both sides tighten the upper engine fixing nut on the internal side of the chass
7. ing off the universal joint Checking Casing unit removal Remove the cover 20 Remove the plug 3 to drain out the oil CHAS 218 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Lift the cap 10 Remove the clamps 9 and 11 Remove the cap 14 Remove the screws 16 Collect the ring 15 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 219 Chassis STELVIO 1200 NTX Remove the screws 7 Remove the casing 4 Remove the clamp 12 Remove the cap 14 Collect the ring 13 CHAS 220 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Remove the support unit 8 Casing unit fitting Assemble the dowel pins to the casing with the buffer hammer Assemble the casing to the special fastening tool Clean the casing faying surfaces carefully Heat the casing Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 221 Chassis STELVIO 1200 NTX Insert the support group in the casing Assemble the cap and the ring Fit the cap on the support Fit the clamp Screw the clamp with the specific pliers CHAS 222 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Apply t
8. Power supply Specification Target engine revs Stepper base CL Stepper Stepper regulator Virtual throttle angle from Stepper 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 STELVIO 1200 NTX Desc Quantity 1150 rom approximate values Parameter valid at idle setting depends especially on the en gine temperature the control unit will try to keep the engine running at this revs acting on the ignition advance and the Stepper motor 70 100 approximate values Steps corresponding to the Stepper motor reference position 70 150 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 con trol unit Difference between current steps of motor at idle and those at the reference position 0 With engine not at idle speed this value indicates the throttle degrees corresponding to the Stepper motor air flow DEVICE STATUS Specification Engine status Throttle position Stand IGNITION RUN STOP switch Clutch Gear engaged Fall sensor Lambda Synchronisation P SUPP 184 Desc Quantity ON run power latch stopped operation conditions Released pressed indicates if the throttle potentiometer is open or closed Retracted expanded indicates th
9. Remove the screws 2 Remove the complete support 3 NOTE FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER BODYW 254 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Bodywork Additional lights Disconnect the additional headlamps connectors Slide off the cables from the opening near the arrows between the side fair ings and fairings Remove the screw M8x20 and be careful to collect the washer and the nut NOTE FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER Rider footrest plate LEFT SIDE Undo and remove the upper screw and collect the washer and the nut Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BODYW 255 Bodywork STELVIO 1200 NTX e Undo and remove the lower screw and collect the two washers and the spacer e Undo and remove the lower screw and collect the washer and the spacer Disconnect the gearbox rod and re lease the spring Remove the left footrest holding plate RIGHT SIDE Undo and remove the upper screw and collect the washer and the nut BODYW 256 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Bodywork e Undo and remove the front lower Screw e Undo and remove the three screws Remove the right under seat fairing Disconnect the connectors o
10. UPON INSTALLING THE BATTERY ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEG ATIVE ONE AND PERFORM THE REVERSE OPERATION UPON REMOVAL WARNING THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS IT CON TAINS SULPHURIC ACID AVOID CONTACT WITH YOUR EYES SKIN AND CLOTHING IN CASE OF CONTACT WITH YOUR EYES OR SKIN WASH WITH 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 OF THE REACH OF CHILDREN CAUTION NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY USING A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE A FIRE Levels check Hydraulic braking system fluid level Clutch system fluid level if present Gearbox oil level if present Transmission oil level if present Engine coolant level if present Engine oil level Mixer oil level if present Road test Cold start Instrument panel operation Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten PRE DE 271 Pre delivery STELVIO 1200 NTX Response to throttle control Stability when accelerati
11. C 86 F 9 Resistance at 40 C 104 F 10 Resistance at 50 C 122 F 11 Resistance at 60 C 140 F 12 Resistance at 70 C 158 F 13 Resistance at 80 C 176 F 14 Resistance at 90 C 194 F 15 Resistance at 100 C 212 F 16 Resistance at 110 C 230 F 17 Resistance at 120 C 257 F Pin out PIN 1 Ground connection PIN 2 0 5 V signal Desc Quantity 100 950 kOhm 53 100 kOhm 29 120 kOhm 16 600 kOhm 9 750 kOhm 5 970 kOhm 3 750 kOhm 2 420 kOhm 1 600 kOhm 1 080 kOhm 0 750 kOhm 0 530 kOhm 0 380 kOhm 0 280 kOhm 0 204 kOhm 0 153 kOhm 0 102 kOhm Electrical system THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE FUEL INJECTION SYSTEM AXONE PARAMETERS Engine temperature In case of recovery this value is set by the control unit AXONE ELECTRICAL ERRORS engine temperature sensor P0115 open circuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has
12. Check shafts for squaring before fitting them It is therefore necessary to check that the head holes and the rod small end are parallel and on the same plane The maximum parallelism and plane error of the two head shafts and connecting rod small end should be 0 10 mm 0 00393 inch 151 0 05 mm 5 944 0 002 in Ke 22 003 22 020mm 0 86626 0 86692 in E i wt T Y 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 production 44 014 44 020 mm 1 73283 1 73307 in PIN BUSHING COUPLING DATA Specification Desc Quantity Fitted and machined bushing inside 22 003 22 020 mm 0 86626 0 86692 in Pin diameter 21 998 21 994 mm 0 86606 0 86590 in Clearance between pin and bushing 0 005 0 026 mm 0 000197 0 001024 in Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 161 Engine The connecting rode have a marked area for weight selection The weight indicated in the chart includes screws dowels and the bushing STELVIO 1200 NTX CONNECTING ROD WEIGHT SELECTION Specif
13. Fitting of Plastic Parts Scratches Dirt Tightening torques inspection Safety locks front and rear Suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine chassis retainers steering assembly Plastic parts fixing screws Electrical system Main switch STELVIO 1200 NTX 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 via emergency stop switch and side stand Helmet compartment electrical opening switch if present PRE DE 270 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Pre delivery Through the diagnosis tool check that the last mapping version is present in the control unit s and if required program the control unit s again consult the technical service website to know about available upgrades and details regarding the operation CAUTION TO ENSURE MAXIMUM PERFORMANCE THE BATTERY MUST BE CHARGED BEFORE USE INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE IT IS FIRST USED SHORTENS BATTERY LIFE CAUTION
14. Inside diameter of crankshaft bushing timing system side 38 016 38 0 mm 1 49669 1 49606 in Clearance between bushing and main journal timing system 0 025 0 057 mm 0 00098 0 00224 in side CRANKSHAFT SEAT CLUTCH SIDE Specification Desc Quantity Diameter of crankshaft main journal clutch side 53 97 53 961 mm 2 12480 2 12444 in Inside diameter 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 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 shaft gear lock Thoroughly clean the upper surface of both cylinders Place the tool on the left cylinder to de termine the squish X Fasten the tool with the nuts of the stud bolts Specific tooling 020676Y Comparator support for piston posi tion checking Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAR 21 Characteristics STELVIO 1200 NTX Reset the micrometer on the cylinder rim Move the tool so that the micrometer feeler reaches the top point of the piston crown Take note of the measurement and according to the val
15. 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 SUSP 210 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS Cassis CHAS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis STELVIO 1200 NTX Swinging arm Removing To remove the fork first remove the footrest holding plate and the exhaust silencer Slide off the rear brake calliper from the disc and release the brake pipe Engage the first gear Unscrew and remove the four screws collecting the spacers and the dust pro tection ring Remove the rear wheel Unscrew and remove the two screws Remove the speed sensor from the fork CHAS 212 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Unscrew and remove the nut fixing the reaction rod Remove the screw Fix the reaction rod to the chassis with a clamp Remove the clamp from the dust guard cap Loosen the two swingarm terminal Screws Unscrew and remove the fixing nut of the connecting rod assembly and col lect the screw Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 213 Ch
16. SERVICE STATION MANUAL 981127 STELVIO 1200 NTX SERVICE STATION MANUAL STELVIO 1200 NTX 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 manual 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 ma
17. Speed sensor Function To indicate the vehicle speed by reading the rear wheel turning speed Operation Operating principle HALL effect sensor a square wave pulse is gen erated with voltage between 12 V and 0 3 0 4V approx Level in wiring diagram Speed sensor Location M Sensor on swingarm right side near the rear brake calliper e Connector near the upper retainer of the rear shock absorber Pin out 1 Supply voltage green 2 Output signal grey white 3 Ground blue orange PIN PINS 1 3 Voltage approx 12 V PINS 2 3 Voltage variable 0 4V 12V by turning the rear wheel AXONE ELECTRICAL ERRORS Speed sensor invalid signal Error cause ELE SYS 60 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system Error signal if a speed below the default value set by the manufacturer for the running vehicle is detected Possibly shorted to ground battery or speed sensor circuit open lack of supply from the control unit also possible Troubleshooting CARRY OUT THE CASCADE OPERATIONS UNTIL THE FAILURE IS FOUND Check correct position of the sensor in its fitting Check that the air gap thickness is correct 0 6 2 2 mm 0 024 0 087 in Check voltage between PINS 1 3 of the sensor In case of null voltage check continuity between PIN 1 of the sensor and PIN 17 of the ECU BLUE connector Check PIN 17 of the BLUE connector
18. WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 131 STELVIO 1200 NTX Engine e Remove the head cover e Unscrew and remove the two screws Remove the cap e Unscrew and remove the screw Remove the timing system upper gear bulkhead For the right head e Unscrew and remove the chain ten sioner cap Remove the right chain tensioner For the left head Unscrew and remove the screw and the washer Relief oil pressure from the left chain tensioner ENG 132 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine e Slide off the timing system gear from the chain to remove it from the cam shaft e Unscrew and remove the four nuts on the stud bolts Remove the complete cam cap Unscrew and remove the two screws e Remove the head Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 133 Engine STELVIO 1200 NTX Fit the timing system upper gear back to the chain Fit the chain tensioner cap temporarily and keep the chain taut on the service shaft Collect the two head dowel pins Collect the gasket between the head and the cylinder See also Removing the head cover Cylinder h
19. Wiederverkauf Verboten ENG 155 Engine STELVIO 1200 NTX Fit the gasket with the correct thick ness between the head and the cylin der Fit the right cylinder head Unscrew and remove the right chain tensioner cap Screw two screws in the threaded holes of the timing system upper gear Rotate the camshaft so that its pin is aimed towards the hole in the timing system chain Place the gear in the chain M On the right camshaft pin fit the hole marked with the letter R of the timing system gear Screw the cap of the right chain ten sioner Undo and remove the screws used to place the gear on the camshaft Place the bulkhead and align the holes with the timing system gear Fix the bulkhead on the timing system gear using a screw with Loctite on the thread Tighten the screw to the prescribed tor que Also place the bulkhead of the other head ENG 156 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Place the cap Tighten the two screws to the prescri bed torque Also place the cap of the other head 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 Tighten the four screws to the prescri bed torque Boo re n
20. for example rider with passenger or with luggage Maximum load adjustment for example rider passenger and luggage FORK SETTING Regular load adjustments are the standard settings by the manufacturer FORK ADJUSTMENT 1 2 Specification Desc Quantity Spring preloading nut 1 regular load conditions tighten clockwise 6 turns from fully open Spring preloading nut 1 half load conditions tighten 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 unscrew anticlockwise 2 turns from fully closed ditions Rebound damping right stem set screw 2 half load condi unscrew anticlockwise 2 turns from fully closed tions Rebound damping right stem set screw 2 maximum load unscrew anticlockwise 2 turns from fully closed conditions Compression damping left stem set screw 2 regular load unscrew anticlockwise 2 turns from fully closed conditions Compression damping left stem set screw 2 half load con unscrew anticlockwise 2 turns from fully closed ditions Compression damping left stem set screw 2 maximum load unscrew anticlockwise 1 5 turns from fully closed conditions 1 THE SETTING SHOWN IN THE TABLE MAY NEED BE MODIFIED ACCORDING TO THE TYRE AND ROAD TYPE NOTE 2 IF FITTED Revente Interdite Revendita Vietata Resaling Forbiden Wi
21. store the cable harness if there is not continuity replace the injector The circuit is open check the component correct electrical characteristic if it is not the cor rect one replace the component if it is correct check the connector on the component and the Marelli control unit connector If they are not OK restore If OK check cable continuity Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 71 Electrical system STELVIO 1200 NTX between PIN 37 of the BROWN connector and the component PIN and restore the cable harness Coil Function It controls the ignition spark plug in order to gen erate the fuel ignition spark Operation Operating principle Inductive discharge system Level in wiring diagram Coils and injectors Location In front of the fuel tank left and right side Connector on the coils Electrical characteristics Primary winding resistance 550 mQ 10 at approx 23 C 73 4 F Secondary winding resistance 3 mQ 10 at approx 23 C 73 4 F Tube resistance 5 kQ Pin out 1 Supply batt V 2 Circuit earthing AXONE PARAMETERS Left coil ignition advance AXONE ACTIVATION Left 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
22. 19 Characteristics STELVIO 1200 NTX Specification Desc Quantity Piston diameter selection F 94 955 94 965 mm 3 73837 3 73877 in Cylinder diameter selection F 95 020 95 030 mm 3 74093 3 74133 in PIN PISTON COUPLING Specification Desc Quantity Pin diameter 21 998 21 994 mm 0 86606 0 86590 in Pin hole diameter on piston 22 016 22 011 mm 0 86677 0 86657 in Clearance between pin and holes on piston 0 013 0 022 mm 0 00051 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 00177 in Gap between the end of the piston rings inserted in the cylinder Top and middle piston ring 0 40 0 65 mm 0 00158 0 00255 in M Oil scraper piston ring 0 30 0 60 mm 0 00118 0 00236 in CHAR 20 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Characteristics Crankcase crankshaft connecting rod CRANKSHAFT SEAT TIMING SYSTEM SIDE Specification Desc Quantity Diameter of crankshaft main journal timing system side 37 975 37 959 mm 1 49507 1 49444 in
23. Check continuity to ground of PIN 3 of the sensor Check continuity of the grey white cable harness from PIN 24 of the ECU BLUE connector Check PIN 24 of the BLUE connector If after all these checks the failure is not found replace the sensor Speed sensor over the maximum limit Error cause Error signal if a speed above the default value set by the manufacturer for the running vehicle is detected Troubleshooting above the maximum threshold replace the sensor Engine rpm sensor Function 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 Location Sensor Front left side of the engine under the generator e Connector Under the fuel tank Electrical characteristics Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 61 Electrical system STELVIO 1200 NTX Winding resistance 650 Ohm 15 Output alternating voltage value range minimum 0 5 V maximum 5 V PIN 1 Engine revolution sensor positive signal 2 Engine revolution sensor negative signal 3 Revolution sensor anti jamming cable AXONE PARAMETERS Target engine revs Example value 1100 100 rom Parameter valid at idle setting depends especially
24. Coil 1 Error DC V DC ECU 22 Coil 1 Error DC Gnd ECU 23 Coil 2 Error DC V DC ECU 24 Coil 2 Error DC Gnd ECU 25 Injector 1 Error DC V DC ECU 26 Injector 1 Error DC Gnd ECU 27 Injector 2 Error DC V DC ECU 30 Pump Relay Error ECU 36 Local Loopback Error ECU 37 Start up Remote Error DC V DC ECU 44 Start up Remote Error DC Gnd ECU 45 Canister Error DC V DC ECU 46 Canister Error DC Gnd ECU 47 Battery Error Hig ECU 50 Generic ECU Error ECU 51 Signal Panel Error ECU 54 Self adaptability Value Error ECU 55 Vehicle Speed Error ECU 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 Electrical system In this mode a chart is displayed showing potential errors in the immobilizer and its sensors This is the error decoding chart Description Immobilizer failure Key code read but not recognised Error code DSB 01 Description Immobilizer failure Key code not read Key not inserted or transponder broken Error code DSB 02 Description Immobilizer failure Aerial not working Open or short circuited Error code DSB 03 Description Immobilizer failure Internal controller failure Error code DSB 04 Description Error code DSB 05 Description Air temperature sensor failure Error code DSB 06 Description Oil sensor failure Error code DSB 07 Description Oil pressure failure Error code DSB 08 The instrument panel keeps all previous
25. 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 the cable harness if OK replace the sensor Oil pressure failure DSB 08 Error cause An oil sensor failure is signalled when with engine running It is detected that the sensor circuit is closed This error is signalled by the bulb icon and the general warning light turns on as well Troubleshooting Detach the sensor connector and check the purple cable is ground insulated if there is continuity to ground restore the cable harness if it is ground insulated replace the switch ELE SYS 74 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system It this error persists use a pressure gauge to check the pressure of the oil in the engine circuit Neutral sensor Function it tells the gear position to the control unit in neutral or in gear Operation operating principle for gear in neutral the circuit is closed to ground connection then via CAN the control unit sends the signal to the instrument panel which turns on the neutral speed warning light Level in wiring diagram start up enabling switches Location Sensor rear upper side of the gearbox Connector on the sensor Electrical characteristics Gear in neutral closed circuit O V on wire from control unit to sensor switch in continuity Ge
26. Revendita Vietata Resaling Forbiden Wiederverkauf Verboten MAIN 35 Maintenance STELVIO 1200 NTX Pour in new oil until it reaches the dipstick open ing 1 e Tighten the filler cap 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 Air filter Undo and remove the six screws Lift the filter housing cover Remove the air filter Cover the inlet duct with 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 INCOMPRESSION STROKE VALVES CLOSED MAIN 36 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Maintenance Disconnect both spark plug tubes Unscrew and remove the four head cover fixing screws and collect the sealing O rings Remove the head cover together with the gasket Loosen the nut 1 Use a screwdriver act set screw 2 until the following clearances obtained Inlet valve 0 10 mm 0 0039 in Outlet valve 0 15 mm 0 0059 in The measurement
27. STELVIO 1200 NTX ENG 98 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX 40 Index lever 41 Spring 42 Ball bearing 43 Gear 44 Gear 45 Ball bearing cage 46 Thrust washer 47 Circlip 48 Gear 49 Circlip 50 Gear 51 Main shaft 52 Transmission gear 53 Fork 5th 1st 54 Fork shaft 55 Fork 8rd 4th 56 Fork 2nd 4th D Gear D I Gear 59 Ball bearing 60 Transmission shaft 61 Gear 62 Spacer Gearbox Removing the gearbox e Remove the starter motor Make sure the transmission Is in idle e Undo and remove the screw and re move the gearbox lever Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine ENG 99 Engine STELVIO 1200 NTX Unscrew and remove the gearbox 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 e Undo and remove the three screws ENG 100 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Undo and remove the two screws Undo and remove the screw Remove the gearbox See also Removing the starter motor Replacement Gearbox shafts Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 101 Engine STELVIO 1200
28. crankpin facing upwards Place the clutch disc with the reference facing upwards Fasten the clutch disc on the crank shaft with the six screws Loctite 243 and the belleville springs Place the clutch pressure plate Fit the tool to centre and compress the plate Fully tighten the two centring tool Screws Specific tooling 020672Y Clutch spring centre and pusher Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 127 Engine STELVIO 1200 NTX 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 a dg E ga pe Fl r Place the clutch bell with the reference facing upwards ENG 128 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Place the start up crown gear with the reference facing upwards Tighten the six screws to the prescri bed torque operating diagonally and in stages Head and timing fe ee ig ONDE Key Right cylinder head Stud bolt Cylinder head gasket Right rocking lever support Screw Pin Nut Right exhaust left intake rocking lever O ge Os oS eS dw Left exhaust right intake rocking lever 10 Set screw Revente Interdite Revendita Vietata Resali
29. lower spring guide spring holder cap SUSP 194 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Suspensions Disassembling the fork Drain out all the oil in the stem Block the wheel holder sleeve with a vice Unscrew the bottom screw and remove it together with its gasket Remove the pumping member Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten SUSP 195 Suspensions STELVIO 1200 NTX Slide off the dust scraper from the sleeve using a screwdriver as a lever Do not damage the sleeve edge while 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 SUSP 196 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Suspensions Remove the ring and the dust guard See also Draining oil Checking the components Stem Check the sliding surface for scorings and or scratches These scorings can be eliminated by rubbing them with wet sandpaper grain 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 W
30. value Installing 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 TTE z i p M Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten SUSP 205 Suspensions STELVIO 1200 NTX Steering bearing Adjusting play Unscrew and remove the U bolt four fixing screws Remove the U bolt Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out 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 SUSP 206 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Suspensions Rivet the safety washer on the head UPON REFITTING REPLACE THE SAFETY WASHER WITH A NEW ONE stock Using the suitable special tool un screw and remove the upper ring nut Specific tooling AP8140190 Tool for steering tightening Remove the safety washer e Using the suitable special tool set the preloading of the steering bearings Specific tooling AP8140190 Tool for steering tightening Revente Interdite Revendita Vietata Resaling Forbiden Wiederver
31. 0 00051 0 00157 in VALVE GUIDE COUPLING VALVES OUTLET Specification Desc Quantity Valve guide inside diameter 5 0 5 012 mm 0 19685 0 19732 in Valve stem diameter 4 960 4 975 mm 0 19527 0 19587 in Fitting clearance 0 025 0 052 mm 0 00098 0 00205 in Checking the cylinder head Check that the faying surfaces with the cover and the cylinder are not scored or damaged jeopardising a perfect sealing Check that the tolerance between the valve guide holes and the valve stems is within the prescribed limits Check the valve seats are in good conditions Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 137 Engine STELVIO 1200 NTX 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 Place the valve guide oil seal 4 in the head Place the lower cap 5 Place the valve 6 inside the head Place the spring 3 Fit the upper cap 2 Place the two cotters 1 on the seats in the valves By compressing the spring 3 with the special tool fit the valve cotters Specific tooling 10 90 72 00 Tool for valve remo
32. 27 12V socket 28 Main fuses 29 Alternator 30 Main injection relay 31 Secondary injection relay 32 Oil pressure bulb 33 Gear in neutral switch 34 Lambda Probe 35 Side stand switch 36 Fuel reserve sensor 37 Fuel pump 38 Intake air temperature thermistor 39 Head temperature thermistor 40 Automatic air 41 Throttle sensor 42 Right cylinder spark plug STELVIO 1200 NTX ELE SYS 50 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX 43 Left cylinder spark plug 44 Right cylinder coil 45 Left cylinder coil 46 Right cylinder injector 47 Left cylinder injector 48 Speed sensor 49 Fall sensor 50 Flywheel pick up 51 ECU 52 Fog lights 53 Front left turn indicator 54 Double Front headlight 55 Tail light bulb 56 Low beam bulb 57 High beam bulb 58 Front right turn indicator 59 Instrument panel diagnosis 60 Antitheft control unit optional equipment 61 Under saddle switch 62 Glove box compartment opening relay Cable colour Ar orange Az sky blue B blue Bi white G yellow Gr grey M brown N black R red Ro pink V green Vi purple Checks and inspections Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system ELE SYS 51 Electrical system STELVIO 1200 NTX Dashboard Diagnosis Changing the CODE If you know the code just enter it and then a new code that will be automatically stored in th
33. 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 47 Electrical system STELVIO 1200 NTX REAR SECTION TABLE C REAR SYSTEM RETAINER Pay attention to the position of the U bolt adhesive cable grommets for the system ELE SYS 48 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system General wiring diagram CENTRALINA OOHKHETTORE GRAM COHSETTORE BL LP errr sag ag EU HI Dar E HE si Pe BET SC Te Key Multiple connectors 2 Clutch switch 3 Start up relay 4 Start up maintenance relay Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 49 Electrical system 5 Light relay 6 Fog lights relay 7 Right light switch 8 Left light switch 9 Horn 10 Instrument panel air temperature thermistor 11 Instrument panel 12 Immobilizer aerial 13 Key switch 14 Heated handgrips 15 GPS coupling 16 Glove box compartment electric lock 17 Rear right turn indicator 18 Rear light LED 19 Left rear turn indicator 20 License plate light 21 Rear stop switch 22 Front stop switch 23 ECU Diagnosis connector 24 Auxiliary fuses 25 Starter motor 26 Battery
34. ESTE ENER Place the spark plug tube Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 157 Engine STELVIO 1200 NTX Crankcase crankshaft Removing the crankshaft Remove the clutch Remove the tone wheel and the oil pump gear Working from the generator side un screw and remove the nut Remove both gears Remove the connecting rods Undo and remove the eight fixing screws and collect the washers 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 AC VE N od 12 91 36 00 Specific tooling 12 91 36 00 Tool to remove the flywheel side flange ENG 158 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Remove the crankshaft afterwards e Collect the shim washer from inside the crankcase See also Disassembling the clutch Removing the phonic wheel Disassembling the connecting rod Remove both heads Remove the cylinders and the pistons Remove the oil sump Undo the coupling screws 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederver
35. NTX Repeat the procedure for both callip ers Screw the bleed valve and remove the pipe Top up the reservoir until the right brake fluid level is obtained Refit and block the front brake fluid reservoir cap Refit the protective rubber cap Rear Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper Air in the system causes a spongy feeling in the brake control and poor braking efficiency CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR 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 calliper bleed valve and insert the other end of this pipe into a container to collect the fluid Remove the rear brake fluid reservoir cap i Operate the brake lever and then open the bleed valve on the calliper by a 1 4 turn to let the air escape Close the bleed valve before reaching the end of travel of the brake lever BRAK S
36. NTX Disassembling the gearbox Remove the gearbox Unscrew and slide off the odometer gear and collect the abutment washer that is inside the gearbox From the outside slide off the thrust cylinder and collect the O Ring and the washer Remove the thrust bearing and the washer ENG 102 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine M Slide off the rod with the two bushings e Undo 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 Open the gearbox using the specific tool Specific tooling 05 91 25 30 Gearbox opening Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 103 Engine STELVIO 1200 NTX Remove the bearings from the gearbox if necessary Release the spring Pressing the selector slide off the whole transmission lever e Use rubber bands to tie down the trans mission shaft unit and extract it ENG 104 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine M Once the transmission shaft unit is in on a bench remove the rubber bands being careful with the group Detach the shafts and label the forks before removal Remove the forks
37. THE CRANKCASE Installing the crankshaft Fit the shim washer inside the crank case with the chamfered side facing the generator side Lubricate the crankshaft bushing on the crankcase generator side Use the sealing ring fitting tool on the flywheel side flange to fit the 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 91 20 00 Tool to fit the flywheel side flange together with sealing ring on the crankshaft Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 163 Engine STELVIO 1200 NTX Place the flywheel side flange on the crankshaft and check if the dowel pin with the O ring is correctly placed When fitting the flange on the crank case make sure that the three dowel pins match the seats on the crankcase Apply Teflon tape on the two lower fix ing screws at the back in order to pre vent 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
38. 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 operation to be carried out after the throttle body is cleaned or in the case a new engine a new lambda probe or a new injector is fitted or the correct operation of the injection system or the valves is restored AXONE RESET PROCEDURE Once the throttle body or the injection control unit is replaced it is necessary to connect to the diagnosis instrument selecting FUEL INJECTION and carry out the operation Throttle positioner autodetection Engine temperature sensor Function tells the engine temperature to the control unit so as to optimise its operation Operation operating principle NTC type sensor resistance sensor inversely variable with temperature Level in wiring diagram Temperature sensors Location ELE SYS 64 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX e sensor inside the V e connector on the sensor Electrical characteristics ENGINE TEMPERATURE SENSOR RESISTANCE Specification 1 Resistance at 40 C 40 F 2 Resistance at 30 C 22 F 3 Resistance at 20 C 4 F 4 Resistance at 10 C 14 F 5 Resistance at 0 C 32 F 6 Resistance at 10 C 50 F uf Resistance at 20 C 68 F 8 Resistance at 30
39. and collect the shaft Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 105 Engine STELVIO 1200 NTX Replace bearings if necessary and re move the clutch shaft See also Removing the gearbox Removing the primary shaft Remove the main shaft Operate on the main shaft from the second gear side Remove the gear of the second gear and collect the ball bearing cage ENG 106 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Remove the gear of the sixth gear and collect the shoulder washer Remove the circlip Remove the gear of the third and fourth gears Remove the circlip and collect the shoulder washer Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 107 Engine STELVIO 1200 NTX Remove the gear of the fifth gear and collect the ball bearing cage Heat the shaft with a specific heater and remove the helical transmission gear Removing the secondary shaft ENG 108 Remove the transmission shaft ee Operate on the shaft from the grooved side Remove the shoulder washer Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Remove the gear of the second gear and collect the ball bearing cage and the shoulder washer Remove
40. and right footrest plate to chassis lower retainer M8x75 2 2 Brake switch on plate retainer Chrome plated ring to plate retainer M5x10 6 Retainer for cable guide on right footrest plate Support retainer for M6 top boxes with countersunk head 6 Support retainer for M6 top boxes 4 Screws retainer behind the M6 bead protection 4 Screws retainer for M6 chassis supports 4 Cross member retainer for M6 top boxes 2 CHAR 16 Torque in Nm 6 7 Nm 6 7 Nm 8 12 Nm Torque in Nm 80 Nm 50 Nm 25 Nm 10 Nm 10 Nm 10 Nm 10 Nm 7 38 Ibf ft Loct 243 Manual Loct 243 10 Nm 20 Nm 14 75 Ibf ft 20 Nm 14 75 Ibf ft Manual 6 Nm 4 42 Ibf ft 6 Nm 9 6 Nm 7 08 Ibf ft 9 6 Nm 7 08 Ibf ft 9 6 Nm 7 08 Ibf ft 23 Nm 16 96 Ibf ft 9 6 Nm 7 08 Ibf ft Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Characteristics FOOTRESTS AND LEVERS Name Torque in Nm Footrest rubber retainer 10 Nm Rider footrest sliding pin M8 25 Nm Passenger footrest support to lateral plates retainer 38 Nm Rider heelrest to plates retainer 6 Nm Passenger heelrest retainer 3 Nm Rod retainer nut 10 Nm Gear shift lever brake pin retainer 10 Nm Gear shift lever pre selector retainer 10 Nm Gear shift lever pin brake retainer M8 1 1 15 Nm 11 06 Ibf ft Loct 243 SIDE STAND Name Torque in Nm Stand plate to engine upper retainer 50 Nm Stand plate to engine lower retainer 25 N
41. body Oil pump gasket Rotor for lubrication Rotor for cooling Hotor control shaft SS po N gt X e Ze Oil pump cover 10 Oil pump control gear 11 Lubrication oil intake filter 12 Cooling oil intake filter The oil pump is operated by the gear 10 which receives the motion directly from the crankshaft The gear 10 is mounted on the shaft 8 on which two rotors are fitted one for engine cooling 7 and another for lubrication 6 Cooling The rotor 7 takes in oil from 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 parts to be lubricated Oil goes down to the sump again and joins the oil used for cooling Oil pump Removing Drain off the engine oil Remove the generator and the timing system cover Unscrew and remove the nipple Collect the gasket ENG 166 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Remove the nipple oil pump fitting Bring the left cylinder piston to the TDC in combustion phase Mark a reference on the oil pump con trol gear and an
42. control unit supply and earth connections Possible internal control unit error Also check the control unit supply and earth connections Possible internal control unit error Also check the control unit supply and earth connections Possible internal control unit error Also check the control unit supply and earth connections ADJUSTABLE PARAMETERS Specification Throttle positioner autodetection P SUPP 186 Desc Quantity Allows the control unit to detect the closed throttle position just press the enter button Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions STELVIO 1200 NTX Front Removing the front wheel Working from both sides undo and re move the two fixing screws from the front brake callipers and remove them from their seats Support the front part of the vehicle Unscrew and remove the nut fixing the wheel bolt and collect the sealing ring Working from both sides loosen the screws on the wheel bolt clamps Hit the wheel pin slightly with a rubber hammer so that the hole on the oppo site side is exposed SUSP 188 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Suspensions Take out the wheel bolt by inserting a screwdriver in the bolt holes Upon extractin
43. damaged 2 Internal retaining clamp or external closing clamp loose 1 Bevel gear pair fitting error 2 Bevel gear pair toothing spoiled or damaged 1 Ball bearings on the wheel axle damaged Revente Interdite Revendita Vietata CHAS 232 Operation 1 Replace the sealing ring and fit it correctly with the suitable tool 2 Replace the wheel axle 1 Open the casing shells clean the surfaces seal and reas semble the casing shells 2 Tighten the closing screws to the correct torque 1 Clean and tighten to the correct torque 2 Replace the sealing ring 3 Tighten the plug to the correct torque 1 Replace the cap 2 Screw the clamp with suitable pliers 3 Replace the sealing ring and fit it correctly with the suitable tool 4 Replace the spacer 1 Replace the cap 2 Screw the internal or external clamp with suitable pliers 1 Replace the bevel gear pair 1 Replace the wheel bearings Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Installing Insert the transmission casing on the swingarm making sure that the univer sal joint engages correctly Tighten the four screws to the prescri bed torque operating diagonally e Place the reaction rod into its seat e 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 Revente Interdite
44. is continuity towards the switch of both the sky blue green and the grey sky blue cables sensor side if there is not continuity replace the sensor if there is check the connector If it is not OK restore the cable harness if it is OK with the key set to ON check if there is voltage on the red black cable cable harness side if there is no voltage restore the cable harness if there is check the ground insulation of the sky blue orange cable cable harness side if there is continuity to ground restore the cable harness if it is OK take the key to OFF and check that the BLUE connector is in good conditions and if there is continuity of the sky blue orange cable between the connector in question and PIN ELE SYS 80 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system 27 of the BLUE connector if not OK restore the cable harness if OK replace the Marelli control unit Indication on Axone always RUN disconnect the connector and with the switch set to STOP check if there is continuity between the two cables of the switch sensor side if there is continuity replace the switch if there is not it means that with the key set to KEY ON the sky blue orange cable is shorted to positive restore the cable harness Connectors Dashboard The pin configuration of the GREY bodied connector is as follows PIN USE 1 KEY 2 RIGHT TURN INDICA
45. key 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 41 Electrical system 5 Throttle valve potentiometer 6 Fall sensor 7 Rear light 8 Main fuses 9 Lambda probe 10 Battery 11 Starter motor 12 Intake air temperature sensor 13 Engine revolution sensor 14 Head temperature sensor 15 Engine control unit 16 Instrument panel air temperature sensor 17 Front headlamp 18 Alternator 19 Oil pressure sensor 20 Speed sensor 21 Auxiliary fuses 22 Relay 23 Additional headlamps Electrical system installation Front side CAUTION STELVIO 1200 NTX 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 ELEG TRICAL SYSTEM INSTALLATION SECTION FRONT SECTION TABLE A Clamp the brake pipes with the throttle grip transmission and right light switch properly ELE SYS 42 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system FRONT SECTION TABLE B TABLE SYSTEM CLAMPS Clamp the clutch pipes with the clutch switch and the left light switch making sure that the fixing part of the lower clamp faces the inside to avoid that by turning the steering the instrument panel is damaged a
46. 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 right Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten MAIN 37 Maintenance STELVIO 1200 NTX For the rear brake keep the vehicle upright so that the fluid in the reservoir is at the same level with the plug e Make sure that the fluid level in the reservoir is above the MIN reference mark MIN minimum level MAX maximum level If the fluid does not reach at least the MIN reference mark Check brake pads and disc for wear If the pads and or the disc do not need replacing top up the fluid Top up Front brake Unscrew the two screws 1 of the brake fluid reservoir 2 using a Phillips screwdriver Lift and remove the cover 3 and screws 1 as well Remove the gasket 4 Rear brake Unscrew remove the 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 LE
47. on engine temperature the ECU unit will try to keep the engine running at this revs acting on the ignition advance AXONE STATUSES Synchronisation Example value Synchronised Not synchronised Indicates if the control unit detects the revolution sensor signal correctly DIAGNOSIS Engine revolution sensor An interruption in the sensor circuit has been detected from PIN 25 to PIN 35 of connector 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 displayed Check the sensor electrical specifications If they are not correct replace the sensor If correct check supply insulation and ground connection insulation of both cables Perform the tests from the sensor connector towards the sensor If they are not OK restore the cable harness or replace the sensor If OK perform the tests for pins 25 and 35 of the Marelli control unit connector A BROWN towards the cable harness Air gap value Place the sensor plus the corresponding spacers the air gap should be between 0 7 and 0 9 mm ELE SYS 62 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVI
48. or routine maintenance procedure carry out pre ride checks and test the ve hicle on private grounds or in an area with low traffic density Clean all coupling surfaces oil guard 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 relative safety clips if applicable Grip the two connectors and disconnect them by pulling them in opposite directions If any signs of dirt rust moisture etc are noted clean the inside of the connector carefully with a jet of compressed air Ensure that the cables are correctly fastened to the internal connector terminals Then connect the two connectors ensuring that they couple correctly if fitted with clips you will hear them click into place CAUTION DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES NOTE THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION CONNECT THEM THE RIGHT WAY ROUND TIGHTENING TORQUES CAUTION REMEMBER THAT THE TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON WHEELS BRAKES WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE Revente Interdite Revendita Vietata Resaling Forbiden
49. secure the vehicle with belts attached to a hoist From the front secure the vehicle with belts attached to the handlebar and fixed to the work bench Remove the exhaust system the fork with the cardan shaft the fuel tank the rear shock absorber 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 remove the three screws and remove the clutch control cylinder Lock the cylinder using a clamp to pre vent oil leaks ENG VE 84 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine from vehicle e Remove the starter motor cover e Unscrew and remove the stud bolt Disconnect the ground leads Disconnect the starter motor tors Disconnect the stand sensor tor and release it from the clamps Slide off the gearbox oil breather pipe Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG VE 85 Engine from vehicle STELVIO 1200 NTX Disconnect the neutral sensor connec tor E lt Disconnect the horn connectors Operating from both sides undo and r
50. set screw in position by screwing the lock nut Specific tooling 020677Y Alternator belt tensioner Belt ten sioning lever ENG 122 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Tighten the alternator fixing screws Place the alternator belt cover Tighten the five screws operating diag onally and in stages Starter motor Removing the starter motor Undo and remove the two screws and collect the washers Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 123 Engine STELVIO 1200 NTX e Slide off the starter motor Clutch side Disassembling the clutch Key 1 Complete clutch 2 Clutch 3 Clutch bell 4 TCEI screw 5 Clutch disc 6 Crown 7 TCEI screw 8 Clutch pressure plate ENG 124 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine 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 Remove the complete gearbox e Undo and remove the six screws Remove the start up crown gear e Remove the clutch bell and the friction disc Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 125 Engin
51. the tool head where the upper cap works with a mallet so that the two cotters 1 get detached from the upper cap 2 Once the two cotters 1 are detached screw these cotters until they can be slid off the valve seats unscrew the tool and remove it from the head ENG 136 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Slide off the upper cap 2 Remove the spring 3 Remove the lower cap 5 and the valve guide oil seal 4 if necessary Remove the valve 6 from inside the head Checking the valve guides Use a punch to extract the valve guides from the heads The valve guides should be replaced only if the clearance between them and the stem cannot be elim inated by simply replacing the valves To refit the valve guides on the head follow this 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 Specification Desc Quantity Valve guide inside diameter 5 0 5 012 mm 0 19685 0 19732 in Valve stem diameter 4 972 4 987 mm 0 19574 0 19633 in Fitting clearance 0 013 0 040 mm
52. to the wheel axle CHAS 226 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Turn the unit over Assemble the bearings to the wheel axle Pinion unit REMOVAL Remove the stop ring 1 from the ring nut Unscrew the ring nut 2 with the special spanner 54 Remove the ring nut 2 and remove the sealing ring from the ring nut NOTE THIS OPERATION DESTROYS THE SEALING RING Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 227 Chassis STELVIO 1200 NTX Assemble the sealing ring 3 to the ring nut 2 with the buffer CA715855 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 54 to the prescribe torque CHAS 228 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Insert the stop ring 1 in the ring nut 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 229 Chassis STELVIO 1200 NTX REMOVAL Remove the bushing 1 with a punch Turn the support 5 over and remove the other bushing 8 Remove the sealing rings 2 and 7 with a screw driver Re
53. unscrew and remove both screws 1 Remove the oil sump guard Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten MAIN 33 Maintenance STELVIO 1200 NTX e Place a container with 4 000 cm 244 SV cu in capacity under the drainage plug 3 Unscrew and remove the drainage plug 3 Pull out the oil filler plug engine oil level dipstick 4 Drain the oil into the container allow several minutes for oil to drain out com pletely Insert the oil filler plug engine oil level dipstick 4 Check and if necessary replace the drainage plug 3 sealing washers Remove any metal deposits attached to the drainage plug 3 magnet e Screw and tighten the drainage plug 3 A 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 es T gt S ee d gt E af JI ES 1 IV 2 E NI Fi 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 Spread a thin layer of oil on the sealing ring of the new engine oil filter Fit and screw the new oil filter in its seat See also Replacement MAIN 34 Revente Interdite Revendita Vietata
54. washer Slide off the frame pin 2 from the right side with the corresponding washer Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BODYW 251 Bodywork STELVIO 1200 NTX Remove the TCEI screw 3 M10x35 on the upper side Remove both TCEI screws 4 M8x40 in the lower part of the engine guard 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 BODYW 252 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Bodywork Remove the TCEI screws 8 M10x35 on the upper side Remove the TCEI screw 9 M8x60 and the corresponding washer e Remove the TCE screws 10 M8x40 Pl in the lower part of the engine guard Remove the right engine guard Instrument panel Undo and remove the four screws Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BODYW 253 Bodywork STELVIO 1200 NTX Disconnect the instrument panel con nector Supplementary light mount 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 Remove the screws 1
55. 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 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 Left coil P0351 shorted to positive open circuit shorted to negative Error cause ELE SYS 72 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system If shorted to positive excessive voltage has been detected at PIN 38 of the BROWN con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 38 of the BROWN connector Troubleshooting Shorted to positive disconnect the coil connector set the key to ON activate the coil with Axone and check voltage at connector PIN 2 if there is voltage restore the cable harness if voltage 0 replace the coil If the circuit is open shorted to negative check the coil connector and the Marelli control unit connector If they are not OK restore if everything is OK check cable continuity be tween PIN 2 of the coil connector and PIN 38 of the BROWN connector If there is not continuity restore the cable harness if there is cable continuity with the key set to KEY ON check the cable gro
56. 86 mm 7 323 in Protrusion 5 3 6 7 mm 0 209 0 264 in Clutch control rod length code 976596 187 5 mm 7 382 in See also Disassembling the gearbox Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 113 Engine STELVIO 1200 NTX Generator Key Alternator Spacer Screw Screw Nut Belt Generator control pulley Nut Washer 10 Magneto flywheel cotter 0 ID ee Ze 11 Screw 12 Nut ENG 114 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Removing the generator Remove the fuel tank Remove the control unit from its seat Disconnect the alternator connectors Undo and remove the five screws and collect the bushings Remove the cover e Unscrew the nut and collect the screw Loosen the screw Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 115 Engine STELVIO 1200 NTX e Loosen the nut and undo the set screw so that the alternator slides down Completely loosen and remove the Screw Remove the belt and the alternator with pulley e Using a compressed air gun unscrew and remove the nut and collect the spacer Remove the lower pulley ENG 116 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Undo and remove the eight screws
57. Aa I gt mm N R o connector pu Ler J p E d W De ET z d 45 SE E BAR H i Bl gr qew 0 i 1 i un ee H UE 4 2477 AN M ER RW AAT un 3 NN COHEN Ue TF AV Unscrew and remove the nut and re move the fixing screw Remove the manifold exhaust end coupling together with the lambda probe See also Removing the exhaust manifold 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 CHAS 236 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis e Unscrew and remove the two nuts on the head exhaust stud bolts Retrieve the washers Loosen the clamp e Remove the exhaust manifold Engine oil cooler Key 1 Complete oil radiator 2 TE flanged screw Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 237 Chassis STELVIO 1200 NTX T shaped bushing Rubber ring Radiator support screw Clip NO oO R Removing lt is necessary to remove the metal oil sump guard in order to change the engine oil an
58. ECTRICAL ERRORS Throttle actuator position sensor P0120 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 63 Electrical system STELVIO 1200 NTX Example value open circuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has been detected at PIN 3 of connector A BROWN If shorted to negative voltage equal to zero has been detected Troubleshooting Circuit is open shorted to positive check the injection control unit connector and the sensor connector if they are not OK restore if they are OK check continuity between PIN 3 of connector A BROWN and PIN C of the sensor red cable if there is not continuity restore the cable harness if there is continuity check continuity of the sensor between PIN A and PIN C if there is not continuity replace the potentiometer if there is continuity check the resistance If resistance is over 2 5 kOhm it means the red cable is shorted to positive and the cable harness should be restored e shorted to negative disconnect the sensor connector and check the ground insulation of the red cable from throttle sensor connector or control unit connector if there is continuity to ground restore the cable harness if it is ground insulated the resistance between PIN A and PIN C is below 1 3 kOhm therefore the throttle body should be replaced AXONE ADJUSTABLE PARAMETERS
59. Front headlamp retainer M6x30 6 10 Nm 7 38 Ibf ft Rear light to license plate retainer M5x16 4 6 Nm 4 42 Ibf ft Screws retainer for additional lights 2 10 Nm 7 37 Ibf ft FUEL PUMP FLANGE Name Torque in Nm Pump support to tank retainer 6 Nm FUEL TANK Name Torque in Nm Filler to tank retainer 5 Nm Screws on cap ring nut aesthetic 5 Nm Tank to chassis front retainer 10 Nm CHAR 18 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Characteristics ENGINE COVER Name Right cover plate retainer M10x20 2 Left cover plate retainer M10 1 Front engine guard retainer M8x40 4 Torque in Nm 40 Nm 29 5 Ibf ft 40 Nm 29 5 Ibf ft 15 Nm 11 06 Ibf ft FRONT BODYWORK Name Front mudguard retainer Air deflector self tapping retainer 4 4 Fairing junction M5 2 2 Glove box self tapping 4 Compartment lock M6 2 Hinge locking bracket self tapping 2 Rear tank cover M5 2 Rear tank cover M6 2 Left right fairing M5 2 Left right fairing M6 2 Torque in Nm 6 Nm Manual Manual Manual Manual Manual 4 Nm 2 95 Ibf ft 10 Nm 7 38 Ibf ft 4 Nm 2 95 Ibf ft 10 Nm 7 38 Ibf ft REAR BODYWORK Name Left right fairings retainer M6 3 3 Retroreflector to support retainer Retroreflector support to license plate holder retainer License plate holder and light reinforcing retainer M5 1 Cases support retainer M6 2 C
60. IP BRAKE 4 BRAKE 5 1 Brake fluid As an alternative for recommended flu ids use top branded fluids that meet or exceed the requirements of SAE J1703 NHTSA 116 DOT 4 ISO 4925 synthetic 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 CHAR 22 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS SPECIAL TOOLS S TOOLS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Special tools Stores code 020677Y 05 91 17 30 020716Y 020470Y 05 92 72 30 01 92 91 00 STELVIO 1200 NTX ENGINE Description Alternator belt tensioner Belt tensioning lever AGS e ng Xd Lech y E We LA be SCH D M ei SSA ne Front cover insertion cone Connecting rod locking Pin snap ring fitting tool Timing system cover sealing ring punch Wrench for removing the cover on sump and filter S TOOLS 24 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Stores code 05 90 25 30 19 92 96 00 17 94 75 60 12 91 18 01 12 91 36 00 AP8140179 AP9100838 Special tools Description Gearbox support Graduated dial to control ignition timing Arrow to control ignition timing Tool to lock t
61. L SYSTEM ENGINE FROM VEHICLE ENG VE ENG P SUPP U AU J o c U U r lt SUSP CHAS CHASSIS BRAKING SYSTEM BRAK SYS BODYW 0 lt JJ PRE DELIVERY PRE DE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS Characteristics CHAR Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle please ensure that you do so in an open or very well ventilated area Never run the engine in an enclosed area If you do work in an enclosed area make sure to use a fume extraction system CAUTION EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE A POISONOUS GAS WHICH CAN CAUSE LOSS OF CONSCIOUSNESS AND EVEN DEATH Fuel CAUTION THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS IT IS THEREFORE RECOMMENDED TO CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH THE ENGINE SWITCHED OFF DO NOT SMOKE DURING REFUELLING OR NEAR FUEL VAPOUR AVOID ANY CONTACT WITH NAKED FLAME SPARKS OR OTHER HEAT SOURCES WHICH MAY CAUSE IGNITION OR EXPLOSION DO NOT ALLOW FUEL TO DISPERSE INTO THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Hot components The engine and the exhaust system comp
62. 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 Installing sliders Fit the crankshaft and the service shaft on the crankcase Fit the fixed chain sliders and tighten the fixing screws Tighten the chain caps with O rings The operations related to the movable chain sliders are described in the cyl inder fitting section See also Installing the crankshaft Installing the service shaft Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 143 Engine STELVIO 1200 NTX 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 Lock crankshaft rotation Unscrew remove the nut fixing the crankshaft gear Remove the oil pump control gear Specific tooling 12 91 18 01 Tool to lock the flywheel and the starting ring gear Fit the timing system gear and align the reference with that on the crankshaft gear Turn the crankshaft to align the two gears
63. NS PARK THE VEHICLE ON STAND ON FIRM AND LEVEL GROUND Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BODYW 263 Bodywork STELVIO 1200 NTX Remove the four 8x40 screws 1 two on each side Be careful to collect the four spacer bushings inside the sump guard NOTE FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER Fuel tank FUEL TANK CAP REMOVAL Open the fuel tank 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 BODYW 264 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Bodywork FUEL TANK UPPER FAIRING Remove the fuel tank cap Undo and remove the four screws Remove the 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BODYW 265 Bodywork STELVIO 1200 NTX Lift the rear part of the fuel tank fairing Disconnect the
64. O 1200 NTX Insert the pin Insert the snap ring Specific tooling 020470Y Pin snap ring fitting tool Installing the cylinder RIGHT 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 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine ENG 151 Engine STELVIO 1200 NTX 020716Y Connecting rod locking Remove the piston ring clamp tool and finish positioning the cylinder Specific tooling 020674Y Piston ring clamp Fit the movable chain slider Fit the upper gear Fit the chain tensioner and the chain 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 so that the coupling ends are 120 degrees from each other Pla
65. O 1200 NTX that the grey black cable from PIN 1 of the sensor to PIN 23 of the BROWN connector is shorted to ground restore the cable harness Clutch lever sensor Function It tells the clutch lever position to the control unit Operation Operating principle If the gear is engaged but the clutch is pulled i e circuit closed to ground vehicle start up is enabled anyway Level in wiring diagram Start up enabling switches Location Sensor under clutch lever e Connector on the sensor Electrical characteristics Clutch pulled closed circuit continuity Clutch released open circuit infinite resistance Pin out 1 Voltage 12V 2 Ground connection AXONE STATUSES Clutch Example value Yes No The statuses regularly viewed are YES NO DIAGNOSIS Troubleshooting Indication on Axone always NO check the correct position of the cable terminals on the sensor and the correct connection of the cables on the terminals If they are not correct restore the cable harness if correct disconnect the two terminals from the sensor and check continuity to ground of PIN 2 cable harness side if there is no continuity restore the cable harness if there is replace the sensor Check continuity of the brown purple cable between PIN 1 of the sensor and PIN 33 of the BLUE connector cable harness side if there is no continuity restore the cable harness if there is replace the sensor With the key set to ON ch
66. O 1200 NTX Electrical system Throttle position sensor Function In charge of telling the control unit the position of the throttle valves Operation operating principle The throttle valve position sensor works as a var lable resistance according to the throttle rotation Level in wiring diagram Throttle and idle motor Location sensor on the right cylinder throttle body connector on the potentiometer Electrical characteristics M G 0 5 30 e PINS A C throttle closed approx 2 5 M Bi 0 5 30 kOhm throttle open approx 1 5 kOhm PINS approx 1 1 Pin out PIN A ground connection PIN B supply voltage 5V PIN C potentiometer signal THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE MAIN CABLE HARNESS AND INTO THE CONNECTOR COMPONENT CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING CAREFULLY READ THE GENERAL TROU BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER AXONE FUEL INJECTION SYSTEM AXONE PARAMETERS Throttle Example value 4 9 AXONE STATUSES Throttle position Example value Released Pressed Full load Indicates if the throttle potentiometer is open or closed in the released position AXONE EL
67. OULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten SUSP 197 Suspensions STELVIO 1200 NTX Bending limit 0 2 mm 0 00787 in Sleeve Check that there are no damages and or cracks otherwise replace it Spring Check the spring is in good conditions Check that the following components are in good conditions e 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 SUSP 198 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Suspensions dust guard O Ring on the cap Reassembling the fork Lock the stem in a vice without dam aging the surface Protect the bearing tube end with ad hesive tape Lubricate the sliding edges with fork oil or sealing grease Fit on the slider the dust scraper the retainer ring and the seal ring Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten SUSP 199 Suspensions STELVIO 1200 NTX The sealing ring must be placed with the stamped part facing the dust gaiter Fit the ring the movable bushing and
68. Quantity 95 x 81 2 mm 3 74 x 3 20 in 1151 cm 70 cu in 11 1 starter 1100 100 rom hydraulic single plate dry clutch with integrated flexible coupling Pressurised circuit with regulator valves and trochoidal pump dry cartridge air filter air oil system with independent trochoidal pump and pressure regulator valve for oil cooling circuit single overhead camshaft with bucket tappets and rockers intake 0 10 mm 0 0039 in exhaust With the A5 series the clearance is 0 15 mm 0 0059 in From the A8 series on the clearance is 0 20 mm 0 0079 in TRANSMISSION Desc Quantity Helical gear ratio 26 85 1 1 346 6 speed mechanical gearbox with foot gearshift lever on left hand side of engine E 20 34 1 1 7 23 31 1 1 3478 26 29 1 1 1154 31 30 1 0 9677 29 25 1 0 8621 cardan shaft 12 44 1 3 6667 CAPACITIES Desc Quantity Oil change and oil filter replacement 3 500 cm 214 cu in 500 cm 30 5 cu in 380 cm 23 2 cu in 18 1 51 3 96 0 33 UK gal 4 0 88 UK gal 2 475 kg 1047 Ib ELECTRICAL SYSTEM Desc Quantity NGK PMRSB long life NGK CRB8EKB long life 0 6 0 7 mm 0 024 0 028 in 12 V 18 Ampere hour 12V 550W 30A 40A 15A 10A for ABS only 40 25A 12V DW Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Specification Low high beam headlight halogen Turn indicators Tail light stop light Supplementary headlamps if fit
69. Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Maintenance Gearbox Oil Inspection CHECKING AND TOPPING UP CAUTION ENGINE MUST BE WARM TO CHECK GEARBOX OIL LEVEL NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM 10 miles Shut off the engine Keep the vehicle upright with both wheels on the ground Unscrew and remove the cap dipstick 1 placed on the gearbox right side e The level is correct if the oil is on the rim of the hole of the cap dipstick 1 If necessary Top up with oil until it reaches 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 e Place a container with suitable capacity underthe 2 m NEN drainage plug 2 Unscrew and remove the drainage plug 2 Unscrew and remove the filler cap 1 Drain the oil into the container allow several mi nutes for oil to drain out completely e a N TS Check and replace if necessary the sealing washers of drainage plug 2 e Remove any metal scrap attached to the drain age plug 2 magnet Screw and tighten the drainage plug 2 Revente Interdite
70. Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 233 Chassis STELVIO 1200 NTX Place the speed sensor and fasten the cable harness with the clamps Place the rear wheel on the fork Tighten the four screws with their spacers and the dust protection ring Place the rear brake calliper on the disc and the brake pipe on the fork Exhaust key 1 Right exhaust pipe 2 Left exhaust pipe CHAS 234 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Gasket Flanged nut Washer Gasket Clamp Central exhaust pipe ON OO TE flanged screw 10 Silent block 11 Flanged self locking nut 12 Lambda probe 13 Gasket 14 Clamp 15 Silencer 16 TCEI screw 17 Silencer fixing bushing 18 Muffler rubber ring 19 Spacer 20 Washer 21 Nut Removing the tail pipe Loosen the sealing clamp between the exhaust and the central manifold Undo and remove the screw and col lect the nut and the washer wm M Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 235 Chassis STELVIO 1200 NTX e Remove the exhaust end Removing the manifold tail pipe Remove the exhaust end and the ex haust manifolds Remove the starter motor protection in Ze SE EE D H F T Ls e H __ 5 Pd order to disconnect the lambda probe
71. S 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 electrical characteristics are observed replace the sensor if not OK if it is OK check the sensor connector and the Marelli control unit connector Air temperature sensor Function It tells the control unit the intake air temperature in order to calculate oxygen presence so as to opti mise the petrol quantity necessary for correct com bustion Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Level in wiring diagram Temperature sensors Location sensor on filter casing e connector on the sensor Electrical characteristics AIR TEMPERATURE SENSOR RESISTANCE Specification Desc Quantity 1 Resistance at 40 C 40 F 100 950 kOhm ELE SYS 66 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system NIOJ O Pin out Specification Desc Quantity Resistance at 0 C 32 F 9 750 kOhm Resistance at 10 C 50 F 5 970 kOhm Resistance at 20 C 68 F 3 750 kOhm Resistance at 30 C 86 F 2 420 kOhm Resistance at 40 C 104 F 1 600 kOhm Resistance at 90 C 194 F 0 280 kOhm PIN 1 Ground connection PIN 2 0 5 V s
72. 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 Specification Fuel system Diffuser Fuel Tightening Torques Name Oil cap 2 FUEL SYSTEM HEADS Rocking lever support nut M10x1 5 8 Camshaft rocking levers support fixing screws 12 Head fixing screw 4 pre tightening Head fixing screw 4 final tightening Screw fixing head to chain compartment M6x120 4 Oil temperature sensor Oil temperature sensor container CHAR 14 Revente Interdite Revendita Vietata Desc Quantity Electronic injection Weber Marelli with Stepper motor diameter 50 mm 1 97 in Premium unleaded petrol minimum octane rating 95 NORM and 85 NOMM Torque in Nm 25 Nm 18 44 Ibf ft 15 Nm 11 06 Ibf ft 42 Nm 30 98 Ibf ft 17 Nm 12 54 Ibf ft 15 Nm 11 06 Ibf ft 42 Nm 31 Ibf ft 10 Nm 7 38 Ibf ft 11 Nm 8 11 Ibf ft Loctite 243 11 Nm 8 11 Ibf ft Loctite 601 Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Name Head covers fixing screws 8 Spark plug 2 CRANKCASE Name Crankcase stud bolt cylinder 8 Transmission side flange stud bolt M8x66 3 Transmission side flange stud bolt M8x75 2 Gear side crankshaft flange screw TE M8x25 8 Timing system cover screw TCE M8x55 4 Timing system cover screw TCEI M6x30 10 Oil vapour union scr
73. TELVIO 1200 NTX Electrical system TABLE C POSITION OF THE FUEL PUMP CA BLE HARNESS Clamp the cable at the front to obtain the correct position e The connection must be between the chassis and the air filter TABLE D LAMBDA PROBE SYSTEM CLAMP ING Clamp the stand system with the return pipes in sump and leave the lambda probe system free The ground lead must be towards the bottom tighten the stud bolt nut to 10Nm 7 37 Ibf ft ELE SYS 46 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system 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 CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION REAR SECTION TABLE A CORRECT FITTING OF THE ODOM ETER CLAMP The clamp fixing the odometer cable must be placed ahead of the brake pipe guide clamp REAR SECTION TABLE B FITTING THE FAIRING COMPART MENT LID SAFETY RELAY Lay down the main system and clamp the stop switch system odometer sen sor and fall sensor to the system Be careful that the latter does not come into contact with clips
74. TO CONTACT WITH THE SKIN WHEN HANDLING BATTERY ELECTROLYTE WEAR TIGHT FITTING GLOVES AND PROTECTIVE APPAREL IN THE EVENT OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID RINSE WELL WITH PLENTY OF CLEAN WATER IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS IN THE EVENT OF CON TACT WITH THE EYES RINSE WITH PLENTY OF WATER FOR FIFTEEN MINUTES AND CON SULT AN EYE SPECIALIST IMMEDIATELY IF THE FLUID IS ACCIDENTALLY SWALLOWED DRINK 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 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 ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY BEING ACTIVATED Maintenance rules GENERAL PRECAUTIONS AND INFORMATION When repairing dismantling and reassembling the vehicle follow the recommendations given below carefully BEFORE DISASSEMBLING COMPONENTS Before dismantling components remove dirt mud dust and foreign bodies from the vehicle Use the special tools designed for this bike as required COMPONENTS REMOVAL Do not loosen and or tighten screws and nuts using pliers or any other tools than the spec
75. TOR CONTROL 3 HIGH BEAM LIGHT INPUT A 5 FOG LIGHTS ON OPT 6 K LINE ra 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 PRESSURE SENSOR INTAKE 18 SENSORS EARTH CONNECTION Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 81 Electrical system STELVIO 1200 NTX 19 GENERAL GROUND OPTIONAL 20 GENERAL GROUND OPTIONAL The pin configuration of the BLACK bodied connector is as follows PIN USE 21 BATTERY 22 FRONT LEFT TURN INDICATOR ACTIVATION 23 REAR LEFT TURN INDICATOR ACTIVATION 24 AERIAL 1 25 LEFT HEATED HANDGRIPS ACTUATOR OPT 26 CAN H 27 CONTROL RESET 28 LIGHTS RELAY ACTIVATION 29 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 ELE SYS 82 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS ENGINE FROM VEHICLE ENG VE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine from vehicle STELVIO 1200 NTX Vehicle preparation Before removing the engine block proceed as follows Park the vehicle on its centre stand From the back
76. VER IF THE BRAKE FLUID RESERVOIR CAP IS LOOSE OR HAS BEEN REMOVED CAUTION N AVOID PROLONGED AIR EXPOSURE OF THE BRAKE FLUID BRAKE FLUID IS HYGROSCOPIC AND ABSORBS MOISTURE WHEN IN CONTACT WITH AIR LEAVE THE BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME NEEDED TO COMPLETE THE TOPPING UP PROCEDURE AVOID SPILLING FLUID WHILE TOPPING UP KEEP THE TANK PARALLEL TO THE RESERVOIR EDGE IN HORIZONTAL POSITION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID MAIN 38 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Maintenance WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN DO NOT EXCEED THE MAX LEVEL MARK WHEN TOP PING UP TOP UP TO MAX LEVEL MARK ONLY WHEN BRAKE PADS ARE NEW WHEN TOPPING UP DO NOT EXCEED THE MAX LEVEL MARK WHEN BRAKE PADS ARE WORN AS YOU RISK SPILLING 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten MAIN 39 INDEX OF TOPICS ELecTRICAL SYSTEM ELE SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system Components arrangement
77. Wiederverkauf Verboten CHAR 9 Characteristics STELVIO 1200 NTX IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES CHECK THE TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS FAILURE TO COMPLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR EVEN DETACH CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING THIS MAY LEAD TO FALLS WITH THE RISK OF SERIOUS INJURY OR DEATH Running in Engine run in is essential to ensure engine long life and correct operation Twisty roads and gradients are ideal to run in engine brakes and suspensions effectively Vary your riding speed during the run in This ensures that components operate under both loaded and unloaded conditions allowing the engine components to cool CAUTION THE CLUTCH MAY EMIT A SLIGHT BURNING SMELL WHEN FIRST USED THIS PHENOMENON SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH DISCS GET ADAPTED ITIS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN IN HOWEVER MAKE SURE NOT TO OVERDO THIS CAUTION THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT THE END OF THE 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 brakes gently avo
78. YS 248 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Braking system then repeat the operation until air no longer escapes Screw the bleed valve and remove 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BRAK SYS 249 INDEX OF TOPICS BODYW Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Bodywork Seat CAUTION Rest the vehicle on its stand Insert the key in the saddle lock Turn the key clockwise and slightly press the centre of the passenger seat rear part to facilitate releasing the pin Lift the passenger seat and slide it off from behind Unscrew and remove the knobs fixing the rider saddle Remove the rider saddle BEFORE LOWERING AND LOCKING THE SADDLE CHECK THAT THE KEY HAS NOT BEEN LEFT INSIDE THE GLOVE BOX TOOLKIT COMPARTMENT Engine guard ENSURE THAT THE ENGINE AND THE THERMAL PARTS OF THE VEHICLE ARE COLD BEFORE OPERATING ACCORDING TO THE FOLLOWING INSTRUCTIONS PARK THE VEHICLE ON STAND ON FIRM AND LEVEL GROUND Undo the screw and remove the rear brake oil reservoir From the left side of the vehicle re move the nut 1 and the correspond ing
79. able harness AXONE ACTIVATION Right injector Operation for 4 ms 5 times The auxiliary injection relay No 29 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 blue 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 activation AXONE ELECTRICAL ERRORS Right injector P0202 shorted to positive shorted to negative open circuit Error cause If shorted to positive excessive voltage has been detected at PIN 37 of the BROWN con nector If shorted to negative no voltage has been detected If the circuit is open an interruption has been detected Troubleshooting If shorted to positive disconnect the injector connector take the key to ON and check if there is voltage on the blue red cable if there is voltage restore the cable harness If there is no voltage replace the injector If shorted to negative disconnect the injector connector take the key to ON and check if the blue red cable has continuity to the ground connection if there is continuity to ground re
80. adjustment for example rider with passenger or with luggage Maximum load adjustment for example rider passenger 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 SETTING TABLE Regular load adjustments are the standard settings by manufacturer REAR SHOCK ABSORBER ADJUSTMENT 1 Specification Desc Quantity Preload regular load conditions 15 clicks starting from knob 2 fully loosened Preload half load conditions 28 clicks starting from knob 2 fully loosened Preload maximum load conditions 33 clicks starting from knob 2 fully loosened Rebound regular load conditions 24 clicks starting from screw 1 fully tightened Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten SUSP 209 Suspensions STELVIO 1200 NTX Specification Desc Quantity Rebound half load conditions 20 clicks starting from screw 1 fully tightened Rebound maximum load conditions 18 clicks starting from screw 1 fully tightened 1 THE SETTING SHOWN IN THE TABLE MAY NEED TO BE MODIFIED ACCORDING TO THE TYRE AND ROAD TYPE NOTE 2 IF FITTED Removing
81. after removing the tape fit the fixed bushing SUSP 200 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Suspensions Get the special tool code 8140758 M Cut the tool along the longitudinal axle so as to obtain two similar half shells to be used on forks with inverted stems e 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 50 mm 1 97 in stems AP8140146 Weight Insert the retainer ring in its position Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten SUSP 201 Suspensions STELVIO 1200 NTX Fit the dust guard with the specific tool Specific tooling AP8140758 tool to fit oil seals and dust guards for 50 mm 1 97 in stems AP8140146 Weight Insert the pumping member in the EN Lud m 0 E Noo M o d sleeve i im Tighten the screw fixing the pumping member on the fork end to the prescri bed torque Filling oil Place the sleeve upright in a vice fitted with protection shoes Compress the sleeve in the stem Place a support under the stem in order to leave it compressed Pour part of the fork oil into the sleeve 110 mm 4 33 in e Wait some minutes until the oil fills all the ducts Pour the remaining oil Pump out oil a few t
82. arshift engaged open circuit 12 V on wire from control unit to sensor open switch infinite resistance Pin out PIN 1 Voltage 12V AXONE STATUSES Gear in neutral Example value yes no DIAGNOSIS Indication on the instrument panel always gear engaged check the control unit connector and the sensor connector if they are not OK restore the cable harness if OK disconnect the connector and with gear in neutral check continuity to ground of the terminal sensor side if there is not continuity replace the sensor after checking cable harness continuity on the sensor side and the correct mechanical position if there is check cable continuity between the sensor connector and PIN 23 of the BROWN connector if there is no continuity restore the cable harness If there is replace the instrument panel if the vehicle performance is correct the engine starts with gear in neutral but the neutral warning light is off or replace the control unit if the vehicle performance is not correct the engine does not start with gear in neutral Indication on the instrument panel always gear in neutral disconnect the terminals from the sensor and check if there is continuity with ground connection at PIN toward the sensor with gear engaged if there is continuity replace the sensor If it is ground insulated it means Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 75 Electrical system STELVI
83. ases support retainer M8 2 2 Passenger grab handle to chassis retainer M8 Passenger grab handle to chassis retainer M6 License plate holder to chassis retainer M5 4 Luggage carrier brackets retainer M8 2 2 2 4 FINISHINGS Name Ignition lock retainer shear head screw Overhaul data Assembly clearances Cylinder piston assy Measurement of the cylinder diameter must be done at three heights turning the dial gauge 90 Torque in Nm 10 Nm 7 38 Ibf ft 4Nm 4Nm 4 Nm 2 95 Ibf ft 10 Nm 7 38 Ibf ft 25 Nm 18 44 Ibf ft 25 Nm 18 44 Ibf ft 10 Nm 7 38 Ibf ft 4 Nm 2 95 Ibf ft 25 Nm 18 44 Ibf ft Torque in Nm Nm Check that cylinders and pistons are of 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 of an engine must be balanced a weight difference of up to 1 5 g 0 0033 Ib is allowed PISTON CYLINDER SELECTION TYPES Specification Piston diameter selection D Cylinder diameter selection D Piston diameter selection E Cylinder diameter selection E Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Desc Quantity 94 935 94 945 mm 3 73759 3 73798 in 95 000 95 010 mm 3 74015 3 74054 in 94 945 94 955 mm 3 73798 3 73837 in 95 010 95 020 mm 3 74054 3 74093 in CHAR
84. assis STELVIO 1200 NTX Loosen the ring nut Specific tooling 05 91 26 30 Tool for tightening the swingarm pin ring nut clutch hub Helped by a second operator remove the pin and remove the swingarm to gether with the cardan shaft Checking Check that the universal joint is not damaged the gear teeth inserting in the sleeve grooves and the grooves on the joint are not deformed or damaged otherwise replace the joint Check that the rubber bellows are not cut or pierced otherwise replace it Check that the fork pin threads and the fork fixing nuts are not damaged de formed or flattened otherwise replace them Check that the sleeve grooves are not damaged deformed or deteriorated otherwise replace the sleeve Check that the sleeve outer toothing and grooves are not damaged CHAS 214 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Installing Spread thin layer of lubricating grease all along the swingarm pin Fit the ring nut in the swingarm pin and screw it manually Working from both sides grease the cardan shaft cables with the recom mended product from the recommen ded products table 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 bo
85. been detected at PIN 5 of connector A BROWN If shorted to negative voltage equal to zero has been detected at PIN 5 of the BROWN connector Troubleshooting Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 65 Electrical system STELVIO 1200 NTX If the circuit is open shorted to positive check the sensor connector and the Marelli control unit connector If they are not OK restore the cable harness if OK check the continuity of the sensor if it is not OK replace the sensor if it is OK check continuity between PIN 5 of the BROWN connector and PIN 2 of sensor restore cable harness if there is not continuity 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 5 and PIN 2 of the sensor should be restored If the air temperature sensor error is displayed at the same time this means that the grey cable common for both sensors is shorted to positive If shorted to negative check sensor correct resistance if resistance is null replace the sen sor if resistance is correct it means that the orange cable has ground connection restore the cable harness NOTE
86. bricate stands and footrests periodically with spray grease after use in particularly hard conditions dirty with salts dust etc or after long inactivity periods km x 1 000 1 5 10 Exhaust pipe flange fixing bolts Spark plugs R Idle mixture CO Throttle body Stands Transmission cables and controls Generator belt Steering bearings and steering clearance Wheel bearings Brake discs Air filter Engine oil filter Fork Vehicle general operation Braking systems Light circuit Safety switches Brake fluid Clutch fluid Gearbox oil Engine oil Fork oil oil seals Final drive oil Tyres pressure wear Engine revs at idle speed Valve clearance adjustment Wheels Bolts and nuts tightening Battery terminals tightening Cylinder synchronisation Footrest joint Suspensions and setting Engine oil pressure warning light Empty oil drain pipe from the filter housing Fuel pipes Brake pipes Clutch wear Brake pad wear 30 50 70 J m DD 0 9 D gt 0O 9 3 DD 0 9 D gt 0O 9 18 DD 0 9 D gt O 9 8 DD 0 9 D gt O 9 8 I DI 2 gt gt DdD DdD D I gt gt DdD DdD D D gt gt DdD D D D ES ee DdD 0 D 20 gt gt m gt gt I gt gt I
87. ce 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 ENG 152 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine M Check that the oil in the left cylinder chain tensioner has been drained off by compressing it If the operation is difficult use a pin drive to push the central hole so that the oil is drained off from the circuit Fit the chain tensioner in the cylinder Lubricate the piston and the cylinder Lock connecting rod motion with the fork tool Using the suitable piston ring clamp tool place the cylinder and fit the chain in the timing system plate CAUTION DURING THIS OPERATION PAY ATTENTION NOT TO DAMAGE THE PISTON Specific tooling 020674Y Piston ring clamp 020716Y Connecting rod locking Fit the movable chain slider Fit the upper gear Fit the chain tensioner cap temporarily and keep the chain taut on the service shaft Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 153 Engine Installing the cylinder head Fit the valves in the head if previously removed Take the left cylinder piston to TDC and lock crankshaft rotation Determine the thickness of the gasket to be fitted between the head and the cylinder as described in the secti
88. col lect the washer Remove the timing system gear on the service shaft Remove the timing sensor and any shim washers Remove the tone wheel Remove the cotter and shim washer from the service shaft See also Removing the generator Service shaft removal Remove the tone wheel Remove both cylinders e Undo and remove the two screws Remove the service shaft closing cap Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 141 Engine See also Mark the timing chains so as not to in vert the direction of rotation upon fit ting Slide off the service shaft from the chains Remove both chains Removing the phonic wheel Installing the service shaft ENG 142 Place the service shaft bearing if pre viously removed on the crankcase Fix it to the seat with the lock washer and screw Fit the timing chains according to the references marked at the removal phase Lubricate the service shaft Insert the service shaft in its crankcase seat by sliding it through the two chains Fit each chain to the corresponding service shaft gear Fit the roller cage and a new O ring on the service shaft closing cap STELVIO 1200 NTX Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Partially fit the service shaft closing cap To screw the cap until it stops use two
89. d replace the oil 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 e Unscrew and remove the two oil pipes 4 on the radiator L Vul K 7 mm screw and collect the washer W aum YT NN gt GC iN ot Su SG CHAS 238 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Undo and remove the two radiator up Tam per screws and collect the washer Remove the oil cooling radiator Installing cle following the operations described in the removal chapter but in reverse order Pull out the oil filler plug oil level dip stick 1 Pour new oil until it goes over the min imum level marked MIN on the dip stick 1 Insert the oil filler plug oil level dipstick 1 Start the vehicle and let the engine run for a few minutes so that the oil circu lates and fills the radiator internal ducts M otop the engine and check the oil level with the dipstick 1 Fill with engine oil as required Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 239 INDEX OF TOPICS Brana SYSTEM BRAK SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Braking system STELVIO 1200 NTX Rear brake calliper Key Rea
90. dita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Removing the primary shaft Fitting the secondary 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 PREVIOUSLY REMOVED See also Removing the secondary shaft Assembling the gearbox NOTE TO REFIT FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER REMEMBER TO REPLACE ALL SEALING RINGS CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED If the clutch is replaced measure the length of the clutch control rod in order to use the correct rod Measure as follows Fit the new clutch on the crankshaft Fit the clutch control bowl in the gear box Fit the gearbox on the engine block Fit the tool in the gearbox to determine the clutch control rod length Measure rod protrusion using a depth gauge see picture According to the value found select the correct rod based on the following table Specific tooling 020678Y Tool for clutch rod checking CLUTCH CONTROL ROD SELECTION Specification Desc Quantity Protrusion 9 8 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 1
91. dita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 119 Engine STELVIO 1200 NTX Installing the generator If the sealing ring has been previously removed replace it using the punch of the timing system cover sealing ring Specific tooling 05 92 72 30 Timing system cover sealing ring punch Place the bolt and the pin in the gen erator cover Replace the gasket and place the al ternator frame using the front cover in sertion cone Remove the insertion cone afterwards Specific tooling 05 91 17 30 Front cover insertion cone Tighten the two screws ENG 120 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Tighten the eight lower screws Operating diagonally and in stages tighten the ten fixing screws on the al ternator fitting Tighten the four screws operating di agonally and in stages Position the lower pulley and the spacer Tighten the nut to the prescribed tor que Position the alternator and the timing system belt Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 121 Engine STELVIO 1200 NTX Position the screw and pre tighten it Position the screw and tighten the nut Using the belt tensioning tool tension the belt to the prescribed torque and tighten the set screw Remove the belt tensioning tool Lock the
92. e STELVIO 1200 NTX Remove the Seeger ring Remove the clutch pressure plate e Undo and remove the six screws and collect the belleville springs e Remove the clutch disc See also Removing the gearbox Checking the clutch actuator If the clutch is replaced measure the length of the clutch control rod in order to use the correct rod Measure as follows Fit the new clutch on the crankshaft Fit the clutch control bowl in the gear box ENG 126 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Fit the gearbox on the engine block Fit the tool in the gearbox to determine the clutch control rod length Measure rod protrusion using a depth gauge see picture According to the value found select the correct rod based on the following table Specific tooling 020678Y Tool for clutch rod checking CLUTCH CONTROL ROD SELECTION Specification Desc Quantity Protrusion 9 8 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 in Assembling the clutch Lock crankshaft rotation with the
93. e memory If the vehicle is new the user code is 00000 Resetting the CODE This function is used to set a new code when the old one is not available in this case at least two of the programmed keys have to be inserted in the ignition lock After the first key has been inserted the second one Is requested with the following message INSERT KEY II If the second key is not inserted within 20 seconds the operation is finished After recognising 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 Errors Error Clearing e Reset Service Update Change Keys km Miles ECU ERRORS The instrument panel receives only the current errors from the control unit Description Error code Throttle Valve Error DC V DC ECU 10 Throttle Valve Error DC Gnd ECU 11 Engine Temperature Error DC V DC ECU 14 Engine Temperature Error DC Gnd ECU 15 Air Temperature Error DC V DC ECU 16 Air Temperature Error DC Gnd ECU 17 Low Battery Error ECU 20 ELE SYS 52 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Lambda Probe Error ECU 21
94. e position of the side stand only with gear engaged Enabled disabled indicates if the control unit consents engine start up Run stop indicates the position of the safety switch No Yes indicates the clutch sensor status No Yes indicates the gear sensor status Normal Tip over indicates the vehicle fall sensor status Open loop Closed loop Indicates if the control unit is using CLOSED the lambda probe signal to keep the stoichiometric combustion At idle CLOSED only if Air T over 20 C 68 F and engine T over 30 C 86 F and engine on for at least 2 3 minutes Synchronised Not synchronised Indicates if the control unit detects the revolution sensor signal correctly Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Devices activation screen page DEVICES ACTIVATION This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit Power supply DEVICES ACTIVATION Specification Left coil Right coil Left injector Right injector Error clearing Fuel pump Stepper control Errors display screen page ERRORS DISPLAY This screen page shows potential errors detected in the vehicle ATT or stored in the control unit MEM and it allows to check error clearing STO Desc Quantity operation for 2 5 m 5 times operation for 2 5 m 5 times Operation for 4 m 5 times Operation for 4 m 5 ti
95. e throttle body connecting rod to reduce the pressure difference in the two pipes Repeat the procedure Throttle posi tion self learning as explained above Bring the engine back to idle and check F e 7 gn gh d j EU F oe the depression values so that they are aligned between the two 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 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 T E engine temperature 30 86 F with linear increase from the air temperature at ignition barometric pressure 1010 hPa throttle valve potentiometer 2 9 at idle otherwise variable idle motor fixed value variable depending on the vehicle Using axone for injection system Injection P SUPP 182 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Power supply Iso screen page ISO This screen page shows general data regarding the control unit for example software type map ping control unit programming date 50 ISO DISPLAY Specification Desc Quantity Mapping Engine parameter reading screen page ENGINE PARAMETER READING This scre
96. 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 e Remove the two rocking levers from Zoe om the cam cap Remove the two rods ENG 134 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Undo and remove the four screws Remove the U bolt e 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 WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 135 Engine STELVIO 1200 NTX Remove the cam cap from the stud bolts e Undo and remove the two screws e Remove the U bolt Remove 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 Tighten the tool screw until fitted then hit
97. eck that 12 Volt is fed to PIN 33 of the BLUE connector Indication on Axone always YES disconnect the terminals from the sensor and check if there is continuity between the two PINS with clutch released if there is continuity replace ELE SYS 76 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system the sensor If the circuit is open it means that the brown purple cable from PIN 1 of the sensor to PIN 33 of the BLUE connector is shorted to ground restore the cable harness Side stand sensor Function lt tells the side stand position to the control unit Operation operating principle If the gear is engaged and the side stand is unfolded and therefore the circuit is open the control unit does not enable vehicle start up or shuts off the engine if it is rotating Level in wiring diagram start up enabling switches Location sensor on side stand supporting plate e connector left side near the starter motor Electrical characteristics Side Stand Up closed circuit continuity Side Stand Down open circuit infinite resistance Pin out 1 Ground connection 2 Voltage 12 V brown sensor side AXONE STATUSES Side stand Example value retracted extended DIAGNOSIS Indication on Axone always EXTENDED check the side stand sensor connector and the ECU connector if they are not OK restore if OK disconnect both terminals from the
98. ederverkauf Verboten SUSP 191 Suspensions STELVIO 1200 NTX Removing the fork legs Rest the vehicle on its centre stand Secure the rear part of the vehicle through belts in order to lift the front wheel Remove the mudguard Remove the front wheel Support the fork stem and loosen the screws on the upper and then the lower plate e UR I ELE Ahin z 1 mm Oe DO Le P e e Remove the fork stem See also Removing the front wheel Draining oil e Lockthe sleeve in a vice with the spe DF cific tool code AP8140149 Set the minimum spring preloading Specific tooling AP8140149 Protection for fitting operations SUSP 192 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Suspensions Unscrew the sleeve upper cap Push the bushing down in order to compress the spring and then fit a tool 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten SUSP 193 Suspensions STELVIO 1200 NTX Remove the spring Let the oil depos ited on the spring turns fully drip into the sleeve Pour the oil into the container Remove in order upper spring guide preload pipe
99. election colour 2 brown Type 1 to be used with brown connecting rods Balance with a 1558 g 54 96 oz 0 2596 weight fitted on the crankpin B Maximum imbalance allowed for each shoulder 2 g 0 07 oz Crankshaft selection colour 2 green Type 2 to be used with green connecting rods Balance with a 1575 g 55 56 oz 0 2596 weight fitted on the crankpin B Maximum imbalance allowed for each shoulder 2 g 0 07 oz Crankshaft selection colour 2 black Type 2 to be used with black connecting rods Balance with a 1592 g 56 16 oz 0 25 weight fitted on the crankpin B Maximum imbalance allowed for each shoulder 2 g 0 07 oz Checking the connecting rod When examining the connecting rods check that Bushing conditions bushings pins clearance Shaft parallelism Connecting rod bearings These are thin shell bearings anti friction alloy that does not allow for any adaptation replace them immediately if seizing or wear marks are found ENG 160 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Upon replacing the bearings it may be necessary to ream the crankshaft pin Before reaming the crankpin measure the pin diameter B comparing it with the maximum wear al lowed as indicated 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
100. emove the screw fixing the oil radiator to the chassis Working on both sides release the clamp and slide off the engine oil breather pipe ENG VE 86 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine from vehicle Working on both sides disconnect the injector connectors Working from both sides undo and re move the three inlet manifold screws Collect the gasket Disconnect the alternator connectors Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG VE 87 Engine from vehicle STELVIO 1200 NTX Disconnect the engine temperature sensor connector Disconnect the engine oil pressure sensor connector Disconnect the revolution 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 e Remove the centre stand ENG VE 88 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Working on both sides unscrew and remove the front screw and collect the washer Operating from both sides undo and remove the upper engine fixing nut on the internal side of the chassis Unscrew and remove the engine lower fixing nut and collect the washer Remove the lower bolt and collect the washer
101. en page shows the parameters meas H C ured by the several sensors engine revs engine temperature etc or values set by the control unit injection time ignition advance etc m ENGINE PARAMETER READING SCREEN PAGE Specification Desc Quantity Engine rpm Engine revolutions per minute the minimum value is set by the control unit cannot be adjusted Injection time ms Ignition advance FA Air temperature C Temperature of the air taken in by the engine measured by the sensor in the filter casing This is not the temperature indicated by the instrument panel Engine temperature C Battery voltage V Throttle Value corresponding to the throttle when closed approximate value between 4 5 and 4 9 left throttle supported by the end of stroke screw If a different value is read it is necessary to activate the parameter Throttle positioner autodetection and obtain this value Atmospheric pressure 1015 mPa approximate values The sensor is inside the instrument panel Lambda probe 100 900 mV approximate values Signal when energised that the control unit receives from the lambda probe inversely proportional to the presence of oxygen Lambda integrator When the control unit uses the lambda probe signal see the Lambda parameter on the Device status display this value should be close to 0 Vehicle speed km h Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten P SUPP 183
102. errors stored in its memory DELETE ERRORS This option deletes instrument panel errors only a further confirmation is requested Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 53 Electrical system STELVIO 1200 NTX INSTRUMENT PANEL SOFTWARE UPGRADE This function is used to program the instrument panel again with a new software through Axone The Display reads Instrument panel disconnec ted Now connect the diagnosis instrument the instrument panel will connect normally after the key is extracted inserted The white connector is placed under the saddle beside the fuse box close to the diagnosis con nector for the injection system Use the Ditech connector in the Axone 2000 Apri lia 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 The procedure finishes once the 4 keys have been programmed or after 20 seconds Should a new key lock be necessary the procedure is once the key is set to ON but the instrument panel does not recognise it the user code is requested enter the user code Now enter MENU DIAGNOSIS en
103. ew M6x20 2 TCEI M6x40 Screw 2 Timing sensor TCEI M5x12 2 Service shaft bearing locking screw 2 Oil pressure sensor 1 Screw fixing oil pressure sensor support TCE M10x20 1 Oil cap 2 OIL SUMP Name Oil pipe on sump reduction 1 Oil pipe on sump Oil sump lower screw TCE M6x30 4 Oil sump screw TCE M6x55 14 Oil sump screw TCEI M6x60 2 Oil drainage plug M10x1 1 Oil filter 1 Oil filter fitting 1 Oil pipe in sump Pressure relief plug Cap on oil sump flange 2 Cap 1 CRANKSHAFT FLYWHEEL Name Connecting rod screw 4 pre tightening Connecting rod screw 4 final tightening Screw fixing clutch disc on crankshaft M8x25 6 Screw fixing clutch bell on disc M7x16 6 Start up crown gear fixing screw 6 OIL PUMP Name Oil pump fixing screws M6x45 3 Oil pump gear nut M10x1 25 1 Pressure relief plug Cooling oil intake filter fixing screw 5 Lubrication oil intake filter fixing screw 2 TIMING SYSTEM Name Service shaft flange screw TBEI M6x14 2 Timing system gear nut on service shaft M18 1 Timing system gear nut on crankshaft M25 1 Timing system upper gear TE screw 2 Screw fixing timing system upper gear closing cap TBEI M5x10 4 Cylinder chain tensioner cap 2 Screw fixing movable chain slider 2 Torque in Nm 8 Nm 5 9 Ibf ft 15 Nm 11 06 lbf ft Molykote Torque in Nm 25 Nm 18 44 Ibf ft 35 Nm 25 81 Ibf ft 35 Nm 25 81 Ibf f
104. f the rear brake lever switch and the speed sen Sor Release the cable harness from the clamps o Undo and remove the two rear lower screws collect the washers and the spacer Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BODYW 257 Bodywork STELVIO 1200 NTX Unscrew and remove the screw Detach the rear brake fluid reservoir but keep it connected to the pipe Remove the right footrest plate keeping the brake fluid reservoir in vertical position Side fairings 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 BODYW 258 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Bodywork Detach the fairing Disconnect the glove box compart ment opening cable e Undo and remove the two front screws Operating from both sides undo and remove the internal screw and collect the washer and the nut o Unscrew and remove the two screws Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BODYW 259 Bodywork STELVIO 1200 NTX Undo and remove the four screws Remove the headlight lower cover Unscrew and remove the two screws Operating from both sides disconnect the turn indicator connector
105. ffer handgrip or Ball joint sealing buffer Wrench for pinion ring nut gU E Pinion oil seal buffer MES S TOOLS 28 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Stores code 05 90 27 36 Stores code AP8140146 AP8140149 AP8140758 Special tools Description Bevel gear pair support gear p pp EA rn c A K 2 Vi D oq Il p N i r TN l F ad Ech A Le S E WW Eg er Zn FRONT FORK Description Weight ma y CS I H LS tt Se Protection for fitting operations i c e w n i mel awe tool to fit oil seals and dust guards for 50 mm 1 97 in stems Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten S TOOLS 29 INDEX OF TOPICS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Maintenance Maintenance chart NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS OFF ROAD OR FOR TRACK USE ROUTINE MAINTENANCE TABLE I INSPECT AND CLEAN ADJUST LUBRICATE OR REPLACE IF NECESSARY C CLEAN R REPLACE A ADJUST L LUBRICATE Check and clean adjust or replace if necessary before every ride Replace every 2 years or 20000 km 12427 miles Replace every 4 years Check at every start up It is recommended to lu
106. g the wheel hold it and then remove it M Collect the spacer from the front wheel right side Front fork Diagram Key Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten SUSP 189 Suspensions sch Complete front fork TCE screw Washer TE flanged screw Bushing ON DOF W nm Nut 10 Complete left pumping member 11 Fork upper plate 12 TCE screw 13 Base with headstock 14 Right sleeve cap 15 Left sleeve cap 16 O ring 17 O ring 18 Washer 19 Snap ring 20 O ring 21 Complete sleeve 22 Spring holder cap 23 Spring guide 24 Preloading pipe 25 Spring guide 26 Spring 27 Bushing 28 Dust guard 29 Snap ring 30 Sealing ring 31 Cap 32 Bushing Stem right wheel holder Stem left wheel holder Complete right pumping member STELVIO 1200 NTX SUSP 190 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Suspensions Adjustment The front suspension consists of a hydraulic fork connected to the headstock by means of two plates To set the vehicle suspension each fork stem fea tures an upper nut 1 to adjust spring preloading and an upper set screw 2 act on the right stem set screw to adjust hydraulic rebound damping e act on the left stem set screw to adjust hydraulic compression damping ADJUSTMENTS Regular adjustment standard only rider Medium load setting
107. he flywheel and the starting ring gear Tool to remove the flywheel side flange Support for valve fitting removal Tool for valve pressure plate Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten S TOOLS 25 Special tools Stores code 14 92 71 00 12 91 20 00 19 92 71 00 020673Y 020672Y 020674Y 020675Y STELVIO 1200 NTX Description Tool to fit the sealing ring on the flywheel side flange Tool to fit the flywheel side flange togeth er with sealing ring on the crankshaft Tool to fit the sealing ring on the flywheel side flange Graduated dial hub Clutch spring centre and pusher Piston ring clamp Service shaft gear lock S TOOLS 26 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Special tools Stores code Description 020676Y Comparator support for piston position checking 020678Y Tool for clutch 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten S TOOLS 27 Special tools Stores code 05 90 27 30 05 90 27 31 05 90 27 32 05 90 27 33 05 90 27 34 05 90 27 35 STELVIO 1200 NTX BEVEL GEAR PAIR Description Gearbox support Gearbox oil seal buffer Bu
108. he prescribed sealant to the casing Fit a new sealing ring using the buffer Lubricate 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 223 Chassis STELVIO 1200 NTX Assemble the fixing screws 7 Tighten the screws 7 to the prescribed torque Remove 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 CHAS 224 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Fit the breather with the washer Screw the breather to the prescribed torque Fill the transmission with the prescribed oil Fit the cap with the washer Screw the cap to the prescribed torque Assemble the cap with the clamps Fit the cap in its seat Wheel axle unit Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 225 Chassis STELVIO 1200 NTX REMOVAL Remove the bearing from the wheel axle with a suitable extractor Turn the unit over Remove the bearing from the wheel axle with a suitable extractor FITTING Heat the bearings to 100 C 212 F Assemble the bearings
109. i control unit connector If they are not OK restore if everything is OK check cable continuity be tween PIN 2 of the coil connector and PIN 10 of the BROWN connector If there is not Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 73 Electrical system STELVIO 1200 NTX continuity restore the cable harness if there is cable continuity with the key set to KEY ON check the cable ground insulation from coil connector or control unit connector If this is not OK restore the cable harness Engine oil pressure sensor Function Indicates the instrument panel if there is enough oil pressure 0 35 0 15 bar 5 1 2 18 PSI in the engine Operation Operating principle normally closed switch With oil pressure above 0 35 0 15 bar 5 1 2 18 PSI open circuit Level in wiring diagram fuel reserve and oil pres sure Location Sensor in between the engine V a little to the left under the generator Connector on the sensor Pin out Voltage 12V Instrument panel Oil sensor failure DSB 07 Error cause An oil sensor failure is signalled when with engine off it is detected that the sensor circuit is open The test is performed only once when the key is set to ON This error is signalled by the bulb icon and the general warning light turns on as well Troubleshooting Check the sensor connector and the instrument panel connector PIN 17 If not OK restore
110. i 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 BRAK SYS 244 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Braking system Rear brake pads Removal Undo and remove the two screws Remove the brake calliper from the disc Turn the pin and pull out the split pin Remove the split pin Remove the pin Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BRAK SYS 245 Braking system STELVIO 1200 NTX Extract pad at time CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS Installing Insert two new pads placing them so that the holes are aligned with the cal liper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER 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 BRAK SYS 246 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Braking system Bleeding the braking s
111. ication Desc Quantity Connecting rod brown 0 588 0 598 mm 0 02074 0 02109 in Connecting rod green 0 598 0 608 mm 0 02109 0 02145 in Connecting rod black 0 608 0 618 mm 0 02145 0 02180 in Assembling the connecting rod To place the connecting rods the two pins must be facing the crankcase internal side ENG 162 Lubricate the crankpin on which the connecting rods are to be fixed If the connecting rods are not replaced be careful not to interchange the right connecting rod with the left one and vice versa 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 pin is 0 028 mm 0 0011 inch minimum and 0 052 mm 0 0020 inch maximum The clearance between the shim washers of the connecting rod and those of the crankshaft is comprised between 0 30 mm 0 01181 in and 0 50 mm 0 019668 in Lock the screws A on the caps B with a torque wrench at the prescribed torque Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine PAY ATTENTION TO CRANKSHAFT ROTATION WHEN ONLY THE CONNECTING RODS ARE FITTED BECAUSE IT COULD HIT THE TWO LUBRICATION JETS INSIDE
112. iding sudden or prolonged braking That is to permit the adequate adjustment of the pad friction material to the brake discs AFTER THE SPECIFIED MILEAGE TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER FOR THE CHECKS INDICATED IN THE AFTER RUN IN TABLE IN THE SCHEDULED MAINTE NANCE SECTION TO AVOID INJURING YOURSELF OTHERS AND OR DAMAGING THE VEHI CLE Vehicle identification SERIAL NUMBER LOCATION These numbers are necessary for vehicle registration NOTE ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW IN PAR TICULAR MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY CHAR 10 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX This number consists of numbers and letters as in the example shown below ZGULZBO00YMXXXXXX KEY ZGU WMI World manufacturer identifier code LZ model BOO version variation 0 digit free Y year of manufacture M production plant M Mandello del Lario XXXXXX progressive number 6 digits CHASSIS NUMBER The chassis number is stamped on the right side of the headstock ENGINE NUMBER The engine number is stamped on the left side close to the engine oil level check cap Dimensions and mass Specification Characteristics 42 E amt E FI PE Yin AV Jo Ve A i WEIGHT AND DIMENSIONS Maximum width without accessories Maximum width at handlebar Desc Quanti
113. ific wrench Mark the positions on all connection joints pipes cables etc before separating them and identify them with different distinctive symbols Each component needs to be clearly marked to enable identification during reassembly Clean and wash the dismantled components carefully using a low flammability detergent CHAR 8 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Characteristics Keep mated parts together since they have adjusted to each other due to normal wear Some must be used together or replaced altogether Keep away from heat sources REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY WITHOUT JAMMING AND OR NOISE OTHERWISE THEY NEED TO BE REPLACED Only use ORIGINAL Moto Guzzi SPARE PARTS Comply with lubricant and consumables use guidelines Lubricate parts whenever possible before reassembling them When tightening nuts and screws start from the ones with the largest section or from the internal ones moving diagonally Tighten nuts and screws in successive steps before ap plying the tightening torque Always replace self locking nuts washers sealing rings circlips O rings OR split pins and screws with new ones if their tread is damaged When assembling the bearings make sure to lubricate them well Check that each component is assembled correctly After a repair
114. ignal AXONE PARAMETERS Air temperature In case of failure 25 C is set as temperature AXONE ELECTRICAL ERRORS air temperature sensor P0110 open circuit shorted to positive shorted to negative Error cause If the circuit is open shorted to positive excessive voltage has been detected at PIN 14 of the BROWN connector If shorted to negative voltage equal to zero has been detected at PIN 14 of the BROWN connector Troubleshooting If the circuit is open shorted to positive check the sensor connector and the Marelli control unit connector If they are not OK restore the cable harness if OK check the continuity of the sensor if it is not OK replace the sensor if it is OK check continuity between PIN 14 of the BROWN connector and PIN 2 of sensor restore cable harness if there is not continuity 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 should be restored If the engine temperature sensor error is displayed at the same time this means that the grey cable common for both sensors is shorted to positive If shorted to negative check sensor correct resistance if resis
115. imes SUSP 202 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Suspensions Measure the air gap between the oil level and the rim THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS Specific tooling AP8140149 Protection for fitting operations Characteristic Oil level from sleeve rim without the spring and preloading pipe 110 mm 4 33 in Insert the spring holder cap in the sleeve Insert the preloading pipe with the two spring guides in the sleeve Fit the spring Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten SUSP 203 Suspensions STELVIO 1200 NTX Fit the bushing Finger tight the upper cap on the pumping member stem Compress the spring and then fit a tool under the pumping member lock nut to keep the spring compressed M Screw the upper cap on the pumping member stem Remove the tool to compress the spring Place the sleeve in the vice using the specified tool Screw the upper cover tightening it to the prescribed torque Specific tooling AP8140149 Protection for fitting operations SUSP 204 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Suspensions Once the operations are completed restore the spring preloading correct
116. inage plug 3 Pour new oil through the fill opening 1 until it reaches the cap dipstick hole 1 CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID WHEN USING A FUNNEL OR ANY OTHER ELEMENT MAKE SURE IT IS PERFECTLY CLEAN Screw and tighten the caps 1 2 MAIN 32 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Maintenance Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM 10 miles CAUTION Stop the engine Keep the vehicle upright with both wheels on the ground Pull the filler plug oil level dipstick 1 straight out Wipe the oil level dipstick 1 clean and AT reinsert it y A R Pull it out again and check the oil level D ESF The oil level is correct when it is close P to the MAX mark Otherwise top up ET with engine oil Si 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 order to change the engine oil and replace the oil filter Operating from both sides
117. is Fit the centre stand Operating from both sides tighten the screws fixing the centre stand plates Remove the engine service stand from under the oil sump Working from both sides place the in let manifold fitting a new gasket be tween the manifold and head Fasten the inlet manifold with the three Screws e Connect the stand sensor connector and fix it to the chassis with new clamps Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG VE 91 Engine from vehicle STELVIO 1200 NTX Insert the oil breather pipe and fasten it with a new clamp Fit the gearbox oil breather pipe Fit the clutch control cylinder Tighten the three screws Connect the starter motor connectors ENG VE 92 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine from vehicle M Connect the ground leads and tighten the stud bolt Fit the starter motor cover Tighten the screws e Connect the neutral sensor connector Connect the alternator connectors Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG VE 93 Engine from vehicle STELVIO 1200 NTX Connect the revolution sensor tor Connect the horn connectors Connect the engine temperature sen sor connector Place the oil radiator Tighten the tw
118. it if not complying with specifications Characteristic Shaft coaxiality limit 0 08 mm 0 0031 in Check transmission gears for signs of pitting and wear and replace damaged gears if necessary Check the gear fitting teeth for cracks damage and wear and replace those damaged if necessary Check the transmission gears movement and if it is not regular replace the damaged part Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 111 Engine STELVIO 1200 NTX Checking the desmodromic drum Check gear drum for damage scratches and wear and replace the desmodromic if necessary Check the desmodromic segment 3 for damage and wear and replace it if necessary Check the desmodromic bearing 4 for damage and cracks and replace it if necessary Checking the forks NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL GEARBOX FORKS Check the transmission fork cam roller 1 and the transmission fork tooth 2 for damage deformation and wear Replace the transmission fork if nec essary e Check the transmission fork move G ment and if it is not regular replacethe 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 SEALING RINGS CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED See also ENG 112 Revente Interdite Reven
119. ixing nut M8 5 TE flanged screw fixing gearbox to crankcase M8x45 1 Oil cap M18x1 5 1 Breather cap 1 Gear in neutral sensor 1 Oil drainage plug M10x1 1 Transmission shaft ring nut 1 OIL RADIATOR Name Radiator to chassis retainer M6x30 3 Nipples to radiator retainer M16x1 5 2 Oil pipes to radiator and engine retainer M16x1 5 2 2 CHASSIS TO ENGINE UNIT STELVIO 1200 NTX Torque in Nm 22 Nm 16 23 Ibf ft 30 Nm 22 13 Ibf ft 80 Nm 59 Ibf ft Loctite 243 50 Nm 36 88 Ibf ft 10 Nm 7 38 lof ft 10 Nm 7 38 lof ft Torque in Nm 10 Nm 7 38 Ibf ft 10 Nm 7 38 Ibf ft 20 Nm 14 75 Ibf ft 20 Nm 14 75 Ibf ft 28 Nm 20 65 Ibf ft 8 Nm 5 9 Ibf ft 10 Nm 7 38 Ibf ft 24 Nm 17 7 Ibf ft 100 Nm 73 76 Ibf ft Torque in Nm 10 Nm 7 38 Ibf ft 20 Nm 14 75 Ibf ft 20 Nm 14 75 Ibf ft Name Torque in Nm M6x40 TCEI DA screw 8 12 Nm Reduction 20 Nm FUEL SUPPLY CONTROL UNIT Name M5x12 TCEI screw Stainless M5x16 TBEI flanged screw M6x25 TCEI DA screw CHASSIS Name Front engine to chassis retainer Transmission to chassis retainer M12x250 M12x230 Right fixing plate transmission retainer Plate clamp Blow by retainer Coil plate retainer Electronic control unit retainer Bushings to electronic control unit retainer M6x35 1 Tank support rubber rings to chassis retainer 2 Filter casing fixing bolts Left and right footrest plate to chassis upper retainer M8x30 2 2 Left
120. kauf Verboten ENG 159 Engine STELVIO 1200 NTX Inspecting the crankshaft components Check the surfaces of the main journals if they are scored or oval shaped reface them observing the undersize charts and replace the main bushing S Reference 1 indicates the position where the col oured reference is applied to select diameter B Reference 2 indicates the position where the col oured reference is applied to select balancing CRANKSHAFT SEAT TIMING SYSTEM SIDE Specification Desc Quantity Diameter of crankshaft main journal timing system side 37 975 37 959 mm 1 49507 1 49444 in Inside diameter of crankshaft bushing timing system side 38 016 38 0 mm 1 49669 1 49606 in Clearance between bushing and main journal timing system 0 025 0 057 mm 0 00098 0 00224 in side CRANKSHAFT SEAT CLUTCH SIDE Specification Desc Quantity Diameter of crankshaft main journal clutch side 53 97 53 961 mm 2 12480 2 12444 in Inside diameter 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 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 s
121. kauf Verboten SUSP 207 STELVIO 1200 NTX Suspensions Fit a new safety washer Screw the upper ring nut manually and then slightly tighten the clamps on the plate so as to align notches on the ring nut Specific tooling AP8140190 Tool for steering tightening 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 SUSP 208 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Suspensions Shock absorbers Adjusting The rear suspension consists of a spring shock absorber unit linked to the frame via Silent block and to the rear fork via a linkage system To set vehicle suspension the shock absorber has a set screw 1 to adjust the hydraulic rebound damping a set knob 2 to adjust spring 3 preloading Standard rear shock absorber setting is adjusted to suit most high and low speed riding conditions to transport the rider plus luggage However this set can be modified for specific needs according to vehicle use LN ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF ics ES BEFORE OPERATING THE SET SCREWS uc Ce ADJUSTMENTS Regular adjustment standard only rider Half load
122. m Side stand retainer pin 10 Nm Switch fixing screw M6x20 1 10 Nm 7 38 Ibf ft Loct 243 Lock nut 30 Nm Stand cable guide to engine retainer M8 1 25 Nm 18 44 Ibf ft Side lever arm retainer M6x16 2 10 Nm 7 38 Ibf ft Loct 243 SWINGARM Name Torque in Nm Swingarm on bushing clamp retainer 10 Nm owingarm 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 Ibf ft Fork stem on lower plate retainer M8x30 4 20 Nm 14 75 Ibf ft Headstock ring nut 40 Nm Headstock counter ring nut manual 90 degrees Upper yoke fixing cap 100 Nm Fork hub closing M6x30 2 2 10 Nm 7 38 Ibf ft REAR SUSPENSION Name Torque in Nm Shock absorber to chassis retainer 8 8 50 Nm Double connecting rod shock absorber retainer 10 9 40 Nm Single connecting rod double connecting rod retainer 10 9 50 Nm Single connecting rod to chassis retainer 8 8 50 Nm Double connecting rod swingarm retainer 10 9 50 Nm AIR FILTER CASING BLOW BY Name Torque in Nm Blow by expansion tank spacer to engine retainer 10 Nm Filter housing to chassis retainer 10 Nm EXHAUST Name Torque in Nm Exhaust pipe to engine retainer 25 Nm Silencer to chassis connecting pipe retai
123. mes By pressing the enter button the stored errors MEM become part of the historical data STO In the next connection be tween the Axone and the control unit the historical errors STO are no longer shown Operation for 30 For 4 advancement control of 32 steps for the next 4 retro cession control of 32 steps and so on for 30 ERRORS DISPLAY Specification Pressure sensor Air temperature Engine temperature Throttle actuator position sensor Lambda probe Left injector Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Desc Quantity 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 Possible short circuit in the earth lead battery or open circuit recovery function hardly noticeable for customer Possible short circuit in the earth lead battery or open circuit recovery function Possible short circuit in the earth lead battery or open circuit recovery function noticeable for customer Possible short circuit on the earth lead battery or open circuit or plausibility recovery function hardly noticeable for customer Possible short circuit in the earth lead battery or open circuit If both injectors do not work the engine does not work P SUPP 185 Power supply Specification Right injector Fuel pump relay Left coil Right coil Idle regulator Batter
124. move the stop rings 3 and 6 from the support 5 with suitable pliers NOTE THIS OPERATION DESTROYS THE SEALING RING CHAS 230 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Remove the ball joint 4 with a suitable buffer and a rubber hammer FITTING Fit the stop ring 6 in the support 5 with suitable pliers 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 P pliers Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 231 Chassis Manually assemble the new sealing rings 2 and 7 Assemble the bushing 1 Drive the bushing 1 in with a plastic hammer Turn the support 5 over and assemble the other bushing 8 STELVIO 1200 NTX TROUBLESHOOTING Possible Cause 1 Fitting error of the radial seal or seal damaged 2 Sliding surface of the wheel axle seal spoiled or damaged 1 Casing not sealed 2 Closing screws of the casing shells not tightened to the prescribed torque 1 Dirt between the sealing ring and the casing 2 A used seal ing ring has been fitted 3 Plug not tightened to the prescribed 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 Cap
125. n The continuity of the wiring is necessary for correct activation no error indications are displayed in case of lack of activation AXONE ELECTRICAL ERRORS Left injector P0201 shorted to positive shorted to negative open circuit Error cause If shorted to positive excessive voltage has been detected at PIN 28 of the BROWN con nector If shorted to negative no voltage has been detected If the circuit is open an interruption has been detected Troubleshooting ELE SYS 70 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system Shorted to positive disconnect the injector connector take the key to ON and check if there is voltage on the grey red cable if there is voltage restore the cable harness If there is no voltage replace the injector If shorted to negative disconnect the injector connector take the key to ON and check if the grey red cable has continuity to the ground connection if there is continuity to ground re store the cable harness if there is not continuity replace the injector The circuit is open check the component correct electrical characteristic if it is not the cor rect one replace the component if it is correct check the connector on the component and the Marelli control unit connector If they are not OK restore If OK check cable continuity between PIN 28 of the BROWN connector and the component PIN and restore the c
126. nd power line if there is voltage at PIN 4 check the white cable ground insulation cable harness side PIN 3 if it is not OK restore the cable harness If OK check continuity of the white cable cable harness side between PIN 3 of the sensor connector PIN 3 and PIN 11 of the BLUE connector and restore the cable harness Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 69 Electrical system STELVIO 1200 NTX Injector Function To supply the correct amount of petrol at the right timing Operation Operating principle Injector coil is excited for the petrol passage to open Level in wiring diagram Coils and injectors Location e on the intake manifold connector on injector Electrical characteristics 14 8 Ohm 5 at 20 C Pin out Supply Ground connection AXONE FUEL INJECTION SYSTEM AXONE PARAMETERS Injection time AXONE ACTIVATION Left injector Operation for 4 ms 5 times The auxiliary injection relay No 29 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 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 activatio
127. nd the clamp gets unhooked 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 HEADLIGHT AND TURN INDICATOR Clamp the right headlight cable 1 and the right turn indicator 2 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 43 Electrical system STELVIO 1200 NTX Clamp the left headlight cable 3 the left turn indicator 4 and the TOM TOM cable 5 Clamp the heated handgrips cable Central part CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED CARRY OUT THE CHECKS INDICATED UNDER SPE CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES IN THE ELEC TRICAL SYSTEM INSTALLATION SECTION ELE SYS 44 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system CENTRAL SECTION TABLE A CORRECT FITTING OF THE ALTER NATOR CABLE The red cable of the alternator must be in upright position TABLE B RED CLAMP STARTING POINT IN THE ELECTRICAL SYSTEM The red clamp must start from the point indicated The cable of heated handgrips must come out under the beam and be clam ped Pass the cable harness under the beam Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 45 S
128. ner 25 Nm Muffler to chassis retainer M8x45 1 25 Nm 18 44 Ibf ft Heat guard retainer M6 3 10 Nm 7 38 Ibf ft Lambda probe retainer 38 Nm Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAH 17 Characteristics STELVIO 1200 NTX Name Torque in Nm Clamps retainer M8 3 20 Nm 14 75 Ibf ft FRONT WHEEL Name Torque in Nm Wheel pin nut 80 Nm REAR WHEEL Name Torque in Nm Disc retainer 25 Nm Rear wheel retainer 10 9 110 Nm FRONT BRAKING SYSTEM Name Torque in Nm Front brake right and left calliper retainer 50 Nm REAR BRAKING SYSTEM Name Torque in Nm Rear brake calliper retainer 50 Nm Rear brake fluid reservoir retainer 3 Nm Rear brake fluid reservoir support to plate retainer 10 Nm Rear brake rod lock nut manual Brake pump retainer M6x20 2 10 Nm 7 38 Ibf ft Loctite 243 HANDLEBAR AND CONTROLS Name Torque in Nm Retainer for handlebar lower 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 2Nm Horn retainer 15 Nm Odometer sensor on bevel gear pair retainer Nm INSTRUMENT PANEL AND LIGHTS Name Torque in Nm Instrument panel retainer 3 Nm Front arrows retainer M4 2 3 Nm 2 21 Ibf ft
129. ng Forbiden Wiederverkauf Verboten ENG 129 Engine 11 Nut 12 Rocking lever rod 13 Tappet bowl 14 Flanged screw 15 Spacer 16 Camshaft 17 Pin 18 Timing system gear 19 Breather plate 20 TE flanged screw 21 O ring 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 3 Left exhaust right intake rocking lever 38 Set screw 39 Nut 40 Rocking lever rod 41 Tappet bowl 42 Flanged screw 43 Spacer 44 Camshaft 45 Pin 46 Timing system gear 47 Breather plate 48 TE flanged screw STELVIO 1200 NTX ENG 130 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine 49 O ring 50 Complete breather cover 51 TBEI screw 52 Timing system chain 53 Chain guide slider 54 Chain tensioner pad 55 Chain tensioner screw 56 Left chain 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 M Unscrew and remove the four head cover fixing screws and collect the sealing O rings Remove the head cover together with the gasket Removing the cylinder head CAUTION
130. ng and braking Front and rear brake efficiency Front and rear suspension efficiency Abnormal noise Static test Static check after test drive Restarting when warmed up Starter operation if present Minimum holding turning the handlebar Uniform turning of the steering Possible leaks Radiator electric fan operation if present Functional inspection Hydraulic braking system Stroke of brake and clutch levers if present Clutch Check for correct operation Engine Check for correct general operation and absence of abnormal noise Other Documentation check Chassis and engine numbers check Supplied tools check License plate fitting Locks checking Tyre pressure check Installation of mirrors and any possible accessories NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST CAUTION CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE PRE DE 272 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten A Air filter 36 Battery 54 60 Brake 241 242 245 C Clutch 76 124 126 127 159 Clutch lever 76 D Display 185 E Engine oil 33 74 237 F Fork 189 192 195 199 205 Forks 112 Fuel 84 118 264 Fuses 57 G Gearbox oil 35 Identification 10 Instrument panel 79 253 Maintenance 8 37 O Oil filter 34 R Recommended products 22 216 S Shock abso
131. nufacturing 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 Copyright 2008 Moto Guzzi All rights reserved Reproduction of this publication in whole or in part is prohibited Moto Guzzi After sales service The Moto Guzzi brand is owned by Piaggio amp C S p A Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten SERVICE STATION MANUAL STELVIO 1200 NTX This manual provides the main information to carry out regular maintenance operations on your vehicle This manual is intended to Moto Guzzi Dealers and their qualified mechanics several concepts have been deliberately omitted as they are considered unnecessary s it is not possible to include complete mechanical notions in this manual users should have basic mechanical knowledge or minimum knowledge about the procedures involved when repairing motorcycles Without this knowledge repairing or checking the vehicle may be inefficient or even dangerous s the vehicle repair and check procedures are not described in detail be extremely cautious so as not to damage components or injure individuals In order to optimise customer satisfaction when using our vehicles Moto Guzzi s p a commits itself to continually improve its products and the relative documentation The main technical modifications and changes in
132. o screws ENG VE 94 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine from vehicle e Place the fork with cardan shaft and the rear wheel Working on both sides connect the in jector connectors Adjust the throttle grip cable clearance Working from both sides connect the spark plug tube Install the fuel tank e Fit the saddle Install the complete exhaust Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG VE 95 INDEX OF TOPICS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Gearbox Diagram y un for i Y en A bs cun d i Key 1 Ball bearing Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 97 Engine Circlip Thickness Pin Complete desmodromic Ball bearing Spring Spacer om AR WD Circlip 10 Fifth wheel 11 Linking pin 12 Gear 13 Circlip 14 Thrust washer 15 Ball bearing cage 16 Gear 17 Sealing ring 18 Ball bearing 19 Gear 20 Circlip 21 Clutch shaft 22 Ball bearing 23 Oil plug 24 Washer 25 Gearbox 26 Aluminium washer 27 Breather cap 28 Neutral sensor 29 Gasket 30 Sealing ring 31 Bushing 32 Gasket 33 Oil drainage plug 34 Sealing ring 35 Thrust bearing 36 Roller bearing 37 Spring 38 Complete pre selector 39 Bushing
133. on 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 ENG 154 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Fix the head with the two screws Tighten nuts and screws to the prescri bed torque operating diagonally and in stages Loosen the valve set screws Using a thin screwdriver relief oil pres sure from the left cylinder chain ten sioner Screw two screws in the threaded holes of the timing system upper gear Rotate the camshaft so that its pin is aimed towards the hole in the timing system chain Place the gear in the chain On the left camshaft pin fit the hole marked with the letter L of the timing system gear Block the left chain tensioner hole with screw and washer Rotate the crankshaft 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 cylinder as described in the section Shimming system Place the two dowel pins Revente Interdite Revendita Vietata Resaling Forbiden
134. onents 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 and transmission oil CAUTION IT IS ADVISABLE TO WEAR LATEX GLOVES WHEN SERVICING THE VEHICLE THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING COMPANY OR THE SUPPLIER DO NOT DISPOSE OF OIL IN THE ENVIRONMENT KEEP OUT OF THE REACH OF CHILDREN Brake and clutch fluid Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAR 7 Characteristics STELVIO 1200 NTX BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COM PONENTS WITH A CLEAN CLOTH ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES IN THE EVENT OF ACCIDENTAL CONTACT WITH YOUR EYES RINSE THEM IMMEDI ATELY WITH ABUNDANT COLD CLEAN WATER AND SEEK MEDICAL ADVICE KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION LN THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID MAY CAUSE BURNING IF IT COMES IN
135. other on the driven gear so as to place them correctly again upon refitting e 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 167 Engine STELVIO 1200 NTX e Undo and remove the three screws Remove the oil pump Remove the gasket between the crankcase and the oil pump See also Replacement Removing the generator Installing Place a new gasket between the crank case and the oil pump Place the oil pump Tighten the three screws fixing the oil pump ENG 168 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Place the driving pin on the oil pump shaft Place the gear on the oil pump shaft Place the washer on the oil pump shaft Tighten the nut to the specified torque Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear Tighten the nut to the specified torque Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verbo
136. pipes Remove the fuel tank fairing See also Seat FUEL TANK Remove the tank side fairings Disconnect the glove box opening control connector e Undo and remove the two rear screws and collect the washers e Undo and remove the two front screws BODYW 266 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX e Lift the tank and disconnect the fuel pipe Disconnect the fuel pump connector e Remove the fuel tank See also Side fairings Pannier mounting Remove 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Bodywork BODYW 267 Bodywork STELVIO 1200 NTX Remove the spacers 6 and 8 Remove the components 11 to 16 from both supports BODYW 268 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Pre delivery Carry out the listed checks before delivering the vehicle WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL Aesthetic inspection Paintwork
137. plete fuel pump unit Nut Fuel pipe Pipe GE eo Screw Injection P SUPP 178 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Diagram Key 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 11 Crankshaft position sensor 12 Side stand Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Power supply P SUPP 179 Power supply STELVIO 1200 NTX 13 Lambda probe 14 Fall sensor THROTTLE BODY PIPES LAYING Pipes from the throttle body to the idle motor should be laid so that the shaped part is inserted in the air filter casing The shortest part of the fuel pipe connected to the throttle bodies should be placed on the right Cylinders synchronisation With engine off connect the Axone 2000 tool to the diagnosis connector and to the vehicle battery Turn on the scanner M 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 P SUPP 180 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Power supply e Make sure there are no errors in the control unit otherwise solve them and repeat the procedure
138. plug Place the thermostatic valve CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 173 Engine STELVIO 1200 NTX Tighten the thermostatic valve plug Place new gasket between the crank case and the flange Fit the flange Fix the flange with the four screws Fit the lubrication oil intake filter ENG 174 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine M Check that the O rings are fitted on the oil pump Fit the cooling oil intake filter Fix 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 175 STELVIO 1200 NTX Engine Place the oil sump Tum Bu Ee bk Tighten the fourteen screws to the pre fr i ew d scribed torque Add engine oil up to the correct level ZS t Fi ENG 176 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Power supply STELVIO 1200 NTX Circuit diagram Key 1 Com
139. r brake calliper 1 2 Screw 3 Pads 4 Pin calliper split pin 5 Spring 6 Gasket 7 Screw 8 Air bleed 9 Air bleed cap 10 Rear brake pipe 11 Oil pipe screw BRAK SYS 241 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Braking system STELVIO 1200 NTX Front brake calliper Key Front right brake calliper Front left brake calliper Pads Air bleed Air bleed cap Pins Calliper springs Spring Aluminium gasket SO ee ow Im Screw Front brake pads BRAK SYS 242 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Braking system Removal e Unscrew and remove the two screws e Slide off the brake calliper from the disc Turn the pins and remove both split pins Remove both pins Remove the vibration damping plate Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BRAK SYS 243 Braking system STELVIO 1200 NTX Extract pad at time CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS Installing Insert two new pads placing them so that the holes are aligned with the cal liper holes CAUTION ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY ARE CORRECTLY POSITIONED INSIDE THE CALLIPER Position the ant
140. rber Shock absorbers 209 Stand 77 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Start up 55 T Tank 84 118 264 Transmission 12 31 Tyres 14 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten
141. repair procedures are communicated to all Moto Guzzi Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case of need or further queries on repair and check procedures consult Moto Guzzi CUSTOMER DEPARTMENT which will be prepared to provide any information on the subject and any further communications on updates and technical changes related to the vehicle NOTE Provides key information to make the procedure easier to understand and carry out CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle WARNING Refers to specific procedures to carry out to prevent injuries to the repairer Personal safety Failure to completely observe these instructions will result in serious risk of personal injury gt Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment Vehicle intactness The incomplete or non observance of these regulations leads to the risk of serious damage to the vehicle and sometimes even the invalidity of the guarantee Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS S TOOLS CHAR o U m gt r o MAIN gt Z m gt Z m ELE SYS ELECTRICA
142. sc Quantity Additional headlamp bulbs 12V 55W H3 ELE SYS 56 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system Fuses AUXILIARY FUSES A Stop horn coil GPS hazard button lighting coils light relay passing 15 A Tail lights starter motor 15 A C Free 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 MAIN FUSES 1 Battery recharge 40 A 2 Motion main fuse 30 A NOTE THERE IS ONE SPARE FUSE Control unit Model Magneti Marelli IAW 5 AM2 BROWN connector pin configuration Pin Use 1 Not used 2 Not used 3 Ignition potentiometer signal 4 Not used 5 Engine temperature signal Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 57 Electrical system 6 Not used 7 Not used 8 Not used 9 Stepper motor 10 Right cylinder coil control 11 Not used 12 Not used 13 Not used 14 Air temperature 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 27 Not used 28 Left cylinder injector control 29 Igni
143. 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 continuity of the green brown cable if it is not OK restore if OK replace the sensor Indication on Axone always RETRACTED disconnect the terminals from the sensor and check if there is continuity between the two PINS with stand down if there is continuity replace the sensor if the circuit is open it means that the brown green cable cable harness side from PIN 2 of the sensor to PIN 38 of the BLUE connector is shorted to ground restore the cable harness Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 77 Electrical system STELVIO 1200 NTX Bank angle sensor Function it tells the vehicle position to the control unit Operation Operating principle When the sensor is inverted the circuit is closed to ground when the Marelli control unit detects this earthing it disables the fuel pump circuit and the engine start up circuit via the injection relay Level in wiring diagram Start up enabling switches Location Electrical Pin out Sensor under the saddle right side Connector near the sensor characteristics Sensor in vertical position open circuit resistance 62 kOhm Sensor inverted closed circuit resist ance below 0 5 kOhm 1 Voltage 12V 2 Ground connection AXONE STATUSES Fall sen
144. sor Example value Normal Tip over DIAGNOSIS Indication on Axone always Normal even when the sensor Is inverted disconnect 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 not check the Marelli control unit connector PIN 35 of the BLUE connector Indication on Axone always Tip over disconnect the connector and check if there is con tinuity between the two PINS when the sensor is in vertical position if there is continuity replace the sensor if there is not it means that with key set to KEY ON there is no 12V voltage at PIN 1 restore the cable harness whose pink yellow cable will be shorted to ground ELE SYS 78 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system Air temperature sensor instrument panel Function It tells the ambient air temperature to the instru ment panel Operation Operating principle NTC type sensor resistance sensor inversely variable with temperature Level in wiring diagram Temperature sensors Location Sensor under the instrument panel Connector
145. sor on the crankcase and move it until it makes contact 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 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 147 Engine Cylinder piston assembly STELVIO 1200 NTX Key 1 Right cylinder Piston Screw Top piston ring Middle piston ring Oil scraper piston ring Pin Snap ring WD 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 ENG 148 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS Remove the head the gasket between the head and the cylinder and the two dowel pins e Slide off the movable chain slider Remove the cylinder from the stud bolts Remove the two dowel pins on the stud bolts Remove the two gaskets between the crankcase and the cylinder Cover
146. stainless steel disc CHAR 13 Characteristics Wheels and tyres Wheel Front standard Front alternative Front alternative Rear standard Rear alternative Rear alternative STELVIO 1200 NTX WHEELS AND TYRES STELVIO NTX Model Metzeler Tourance Metzeler Karoo Pirelli Scorpion Sync Metzeler Tourance Metzeler Karoo Pirelli Scorpion Sync Wheel rim Measure 2 50 x 19 2 50 x 19 2 50 x 19 4 25 x 17 4 25 x 17 5 90 x 17 ment 110 80 R19 59V 110 80 R19 59R M S 110 80 R19 59V 150 70 R17 69V 150 70 R17 69R M S 180 55 R17 73V Tyre pressure with rider only 2 4 bar 240 kPa 34 8 PSI 2 5 bar 250 kPa 36 3 PSI 2 5 bar 250 kPa 36 3 PSI 2 7 bar 270 kPa 36 1 PSI 2 7 bar 270 kPa 36 1 PSI 7 2 9 bar 290 kPa 42 1 PSI Tyre pressure rider passenger 2 5 bar 250 kPa 36 3 PSI 2 5 bar 250 kPa 36 3 PSI 2 5 bar 250 kPa 36 3 PSI 2 9 bar 290 kPa 42 1 PSI 2 9 bar 290 kPa 42 1 PSI 7 2 9 bar 290 kPa 42 1 PSI Maximum speed limit 2 170 km h 105 mi h Tyre pressure must be adjusted to suit terrain conditions for off road use Do not install on vehicles equipped with ABS WHEN FITTING Metzeler Karoo TYRES THE MAXIMUM SPEED WARNING LABEL INCLUDED WITH TYRES MUST BE APPLIED TO THE SPEEDOMETER USE EXTREME CAUTION WHEN RIDING ON
147. 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 closed loop the value must be close to 0 values not within the 10 and 10 range may indicate a fault In an open circuit the lambda probe signal is too low Therefore the control unit takes it as a lean mixture condition and will try to enrich it The value read will be 25 AXONE STATUSES Lambda check Example value Open loop Closed loop ELE SYS 68 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system Closed loop indicates that the control unit is using the lambda probe signal to keep the combustion as close as possible to the stoichiometric value AXONE ELECTRICAL ERRORS Lambda probe P0130 shorted to positive Error cause Excessive voltage battery voltage has been detected at PINS 32 and 22 of the BLUE connector Troubleshooting if shorted to positive with the key set to ON disconnect the sensor connector and measure voltage at PIN 1 on the cable harness side white yellow cable if there is voltage 5 or 12 V restore the cable harness it there is no voltage mea
148. sure voltage at PIN 2 cable harness side green white cable and if there is voltage restore the cable harness if there is no voltage replace the lambda probe Lambda probe heating P0135 shorted to positive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 11 of the BLUE connector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 11 of the BLUE connector Troubleshooting if shorted to positive disconnect the probe connector and check the sensor 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 if there is battery voltage at PIN 4 if not OK check the red black cable cable harness side between the probe connector and 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 If there are also coil and injector errors check that relay and its excitation a
149. t 26 Nm 19 18 Ibf ft 25 Nm 18 44 Ibf ft 10 Nm 7 38 Ibf ft 10 Nm 7 38 Ibf ft 10 Nm 7 38 Ibf ft 6 Nm 4 42 Ibf ft 10 Nm 7 38 Ibf ft 25 Nm 18 44 Ibf ft 18 Nm 13 28 Ibf ft 25 Nm 18 44 Ibf ft N Le oe Torque in Nm 20 Nm 14 75 Ibf ft 20 Nm 14 75 Ibf ft 10 Nm 7 38 Ibf ft 10 Nm 7 38 Ibf ft 10 Nm 7 38 Ibf ft 20 Nm 14 75 Ibf ft 15 Nm 11 06 Ibf ft 40 Nm 29 5 Ibf ft Loctite 243 20 Nm 14 75 Ibf ft Loctite 648 40 Nm 29 5 Ibf ft 20 Nm 14 75 lof ft 40 Nm 29 5 Ibf ft Torque in Nm 40 Nm 29 5 Ibf ft 80 Nm 59 Ibf ft 42 Nm 30 98 Ibf ft Loctite 243 20 Nm 14 75 Ibf ft 10 Nm 7 38 Ibf ft Torque in Nm 10 Nm 7 38 Ibf ft 20 Nm 14 75 Ibf ft 40 Nm 29 5 Ibf ft 10 Nm 7 38 Ibf ft 10 Nm 7 38 Ibf ft Torque in Nm 8 Nm 5 9 Ibf ft 150 Nm 110 6 Ibf ft 200 Nm 147 51 Ibf ft 30 Nm 22 13 lof ft 7 Nm 5 16 lof ft 30 Nm 22 13 Ibf ft 25 Nm 18 44 Ibf ft Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Characteristics ALTERNATOR Name Alternator fixing screw TCEI M8x45 1 Alternator fixing nut M10x1 5 1 Alternator pulley nut on crankshaft M16 1 Belt tension Alternator belt cover screw TCEI M6x16 4 Alternator belt cover screw radiator bracket retainer TCEI M6x40 2 GEAR Name Gear shift cable lever nut Gear shift tie rod lever nut on gear pre selector Gearbox to crankcase f
150. t circuit at 5V Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 79 Electrical system STELVIO 1200 NTX If a short circuit to ground is detected at PIN 10 of the instrument panel connector the display will show a full scale temperature indication of 60 C Check the ground insulation of the sensor connector pink cable if there is a connection restore the cable harness if it is earth insulated check that sensor resistance is correct if it is not OK replace the sensor if it is OK replace the instrument panel RUN STOP switch Function lt tells the control unit if the driver wishes to enable engine start up or to keep the engine running Operation Operating principle If the driver wants to shut off the engine or to disable engine start up the switch should be open i e the Marelli control unit should not detect voltage at PIN 27 of the BLUE connector Level in wiring diagram Start up enabling switches Location right light switch connector right side near the coil Electrical characteristics M STOP position the circuit is open RUN position closed circuit continuity PIN sky blue orange cable OV 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
151. tance 0 replace the sensor if resistance is correct it means that the pink black 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 ambient temperature Check also that the sensor electrical characteristics are observed replace the sensor if not OK if it is OK check the sensor connector and the Marelli control unit connector Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 67 Electrical system STELVIO 1200 NTX Lambda sensor Function It tells the control unit whether combustion is lean or rich Operation Operating principle The Marelli injection control unit reads and inter prets a voltage generated by the difference in oxy gen content between the exhaust fumes and the ambient It does not require an external supply source but in order to work properly it should reach a high operating temperature that is why there is a heating circuit inside Level in wiring diagram Lambda Probe Location Sensor exhaust pipe Connector near the probe Electrical characteristics Heater circuit 12 14 Q at 20 C 68 F Pin out 1 Sensor signal black wire 2 Sensor signal grey wire 3 Heater ground connection white 4 Heater power
152. ted Instrument panel lighting License plate light Turn indicator warning light Neutral gear warning light Alarm warning light Shift indicator Side stand down warning light Low fuel warning light High beam warning light ABS warning light Frame and suspensions Specification Type Trail Steering rake Front Front wheel travel Rear Unloaded shock absorber spring length Rear wheel travel Specification Size A Size B Brakes Specification Front Rear Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Desc Quantity 12 V 55 W 60 W H4 12V 10 LED 12 V 55W LED 12V 5W LED LED LED LED LED LED LED CHASSIS Desc Quantity High strength tubular steel frame with engine as stressed ele ment 125 mm 4 92 in 27 Upside down telescopic hydraulic fork with 50 mm 1 97 in di am stanchions and radial calliper mounting with adjustable spring preload and hydraulic compression and rebound damp ing 170 mm 6 69 in single sided swingarm with progressive linkage and mono shock with adjustable hydraulic rebound and compression damping and spring preload 180 mm 7 09 in 155 mm 6 10 in SIZES A AND B Desc Quantity 745 0 mm 29 33 in 403 16 mm 15 87 in BRAKES Desc Quantity dual 320 mm 12 6 in diam stainless steel floating wavy discs with radial callipers with 4 differentiated horizontally opposed pistons 282 mm 11 1 in diam
153. ten ENG 169 Engine STELVIO 1200 NTX Insert the joint in the oil pump Fit the nipple with the gasket on the crankcase Tighten the nipple to the prescribed torque Removing the oil sump NOTE TO REMOVE THE OIL SUMP PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL If necessary the filter can be removed with the suitable special tool Specific tooling 01 92 91 00 Wrench for removing the cover on sump and filter Unscrew remove the oil level plug and collect the O Ring ENG 170 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Undo and remove the fourteen screws i Per nni SR fixing the oil sump to the engine crank Case Undo and remove the four screws Remove the flange Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 171 Engine STELVIO 1200 NTX Undo and remove the two screws Remove both filters Unscrew and remove the plug Remove the thermostatic valve e Unscrew and remove the pressure re lief valve plug Remove the pressure relief valve com ponents ENG 172 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Refitting the oil sump Place the pressure relief valve compo nents correctly Screw the pressure relief valve
154. tering the service code KEY CHANGE and program the new keys Battery recharge circuit Checking the stator Single phase generator with regulated voltage Maximum load 40A 550W Charging voltage 14 2 14 8 V 5000 rpm ELE SYS 54 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Electrical system Start up system check pick up input about 100 A level indicators Petrol pump Input 3 5 to be measured between pins 1 and 2 with 12V voltage Fuel level sensor Resistance to be measured between pins 3 and 4 250 300 Ohm with fuel level equal to 0 litre 100 Ohm with fuel level equal to 11 25 litres 20 43 pt 10 20 Ohm with fuel level equal to 22 5 litres 40 86 pt The low fuel warning light turns on with values over 230 Ohm In case there is anomaly on the fuel probe the low fuel warning light flashes on the instrument panel The alarm warning light on the instrument panel does not light up and the word Service is not displayed Lights list FRONT HEADLAMP Specification Desc Quantity Front daylight running light 12V DW Low high beam headlight halogen 12 V 55 W 60 W H4 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 55 Electrical system STELVIO 1200 NTX REAR LIGHT Specification Desc Quantity Tail light stop light LED License plate light 12V 5W ADDITIONAL HEADLAMPS Specification De
155. the circlip Remove the gear of the sixth gear Remove the circlip and collect the shoulder washer Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 109 Engine STELVIO 1200 NTX e Remove the gear of the fourth gear and collect the ball bearing Remove the gear of the third gear and WE collect the ball bearing cage and the shoulder washer Remove the circlip 3 Remove the gear of the fifth gear ENG 110 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Remove the circlip the shoulder wash er and remove the gear of the first gear collect the ball bearing cage Remove the bearing if necessary See also Disassembling the gearbox Checking the primary shaft Measure coaxiality of the main shaft with a dial gauge and a centring device and replace it if not complying with specifications Characteristic Shaft coaxiality limit 0 08 mm 0 0031 in Check transmission gears for signs of pitting and wear and replace damaged gears if necessary Check the gear fitting teeth for cracks damage and wear and replace those damaged if necessary Check the transmission gears movement and if it is not regular replace the damaged part Checking the secondary shaft Measure the coaxiality of the transmission shaft with a dial gauge and a centring device and re place
156. 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 149 Engine STELVIO 1200 NTX Mark the piston crown on the exhaust side so as to remember the refitting po sition Remove the piston Fitting the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS The reference on the piston ring must be facing the piston crown Fit the piston rings on the piston the oil scraper 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 snap rings on the piston e 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 ASSEMBLE PISTONS AND CYLINDERS OF DIFFERENT SELECTOR TYPES ENG 150 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVI
157. tion potentiometer power supply 30 Not used 31 Not used 32 Ignition potentiometer negative 33 Not used 34 Revolution sensor anti jamming cable 35 Engine revolution sensor signal 36 Not used 37 Right cylinder injector control 38 Left cylinder coil control BLUE connector pin configuration Pin Use 1 Pin 85 ignition relay control 2 Not used 3 Not used STELVIO 1200 NTX ELE SYS 58 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX 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 probe signal 23 Not used 24 Vehicle speed signal input 25 Not used 26 Not used 27 Engine stop signal input 28 Ignition signal input 29 CAN L line ccm instrument panel 30 Not used 31 Not used 32 Oxygen probe power supply 33 Clutch sensor signal 34 Not used 35 Fall sensor signal 36 Not used 37 Not used 38 Side stand sensor signal Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system ELE SYS 59 Electrical system STELVIO 1200 NTX Battery 12 V 18 Ampere hour
158. 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 ENG 164 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine 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 interchange them upon refitting because they have a different length Lubrication Conceptual diagrams P GC A Ki F WA us P a een d d TT wf d SzcAb Wor oa i ET WEN LLL v VA di Ka is p fw es A E LER Deen Li la LS n 1 L E d lu rm pm 1 A H E ik sel 3 Kg P GEN D ZP ER Li i r r d A Kafe E taria Je KK e aud D 1 E rt ue i 1 er da kl n QU zg Wa H H k a ih W mi y i L r 7 ir ba D bk eich 5 SL a Ai ie i F P rt JJ LM A P I Mr p I Le i Wb A m W lt To X un w OSC o Kei l 1 A n CN xm 35 A Key Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 165 Engine STELVIO 1200 NTX Oil cooling radiator Oil delivery pipe to heads Oil delivery pipe to radiator Oil pump
159. ty 2305 mm 90 75 in 910 mm 35 83 in Maximum width of vehicle with accessories Minimum maximum height adjustable windshield Saddle height 1080 mm 42 52 in 1395 1440 mm 54 92 56 69 in 800 mm 31 5 in 0000 Minimum ground clearance J mmG in Wheelbase Kerb weight 185 mm 7 3 in 1535 mm 60 43 in 251 kg 553 Ib Kerb weight of vehicle with accessories Engine Specification Type ENGINE 278 kg 613 Ib Desc Quantity Four stroke 90 transverse V twin 2 Number of cylinders Cylinder layout 90 V Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAR 11 Characteristics Specification Bore stroke Engine capacity Compression ratio Electric Idle speed Clutch Lubrication system Air filter Cooling Timing system diagram Values valid with control clearance between rocker and valve Transmission Specification Primary drive Gearbox 1st gear ratio 2nd gear ratio 3rd gear ratio 4th gear ratio 5th gear ratio 6th gear ratio Final drive Ratio Capacities Specification Engine oil Gearbox oil Transmission oil Fuel reserve included Fuel reserve Seats Maximum weight limit Electrical system Specification Spark plug Alternatively Spark plug Electrode gap Battery Alternator permanent magnet type Main fuses Auxiliary fuses ABS fuses Front daylight running light CHAR 12 STELVIO 1200 NTX Desc
160. ues found consult the chart at the bottom of the page to decide the thickness of the gasket to be fitted between cylinder and head Unlock crankshaft rotation Rotate the crankshaft by 90 until the right cylinder piston reaches the TDC Lock crankshaft rotation Place the tool on the right cylinder stud bolts to determine the squish X Specific tooling 020676Y Comparator support for piston position checking Repeat the same operations to determine the thickness of the left cylinder gasket between cylinder and head also for the right cylinder CYLINDER GASKET THICKNESS HEAD Specification Desc Quantity Value X 0 56 0 37 mm 0 022 0 0146 in gasket thickness 0 65 mm 0 0256 in Value X 0 37 0 19 mm 0 0146 0 0075 in gasket thickness 0 85 mm 0 0335 in Value X 0 19 0 mm 0 0075 0 in gasket thickness 1 05 mm 0 0413 in Recommended products chart RECOMMENDED PRODUCTS Product Description Specifications AGIP RACING 4T 10W 60 Engine oil SAE 10W 60 As an alternative to rec ommended fluids use top branded oils with performances that meet or exceed the requirements of CCMC G 4 API SG specifications AGIP GEAR SAE 80 W 90 Transmission oil AGIP GEAR MG S SAE 85 W 90 Gearbox oil AGIP FORK 7 5W Fork oil SAE 5W SAE 20W AGIP GREASE SM2 Lithium grease with molybdenum for NLGI 2 bearings and other points needing lubri cation Neutral grease or petroleum jelly BATTERY POLES AG
161. und insulation from coil connector or control unit connector If this is not OK restore the cable harness AXONE PARAMETERS Right coil ignition advance AXONE ACTIVATION Right 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 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 in case of lack of activation AXONE ELECTRICAL ERRORS Right coil P0352 shorted to positive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 10 of the BROWN con nector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 10 of the BROWN connector Troubleshooting if shorted to positive disconnect the coil connector set the key to ON activate the coil with Axone and check voltage at connector PIN 2 if there is voltage restore the cable harness if voltage 0 replace the coil if the circuit is open shorted to negative check the coil connector and the Marell
162. under the instrument panel Electrical characteristics Pin out Resistance at 0 C 32 5 kOhm 5 Resistance at 25 C 10 0 kOhm 5 1 Voltage 5V 2 Ground connection Instrument panel Air temperature sensor failure DSB 06 Error cause An oil sensor failure is signalled when it is detected that the sensor circuit is open or shorted to positive Troubleshooting Notes Check the sensor connector and the instrument panel connector PINS 10 and 18 If they are not OK restore If OK check continuity of the pink cable between the sensor connector and the instrument panel connector PIN 10 if it is not OK restore the cable harness if OK check the correct sensor resistance if it is not OK replace the sensor if it is OK check continuity of the brown cable between the sensor connector and PIN 18 of 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 connector PIN 1 if there is no voltage replace the instrument panel if there is approximately 12V restore the cable harness there is a short circuit in the battery If there is 5V voltage connect a 10 kOhm resistance to PIN 1 of the sensor con nector and to the vehicle ground connection if with key set to KEY ON the voltage measured upstream the resistance decreases replace the instrument panel If voltage con tinues to be approximately 5V restore the pink cable there is a shor
163. val and refitting AP9100838 Tool for valve pressure plate ENG 138 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Remove the special tool Installing the rocker arms Fit the camshaft e Fit the two rods WARNING MAKE SURE THAT THE NOTCH ON THE DIPSTICK BODY FACES THE ROCKING LEVER Place the two rocking levers in the cam tower seats Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine ENG 139 Engine STELVIO 1200 NTX Place the U bolt on the rocking levers making sure the two reference pins match the seats on the cam tower Tighten the two screws operating diag onally and in stages 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 Place the camshaft with the gear seat on the dowel side Place the U bolt on the camshaft mak ing sure the two reference pins match the seats on the cam tower Tighten the four screws operating di agonally and in stages ENG 140 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Engine Timing Removing the phonic wheel e Remove the generator and the timing V Ca i b e w system cover Unscrew and remove the nut and
164. x 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 215 Chassis STELVIO 1200 NTX Fit the dust guard cap in the gearbox Lock the dust guard cap with a new clamp e Place the reaction rod into its seat e Insert the screw M Screw the nut fixing the reaction rod Place the connecting rod 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 CHAS 216 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten STELVIO 1200 NTX Chassis Bevel gears Removing Remove the rear wheel Unscrew and remove the two screws Remove the speed sensor from the fork Unscrew and remove the nut fixing the reaction rod Remove the screw Fasten the reaction rod to the chassis with a clamp Undo and remove the four screws Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAS 217 Chassis STELVIO 1200 NTX Remove the transmission casing slid
165. y voltage Starter diagnosis Engine revolution sensor Lambda heater SPEED SENSOR CAN line diagnosis RAM memory ROM memory Microprocessor Checksum EPROM Adjustable parameters screen page ADJUSTABLE PARAMETERS This screen page is used to adjust some control unit parameters STELVIO 1200 NTX Desc Quantity Possible short circuit in the earth lead battery or open circuit If both injectors do not work the engine does not work Possible short circuit in the earth lead battery or open circuit the engine does not start Possible short circuit in the earth lead battery or open circuit If both coils do not work the engine does not work Possible short circuit in the earth lead battery or open circuit If both coils do not work the engine does not work Possible short circuit in the earth lead battery or open circuit recovery function noticeable for the customer due to no idle management Battery voltage detected is too low 7V or too high 16V fora certain period Possible short circuit in the earth lead battery or open circuit Possible open circuit Possible short circuit in the earth lead battery or lambda probe heating circuit open Possible short circuit in the earth lead battery or soeed sensor circuit open also possible lack of supply from the control unit Possible error on the CAN line short circuit or line break or no signal or plausibility error detected Possible internal control unit error Also check the
166. ystem Front Any air trapped in the hydraulic circuit acts as a cushion absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper Air in the system causes a spongy feeling in the brake control and poor braking efficiency CAUTION CONSIDERING THE DANGER FOR VEHICLE AND RIDER IT IS STRICTLY NECESSARY AFTER REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CON DITIONS THAT THE HYDRAULIC CIRCUIT BE AIR PURGED NOTE THE FOLLOWING OPERATIONS REFER TO ONLY ONE FRONT BRAKE CALLIPER BUT APPLY TO BOTH CALLIPERS THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED WHILE PURGING THE HYDRAULIC SYSTEM FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR Remove the rubber protection cover from the bleed valve Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con tainer to collect the fluid e Remove the front brake fluid reservoir cap Operate the brake lever and then open the bleed valve on the calliper by a 1 4 turn to let the air escape Close the bleed valve before reaching the end of travel of the brake lever then repeat the operation until air no longer escapes Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BRAK SYS 247 Braking system STELVIO 1200

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