Home

Stelvio 1200 8V - Service Manual - 2011

1. 2 Viti chiusura mozzetti M6x30 10 Nm 7 38 Ibf ft Fork cap 1 1 Nm te Ibf ft SUSP 248 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Suspensions Diagram Key Complete front fork TCE screw Washer TE flanged screw Stem right wheel holder Bushing Stem left wheel holder Complete right pumping member Nut 10 Complete left pumping member ON DO sa nm 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 SUSP 249 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions Stelvio 1200 MY11 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 Adjustment The front suspension consists of a hydraulic fork connected to the headstock by means of two plates For adjusting the suspension set up each stan chion has an upper nut 1 for adjusting spring preloading and an upper set screw 2 act on the right stem set screw to adjust hydraulic rebound damping act on the left stem set screw to adjust hydraulic compression damping ADJUSTMENTS Regular adjustment standard rider only Medium load setting for
2. ENG VE 138 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine from vehicle Connect the revolution sensor connec tor Connect the horn connectors Connect the engine temperature sen sor connector Place the oil radiator Tighten the two screws ENG VE 139 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine from vehicle Stelvio 1200 MY11 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 Fit the saddle Install the complete exhaust ENG VE 140 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 Gearbox Diagram Key 1 Ball bearing ENG 142 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Circlip Thickness Pin Complete desmodromic Ball bearing Spring Spacer N OO N 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 be
3. i i gt MAIN 62 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Maintenance km x 1 000 15 10 20 30 40 50 60 70 80 Brake lines 3 pup eee RR Brake pad wear 1 Transmission fluid Check Keep the vehicle upright with both wheels on the ground Unscrew and remove the cap dipstick 1 he 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 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 and if necessary replace the sealing washer of drainage plug 3 Remove any metal scrap attached to the drainage plug 3 magnet e Screw and tighten the drainage plug 3 Pour new oil through the fill op
4. Vite TE Flang fissaggio sensore 1 10Nmi 788 bffii i cs 110 Nm 81 13 Ibf ft CHAR 35 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 REAR SUSPENSION pos Description Type Quantity Torque Notes 1 Vite TE Flang fissaggio superiore ammortiz M10x80 1 50 Nm 36 88 Ibf ft E zatore 2 Vite TCEI fissaggio biella doppia forcellone M10x82 1 50 Nm 36 88 Ibf ft 3 Vite TE fissaggio biella doppia ammortizza M10x47 1 40 Nm 29 50 Ibf ft tore 4 Vite TE flang fissaggio biella singola biella M10x95 1 50 Nm 36 88 Ibf ft doppia 5 Vite TE flang fissaggio biella singola al telaio M10x85 1 50 Nm 36 88 Ibf ft SADDLE pos Description Type Quantity Torque Notes Vite TBEI fissaggio piastra attacco sella 10 Nm 7 38 lbfft 2 Dado serratura 1 Manual CHAR 36 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics Engine O E S Pb de 5 A LUBRICATION SYSTEM pos Description Type Quantity Torque Notes 1 Pump outlet oil pipe nipple M14x1 5 1 40 Nm 29 50 Ibf ft 2 Slot screw for oil pipe on the cylinder head M14x1 5 2 20 Nm 14 75 Ibf ft 3 Nipple on the radiator and the oil pipe M16x1 5 2 20 Nm 14 75 Ibf ft Apply vaseline oil 4 Oil delivery pipe to radiator slot screw M14x1 5 1 35 Nm 25 81 Ibf ft 5
5. tn Qum Te 1 i Pai AR i L i d at a V l i i n E AY E i 1 LIZA E NE E leo M x Sy Pinion oil seal buffer FRONT FORK Description Weight S TOOLS 59 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Special tools Stelvio 1200 MY11 Stores code Description AP8140149 Protection for fitting operations me p WW i 9100903 Marzocchi fork oil seal 45 mm 1 77 in S TOOLS 60 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Maintenance Stelvio 1200 MY11 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 1 Check and clean and adjust or replace if necessary before every journey 2 3 4 Check at each engine start 2 Replace every 2 years or 20000 Km 12427 mi 3 Replace every 4 years 4 5 It is recommended to lubricate stands and footrests periodically with spray grease after use in par ticularly hard conditions dirty with salts dust etc or after long inactivity periods 6 Lubricate if you are
6. Undo and remove the two screws ENG 164 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Undo and remove the two screws Remove the alternator frame Remove the sealing ring if necessary See also Fuel tank Tensioning the belt Remove the left fairing lug Undo and remove the two front fixing screws of the oil radiator e Collect the spacers 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 ENG 165 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Remove the generator belt cover by lightly loosening the oil radiator 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 e Screw the set screw Tighten the lock nut Specific tooling 020677Y Generator belt tensioner lever for belt tensioning Locking torques N m Belt tension 50 Nm 36 88 Ibf ft See also Engine oil cooler ENG 166 Revente Interdite Revendita Vietata R
7. 3 Nipple on the radiator and the oil pipe M16x1 5 2 20 Nm 14 75 Ibf ft Apply vaseline oil 4 Oil delivery pipe to radiator slot screw M14x1 5 1 35 Nm 25 81 Ibf ft 5 Jets fixing screw 3 Using a T spanner close Loctite 243 by hand 6 Minimum oil pressure sensor M12 1 25 Nm 18 44 Ibf ft 7 Intake oil filter fixing screw 2 4 Nm 2 95 Ibf ft ENG 218 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine OiL RADIATOR pos Description Type Quantity Torque Notes 1 Viti fissaggio radiatore a telaio M6x30 3 10 Nm 7 38 Ibf ft Oi Pump pos Description Type Quantity Torque Notes Oil pump fixing screw um 10 Nm 7 37 Ibf ft Loctite 243 Oil pump driven gear locking nut 8 Nm 73 90 Ibf ft Loctite 243 ENG 219 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 pos Description Type Quantity Torque Notes 3 Oil pressure valve cap 1 40 Nm 29 50 Ibf ft CRANKCASE AND Sump pos Description Type Quantity Torque Notes 1 otud bolt M8x75 2 10 Nm 7 37 Ibf ft 2 Stud bolt M8x66 3 10 Nm 7 37 Ibf ft 3 Crankshaft rear support flange fixing screw M8x25 8 26 Nm 19 18 Ibf ft 4 Oil cap on the crankcase 2 25 Nm 18 44 Ibf ft 5 Flange fixing screw under the crankcase M6x60 2 10 Nm 7 37 Ibf ft 6 Flange fixing screw under the crankcase
8. Undo and remove the upper screw and collect the washer and the nut BODYW 341 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Bodywork Stelvio 1200 MY11 e Undo and remove the front lower Screw e Undo and remove the three screws Remove the right under seat fairing Disconnect the connectors of the rear brake lever switch and the speed sen SOr Release the cable harness from the clamps Undo and remove the two rear lower screws collect the washers and the spacer BODYW 342 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Bodywork 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 Rimuovere la vite interna prestando at tenzione a recuperare la relativa ron della e Himuovere la vite inferiore esterna Scollegare il connettore della freccia anteriore e rimuovere il fianchetto lat erale CAUTION BODYW 343 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Bodywork Stelvio 1200 MY11 ESEGUIRE LA MEDESIMA OPERAZIONE DI SMONTAGGIO ANCHE PER IL FIANCHETTO OP POSTO Air box ay A AIR FILTER pos Description Type Quantity Torque Notes Vite fissaggio cassa
9. 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 Undo and remove the three screws Remove the oil pump Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Remove the gasket between the crankcase and the oil pump See also Removing the generator Installing Place a new gasket between the crank case and the oil pump Place the oil pump Tighten the three screws fixing the oil pump Place the driving pin on the oil pump shaft ENG 225 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 Insert the joint in the oil pump ENG 226 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Fit the nipple with the gasket on the crankcase Tighten the nipple
10. FITTING Fit the stop ring 6 in the support 5 with suitable pliers CHAS 291 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 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 IT pliers p gt E 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 TROUBLESHOOTING Possible Cause Operation 1 Fitting error of the radial seal or seal damaged 2 Sliding 1 Replace the sealing ring and fit it correctly with the suitable surface of the wheel axle seal spoiled or damaged tool 2 Replace the wheel axle CHAS 292 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis Possible Cause Operation 1 Casing not sealed 2 Closing screws of the casing shells not 1 Open the casing shells clean the surfaces seal and reas tightened to the prescribed torque semble the casing shells 2 Tighten the closing screws to the correct torque 1 Dirt between the sealing ring and the casing 2 A used seal 1 Clean and tighten to the correct torque ing ring has been fitted 3 Plug not tightened to the prescribed 2 Replace the sealing ring torque 3 Tighten the plug to t
11. 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 ENG 208 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 M 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 timin
12. 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 Navigator 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 238 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Power supply e Make sure there are no errors in the control unit otherwise solve them and repeat the procedure Make sure the left throttle is fully in DO NOT TOUCH THE THROTTLE ABUTMENT SCREW OR THE THROTTLE BODY MUST BE REPLACED CHECK P THAT THE THROTTLE RETURN CABLE IS NOT TAUT 4 J Tol j p i m Li ra a 1 j bi i j Jt N Ee Fd J j The instrument 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 instrument 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
13. 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 NAVIGATOR 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 position 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 electrical circuit diagram Temperature Sensors Location sensor all interno della V del motore 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 7 Resistance at 20 C 68 F 8 Resistance at 30 C 86 F 9 Resistance at 40 C 104 F 10 Resistance at 50
14. 1 Thermal group fixing stud bolt M10x1 25 8 5 Nm 3 69 Ibf ft Loctite 243 2 Connecting rod screws 4 40 Nm 29 50 Ibf ft Pre tightening 2 Connecting rod screws 4 80 Nm 59 00 Ibf ft Final tightening 3 Right hydraulic tensioner cover 1 42 Nm 30 98 Ibf ft 4 Left hydraulic tensioner cover 1 30 Nm 22 13 Ibf ft FUEL SUPPLY SYSTEM pos Description Type Quantity Torque Notes 1 Vite fissaggio protezioni corpo farfallato 6 2 10 Nm 7 38 Ibf ft CHAR 44 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 pos BLow Bv SYSTEM Description Type Quantity Torque Vite fissaggio distanziale vaso espansione SWP 1 10 Nm 7 38 Ibf ft Blow By a motore M5x14 Reduction joint for oil return pipe 1 20 Nm 14 75 Ibf ft Oil return pipe on sump 1 20 Nm 14 75 Ibf ft Characteristics Notes Vaseline oil Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten CHAR 45 Characteristics Stelvio 1200 MY11 STARTER MOTOR pos Description Type Quantity Torque Notes Starter motor fixing screw 2 2B Nm 18 44 IbFft 2 Stud bolt 1 10 Nm 7 37 Ibf ft Starter motor cover fixing screw M6x10 8 Nm E 90 Ibf ft ft Pump pos Description Type Quantity Torque Notes mm Oil pump fixing screw M6x45 3 10Nm 7 37 Ibf ft Loctite
15. 87 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 TABLE C 1 Rear plug socket 2 Cable grommet 3 ECU diagnosis connector TABLE D 1 Adhesive cable grommet TABLE E 1 Plastic cable guides TABLE F 1 Medium clamp that groups the oxygen sensor leads the rear stop and the rear taillight cable har Ness ELE SYS 88 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 TABLE G 1 Fall sensor connector with cover TABLE 1 Cable grommets TABLE 1 Cable grommet 2 Lambda leads TABLE L 1 Reused clamps 2 Small clamp that has the lambda and the rear stop cable together with the pipes group Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system ELE SYS 89 Electrical system Stelvio 1200 MY11 General wiring diagram CENTRALINA ECU COMMETTORE MAREDNE CONNETTORE BLU E spie HO H AL n zn n n EIE Te LR Fu Lh A Cx key 1 2 3 4 MULTIPLE CONNECTORS CLUTCH SWITCH START UP RELAY MAINTENANCE RELAY ELE SYS 90 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 LIGHT LOGIC RELAY FOG LIGHTS RELAY OPTIONAL EQUIPMENT Right light switch LEFT LIGHT SWITCH HORN 10 AMBIENT AIR
16. Check that the fork pin threads and the fork fixing nuts are not damaged de formed or flattened otherwise replace them CHAS 274 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis 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 Installing e opread a 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 box spanner to tight en the ring nut Specific tooling 05 91 26 30 Tool for tightening the swingarm pin ring nut clutch hub CHAS 275 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 Tighten the two screws of the swing arm clamp Fit the dust guard cap in the gearbox Lock the dust guard cap with a new clamp Place the reaction rod into its seat Insert the screw Screw the nut fixing the reaction rod
17. GN C 5 Remove the exhaust end Removing the manifold tail pipe Remove the exhaust end and the ex haust manifolds Remove the starter motor protection in order to disconnect the lambda probe connector e 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 CHAS 297 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 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 Unscrew remove the two nuts on the head exhaust stud bolts e Retrieve the washers Loosen the clamp Remove the exhaust manifold CHAS 298 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis Engine oil cooler OiL RADIATOR pos Description Type Quantity Torque Notes 1 Viti fissaggio radiatore a telaio M6x30 3 10 Nm 7 38 Ibf ft Key 1 Complete oil radiator CHAS 299 Revente Interdite Revendita Vietata Resaling Forbide
18. 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 E 1 top piston ring e 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 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 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 Clearan
19. Remove the screws 16 Collect the ring 15 Remove the screws 7 Remove the casing 4 CHAS 280 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis Remove the clamp 12 Remove the cap 14 Collect the ring 13 Remove the support unit 8 Casing unit fitting CHAS 281 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 Casing unit fitting Assemble the dowel pins to the casing with the buffer and a hammer Assemble the casing to the special fastening tool Clean the casing faying surfaces carefully Heat the casing Pe ad Li Insert the support group in the casing CHAS 282 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis Assemble the cap and the ring Fit the cap on the support Fit the clamp Screw the clamp with the specific pliers Apply the prescribed sealant to the casing CHAS 283 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 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 Assemble the fixing scr
20. Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Braking system Stelvio 1200 MY11 CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEEDING AS DESCRIBED AT THE END OF THE CHAPTER Always fill the reservoir up to the reference MAX and refit the cap Check the stroke and the sensitivity of both the lever and the brake pedal If after bleeding the pedal or the lever stroke is too long check that there are no leaks in the braking system and if everything is ok continue bleeding operations using Navigator as described Detach the bleed hoses and close the bleed screws again to the correct tightening torque See also Front Rear REPLACE THE ABS CONTROL UNIT VEHICLE PREPARATION Connect the bleed bottle to the bleed screws of the front and rear callipers and open it Fully press down the lever and the brake pedal and fix them into position with the respective locking devices Close the bleed screws of the front and rear callipers and remove the bleed bottle Remove the damaged ABS control unit Note First of all detach the brake pipes that go from the ABS control unit to the brake pump 1 4 and immediately seal the opened unions of the ABS control unit with protective caps Afterwards remove pipes 2 3 that go from the ABS control unit to the brakes and also seal these unions with protective caps Install the new ABS control unit previ ously
21. Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Braking system light 5 on the instrument panel 4 turns off CAUTION IF THE ABS SWITCH IS PRESSED FOR MORE THAN TEN SECONDS THE SYSTEM DETECTS A FAILURE TO ACTI VATE THE ABS SYSTEM AGAIN TURN THE IGNITION SWITCH TO OFF AND THEN TO ON IN CASE OF FAILURE OR WITH ABS DISCONNECTED THE VEHICLE OPERATES AS IF IT DID NOT HAVE THIS SYSTEM 20 A fuse ABS Main fuse 6 Protects ABS Control unit Guide to diagnosis PREMISE Each time the key is ON if at least one current or stored error is detected the ABS warning light turns on permanently The ABS system is deactivated The system operates perfectly just as any other braking system without ABS The diagnosis requires exceeding the 5 km h 3 1 mph Each time the key is ON if at least one current or stored error of the ABS system is not detected the ABS warning light flashes When the 5 km h 3 1 mph are exceeded if errors are not detected the ABS warning light turns off if at least one malfunction is detected the ABS warning light turns on permanently The ABS system is deactivated The system operates perfectly just as any other braking system without ABS The detection of malfunctions may require more or less time according to the type of failure Error detection logic foresees that for the errors to be diagnosed one or more condi
22. SERVICE STATION MANUAL B043078 Stelvio 1200 MY11 SERVICE STATION MANUAL Stelvio 1200 MY11 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 riding it carrying out routine maintenance and using only Moto Guzzi Original Spare parts is fundamental For information about the nearest Official Dealer and or Service Centre consult the Yellow Pages or search directly on the inset map in our Official Website www motoguzzi it Only by purchasing Moto Guzzi Original Spare Parts will you get a product designed and tested during the bike designing phase Moto Guzzi Original Spare Parts are subject to systematic quality control procedures so that their reliability and performance over time is guaranteed The descriptions and illustrations given in this publication are not binding While the basic features as described and illustrated in this booklet remain unchanged Moto Guzzi reserves the right at any time and without being required to update this publication beforehand to make any changes to components parts or accessory supplies which it deems necessary to improve the product or which are required fo
23. SUSP 261 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions Stelvio 1200 MY11 Insert the spring holder cap in the sleeve Insert the preloading pipe with the two spring guides in the sleeve Fit the spring Tighten the nut completely Support the pumping member pin in order to screw the upper cover SUSP 262 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Suspensions Screw the upper cap on the pumping member pin 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 Once the operations are completed restore the spring preloading correct value Installing the fork legs Insert the fork stem in position Insert the wheel pin so that the stems are aligned SUSP 263 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions Stelvio 1200 MY11 Tighten the screws on the fork plates to the prescribed torque Tum nid arme mena INR E gt Steering bearing STEERING pos Description Type Quantity Torque Notes Fe Viti fissaggio piastra fermatubi BICE 6 Nm 4 42 Ibf ft BEE 2 _ Viti fissaggio piastre M8x30 20 Nm 14 75 Ibf ft o Headstock ring nut 40 Nm e 50 Ibf
24. 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 Assemble the sealing ring 3 to the ring nut 2 with the buffer CA715855 see Fig 1 and a ham Mer CHAS 288 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis Lubricate the sealing ring 3 Assemble the ring nut 2 Tighten the ring nut 2 with the special spanner s4 to the prescribe torque v j mE Bw Insert the stop ring 1 in the ring nut 2 in the in dicated direction CHAS 289 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 Assembly position of the stop ring 1 CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT Support unit CHAS 290 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis Support unit 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 Remove the stop rings 3 and 6 from the support 5 with suitable pliers NOTE THIS OPERATION DESTROYS THE SEALING RING Remove the ball joint 4 with a suitable buffer and a rubber hammer
25. As a consequence the system works like any regular braking system BRAK SYS 307 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Braking system Riding with an active ABS system At engine starter the ABS warning light 5 on the instrument panel 4 flashes until the vehicle exceeds 5 km h 3 1 mph If the ABS warning light remains on when the vehicle is running it means that a fault has been detected and the ABS system has been automatically deactivated Riding with a deactivated ABS system The warning light 5 turns on permanently the system was deactivated ABS device deactivation To deactivate the system proceed as follows Start the engine With the vehicle at a standstill press and hold the button After roughly three seconds the indicator light ABS 5 on the instrument panel 4 becomes steadily on Release the button immediately Now the ABS warning light 5 on the instrument panel 4 continues to be on the ABS system is then completely deactivated ABS system reactivation With the vehicle at a standstill press and hold the button After roughly three seconds the indicator light ABS 5 on the instrument panel 4 will start to flash Release the button immediately e Once riding the ABS system will be re activated only after riding faster than 5 km h 3 1 mi h and the ABS warning BRAK SYS 308 Stelvio 1200 MY 11
26. NAVIGATOR ERRORS Throttle actuator position sensor P0120 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 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 NAVIGATOR ADJUSTMENT ELE SYS 104 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system
27. Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics TELAIETTO pos Description Type Quantity Torque Notes Viti TCEI fissaggio telaietto M8x40 25 Nm 18 44 lbf f 2 Viti TE Flang M6x20 2 10 Nm 7 38 Ibf ft HANDLEBAR AND CONTROLS pos Description Type Quantity Torque Notes 1 Viti TCC fissaggio cavallotti superiori manu M8x30 4 25 Nm 18 44 Ibf ft brio CHAR 19 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 pos Description Type Quantity Torque Notes 2 Viti TE Flangiate fissaggio cavallotti inf man 2 50 Nm 36 88 Ibf ft ubrio 3 Vite autof 1 1 5 Nm 1 11 Ibf ft 4 Raccordo fissaggio pesi antivibranti M18x15 2 Nm Ibf ft 5 Viti TCEI fissaggio pesi antivibranti 2 10 Nm 7 38 Ibf ft Loct 243 6 Raccordi fissaggio specchi retrovisori M10 2 30 Nm 22 13 Ibf ft FRONT BRAKE LEVER pos Description Type Quantity Torque Notes 1 Viti TBEI fissaggio interruttore M4x12 1 3 Nm 2 21 Ibf ft 2 Lever pin 6 1 5 7 Nm 3 69 5 16 Ibf ft 3 Viti fissaggio tappo serbatoio 2 0 8 1 5 Nm 0 59 1 11 Ibf ft 4 Dado perno leva M6 1 10 Nm 7 38 Ibf ft 5 Viti fissaggio cavallotto M6 2 10 Nm 7 38 Ibf ft 6 Viti fissaggio tubo olio M10 1 23 26 Nm 16 96 19 18 Ibf ft CHAR 20 Revente Interdite Revendita Vietata Resaling For
28. nil Chem paih Harra pairi n Dan Tard or chi I ni Freda wriin Sh Patpa bari hae uh i Carson ko AB si Ri In bon brat fad Deshbexarci i Sur AB post dz u Ban san caduia lan r Drep tech ac 1 i Sin por i r1 H nacti 1 Erei CRG don rkl 1 Grades un 1 Pin iHrorndeh een gt 1 re bia L RII PTT ird diria in Freri Lt tom ine Cai Eu ore i gue oe Basra aa B DP bea MAIN CABLE HARNESS Description Viti TE Flang fissaggio piastre bobine Viti TCEI fissaggio bobine Viti TCEl fissaggio centralina Viti TCEl fissaggio supporto sensore temp olio 5 Viti TCEI fissaggio sensore di fase pos M6x20 M10x20 Quantity 2 2 2 2 2 1 2 Mek 1 Ic bris seen Torque 10 Nm 7 38 Ibf ft 2 Nm 1 47 Ibf ft 10 Nm 7 38 Ibf ft 11 Nm 8 11 Ibf ft 3 Nm 2 21 Ibf ft Loct 243 ELE SYS 73 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 Components arrangement ia d Th b 1 x A gt an A x E zt 2 h k LE Diu E orn m ET a ES key 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector 5 Throttle valve pot
29. screwing the lock nut Specific tooling 020677Y Generator belt tensioner lever for belt tensioning ENG 169 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 ENG 170 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 plate 6 Sprocket 7 TCEl screw 8 Clutch thrust plate ENG 171 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 CLUTCH pos Description Type Quantity Torque Notes 1 Clutch to crankshaft fixing screw 42 Nm 30 98 Ibf ft Tighten with cross sequence 2 Clutch external flange fixing screw on flywheel M7x16 6 20 Nm 14 75 Ibf ft Loctite 243 3 Start up crown fixing screw on flywheel
30. 243 ru Oil pump driven gear locking nut meli 8 Nm 5 90 Ibf ft Loctite 243 Cil pressure valve cap 40 Nm 29 50 Ibf ft CHAR 46 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics OiL RADIATOR pos Description Type Quantity Torque Notes 1 Viti fissaggio radiatore a telaio M6x30 3 10 Nm 7 38 Ibf ft 19 Testa DESTRA Pos Descrizione Tipo Quantit Coppia Note 1 Movable chain tensioner pad fixing screw 1 20 Nm 14 75 Ibf ft Loctite 243 CHAR 47 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 Pos Descrizione Tipo Quantit Coppia Note 2 Head tightening nut M10x1 25 4 15 Nm 11 06 Ibf ft Engine Oil Pre tightening 2 Head tightening nut M10x1 25 4 42 Nm 30 98 Ibf ft Final tightening 3 Head tightening screws chain compartment M6x120 2 10 Nm 7 37 Ibf ft 4 Plate locking screw and timing gear 1 30 Nm 22 13 Ibf ft Loctite 243 5 Timing cover fixing screw on the cylinder head M5x10 2 8 Nm 5 90 Ibf ft 6 Camshaft support fixing screw 6 18 Nm 13 28 Ibf ft 7 Vite fissaggio molla a tazza 1 18 Nm 13 28 Ibf ft 5 oo c 7 9 RT TESTA SINISTRA Pos Descrizione Tipo Quantit Coppia Note 1 Movable chain tensioner pad fixing screw 1 20 Nm 14 75 Ibf ft Loctite 243 2 Head tightening
31. 4 Type M10x55 50 Nm 36 88 Ibf ft Torque Notes Central part ree Lisa Lo PI SE PS an Caw Ruki Ses wizh mia TES IRL jg Main Mage a Bux opa m T sen cru Fab smi Zr AH cd Powe z Damhin der Her na inv fanar H Reid mediani Saik at Siro ar og relay Batang Vorrat a eb Fui bc Molin do rne Me tini Frond faq rh m csi Fee ca C team in E kr ral ry Fon rhi rind oe Chena mj Fas boiberis T 4 Caria ce d Hl adl alora Enn ri Fin sesti 1 al d ini ila ud Chgrn a 1 Harra mairi n i Diag Derstoluci cn 2 Tam ADS saran rain di imc ni i Frediss E Ti REI An Shines Pampa barn Errrla ka nn t ET TTE Ind dr post ce wii Fund pimp Ri larida uran qug Deg astio Ri rear no ind 1 1 Far AE post iisdem E IE 1 BE F is si FIR SARA Ban hr rade esu 1 Gana cada T ana si una Larga Drep sich Am Learns piiri ni Lat tha Tiris police apra 7 mom 3 LE lembo ro Draad ac 1 Funk pisi 2 iS i Sinni por Foe ies 41 o Der Viin fluxes 2 Fine Hoe werk 1 Flea bers 3 Fonti precise Geass
32. 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten 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 ELE SYS 105 Electrical system Stelvio 1200 MY11 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 NAVIGATOR FUEL INJECTION SYSTEM NAVIGATOR PARAMETERS Engine temperature In case of recovery this value is set by the control unit NAVIGATOR ERRORS engine temperature sensor P0115 open circuit shorted to positive shorted to negative Error cause If the circuit is
33. ELECTRICAL SYSTEM ENGINE FROM VEHICLE ENG VE ENG SUPP U O m 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 MY11 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 let the engine run 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 CANCAUSE 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 exhau
34. FUEL LEVEL SENSOR 10 AIR TEMPERATURE SENSOR 11 BATTERY 12 LEFT TURN INDICATOR CONTROL 13 14 15 16 GENERAL EARTH CONNECTION Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 125 Electrical system Stelvio 1200 MY11 17 OIL PRESSURE SENSOR INTAKE 18 SENSORS EARTH CONNECTION 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 26 CAN H 27 CONTROL RESET 28 LIGHTS RELAY ACTIVATION 29 ANTITHEFT DEVICE LED 412v 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 36 CAN L 37 HAZARD CONTROL 38 39 ABS 40 CONTROL UP ABS Modulator Pin Use 9 1 Ground connection Not used Speed signal for injection ECU ABS control unit power supply Not used Not used Asa WO N ABS deactivation switch ELE SYS 126 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system 8 ABS warning light 9 Not used 10 Not used 11 Rear ABS speed sensor supply 12 Rear ABS speed sensor signal ground 13 Front ABS spee
35. Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine ENG 211 Engine Stelvio 1200 MY11 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 A inside the crankcase and remove the con necting rods B See also Removing the flywheel Disassembling the piston Removing the cylinder Removing the cylinder head ENG 212 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 journ
36. MEM to the historical record STO In the next connection between Navigator and the control unit the historical errors STO are no lon ger shown ERRORS screen page 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 BRAK SYS 312 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristic Front speed sensor 5D90 electric malfunction Front speed sensor 5D91 the signal works irregularly Front speed sensor 5D92 the signal decreases periodically Front speed sensor no signal or speed measured too low in relation to the rear wheel 5D93 Front speed sensor 5D94 no accel eration after pressure reduction Front speed sensor 5D95 excessive measured speed Rear speed sensor 5DAO electric malfunction Rear speed sensor 5DA1 the signal works irregularly Rear speed sensor 5DA2 the signal decreases periodically Rear speed sensor 5DA3 no signal or speed measured too low in rela tion to the front wheel Rear speed sensor 5DA4 no accel eration after pressure reduction Rear speed sensor excessive meas ured speed 5DA5 Control unit missing valve calibra tion 5DD2 Control unit 5DD3 Recirculation pump 5DFO Recirculation pump 5DF1 Control unit 5DF2 Low electric voltage long period measurement 5DF3 Control unit 5DF5 High electric vo
37. Nm 5 90 Ibf ft Loctite 243 4 Gear oil magnetic drainage cap 1 24 Nm 17 70 Ibf ft 5 Oil filler cap M18x1 5 1 28 Nm 20 65 Ibf ft Overhaul data Assembly clearances Cylinder piston assy Measurement of the cylinder diameter must be done at three heights turning the dial gauge 90 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 Piston diameter selection F Cylinder diameter selection F CHAR 50 94 935 95 000 94 945 95 010 94 955 95 020 94 945 mm 3 73759 Desc Quantity 3 73798 in 95 010 mm 3 74015 94 955 mm 3 73798 95 020 mm 3 74054 94 965 mm 3 73837 3 73877 in 95 030 mm 3 74093 3 74054 in 3 73837 in 3 74093 in eee 3 74133 in Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics PIN PISTON COUPLING Specification Desc Quantity Pin diameter 21 998 21 994 mm 0 86606 0 86590 in
38. 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 for a 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 lt span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi lan guage AR SA gt Possible error on line CAN short circuit or line break or no signal or plausibility error detected 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 Possible internal control unit error Also check the control unit supply and earth connections ADJUSTMENTS Specification Throttle positioner autodetection P SUPP 244 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 Suspensi
39. Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 e Collect the gasket Remove the nipple oil pump fitting ENG 223 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine ENG 224 Stelvio 1200 MY11 Bring the left cylinder piston to the TDC in combustion phase Mark a reference on the oil pump con trol gear and another on the driven gear so as to place them correctly again upon refitting Unscrew and remove the nut on the
40. Screw M8x35 1 25 Nm 18 44 Ibf ft 4 Viti TBEI fissaggio piastre M12x35 4 80 Nm 59 00 Ibf ft 5 Viti TCEI fissaggio interruttore cavalletto 5 2 6 Nm 4 42 Ibf ft Loct 243 7 Dado fissaggio cavalletto laterale M10 1 30 Nm 22 13 Ibf ft Loct 243 CHAR 24 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics COMANDO CAMBIO pos Description Type Quantity Torque Notes 1 Viti TCEl fissaggio leva rinvio cambio M6x20 1 10 Nm 7 38 Ibf ft 2 Dadi fissaggio tirante 2 10 Nm 7 38 Ibf ft 3 Vite TCEI fissaggio piolo leva freno M6x16 1 10 Nm 7 38 Ibf ft 4 Brake lever pin M8 1 15 Nm 11 06 Ibf ft Loct 243 CHAR 25 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics REAR BRAKE LEVER pos Description Dado bloccaggio asta pompa freno Brake lever pin Stop switch Vite TCEI fissaggio piolo leva freno Vite TE Flang fissaggio supporto serbatoio Vite SWP autofil per supporto serbatoio NIOO amp Go Po Type M6x20 Viti te Flang fissaggio pompa freno M8 6 M6x16 M5x20 Quantity 2 9 Stelvio 1200 11 Torque 10 Nm 7 38 Ibf ft 15 Nm 11 06 Ibf ft 10 Nm 7 38 Ibf ft 10 Nm 7 38 Ibf ft 10 Nm 7 38 Ibf ft Manual Notes 10 Nm 7 38 Ibf ft Loct 243 Loct 243 pos Description Dadi Fla
41. THE TYRE AND ROAD TYPE NOTE 2 IF FITTED 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 TUNE aut m Remove the ABS sensor Remove the stanchion SUSP 251 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions Stelvio 1200 MY11 See also Removing the front wheel Draining oil e Lock the sleeve in a vice with the spe PPF cific tool code AP8140149 Set the minimum spring preloading Specific tooling AP8140149 Protection for fitting operations Unscrew the sleeve top cap Remove the complete cap SUSP 252 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 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 lower spring guide spring holder cap Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions SUSP 253 Suspensions Stelvio 1200 MY11 Disassembling the fork Drain all the oil from the stem Tighten the
42. 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 Inserire e serrare la rondella di rasa mento 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 190 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Timing TIMING SYSTEM CONTROL pos Description Type Quantity Torque Notes 1 Control timing system shaft support flange M6x14 2 8 Nm 5 90 Ibf ft fixing screw 2 Bearing fixing screw M6x16 1 10 Nm 7 37 Ibf ft Loctite 243 3 Driving gears locking nut on the crankshaft M25 1 200 Nm 147 51 Ibf ft Loctite 601 4 Timing system driven gear locking nut M18 1 25 Nm 18 44 Ibf ft Pre tightening 4 Timing system driven gear locking nut M18 1 150 Nm 110 63 Ibf ft Final tightening Removing the phonic wheel mm em e Remove the generator and the timing PEE A MWE ira system cover FICA e Unscrew and remove the nut and col 44
43. Verboten Stelvio 1200 MY11 Electrical system Front side TABLE A 1 Front headlamp 2 Small clamps 3 Cable grommet 4 Headlamp cable harness TABLE B 1 Rubber clamps TABLE C 1 Front brake switch 2 Faston Check the faston are connected up to the end TABLE D 1 Cable grommets 2 Pipe tightening clamp 3 Front ABS sensor ELE SYS 77 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 TABLE E 1 Main cable harness 2 Small clamp 3 Middle clamp TABLE F 1 Middle clamp 2 Clamp already present on the cable harness TABLE G 1 Medium clamp TABLE No part of the cable harness must pro trude to the inside of the support so as not to obstruct the forks ELE SYS 78 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system TABLE 1 Clamp that groups the cable harness of the right light switch the front stop switch the front ABS sensor and the key TABLE L 1 Medium clamps 2 Small clamps Check correct closure of the secondary fuses housing cover TABLE N 1 Middle clamp 2 Ground lead oriented as in the photo 3 Small clamp 4 Cable grommet ELE SYS 79 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 TABLE O 1 Med
44. Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 TABLE F 1 Cable guide 2 Plastic cable guides TABLE G 1 Neutral switch Correctly fit the hood on the gear switch TABLE H Correct laying of cables for the injec tors TABLE I 1 Left injector 2 Right injector Check that the steel clip is correctly placed after the connection Electrical system Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ELE SYS 83 Electrical system Stelvio 1200 MY11 TABLE L 1 Middle clamp 2 Big clamp 3 Right light switch key and front ABS sensor connections 4 Heated hand grips connectors 5 Small clamp that blocks the heated hand grips connectors to the brake pipe TABLE M 1 Ground cable harness 2 Battery ground lead 3 Left lambda sensor 4 Clamp to keep the starter motor cable harness far from the throttle bodies control pin ELE SYS 84 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system TABLE N 1 Starter motor Make sure that the end is oriented to the inside to avoid touching the protec tion of the starter motor TABLE O 1 Starter motor cover 2 Cable grommet If the cable grommet is correctly fitted it will be hidden by the cover TABLE P 1 Oxygen sensor cable harness 2 Cable grommet Hook the cable grommet with
45. 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 ENG 185 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 and then hit the tool head where the upper cap works with a mallet so that the two cotters 1 get detached from the upper cap 2 Once the two cotters 1 are detached screw these cotters until they can be ENG 186 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine slid off the valve seats unscrew the tool and remove it from the head e 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 gui
46. 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 check that 12 Volt is fed to PIN 33 of the BLUE connector Indication on Navigator 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 118 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 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 It 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 electrical circuit diagram Start up enabling switches L
47. filtro aria a telaio 10 Nm 7 38 Ibf ft SS Air filter box cover fastening screw SWP 5x20 3 Nm 2 21 Ibf ft Remove the saddle Remove the passenger grab handle e Undo and remove the two screws and collect the cable guide BODYW 344 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Bodywork Disconnect the air temperature sensor connector Slide off and remove the main fuse box from its holder Disconnect the rear light connectors Release the clutch bleeding pipe from the cable guide BODYW 345 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Bodywork Stelvio 1200 MY11 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 Remove the two breather pipes BODYW 346 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Bodywork Operating from both sides undo and remove the stud bolt Remove the filter casing See also Seat Fuel tank RIMOZIONE COPRI SERBATOIO CARBURANTE Rimuovere le viti 1 dal lato destro del motociclo Rimuovere le viti 2 dal lato destro del motociclo Remove the side fairings Remove
48. 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 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 ENG 156 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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
49. ft SUSP 264 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Suspensions pos Description Type Quantity Torque Notes Headstock counter lock ring 1 manual 90degrees 5 Upper yoke fixing 1 100 Nm 73 76 Ibf ft 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 265 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions Stelvio 1200 MY11 Rivet the safety washer on the head stock UPON REFITTING REPLACE THE SAFETY WASHER WITH A NEW ONE 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 SUSP 266 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Suspensions Fit a new safe
50. ft 6 Vite TCEI fissaggio supporto pedane M8x60 1 25 Nm 18 44 Ibf ft 7 Vite fissaggio supporto pedane 1 25 Nm 18 44 Ibf ft PASSENGER FOOTRESTS pos Description Type Quantity Torque Notes Viti TE Flang fissaggio piastrine 10 Nm 7 38 Ibf ft a Viti TE Flang fissaggio protezione pedana M6x12 10 Nm z 38 Ibf ft passeggero SX CHAR 28 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics t o zd i 9 ILA sti wg J f ar a e FUEL TANK pos Description Type Quantity Torque Notes Vite TCEI fissaggio anteriore M6x35 1 10Nm 738lbff 2 Vite TE Flang fissaggio posteriore M6x25 2_ 10 Nm 7 38 Ibf ft Viti TCEl fissaggio tappo benzina M5x15 4 Nm 8 95 Ibf ft COPERTURA SERBATOIO CARBURANTE pos Description Type Quantity Torque Notes 1 Vite TBEI Flang fissaggio copertura 4 5 Nm 3 69 Ibf ft CHAR 29 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 diaz Ci e x T ee Cees Z CHASSIS pos Description Type Quantity Torque Notes 1 Pin M12 1 50 Nm 36 88 Ibf ft 2 Pin M12x260 1 50 Nm 36 88 Ibf ft 3 Viti TCEl fissaggio anteriore motore a telaio M12x50 2 80 Nm 59 00 Ibf ft 4 Screws M8x14 2 25 Nm 18 44 Ibf ft 5 Viti TE
51. ft BODYW 336 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Bodywork MANIGLIONE E PORTAPACCHI pos Description Type Quantity Torque Notes 1 Vite TCEI fissaggio maniglione passeggero M6x25 4 10 Nm 7 38 Ibf ft 2 Vite TCEI fissaggio maniglione passeggero M8 2 25 Nm 18 44 Ibf ft 3 Vite fissaggio portatarga a maniglione M5 2 6 Nm 4 42 Ibf ft 4 Vite TBEI fissaggio supporti portapacchi M8x20 2 25 Nm 18 44 Ibf ft 5 Vite TBEI fissaggio supporti portapacchi M8x30 2 25 Nm 18 44 Ibf ft 6 Vite TSPEI fissaggio coperchio portapacchi M6x35 2 10 Nm 7 38 Ibf ft 7 Vite autofil fissaggio coperchio portapacchi 5 4 Manual Instrument panel Rimuovere i deflettori laterali traspar enti BODYW 337 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Bodywork Stelvio 1200 MY11 Remove the screws 1 Sganciare le estremit della plancia e sollevarla Scollegare il connettore cruscotto 2 e il connettore della presa di corrente 3 Remove the instrument panel NOTE FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER BODYW 338 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Bodywork Additional lights Liberare i cablaggi dei fari supplemen tari rimuovendo le fascette 1 sul telaio e scollegare i connet
52. fuse 20 A 4 Primary ABS fuse 20 A where foreseen NOTE THERE IS ONE SPARE FUSE Control unit Model Magneti Marelli IAW 5 AM2 Battery 12 V 18 Ampere hour ELE SYS 98 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system Speed sensor FRONT FUNCTION To indicate the vehicle speed by read ing the front wheel turning speed OPERATION OPERATING PRINCIPLE Magne toresistive sensor a square wave pulse is gener ated with voltage approx between 11 55 V and 11 25 V WIRING DIAGRAM Level in wiring diagram ABS REMOVAL LOCATION ON THE VEHICLE on the fork right stem next to the brake calliper support CONNECTOR LOCATION if available under the fuel tank front position PINS PIN 1 Ground connection white PIN 2 Power supply voltage Output signal white brown NAVIGATOR PARAMETERS Speed sensor Vehicle speed km h FRONT SPEED SENSOR ELECTRICAL ERRORS 5D90 electric malfunction Electrical fault in sensor or cable harness Troubleshooting Check the sensor connector and the ABS control unit connector If it is not OK restore the connectors if it is OK check continuity of the cable between sensor PIN 2 on the cable harness side and PIN 14 ABS control unit connector If there is no continuity restore them If there is PIN 2 of the sensor on the cable harness side with the sensor disconnected and key set to O
53. knob 2 fully loosened Rebound regular load conditions 24 clicks starting from screw 1 fully tightened 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 SUSP 269 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions Stelvio 1200 MY11 Removing Park the vehicle on its centre stand Lock the vehicle handlebar so that the rear wheel is off the ground Remove the fork M Undo and remove the shock absorber upper screw e Remove the shock absorber SUSP 270 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS Cassis CHAS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 Swinging arm REAR SWINGARM pos Description Type Quantity Torque Notes 1 Swingarm clamp fixing screw on the bushing M6x25 2 10 Nm 7 37 Ibf ft 2 2 Swingarm fixing screw the transmission M10x35 4 50 Nm 36 87 Ibf ft housing 3 Swingarm pin on the swingarm M12 1 60 Nm 44 25 Ibf ft 4 Preloading bushing to the swingarm pin M25 1 10 Nm 7 37 Ibf ft Removing To remove the fork first remove the footrest holding
54. lect the washer P Bi E Remove the timing system gear on the service shaft ENG 191 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 e Remove the tone wheel Remove both cylinders e Undo and remove the two screws Remove the service shaft closing cap 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 See also Removing the phonic wheel ENG 192 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Installing the service shaft i e Place the service shaft bearing if pre MN ZO e t viously removed on the crankcase A x 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 Partially fit the service shaft
55. no voltage has been detected If the circuit is open interruption has been detected Troubleshooting If short circuit 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 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 ELE SYS 113 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 between PIN 37 of tte BROWN connector and the component PIN and restore the cable harness Coll Function It controls the ignition spark plug in order to gen erate the fuel ignition spark Operation Operating principle Inductive discharge system Level in electrical circuit diagram Coils and in jectors Location In front of the fuel tank left and right side Connector on the coils Electrical char
56. on the instrument panel does not light up and the word Service is not displayed ELE SYS 96 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system Lights list FRONT HEADLAMP Specification Desc Quantity Front daylight running light 12V 5W Low high beam light halogen 12V 55W 60W H4 REAR LIGHT Specification Desc Quantity Rear daylight running light stop light LED License plate light 12V 5W Fuses AUXILIARY FUSES The secondary fuses are located in the front part of the motorcycle below the instrument panel on the left side of the front sub frame A Stop horn coil GPS hazard button lighting coils light relay passing heated grips 15 A B Tail lights license plate lamp 15 C Live positive ABS control unit power supply 10 A where foreseen ELE SYS 97 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 D Fuel pump coils injectors 15 A D Lambda burner secondary injection relay coil Start up relay coil 15 A F Permanent positive ECU power supply starter relay 3A G Plug socket 5A NOTE THREE OF THE FUSES ARE SPARES MAIN FUSES The main fuses are located in the central part of the motorcycle under the rider saddle on the right side 1 Battery recharge 40 A 2 Motion main fuse 30 A 3 High beam
57. open shorted to positive excessive voltage has 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 If the circuit is open shorted to positive check sensor connector and Marelli control unit connector if not OK restore cable harness if OK check sensor continuity 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 NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty then chec
58. pliers or any other tools than the specific 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 MY11 Characteristics Keep mated parts together since they have adjusted to each other due to normal wear Some components 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 assem
59. rebound damping a set knob 2 for spring 3 preloading adjust ment SUSP 268 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Suspensions 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 BEFORE MAKING ANY ADJUSTMENTS WAIT FOR THE ENGINE AND SILENCER TO COOL COMPLETELY ADJUSTMENTS Regular adjustment standard rider only Half load adjustment for example rider with passenger or with luggage Maximum load adjustment e g rider passenger and luggage CAUTION SET SPRING PRELOADING AND SHOCK ABSORBER REBOUND DAMPING ACCORDING TO THE VEHICLE USE CONDITIONS HYDRAULIC REBOUND DAMPING MUST ALWAYS BE IN CREASED TOGETHER WITH SPRING PRELOAD TO PREVENT UNDESIRABLE BOUNCING IF NECESSARY CONTACT AN Official Moto Guzzi Dealer TRY RIDING THE VEHICLE 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 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
60. riding in the rain on wet roads or after the vehicle has been washed ROUTINE MAINTENANCE TABLE km x 1 000 1 5 10 Exhaust pipe flange bolts Spark plugs R Carburetion at idle CO Throttle body Stands 5 Transmission cables and controls Alternator 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 2 Clutch fluid 2 Gearbox oil Engine oil Fork oil oil seals Final drive oil Clutch lever pin 6 Tyres pressure wear 1 Engine idle speed Valve clearance adjustment Wheels Bolts and nuts tightening Battery terminals tightening Wheel nipple tightening 1 Cylinder synchronisation Footrests joint 5 Suspension and setting Engine oil pressure warning light 4 Empty oil drain pipe from the filter housing C C C C C C C C Fuel lines 3 N eo 30 50 70 DI 2 2 D 2 2 2 gt 0 2 3 2 m 2 2 3 12 O 3 23 m 2 2 2 3 O 2 8 13 m 2 2 2 3 J O 2 8 J i 3 9g9 ir 3 3 9 i 3 9 gt gt E EI gt IRI E i d zZ gt LU d gt E Id gt
61. screen page shows general data regarding the control unit for example software type map ping control unit programming date INFO ECU SCREEN PAGE Characteristic Value example Unit of Notes measure ment Vehicle manufacturing date Chassis number Software version Vehicle code Vehicle identification according to Stelvio Norge the status of Pin 2 and 15 of the ABS control unit connector Stelvio Norge The vehicle code stored in the control unit is read Depending on the detected connection of PIN 2 and PIN 15 of the ABS control unit connector cor responds to a different type of vehicle see the following table NOTE the X in the table identifies the connector pin is grounded ABS CONNECTOR IS GROUNDED Vehicle PIN 2 PIN 15 Stelvio 1200 4V ABS e SSS SSS X Norge 1200 4V ABS PARAMETERS screen page This screen page shows the parameters meas ured by the several sensors engine revs engine temperature etc or values set by the control unit injection time ignition advance etc PARAMETERS Characteristic Value example Unit of Notes measure ment Rear wheel speed NENNEN EN Battery voltage 11 9 Front wheel speed O km h With stopped wheel 0 Km h is displayed With stopped wheel 0 Km h is displayed V BRAK SYS 311 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Braking system ACTIVATION screen page Stelvio 1200
62. screw M6x30 9 12 Nm 8 85 Ibf ft 4 Generator cover fixing screw M6x16 5 12 Nm 8 85 Ibf ft CHAR 41 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 E i 2 Mr x Air FILTER pos Description Type Quantity Torque Notes E Vite fissaggio cassa filtro aria a telaio ee NINA IONmQaBb ii Air filter box cover fastening screw SWP 5x20 3 Nm 2 21 Ibf ft THROTTLE BODY pos Description Type Quantity Torque Notes 1 Intake pipe fixing screw 6 10 Nm 7 37 Ibf ft CHAR 42 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics pos Description Type Quantity Torque Notes 2 Flange fixing screw on the throttle body M5x12 2 6 Nm 4 42 Ibf ft CLUTCH pos Description Type Quantity Torque Notes 1 Clutch to crankshaft fixing screw 6 42 Nm 30 98 Ibf ft Tighten with cross sequence 2 Clutch external flange fixing screw on flywheel M7x16 6 20 Nm 14 75 Ibf ft Loctite 243 3 Start up crown fixing screw on flywheel 6 10 Nm 7 37 Ibf ft Loctite 243 4 Clutch control cylinder fixing screw 3 10 Nm 7 37 Ibf ft Loctite 243 CHAR 43 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 CONNECTING ROD ASSEMBLY CYLINDERS pos Description Type Quantity Torque Notes
63. 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 Navigator if the temperature indicated is plausible in relation to the ambient temperature Check also that the sensor electrical charac teristics are observed replace the sensor if not OK if it is OK check the sensor connector and the Marelli control unit connector Lambda Function In charge of telling the control unit whether the mixture IS Operation Operating principle The Marelli injection control unit reads and inter prets a voltage generated by the difference in gen content between the exhaust fumes and the ambient It does not require an external supply sensor lean or rich 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 electrical circuit diagram Oxygen sen sor Location Electrical sensor exhaust pipe Connector near the probe characteristics Heater circuit 12 14 at 20 C 68 F ELE SYS 108 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system Pin out 1 Sensor signal black wire 2 Sensor signal grey wire 3 Heater gr
64. 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 4 Power supply protected from instrument panel 5 Not used 6 Pin 86 auxiliary relay control 7 Immobilizer line 8 Not used 9 Not used 10 Not used 11 Oxygen probe negative control 1 left 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 line ccm instrument panel 21 Ingresso sensore Lambda 2 destra 22 Ingresso sensore Lambda 1 sinistra ELE SYS 124 Stelvio 1200 MY11 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 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 Ingresso sensore Lambda 2 destra 32 Ingresso sensore Lambda 1 sinistra 33 Clutch sensor signal 34 Not used 35 Fall sensor signal 36 Not used 37 Not used 38 Side stand sensor signal Dashboard Electrical system The pin configuration of the GREY bodied con nector is as follows PIN USE 1 KEY 2 RIGHT TURN INDICATOR CONTROL 3 HIGH BEAM LIGHT INPUT 4 5 FOG LIGHTS ON OPT 6 K LINE 7 HEATED HANDGRIP CONTROL 8 CONTROL SET 9
65. the engine Take the engine to the prescribed tem perature 60 C 140 F Make the engine rev at 2000 3000 rpm andwith 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 P SUPP 239 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Power supply If there is a larger difference act on the set screw of the throttle body connecting rod to reduce the pressure difference in the two pipes Repeat the procedure Throttle posi tion self acquisition as explained above 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 Recovery function Stelvio 1200 MY11 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 Navigator also signal the problem RECOVERY FUNCTION Specification air temperature engine temperature barometric pressure throttle valve potentiometer idle motor Using Navig
66. 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 and remove the oil level plug and collect the O Ring Undo and remove the fourteen screws fixing the oil sump to the engine crank case t i E ER Ec ENG 227 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 Undo and remove the four screws Remove the flange e Undo and remove the two screws Remove both filters ENG 228 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Unscrew and remove the plug Remove the thermostatic valve Unscrew and remove the pressure re lief valve plug Remove the pressure relief valve com ponents ENG 229 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 Refitting the oil sump Place the pressure relief valve compo nents correctly Screw the pressure relief valve plug Place the thermostatic valve CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED Tighten the thermostatic valve pl
67. uml zi pr iH wer 2 Malin pe x Engins groan ep o Mn i Ferretti n A Fewer ars Lhar ham ind rans og lg Una ET ur inter iargain ECU a E die bel dea del Bebe Heed sento rae Freri LE tem ind Tric Erjar run Wl ih ignfion call A Parka 7 incon F Luini B bris een EC klarer a ub ih CCU by SLATES reins Sende GPS m i A FELL gt Pals 2 jin Garn olla arcu ax LF banks Fercprr m d DO ara E nem CHAR 23 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics MAIN CABLE HARNESS Stelvio 1200 MY11 pos Description Type Quantity Torque Notes 1 Viti TE Flang fissaggio piastre bobine M6x20 242 10 Nm 7 38 Ibf ft 2 Viti TCEl fissaggio bobine 2 2 2 Nm 1 47 Ibf ft 3 Viti TCEI fissaggio centralina 2 10 Nm 7 38 Ibf ft 4 Viti TCEI fissaggio supporto sensore temp M10x20 1 11 Nm 8 11 Ibf ft Loct 243 olio 5 Viti TCEl fissaggio sensore di fase 2 3 Nm 2 21 Ibf ft CAVALLETTO CENTRALE E LATERALE pos Description Type Quantity Torque Notes 1 Viti TCEI fissaggio cavalletto centrale M10x30 2 50 Nm 36 88 Ibf ft Loct 270 2 Viti TE Flang fissaggio piastre M8 2 25 Nm 18 44 Ibf ft 3
68. wheel holder sleeve in a vice Undo the fork end bottom screw and remove it with the corresponding gas ket Remove the pumping member pin Slide off the dust scraper from the sleeve using a screwdriver as a lever During this operation pay attention not to damage the sleeve rim SUSP 254 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Suspensions Remove the retainer 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 255 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions Stelvio 1200 MY11 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 WOULD BE WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS Characteristic Bending limit 0 2 mm 0 00787 in Sleeve Check that there are no damages and or cracks otherwise replace it Spring Ch
69. 0059 in Front brake pads Removal Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Unscrew and remove the two screws Slide off the brake calliper from the disc Turn the pins and remove both split pins Braking system BRAK SYS 321 Braking system Stelvio 1200 MY11 Remove both pins Remove the vibration damping plate Extract one pad at a time CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE 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 BRAK SYS 322 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Braking system Position the anti vibration plate Insert both pins Position both split pins Abut the plungers against the pads acting on the brake pump lever several times e Check the brake fluid level in the res ervoir 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 BRAK SYS 323 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Braking s
70. 1 Measuring air gap e Undo and remove the two screws and remove the sensor Insert a suitable plain washer on the sensor and note its thickness Place the sensor 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 ENG 198 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Cylinder piston assembly Key Right cylinder Piston Screw Top piston ring Middle piston ring Oil scraper piston ring Pin Retainer ring a 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 199 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 CONNECTING ROD ASSEMBLY CYLINDERS Engine pos Description 1 Thermal group fixing stud bolt 2 Connecting rod screws 2 Connecting rod screws 3 Right hydraulic tensioner cover 4 Left hydraulic tensioner cover Typ
71. 100 Km 62 miles use the brakes gently avoiding 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 MY11 This number consists of numbers and letters as in the example shown below ZGULZGO000YMXXXXXX KEY ZGU WMI World manufacturer identifier code LZ model 001 version variation 0 free digit Y year of manufacture La E Lal n z We E E A n n L LA n uL X L o LN bi LA ee WX i L L1 LA 1 Pa Li T a A 4 We Ki 7 zx A JP pou ot dar pi JA p eh ro M production plant M Mandello del Lario XXXXXX serial number 6 digits CHASSIS NUMBER The chassis number is stamped on the right hand side of the headstock ENGINE NUMBER The engine number is sta
72. 2 10 Nm 7 37 Ibf ft 7 Oil sump fixing screw filter contour M6x35 4 10 Nm 7 37 Ibf ft 8 Oil sump fixing screw 6 14 10 Nm 7 37 Ibf ft 9 Cover on the flange under the crankcase 2 20 Nm 14 75 Ibf ft 10 Magnetic oil drainage cap 1 20 Nm 14 75 Ibf ft 11 Gear to engine fixing nut M8 5 20 Nm 14 75 Ibf ft 12 Gear to engine fixing screw 1 20 Nm 14 75 Ibf ft Loctite 542 ENG 220 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine OiL SUMP COMPONENTS pos Description Type Quantity Torque Notes 1 Cover on the flange under the crankcase 1 40 Nm 29 50 Ibf ft 2 Oil filter joint 1 10 Nm 7 37 Ibf ft Loctite 243 3 Oil sump pipe 1 20 Nm 14 75 Ibf ft Loctite 648 4 Oil filter 1 15 Nm 11 06 Ibf ft Engine oil 5 Rose pipe fixing screw 6 10 Nm 7 37 Ibf ft 6 Maximum pressure valve cover M18 40 Nm 29 50 Ibf ft ENG 221 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 Conceptual diagrams Key Oil cooling radiator Oil delivery pipe to heads Oil delivery pipe to radiator Oil pump body Oil pump gasket Rotor for lubrication Rotor for cooling Hotor control shaft oe LV SOM SENS e LM Oil pump cover 10 Oil pump control gear 11 Lubrication oil intake filter 12 Cooling oil intake filter ENG 222 Revente Interdite
73. 6 10 Nm 7 37 Ibf ft Loctite 243 4 Clutch control cylinder fixing screw 3 10 Nm 7 37 Ibf ft Loctite 243 ENG 172 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Remove the complete gearbox e Unscrew and remove the six screws Remove the start up crown gear Remove the clutch bell and the friction disc Remove the retainer ring Remove the clutch pressure plate ENG 173 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 e Undo and remove the six screws and collect the belleville springs Remove the clutch plate 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 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 ENG 174 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 020678Y Tool for clutch rod checking CLU
74. 78Y 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 See also ENG 158 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Disassembling the gearbox Gear selector GEAR INTERNAL CONTROLS pos Description Type Quantity Torque Notes 1 Spring guide pin 1 24 Nm 17 70 Ibf ft Loctite 243 ENG 159 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 Generator Key 1 Alternator Spacer Screw Screw Nut Belt Generator control pulley Nut Washer 10 Magneto flywheel cotter o NO Aa 11 Screw 12 Nut ENG 160 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine ALTERNATOR pos Description Type Quantity Torque Notes Generator control pulley locking nut 80 Nm 59 00 Ibf ft Loctite 243 Generator upper fixing screw 22 Nm 16 23 lbf ft 3 Generator l
75. AY CAUSE BURNING IF IT COMES INTO 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 IT OR SPILL IT PARTICULARLY ON PLASTIC COMPONENTS ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT TERY 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
76. EL INJECTION SYSTEM NAVIGATOR PARAMETERS Injection time NAVIGATOR ACTIVATION Left injector operation for 4 ms 5 times Viene eccitato il rel iniezione secondario n 37 dello schema elettrico posizione lato sinistro anteriore del motociclo primo rel a sinistra vicino alla bobina VERIFICARE comunque l identificazione del rel con il colore dei cavi per 5 secondi e viene chiuso a massa il cavo grigio rosso dell iniettore per 4 ms ogni secondo Disconnect the 4 way connector of the fuel pump to be able to hear the relay and injector activation The continuity of the cable harness is necessary for correct activation no error indications are displayed in case of lack of activation NAVIGATOR 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 112 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system If short circuit 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 c
77. EM 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 Remove the front brake fluid reservoir cap Operate the brake lever and then open the bleed valve on the calliper 1 4 of a turn to let the air out Close the bleed again before reaching the lever end of the stroke and repeat the operation until there is no air e Repeatthe 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 rubber protection cover 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 The presence of air is signalled by the sponginess of the brake control and by 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 BRAK SYS 329 Revente Interdite Revendita Vi
78. Flang M8x25 4 25 Nm 18 44 Ibf ft 6 Screws M10 2 50 Nm 36 88 Ibf ft CHAR 30 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics Back side REAR BODYWORK pos Description Type Quantity Torque Notes 1 Viti SWP fissaggio piastra batteria M5x20 4 Manual 2 Viti TBEI Flang fissaggio fianchetti e para M5x9 10 6 Nm 4 42 Ibf ft spruzzi 3 Viti TE Flang fissaggio supporti valigie 6 4 10 Nm 7 38 Ibf ft 4 Viti TBEI Flang fissaggio paraspruzzi M5x12 2 6 Nm 4 43 Ibf ft L 1 et CHAR 31 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 LICENSE PLATE HOLDER pos Description Type Quantity Torque Notes Viti TBEI Flang fissaggio portatarga 6 Nm 4 43 Ibf ft m Viti TBEI speciali 2 6Nm 443iff 3 Dado autobloc flang fissaggio catadiottro M5 1 6 Nm 4 43 Ibf ft TRANSMISSION CONNECTION ENGINE pos Description Type Quantity Torque Notes 1 Reaction rod fixing screw M10x55 2 50 Nm 36 87 Ibf ft CHAR 32 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics 4 REAR SWINGARM pos Description Type Quantity Torque Notes 1 Swingarm clamp fixing screw on the bushing M6x25 2 10 Nm 7 37 Ibf ft 2 2 Swingarm fixi
79. GHT 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 ELE SYS 92 Stelvio 1200 MY11 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system Vi purple Checks and inspections Dashboard Diagnosis Changing the CODE If you know the code just enter it and then a new code that will be automatically stored in the 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 o
80. Guzzi Dealer AS IT MAY BE NECES SARY TO PURGE THE AIR IN THE SYSTEM MAIN 71 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS ELECTRICAL SYSTEM ELE SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Hk ruin rompen Maz Fiom STOP eich kisia mait Hinrarra meds Pa Boney C Gr NH und Arctia de Faria ds Frati har RH x Froni faq lr chi Light rate ES E Caria ce d Dorado ew modii 1 dii et i rn 1 1 Fram ADS mrar Tnrseribo py ich i LI EX Cerca DE Ae i AHH Rt dien pari LH naci tha peice 7 Bondo ta m Li lambris para cr iiri ara M oF Sera Engine prati Bep inter erg bec Ge trento Tric TALI F E ED d ud taniej bandgap D is premo nbl Cal pirscamr LF faregne an Pie rg posi sappia ERM E Feii vers TY i G Tasca ree 3 Lay der ge Zr i EI Creer Lato Electrical system apad fanar Furabe ai Freri beater amp ias da peed om Lh Burr i3 n Sl ko Lanp cg n pp Pot tn 1 reiner rin d icri beam smin Fret rhum ind Pas baherin Vp need Portia Dii ovs mi ri ism
81. IN 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 shorted to positive disconnect the coil connector set the key to ON activate the coil with Navigator and check voltage at connector PIN 2 if there is voltage restore the cable har ness 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 10 of the BROWN connector If there is not ELE SYS 115 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 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 u
82. Ibf ft 5 Viti TCEl fissaggio fanale a telaietto M5x25 5 6 Nm 4 42 Ibf ft BODYW 332 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Bodywork INSTRUMENT PANEL pos Description Type Quantity Torque Notes 1 Viti TCEl fissaggio sensore velocit anteriore M5x16 2 6 Nm 4 42 Ibf ft 2 Viti TCEI fissaggio blocchetto avviamento M8x30 1 25 Nm 18 44 Ibf ft 3 Viti autofil fissaggio supporto cruscotto 5x14 3 Manual 4 Viti autofil fissaggio supporto cruscotto a 3 9x14 4 Manual nice 5 Viti autofil fissaggio cornice 4 Manual 6 Viti TCE M5 2 6 Nm 4 42 Ibf ft CARROZZERIA ANTERIORE CUPOLINO pos Description Type Quantity Torque Notes 1 Viti fissaggio parabrezza 6 4 10 Nm 7 38 Ibf ft 2 Viti TBEI Flang fissaggio cupolino 5 12 4 6 Nm 4 42 Ibf ft 3 Viti fissaggio deflettori superiori M5 4 6 Nm 4 42 Ibf ft 4 Colonnette fissaggio deflettori M5 2 6 Nm 4 42 Ibf ft 5 Viti TE Flang fissaggio staffa parabrezza M6x16 4 10 Nm 7 38 Ibf ft 6 Perno filettato fissaggio supporto parabrezza M8 2 25 Nm 18 44 Ibf ft 7 Viti TBEI Flang fissaggio deflettori inferiori M5 2 Manual BODYW 333 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Bodywork Stelvio 1200 MY11 CARROZZERIA ANTERIORE CONVOGLIATORI pos Description Type Quan
83. Jets fixing screw 3 Using a T spanner close Loctite 243 by hand 6 Minimum oil pressure sensor M12 1 25 Nm 18 44 Ibf ft 7 Intake oil filter fixing screw 2 4 Nm 2 95 Ibf ft CHAR 37 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics pos Description Generator control pulley locking nut Stelvio 1200 MY11 ALTERNATOR Type Quantity Torque 80 Nm 59 00 Ibf ft Notes Loctite 243 Generator upper fixing screw 3 Generator lower fixing screw M10x60 1 22 Nm 16 23 Ibf ft 30 Nm 22 13 Ibf ft CHAR 38 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics CRANKCASE AND Sump pos Description Type Quantity Torque Notes 1 Stud bolt M8x75 2 10 Nm 7 37 Ibf ft 2 Stud bolt M8x66 3 10 Nm 7 37 Ibf ft 3 Crankshaft rear support flange fixing screw M8x25 8 26 Nm 19 18 Ibf ft 4 Oil cap on the crankcase 2 25 Nm 18 44 Ibf ft 5 Flange fixing screw under the crankcase M6x60 2 10 Nm 7 37 Ibf ft 6 Flange fixing screw under the crankcase 2 10 Nm 7 37 Ibf ft 7 Oil sump fixing screw filter contour M6x35 4 10 Nm 7 37 Ibf ft 8 Oil sump fixing screw 6 14 10 Nm 7 37 Ibf ft 9 Cover on the flange under the crankcase 2 20 Nm 14 75 Ibf ft 10 Magnetic oil drainage cap 1 20 Nm 14 75 Ib
84. LING 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 IMMEDIATE MEDICAL ATTENTION 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 PRE DE 352 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Pre delivery Response to throttle control Stability when accelerating and braki
85. MY11 This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit ACTIVATION Characteristic Value example Unit of measure ment Front brake bleeding procedure Rear brake bleeding procedure ABS warning light Ambient parameter error reading 1 Ambient parameter error reading 2 Ambient parameter error reading 3 Ambient parameter error reading 4 Ambient parameter error reading 5 Error clearing 1 Error clearing 2 Notes Useful in case of lever sponginess although the bleeding has been done as in a regular braking system Useful in case of lever sponginess although the bleeding has been done as in a regular braking system During the test the warning light stays on The ambient parameters are 4 Number of error detections Operation cycles from the last detec tion Battery voltage Speed Number of error detections number of times the error has been detected by the control unit for example if itindicates 2 it means that the error has been detected ATT then it has not been de tected for a while sent to the MEM and then it has been detected again Operation cycles from the last reading a cycle is counted if the following occurs key ON and speed over 20 km h If for example 5 is shown it means that the last time the error has been measured was 5 cycles ago Press enter to transfer errors from the memory
86. N must have 12V voltage approximately if there is no voltage check PIN 2 for continuity with the vehicle ground connection if it is grounded restore the cable harness If OK replace the control unit If PIN 2 has approx 12 V check continuity of the cable between PIN 1 of the sensor on the cable harness side and PIN 13 of the ABS control unit connector If this is not OK restore the cable harness If itis OK replace the sensor LOGIC ERRORS Speed sensor 5D91 the signal works irregularly faulty sensor or signal interference ELE SYS 99 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 Troubleshooting Check speed sensor retainer If it is not OK restore it If it is OK check if the tone wheel is dirty deformed or wrongly fixed If any of this happens replace the tone wheel Otherwise replace the speed sensor 5D92 the signal decreases periodically Possible tone wheel fault due to deformations or dirt pos sible alterations on the wheel bearing surface In very rare cases abnormal tone wheel vibrations Troubleshooting Check if the tone wheel is dirty deformed or wrongly fixed If the tone wheel is not OK replace it If it is OK check for possible faults in the wheel bearings and if it is not OK replace the bearings 5D93 missing signal or speed measured too low in relation to the rear wheel faulty sensor or missing sensor tone wheel Or excessive
87. NE 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 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 203 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Insert the pin Insert the snap ring Specific tooling 020470Y Pin snap ring fitting tool Installing the cylinder RIGHT CYLINDER CAUTION 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 DURING THIS OPERA
88. ON 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 M Shut off the engine Keep the vehicle upright with both wheels on the ground Unscrew 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 MAIN 66 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Maintenance e Place a container with suitable capacity underthe 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 Check and replace if necessary the sealing washers of drainage plug 2 Remove any metal scrap attached to the drain age plug 2 magnet Screw and tighten the drainage plug 2 Pour in new oil until it reaches the dipstick
89. 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 electrical circuit 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 Gearshift engaged open circuit 12 V on wire from control unit to sensor open switch infinite resistance Pin out PIN 1 Voltage 12V NAVIGATOR 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 co
90. Place the connecting rod assembly on the swingarm Insert the screw Tighten the fixing nut of the connecting rod assembly CHAS 276 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis 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 Bevel gears Removing Remove the rear wheel Unscrew and remove the two screws Remove the speed sensor from the fork CHAS 277 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 Unscrew and remove the nut fixing the reaction rod Remove the screw Fasten the reaction rod to the chassis with a clamp e Undo and remove the four screws Remove the transmission casing slid ing off the universal joint Checking Casing unit removal CHAS 278 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis Casing unit removal Remove the cover 20 Remove the plug 3 to drain out the oil Lift the cap 10 CHAS 279 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 Remove the clamps 9 and 11 Remove the cap 14
91. TCH 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 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 ENG 175 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 Li 5 re ka 3 aun cen T F Place the clutch bell with the reference facing upwards Place the start up crown gear with the reference facing upwards Tighten the six scr
92. TE the X in the table identifies the connector pin is grounded ABS CONNECTOR IS GROUNDED Vehicle PIN 2 PIN 15 Stelvio 1200 4V ABS I Ce x Norge 1200 4V ABS Abs screen pages Modulator Remove the fuel tank Cut the cable harness clamp BRAK SYS 314 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Braking system With a felt tip pen mark a reference on the pipes and on the ABS control unit to avoid inverting them when refitting Protect with a clean cloth the plastic materials near the ABS control unit Loosen the nuts and remove the pipes Cover the pipes to prevent brake fluid spilling See also Fuel tank Unscrew and remove the two screws e Disconnect the ABS control unit con nector Remove the ABS control unit INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR e Check the initial position of the lever that couples the connector BRAK SYS 315 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Braking system Stelvio 1200 MY11 When the connector is fully inserted Pu the distance between the connector and the ABS control unit must be 7 5 mm 0 29 in If the initial position of the connector and the driving lever is not that shown in fig 1 the connector will not be prop erly coupled and the distance meas ured will be greater 12 mm appro
93. TEMPERATURE SENSOR 11 INSTRUMENT PANEL 12 IMMOBILIZER AERIAL 13 IGNITION KEY 14 HEATED HANDGRIPS 15 GPS COUPLING 16 iz 18 Rear right turn indicator 19 TAILLIGHT ASSEMBLY 20 REAR LEFT TURN INDICATOR 21 LICENSE PLATE LIGHT BULB 22 REAR STOP SWITCH 23 FRONT STOP SWITCH 24 ABS CONTROL UNIT 25 FRONT WHEEL SPEED SENSOR 26 REAR WHEEL SPEED SENSOR 27 ANTITHEFT CONTROL UNIT OPTIONAL EQUIPMENT 28 29 Secondary fuses 30 STARTER MOTOR 31 MAIN FUSES 2 32 MAIN FUSES 1 33 BATTERY 34 PLUG SOCKET 1 35 ALTERNATOR 36 MAIN INJECTION RELAY 37 AUXILIARY INJECTION RELAY 38 0IL PRESSURE SENSOR 39 NEUTRAL SENSOR 40 LAMBDA PROBE LEFT 41 SIDE STAND SWITCH 42 FUEL RESERVE SENSOR Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system ELE SYS 91 Electrical system 43 FUEL PUMP 44 INTAKE AIR TEMPERATURE SENSOR 45 Engine temperature sensor 46 IDLE MOTOR 47 THROTTLE POSITION SENSOR 48 RIGHT CYLINDER COIL 49 LEFT CYLINDER COIL 50 RIGHT SPARK PLUG 51 LEFT SPARK PLUG 52 RIGHT CYLINDER INJECTOR 53 LEFT CYLINDER INJECTOR 54 FALL SENSOR OPTIONAL EQUIPMENT 55 PICK UP 56 ECU 57 FOG LIGHT OPTIONAL EQUIPMENT 58 FRONT LEFT TURN INDICATOR 59 COMPLETE HEADLAMP 60 TAIL LIGHT BULB 61 HIGH LOW BEAM BULB 62 FRONT RIGHT TURN INDICATOR 63 INSTRUMENT PANEL DIAGNOSIS 64 ECU DIAGNOSIS 65 HIGH BEAM LIGHT RELAY 66 PLUG SOCKET 2 67 LAMBDA PROBE RI
94. TION PAY ATTENTION NOT TO DAMAGE THE PISTON Specific tooling 020674Y Piston ring clamp ENG 204 Stelvio 1200 MY11 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 Place a new metal gasket between the crankcase and the cylinder Place the two dowel pins on the stud bolts Undo the screw which will be used to time the upper gear ENG 205 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine CAUTION Stelvio 1200 MY11 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
95. V 55 W 60 W H4 12V 10 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Specification Rear daylight running light stop light Characteristics Desc Quantity LED 12 V 55W Supplementary headlamps if fitted Dashboard lighting License plate light LED 12V 5W LED Turn indicator warning light Neutral gear warning light Alarm shift warning light LED LED LED Low fuel warning light High beam warning light ABS warning light Frame and suspensions Specification Type Trail Headstock angle Front 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 45mm 1 77 in di Front wheel travel Rear am stanchions and radial calliper mounting bracket with ad justable spring preload and hydraulic compression and re bound damping 170 mm 6 69 in single arm with progressive linkage single shock absorber with spring preload hydraulic compression and rebound damping adjustment Unloaded shock absorber spring length Rear wheel travel Specification Size A Size B Brakes Specification Front Rear 180 mm 7 09 in 155 mm 6 10 in SIZES A ano B Desc Quantity 745 0 mm 29 33 in 403 16 mm 15 87 in BRAKES Desc Quantity 320 mm 12 6 in stainless steel double floating disc radial
96. a m STEERING pos Description Type Quantity Torque Notes Viti fissaggio piastra fermatubi 2 6 Nm 4 42 Ibf ft Viti fissaggio piastre M8x30 20 Nm 14 75 Ibf ft 40 Nm 29 50 Ibf ft manual 90 degrees 3 100 Nm 73 76 Ibf ft Headstock ring nut Headstock counter lock ring Upper yoke fixing cap lt OD CHAR 17 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 CARROZZERIA ANTERIORE CONVOGLIATORI pos Description Type Quantity Torque Notes 1 Viti TBEI Flang fissaggio convogliatori M5x9 2 6 Nm 4 42 Ibf ft BE 2 Viti TBEI Flang fissaggio convogliatori Me le 6 Nm 4 42 Ibf ft Viti SWP Autofil fissaggio telaietto griglie 2 9x12 Manual CARROZZERIA ANTERIORE CUPOLINO pos Description Type Quantity Torque Notes 1 Viti fissaggio parabrezza 6 4 10 Nm 7 38 Ibf ft 2 Viti TBEI Flang fissaggio cupolino M5x12 4 6 Nm 4 42 Ibf ft 3 Viti fissaggio deflettori superiori M5 4 6 Nm 4 42 Ibf ft gt 4 Colonnette fissaggio deflettori M5 2 6 Nm 4 42 Ibf ft 5 Viti TE Flang fissaggio staffa parabrezza M6x16 4 10 Nm 7 38 Ibf ft 6 Perno filettato fissaggio supporto parabrezza 8 2 25 Nm 18 44 Ibf ft 7 Viti TBEI Flang fissaggio deflettori inferiori M5 2 Manual CHAR 18 Revente Interdite Revendita Vietata
97. a Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system cable and if there is voltage restore the cable harness if there is no voltage replace the lambda sensor Right lambda sensor heating P0141 shorted to positive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at PIN 1 of the BLUE connector If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 1 of the BLUE connector Troubleshooting shorted to positive disconnect the probe connector and check the sensor correct resistance replace the sensor if not OK if it is OK restore the cable harness 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 se non ok verificare cavo rosso nero lato cablaggio tra connettore sonda e rel iniezione secondario n 37 dello schema elettrico posizione lato sinistro anteriore del motociclo primo rel a sinistra vicino alla bobina VERIFICARE comunque l identificazione del rel con il colore dei cavi se pre senti anche errori bobine e iniettori verificare il rel stesso e la sua linea di eccitazione e potenza se t
98. acteristics Primary winding resistance 550 mQ 10 at approx 23 C 73 4 F M Secondary winding resistance mQ 1096 at approx 23 C 73 4 F M Tube resistance 5 Pin out 1 Power supply Vbatt 2 Circuit ground NAVIGATOR PARAMETERS Left coil ignition advance NAVIGATOR ACTIVATION Left coil Viene eccitato il rel iniezione secondario n 37 dello schema elettrico posizione lato sinistro anteriore del motociclo primo rel a sinistra vicino alla bobina VERIFICARE comunque l identificazione del rel con il colore dei cavi per 5 secondi e viene chiuso a massa il cavo verde arancio della bobina per 2 ms ogni secondo 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 NAVIGATOR ERRORS Left coil P0351 shorted to positive open circuit shorted to negative Error cause ELE SYS 114 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 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 If short circuit to positive disconnect the coil connector set the key to ON activate th
99. al 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 selection colour 2 brown Type 1 to be used with brown connecting rods Balance with a 1558 g 54 96 oz 0 25 weight fitted on the crankpin B Maximum imbalance 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 25 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 cond
100. aring 19 Gear 20 Circlip 21 Clutch shaft 22 Ball bearing 23 Oil plug 24 Washer 25 Gearbox 26 Aluminium washer 27 Breather cap 28 Neutral sensor 29 Gasket 30 Sealing ring 31 Bushing 32 Gasket 33 Oil drainage plug 34 Sealing ring 35 Thrust bearing 36 Roller bearing 37 Spring 38 Complete pre selector 39 Bushing Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine ENG 143 Engine 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 3rd 4th 56 Fork 2nd 4th 57 Gear 58 Gear 59 Ball bearing 60 Transmission shaft 61 Gear 62 Spacer Gearbox Removing the gearbox Remove the starter motor Make sure the transmission is in idle Undo and remove the screw re move the gearbox lever ENG 144 Stelvio 1200 MY11 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 joint on the sump e Undo and remove the three screws ENG 145 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkau
101. ator for injection system Desc Quantity 2506 77 F 30 C 86 F with linear increase from the air temperature at ignition 1010 hPa 2 9 at idle otherwise variable fixed value variable depending on the vehicle Injection system SUPP 240 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 ECU INFO screen page This screen page shows general data regarding the control unit for example software type map ping control unit programming date Power supply INFO ECU SCREEN PAGE Specification Mapping PARAMETERS screen page This screen page shows the parameters meas ured by the several sensors engine revs engine temperature etc or values set by the control unit injection time ignition advance etc Desc Quantity PARAMETERS SCREEN PAGE Specification Engine rpm Injection time Ignition advance Air temperature Engine temperature Battery voltage Throttle Atmospheric pressure Lambda probe Lambda integrator Vehicle speed Desc Quantity Engine revolutions per minute the minimum value is set by the control unit cannot be adjusted MS o 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 C V Value corresponding to the throttle when closed approximate value between 4 5 and 4 9 left throttle supported b
102. biden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics CLUTCH CONTROL pos Description Type Quantity Torque Notes 1 Viti fissaggio tubo olio M10 3 23 26 Nm 16 96 19 18 Ibf ft 2 Viti TE Flang fissaggio cilindro comando fri 6 3 10 Nm 7 38 Ibf ft zione 3 Viti fissaggio tappo serbatoio 2 0 8 1 5 Nm 0 59 1 11 Ibf ft 4 Lever pin 1 5 7 Nm 3 69 5 16 Ibf ft 5 Dado perno leva 6 1 10 Nm 7 38 Ibf ft 6 Viti fissaggio cavallotto 2 10 Nm 7 38 Ibf ft 5 CHAR 21 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics e mam AN Cx Ps o ae d FRONT MUDGUARD pos Description Type Quantity Torque Notes 1 Viti TBEI Flang fissaggio parafango anteriore M5x12 6 6 Nm 4 42 Ibf ft FRONT WHEEL pos Description Type Quantity Torque Notes 1 Viti TE lang fissaggio dischi freno M8x20 25 Nm 18 44 bl 2 Nut fixing wheel pin 1 80 59 0016 3 Vite flang fissaggio sensore 1 6 Nm 4 42 Ibf ft Loct 243 CHAR 22 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 pos Description Vite TCB fissaggio passacavo Quantity 1 Type M4x6 3 Nm 2 21 Ibf ft Characteristics Torque Notes pos Description Viti TE Flang fissaggio pinze FRONT BRAKE CALLIPERS Quantity
103. bled correctly After a repair 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 CHAR 9 Revente Inter
104. bolt with the washer From the opposite side fit the washer and tighten the nut ENG VE 135 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine from vehicle Stelvio 1200 MY11 Operating from both sides tighten the upper engine fixing nut on the internal side of the chassis 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 ENG VE 136 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine from vehicle 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 137 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine from vehicle Stelvio 1200 MY11 M Connect the ground leads and tighten the stud bolt Fit the starter motor cover Tighten the screws Connect the neutral sensor connector Connect the alternator connectors
105. callipers with 4 opposed pistons 282 mm 11 1 in stainless steel disc floating calliper with 2 different pins CHAR 13 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics Wheels and tyres WHEELS AND TYRES Wheel Model Wheel rim Measure Tyre pressure with Tyre pressure rider ment rider only passenger Front standard H SPECIFIC Pirelli 2 50 x 19 110 80 2 5 bar 250 kPa 36 3 2 5 bar 250 kPa 36 3 Scorpion Trail R19 59V PSI Rear standard H SPECIFIC Pirelli 4 25 x 17 150 70 2 9 bar 290 kPa 42 1 2 9 bar 290 kPa 42 1 Scorpion Trail H17 69V PSI PSI THE USE OF M S TYRES IS ALLOWED ONLY ON VEHICLES WITHOUT THE ABS SYSTEM WITH THIS TYRE TYPE THE MAXIMUM SPEED ALLOWED IS 170 km h 105 63 mi IT IS MANDATORY TO APPLY THE LABEL ONTO THE SPEEDOMETER SUPPLIED WITH THE TYRES INDICATING THE MAXIMUM SPEED WHEN FITTING M S TYRES WITH OFF ROAD ALLROUND TYRES PAY CLOSE ATTENTION WHEN DRIVING ON PAVED ROAD DUE TO ITS LACK OF GRIP AND STABILITY Supply FUEL SYSTEM Specification Desc Quantity Fuel system Electronic injection Weber Marelli with stepper motor Diffuser diameter 50 mm 1 97 in Fuel Premium unleaded petrol minimum octane rating 95 NORM and 85 NOMM Tightening Torques CHAR 14 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 C
106. ccitazione e potenza 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 8 of the sensor connector and PIN 11 of the BLUE connector and restore the cable harness LOGIC ERRORS Left lambda sensor P0134 voltage without variation Error cause An abnormal behaviour of the voltage at PIN 22 of the BLUE connector has been detected the voltage that should vary over time keeps a constant value instead Troubleshooting e check circuit continuity of the lambda sensor connector PIN 1 PIN2 toward the probe replace the probe if there is no continuity if there is continuity check the sensor connector and the Marelli control unit connector If not OK restore If OK check continuity between the BLUE connector PIN 22 and PIN 32 and restore the cable harness ELECTRICAL ERRORS Right lambda sensor P0136 Shorted to positive Error cause Excessive voltage battery voltage has been detected at PINS 21 and 31 of the BLUE connector Troubleshooting shorted to positive con chiave ON scollegare il connettore del sensore e misurare la ten sione al PIN 1 lato cablaggio cavo viola giallo if there is voltage 5 or 12 V restore the cable harness it there is no voltage measure voltage at PIN 2 cable harness side brown ELE SYS 110 Revente Interdite Revendita Vietat
107. ce between bushing and main journal clutch side 0 030 0 058 mm 0 00118 0 00228 in CHAR 51 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 Slot packing system Specific tooling Fitboth 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 020675Y Service shaft gear lock Specific tooling 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 020676Y Comparator support for piston posi tion checking Reset the micrometer on the cylinder rim Move the tool so that the micrometer feeler reaches the top point of the piston crown Take note of the measurement and according to the values found consult the chart at the bottom of the page to decide the thickness of the gasket to be fitted between cylinder and head Unlock crankshaft rotation Rotate the crankshaft by 90 until the right cylinder piston reaches the TDC Lock crankshaft rotation Place the tool on the right cylinder stud bolts to determine the squish X Specific tooling 020676Y Comparator support for piston position checking CHAR 52 Revente Interdite Revendita Vietata Resa
108. cle braking stability when compared to a traditional braking system Sometimes when the brake is operated the tyre locks with a consequent loss of grip which makes it difficult to control the vehicle A position sensor 3 on the tone wheel 2 forming an integral unit with the vehicle wheel reads the status of the vehicle wheel spotting any possible lock A control unit 1 signals this out and adjusts the pressure in the braking circuit accordingly NOTE WHEN THE ABS SYSTEM STARTS WORKING A VIBRATION IS FELT ON THE BRAKE LEVER THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED HANDLE BAR TURNED ON UN EVEN OR SLIPPERY ROADS OR WITH POOR GRIP CREATES LACK OF STABILITY DIFFICULT TO HANDLE THEREFORE RIDE CAREFULLY AND SENSIBLY AND ALWAYS BRAKE GRADU ALLY BRAKING WHILE TURNING A CORNER IS SUBJECT TO LAWS OF PHYSICS WHICH NOT EVEN ABS CAN ELIMINATE When the sensors 3 detect a significant speed difference between the rear and the front wheels for example when rearing up on the back wheel the ABS system could take this as a dangerous situation In this case two things may occur The ABS system intervenes by releasing pressure from the calliper until the wheel turns again at the same speed of the other wheel It is not possible to brake for an instant if the speed difference lasts long the system may detect an error and deactivate the ABS system
109. closing cap To screw the cap until it stops use two M6 flanged screws larger than the orig inal screws Tighten the two 6 flanged screws erating in stages until the cap stops against the crankcase Undo and remove the two M6 flanged Screws ENG 193 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 ENG 194 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Cam timing e crankshaft and the service shaft e on the crankcase NC 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 i Unscrew and remove the fixing the crankshaft gear Remove the oil pump control gear Specific t
110. d cap Pins Calliper springs Spring Aluminium gasket op N gt Pi N Screw Rear brake disc Disc Inspection CAUTION THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECI FICATIONS OF THE SYSTEM The following operations are to be car ried out with brake disc fitted on the wheel Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the mini mum thickness even in a single point of the disc is less than the minimum value replace the disc Disc thickness minimum value 4 5 mm 0 18 in Front brake disc Disc Inspection CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM BRAK SYS 320 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 The following operations must be car ried out with the brake discs fitted on the wheel they refer to a single disc but are valid for both Check the disc for wear by measuring the minimum thickness with a micro meter in different points If the mini mum thickness even in a single point of the disc is less than the minimum value replace the disc Disc thickness minimum value 4 mm 0 16 in Using a dial gauge check that the max imum oscillation of the disc does not exceed the tolerance otherwise re place it Disc oscillation tolerance 0 15 mm 0
111. d sensor signal ground 14 Front ABS speed sensor supply 15 Ground connection 16 Diagnosis 17 Not used 18 ABS pump supply ELE SYS 127 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS FROM VEHICLE ENG VE Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine from vehicle Vehicle preparation Before removing the engine block proceed as follows See also Exhaust Removing Fuel tank Removing Rest the vehicle on its centre stand From the back 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 cardan shaft the fuel tank and the rear shock absorber Removing the engine from the vehicle Disconnect the spark plug tubes Unscrew and remove the three screws and remove the clutch control cylinder Lock the cylinder using a clamp to pre vent oil leaks Remove the starter motor cover Unscrew and remove the stud bolt Disconnect the ground leads ENG VE 129 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine from vehicle Disconnect the connectors of the start er motor Disconnect the stand sensor connec tor and release it from the clamps Slide off the gearbox oil br
112. des 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 oven at about 60 140 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 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 e 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 e Check the valve seats are in good conditi
113. distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is OK replace the speed sensor 5D94 no acceleration after pressure reduction Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is OK replace the speed sensor 5D95 excessive speed measured Faulty sensor or tone wheel or tone wheel with wrong number of teeth or wrong tyre size Troubleshooting Check that the speed sensor and the tone wheel are installed If they are not install them If they are check the speed sensor retainer If it is not OK restore it If it is check if the tone wheel has the correct number of teeth or if it is dirty deformed or wrongly fixed If it is not OK replace the tone wheel and if it is OK c
114. dite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 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 RUNNING 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
115. down the brake lever and fasten it into position with a locking de vice so as to avoid fluid flowing out from the open system Close the bleed screws of the front cal liper and remove the bleed bottle Replace the damaged calliper with a new one e Unlock the brake lever BRAK SYS 327 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Braking system Stelvio 1200 MY11 Remove the reservoir cap and fill it with new brake fluid up to the reference MAX CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEEDING AS DESCRIBED AT THE END OF THE CHAPTER Always fill the reservoir up to the reference MAX and refit the cap e Check the stroke and the sensitivity of both the lever and the brake pedal If after bleeding the pedal or the lever stroke is too long check that there are no leaks in the braking system and if everything is ok continue bleeding operations using Navigator as described Detach the bleed hoses and close the bleed screws again to the correct tightening torque See also Front Rear BLEEDING SYSTEM WITH NAVIGATOR This type of bleeding has to be carried out if after all the checks the brake lever and the pedal are still spongy The operations described here are valid for both systems even though the description refers to the front system FRONT With Navigator properly connected select the function FRONT BRAKE BLEEDING PRO CEDURE The pump
116. e M10x1 25 Quantity 8 gt gt Torque 5 Nm 3 69 Ibf ft 40 Nm 29 50 Ibf ft 80 Nm 59 00 Ibf ft 42 Nm 30 98 Ibf ft 30 Nm 22 13 Ibf ft oa In Notes Loctite 243 Pre tightening Final tightening p ENG 200 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine TESTA SINISTRA Pos Descrizione Tipo Quantit Coppia Note 1 Movable chain tensioner pad fixing screw 1 20 Nm 14 75 Ibf ft Loctite 243 2 Head tightening nut M10x1 25 4 15 Nm 11 06 Ibf ft Engine Oil Pre tightening 2 Head tightening nut M10x1 25 4 42 Nm 30 98 Ibf ft Final tightening 3 Head tightening screws chain compartment M6x120 2 10 Nm 7 37 Ibf ft 4 Plate locking screw and timing gear 1 30 Nm 22 13 Ibf ft Loctite 243 5 Timing cover fixing screw on the cylinder head M5x10 2 8 Nm 5 90 Ibf ft 6 Camshaft support fixing screw 6 18 Nm 13 28 Ibf ft 7 Vite fissaggio molla a tazza 1 18 Nm 13 28 Ibf ft TESTA DESTRA Pos Descrizione Tipo Quantit Coppia Note 1 Movable chain tensioner pad fixing screw 1 20 Nm 14 75 Ibf ft Loctite 243 2 Head tightening nut M10x1 25 4 15 Nm 11 06 Ibf ft Engine Oil Pre tightening 2 Head tightening nut M10x1 25 4 42 Nm 30 98 Ibf ft Final tightening 3 Head tightening screws chain compartment M6x120 2 10 Nm 7 37 Ibf ft 4 Plate locking screw and timi
117. e control unit memory and to activate some systems controlled by the control unit Power supply ACTIVATION Specification Left coil Right coil Left injector Right injector Error clearing Fuel pump Stepper control ERRORS screen page 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 times By pressing the enter button the stored errors MEM become part of the historical data STO In the next connection be tween the Navigator and the control unit the historical errors STO are no longer shown Operation for 30 lt span style FONT SIZE 12pt FONT FAMILY Times New Roman mso fareast font family Times New Roman mso ansi language IT mso fareast language IT mso bidi lan guage AR SA gt For 4 advancement command of 32 steps for the next 4 retrocession command of 32 steps and so on for 30 ERRORS Specification Pressure sensor Air temperature Engine temperature Throttle actuator position sensor 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
118. e Check the transmission fork move ment and if it is not regular replace the transmission forks See also Disassembling the gearbox Fitting the primary shaft NOTE TO REFIT FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER REMEMBER TO REPLACE ALL SEALING RINGS CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED See also Removing the ENG 157 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 0206
119. e coil with Navigator and check voltage at connector PIN 2 if there is voltage restore the cable harness if voltage 0 replace the coll 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 ground insulation from coil connector or control unit connector If this is not OK restore the cable harness NAVIGATOR PARAMETERS Right coil ignition advance NAVIGATOR ACTIVATION Right coil Viene eccitato il rel iniezione secondario n 37 dello schema elettrico posizione lato sinistro anteriore del motociclo primo rel a sinistra vicino alla bobina VERIFICARE comunque l identificazione del rel con il colore dei cavi per 5 secondi e viene chiuso a massa il cavo azzurro verde della bobina per 2 ms ogni secondo 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 NAVIGATOR ERRORS Right coil P0352 shorted to positive open circuit shorted to negative Error cause If shorted to positive excessive voltage has been detected at P
120. e requirements of SAE J1703 NHTSA 116 DOT 4 ISO 4925 synthetic fluid specifications CHAR 53 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS SPECIAL TOOLS S TOOLS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Stores code 020677Y 05 91 17 30 020716Y 020470Y 05 92 72 30 01 92 91 00 Special tools MOTORE Description Generator belt tensioner lever for belt tensioning S X 1 Af E x Se i X N A mir uec 7 por FS M AN 1 DA ptum 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 55 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Special tools Stores code 05 90 25 30 19 92 96 00 12 91 18 01 12 91 36 00 AP8140179 AP9100838 14 92 71 00 S TOOLS 56 Stelvio 1200 MY11 Description Gearbox support Graduated dial to control ignition timing Tool to lock the flywheel and the starting ring gear Tool to remove the flywheel side flange Support for valve fitting removal Tool for valve pressure plate Tool to fit the sealing ring on the flywheel side flange Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten S
121. eather pipe Disconnect the gear in neutral sensor connector ENG VE 130 Stelvio 1200 MY11 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine from vehicle Disconnect the horn connectors Operating from both sides undo and remove the screw fixing the oil radiator to the chassis Working on both sides release the clamp and slide off the engine oil breather pipe Working on both sides disconnect the injector connectors ENG VE 131 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine from vehicle Stelvio 1200 MY11 Working from both sides undo and move the three inlet manifold screws M Collect the gasket e Disconnect the alternator connectors Disconnect the engine temperature sensor connector ENG VE 132 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine from vehicle 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 Remove the centre stand Working on both sides unscrew and remove the front screw and collect the washer ENG VE 133 Revente Interd
122. eck the spring is in good conditions SUSP 256 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Suspensions Check that the following components are in good conditions upper bushing lower bushing piston 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 seal ring dust gaiter SUSP 257 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions Stelvio 1200 MY11 O Ring on the Reassembling the fork Lock the stem 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 SUSP 258 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Suspensions The sealing ring must be placed with the stamped part facing the dust gaiter Fit the ring the movable bushing and after removing the tape fit the fixed bushing SUSP 259 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions Stelvio 1200 MY11 Fit the s
123. ed clamps 7 Cable grommets 5 Rubber clamps 7 Cable grommets 1 Adhesive cable grommet 1 Cable grommet with clip Special checks for the correct connection and laying of cables It is extremely important that any security locks for the following connectors are properly connected and correctly tightened to ensure proper engine and therefore proper vehicle operation Instrument panel connector Pick Up connector and alternator Side Stand Switch Connector Coils connectors Control unit connectors Fuel pump connector Key Connector Right Light Switch Connectors Left Light Switch Connectors ABS connector and correct positioning of the cap Front and rear speed sensor connector Auxiliary Fuses rubber housing correct positioning and closing Intake air temperature sensor Fuel injector connectors The connectors in the list are circled in the different pictures The listed connectors are con sidered more critical than the others because their disconnection could cause the vehicle to stop or malfunction Obviously the correct connection of the other connectors is also important and essential for proper vehicle operation It is also important and essential that the instructions regarding the routing and fixing of the cable har ness in the various areas are followed meticulously in order to guarantee functionality and reliability ELE SYS 76 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf
124. eduction it coincides with danger recognition wheel slippage above threshold the system closes the inlet valve 10 12 and opens the outlet valve 13 15 temporarily At this stage the rider cannot increase the pressure on the callipers 8 9 and the system reduces the pressure on the callipers partially The excess fluid temporarily fills the front reservoir 18 19 until the ABS pump 17 self activates and delivers the fluid back to the brake pump 2 5 C Pressure maintained the pressure in the callipers 8 9 remains low until total recovery of speed wheel grip The system restores the fluid taken from the calliper 8 9 in the section of the system between the brake pump 2 5 and the ABS inlet valve 10 12 BRAK SYS 306 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Braking system D Pressure restored by opening the inlet valve 10 12 momentarily the pressure of the callipers 8 9 is increased until maximum deceleration is reached Then the system gives the control over the braking back to the rider E If the wheel does not reach complete grip the system continues operating as before until complete grip is obtained or until the vehicle stops An error can be detected if the duration of the pressure reduction phase exceeds the pre set time limit ABS SYSTEM DESCRIPTION The ABS system is a device to avoid wheels locking in case of emergency braking increasing vehi
125. en 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 ELE SYS 107 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 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 resistance 0 replace the
126. engine oil as required CHAS 301 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS Brain SYSTEM BRAK SYS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Braking system E RN Via BRAKE SYSTEM pos Description Type Quantity Torque Notes 1 Brake pipe slot screw on the pump M10 2 25 Nm 18 44 Ibf ft 2 Joint with brake pipes retainer bleeding on the M10 3 25 Nm 18 44 Ibf ft calliper 3 Brake pipes joint on the ABS hydraulic unit 4 25 Nm 18 44 Ibf ft Interventions rules CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten BRAK SYS 303 Braking system Stelvio 1200 MY11 ABS 16 key ABS ECU control unit Front ABS sensor Rear ABS sensor Battery Main relay ECU Instrument panel K line diagnosis O pi gt dd BS Key 10 Fuses BRAK SYS 304 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Braking system Operating diagram AD ABS functional diagram key 1 Front system circuit Front brake pump Front brake lever E I Rear system circuit BRAK SYS 305 Revente In
127. ening 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 MAIN 63 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Maintenance Stelvio 1200 MY11 Screw and tighten the caps 1 2 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 Shut off 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 reinsert it Pull it out again and check the oil level The oil level is correct when it is close to the MAX mark Otherwise top up with engine oll CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE 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 MAIN 64 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Maintenance To change the engine oil and to replace the oil fil ter remove the oil sump gua
128. ensione al PIN 4 presente verificare isolamento da massa del cavo rosa mar rone lato cablaggio PIN 3 se non ok ripristinare cablaggio se ok verificare continuit del cavo rosa marrone lato cablaggio tra PIN 3 del connettore sensore e PIN 1 connettore BLU e ripristinare il cablaggio LOGIC ERRORS Lambda sensor P0140 voltage without variation Error cause An abnormal behaviour of the voltage at PIN 31 of the BLUE connector has been detected the voltage that should vary over time keeps a constant value instead Troubleshooting check circuit continuity of the lambda sensor connector PIN 1 PIN2 toward the probe replace the lambda sensor if there is no continuity if there is continuity check the sensor connector and the Marelli control unit connector If not OK restore If OK check continuity between the BLUE connector PIN 31 and PIN 21 and restore the cable harness ELE SYS 111 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 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 electrical circuit diagram Coils and in jectors Location on the intake manifold connector on injector Electrical characteristics 14 8 Ohm 5 at 20 C Pin out Supply Ground connection NAVIGATOR FU
129. entiometer ELE SYS 74 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system 6 Fall sensor optional equipment 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 Front ABS sensor 21 Auxiliary fuses 22 Relay 23 Supplementary headlamps optional equipment 24 ABS Control unit 25 Rear ABS sensor 26 ABS Fuses Electrical system installation INTRODUCTION Scope and applicability This document aims at defining the cable harness routing in order to achieve the vehicle reliability targets Materials used and corresponding quantities The electrical system consists of the following cable harnesses and parts 1 Main cable harness 1 Ground lead 1 Headlamp cable harness 1 Fall sensor connector 1 Antitheft cable harness optional equipment 8 Small clamps 18 Medium clamps 1 Big clamp ELE SYS 75 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 Motorcycle division The wiring timing is subdivided in three essential sections as indicated in the figure 1 Front section 2 Central section 3 Rear part 4 Reus
130. es in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International Subsidiaries These changes will be introduced in the subsequent editions of the manual In case 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 2011 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 Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle to prevent damaging the environment A 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 Im Z gt Z O m ELE SYS
131. esaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 167 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine ENG 168 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 Stelvio 1200 MY11 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 set screw in position by
132. etata Resaling Forbiden Wiederverkauf Verboten Braking system Stelvio 1200 MY11 CHECK THAT DURING THE OPERATION THERE IS ALWAYS BRAKE FLUID IN THE RESER VOIR REGULAR AIR BLEEDING SYSTEM 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 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 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 BRAK SYS 330 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS Bopywork BODYW Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Bodywork Stelvio 1200 MY11 FRONT LIGHTS pos Description Type Quantity Torque Notes 1 Horn fixing screw M6x20 1 15 Nm 11 06 Ibf ft 2 Viti fissaggio freccie anteriori M4 2 3 Nm 2 21 Ibf ft 3 Vite fissaggio superiore fanale a carozzeria 4 1 3 Nm 2 21 Ibf ft 4 Viti fissaggio fanale a carozzeria M4x25 2 3 Nm 2 21
133. ews 7 Tighten the screws 7 to the prescribed torque Remove excessive sealant CHAS 284 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis 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 Fit the breather with the washer Screw the breather to the prescribed torque CHAS 285 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 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 Gruppo asse ruota Removal Remove the bearing from the wheel axle with a suitable extractor CHAS 286 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis Turn the unit over Remove the bearing from the wheel axle with a suitable extractor FITTING Heat the bearings to 100 C 212 F Assemble the bearings to the wheel axle Turn the unit over Assemble the bearings to the wheel axle Pinion unit CHAS 287 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 Pinion unit Removal Remove the stop ring
134. ews 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 01968 in Lock the screws A on the caps B with a torque wrench at the prescribed torque ENG 215 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 PAY ATTENTION TO CRANKSHAFT ROTATION WHEN ONLY THE CONNECTING RODS ARE FITTED BECAUSE IT COULD HIT THE TWO LUBRICATION JETS INSIDE 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 the crankcase generator side Use the sealing ring fitting tool on the flywheel side flange to fitthe sealing ring on the flange Specific tooling 19 92 71 00 Tool to fit the seal ring on the flywheel side flange Predisporre loctite 510 tra carter e flangia albero motore sul lato volano 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 crankshaf
135. ews to the prescri bed torque operating diagonally and in stages ENG 176 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine CYLINDER HEAD COVERS pos Description Type Quantity Torque Notes ENG 177 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 RiGHT CYLINDER HEAD pos Description Type Quantity Torque Notes 1 Movable chain tensioner pad fixing screw 1 20 Nm 14 75 Ibf ft Loctite 243 2 Head tightening nut M10x1 25 4 15 Nm 11 06 Ibf ft Engine Oil Pre tightening 2 Head tightening nut M10x1 25 4 42 Nm 30 98 Ibf ft Final tightening 3 Head tightening screws chain compartment M6x120 2 10 Nm 7 37 Ibf ft 4 Plate locking screw and timing gear 1 30 Nm 22 13 Ibf ft Loctite 243 D Timing cover fixing screw on the cylinder head M5x10 2 8 Nm 5 90 Ibf ft 6 Camshaft support fixing screw 6 18 Nm 13 28 Ibf ft ch 9 LEFT CYLINDER HEAD pos Description Type Quantity Torque Notes 1 Movable chain tensioner pad fixing screw 1 20 Nm 14 75 Ibf ft Loctite 243 2 Head tightening nut M10x1 25 4 15 Nm 11 06 Ibf ft Engine Oil Pre tightening 2 Head tightening nut M10x1 25 4 42 Nm 30 98 Ibf ft Final tightening 3 Head tightening screws chain compartment M6x120 2 10 Nm 7 37 Ibf ft 4 Plate locking screw and timing gear 1 30 Nm 22 13 Ibf ft Loc
136. example rider with passenger or with luggage Maximum load adjustment e g rider passenger and luggage FORK SETTING Normal load adjustments are the standard settings by manufacturer FORK SETTINGS Specification Desc Quantity Spring preloading nut 1 regular load conditions tighten clockwise 8 turns from fully open SUSP 250 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Suspensions Specification Desc Quantity Spring preloading nut 1 half load conditions tighten clockwise 9 turns from fully open Spring preloading nut 1 maximum load conditions tighten clockwise 9 turns from fully open Rebound damping right stem set screw 2 regular load con unscrew anticlockwise 1 turn from fully closed ditions Rebound damping right stem set screw 2 half load condi unscrew anticlockwise 1 turn from fully closed tions Rebound damping right stem set screw 2 maximum load unscrew anticlockwise 1 turn from fully closed conditions Compression damping left stem set screw 2 regular load unscrew anticlockwise 1 turn from fully closed conditions Compression damping left stem set screw 2 half load con unscrew anticlockwise 1 turn from fully closed ditions Compression damping left stem set screw 2 maximum load unscrew anticlockwise 1 turn from fully closed conditions 1 THE SETTING SHOWN IN THE TABLE MAY NEED TO BE MODIFIED ACCORDING TO
137. f Verboten Engine Stelvio 1200 MY11 Undo and remove the two screws Undo and remove the screw Remove the gearbox See also Removing the starter motor Replacement Gearbox shafts ENG 146 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 147 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 ENG 148 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 mi
138. f ft 11 Gear to engine fixing nut M8 5 20 Nm 14 75 Ibf ft 12 Gear to engine fixing screw 1 20 Nm 14 75 Ibf ft Loctite 542 GEAR INTERNAL CONTROLS pos Description Type Quantity Torque Notes 1 Spring guide pin 1 24 Nm 17 70 Ibf ft Loctite 243 CHAR 39 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 OIL SUMP COMPONENTS Type pos Description Cover on the flange under the crankcase Oil filter joint Oil sump pipe Oil filter Rose pipe fixing screw Maximum pressure valve cover O O01 BR GO Po M6 M18 Quantity 1 1 1 1 Torque 40 Nm 29 50 Ibf ft 10 Nm 7 37 Ibf ft 20 Nm 14 75 Ibf ft 15 Nm 11 06 Ibf ft 10 Nm 7 37 Ibf ft 40 Nm 29 50 Ibf ft Notes Loctite 243 Loctite 648 Engine oil CHAR 40 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 CYLINDER HEAD COVERS Quantity Torque Notes pos Special cylinder head fixing screw 8 Nm 5 90 Ibf ft Locked with cross Sequens M5x10 2 8 Nm 5 90 Ibf ft Spark plug cover fixing screw Description Type GENERATOR COVER pos Description Type Quantity Torque Notes 1 Timing system cover cap fixing screw M6x20 2 10 Nm 7 37 Ibf ft Loctite 243 2 Timing system cover fixing screw M8x55 4 25 Nm 18 44 Ibf ft 3 Timing system cover fixing
139. fication 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 ENG 214 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine The connecting rods have a marked area for weight selection The weight indicated in the chart includes screws dowels and the bushing CONNECTING ROD WEIGHT SELECTION Specification Desc Quantity Connecting rod brown 0 588 0 598 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 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 scr
140. filled up So that the brake fluid remains in the ABS control unit first remove the pro BRAK SYS 326 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 tective caps of the braking circuit un ions and connect the respective pipes Once all the braking circuits have been con nected remove the protective caps from the braking pump unions and connect the braking pump pipes to the ABS control unit Unlock the lever and the brake pedal Remove the reservoir cap and fill it with new brake fluid up to the reference MAX CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEEDING AS DESCRIBED AT THE END OF THE CHAPTER Always fill the reservoir up to the reference MAX and refit the cap Braking system Check the stroke the sensitivity of both the lever and the brake pedal If after bleeding the pedal or the lever stroke is too long check that there are no leaks in the braking system and if everything is ok continue bleeding operations using Navigator as described Detach the bleed hoses and close the bleed screws again to the correct tightening torque See also Front Rear CALLIPERS REPLACEMENT VEHICLE PREPARATION The operations are described for the front system but they are al so valid for both braking systems Connect the bleed bottles to the bleed screw of the front calliper and open it Fully press
141. g 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 209 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 Sostituire le guarnizioni ed installare il coperchio testa Place the plastic half cover Replace the four rubber rings Tighten the four screws to the prescri bed torque Place the spark plug tube ENG 210 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Crankcase crankshaft Removing the crankshaft Specific tooling 12 91 36 00 Tool to remove the flywheel side flange Remove the clutch Remove the tone wheel and the oil pump gear v Working from the generator side un a screw and remove the nut W 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 Revente
142. grees corresponding to the Stepper motor air flow STATUS screen page 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 STATUSES Specification Desc Quantity Engine status ON run power latch stopped operation conditions Throttle position Released pressed indicates if the throttle potentiometer is open or closed Stand Retracted extended indicates the position of the side stand only with gear engaged Ignition Enabled disabled indicates if the control unit consents engine start up RUN STOP switch Run stop indicates the position of the safety switch Clutch No Yes indicates the clutch sensor status Gear engaged No Yes indicates the gear sensor status fall sensor Normal Tip over indicates the vehicle fall sensor status Lambda 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 over 20 C 68 F and engine T over 30 C 86 F and engine on for at least 2 3 minutes Synchronisation Synchronised Not synchronised Indicates if the control unit detects the revolution sensor signal correctly P SUPP 242 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 ACTIVATION screen page This screen page is used to delete errors in th
143. haracteristics Front side FRONT LIGHTS pos Description Type Quantity Torque Notes 1 Horn fixing screw M6x20 1 15 Nm 11 06 Ibf ft 2 Viti fissaggio freccie anteriori M4 2 3 Nm 2 21 Ibf ft 3 Vite fissaggio superiore fanale a carozzeria M4 1 3 Nm 2 21 Ibf ft 4 Viti fissaggio fanale a carozzeria M4x25 2 3 Nm 2 21 Ibf ft 5 Viti TCEI fissaggio fanale a telaietto M5x25 5 6 Nm 4 42 Ibf ft CHAR 15 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 INSTRUMENT PANEL pos Description Type Quantity Torque Notes 1 Viti TCEI fissaggio sensore velocit anteriore M5x16 2 6 Nm 4 42 Ibf ft 2 Viti TCEI fissaggio blocchetto avviamento M8x30 1 25 Nm 18 44 Ibf ft 3 Viti autofil fissaggio supporto cruscotto 5x14 3 Manual 4 Viti autofil fissaggio supporto cruscotto a 3 9x14 4 Manual nice 5 Viti autofil fissaggio cornice 4 Manual 6 Viti TCE M5 2 6 Nm 4 42 Ibf ft ca ED i lt gt s i Tii n FRONT FORK pos Description Type Quantity Torque Notes 1 Viti piede forcella 25 Nm 18 44 lff 2 Viti chiusura mozzetti M6x30 10 Nm 7 38 Ibf ft Fork cap 1 1 Nm Ibf ft CHAR 16 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics k ns i n
144. he cable harness if there is no voltage replace the lambda sensor Left lambda sensor 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 ELE SYS 109 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 If the circuit is open shorted to negative voltage equal to zero has been detected at PIN 11 of the BLUE connector Troubleshooting shorted to positive disconnect the probe connector and check the sensor correct resistance replace the sensor if not OK if it is OK restore the cable harness circuit is open shorted to negative check the continuity from probe connector 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 se non ok verificare cavo rosso nero lato cablaggio tra connettore sonda e rel iniezione secondario n 37 dello schema elettrico posizione lato sinistro anteriore del motociclo primo rel a sinistra vicino alla bobina VERIFICARE comunque l identificazione del rel con il colore dei cavi se pre senti anche errori bobine e iniettori verificare il rel stesso e la sua linea di e
145. he correct torque 1 Cap damaged 2 Retaining clamp or closing cover loose 3 1 Replace the cap Fitting error of the radial seal or seal damaged 4 Sliding sur 2 Screw the clamp with suitable pliers face of the wheel spacer spoiled or damaged 3 Replace the sealing ring and fit it correctly with the suitable tool 4 Replace the spacer 1 Cap damaged 2 Internal retaining clamp or external closing 1 Replace the cap clamp loose 2 Screw the internal or external clamp with suitable pliers 1 Bevel gear pair fitting error 2 Bevel gear pair toothing spoiled 1 Replace the bevel gear pair or damaged 1 Ball bearings on the wheel axle damaged 1 Replace the wheel bearings 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 Place the reaction rod into its seat Insert the screw Screw the nut fixing the reaction rod CHAS 293 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 Place the dust protection ring between the rim and the cardan shaft taking care to mount it with the collar facing the transmission unit 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
146. heck that the tyre size is the correct one If it is not OK replace it If it is OK check that the tyre pressure is the correct one If it is not OK restore it if itis OK replace the speed Sensor REAR FUNCTION It is used by the ABS module and then by the ECU and the instrument panel OPERATION OPERATING PRINCIPLE Differ ential Hall effect sensor ELECTRICAL CIRCUIT DIAGRAM Level in wir ing diagram ABS REMOVAL ELE SYS 100 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system LOCATION ON THE VEHICLE Under the bevel gear set box right side CONNECTOR LOCATION if available Under the saddle right side PIN OUT PIN1 Ground PIN2 Signal NAVIGATOR PARAMETERS Speed sensor Vehicle speed km h REAR SPEED SENSOR OPEN CIRCUIT OR SHORT CIRCUIT NAVIGATOR ERROR Description of the defect the control unit detects abnormal voltage in the rear speed sensor signal Checks check battery voltage on the cable between pin 2 of the rear speed sensor connector and pin 11 of the ABS module connector If there is not enough voltage check cable continuity from the ABS module to the speed sensor connector and make sure that the cable is ground insulated Solution restore wiring It is normal that when the speed sensor connector is disconnected no voltage is detected If functioning is correct proceed to the next check Checks check the speed senso
147. her Relief oil pressure from the left chain tensioner ENG 182 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 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 ENG 183 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 head Removing the overhead camshaft CAUTION WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING Remove the two rocking levers from the cam cap Remove the two rods ENG 184 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Undo and remove the four screws Remove the U bolt Remove the camshaft Remove the bowls from the cam cap and mark their position so as not inter change them when refitting See
148. hillips screwdriver Lift and remove the cover 3 and screws 1 as well Remove the gasket 4 Rear brake Unscrew and remove the cap 5 Remove the gasket 6 Top up the reservoir with brake fluid to the correct level which is between the two MIN and MAX reference marks N RISK OF BRAKE FLUID SPILLS DO NOT OPERATE THE BRAKE LEVER WITH BRAKE FLUID RESERVOIR CAP LOOSENED OR REMOVED CAUTION AA 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 TO 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 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 MAIN 70 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Maintenance TO AN Official Moto
149. ic drum 157 E ECU 123 241 311 Electrical system 12 73 75 351 Engine oil 64 166 299 Engine temperature sensor 105 Exhaust 129 295 297 298 Exhaust manifold 297 298 Fairings 343 347 Fork 248 251 254 258 263 Forks 157 Front headlamp Front wheel 246 252 Fuel 129 165 315 347 Fuses 97 G Gearbox oil 66 H Handlebar Head cover 181 184 210 Headlight 339 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Identification 10 Instrument panel 121 337 L License plate holder M Maintenance 8 62 316 Maintenance Table Mudguard Oil filter 66 Oil pressure sensor 116 Oil sump 227 230 Primary shaft 151 156 158 R Radiator Rear light Rear wheel 267 Recommended products 53 277 Run Stop switch 122 S Saddle Secondary shaft 153 156 158 Shock absorber Shock absorbers 268 Side fairings 343 Side stand 719 Side stand sensor 119 Speed sensor 99 Stand 119 Start up 96 Starter motor 146 170 T Tank 129 165 315 347 Throttle body Transmission 12 63 Tyres 14 W Wiring diagram 90 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten
150. ing 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 ENG 180 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Removing the head cover NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS Scollegare la pipetta candela facendo leva mediante un cacciavite attraverso la feritoia CAUTION PRESTARE ATTENZIONE A FARE LEVA SULLA GOMMA DELLA PIPETTA CANDELA E NON SULLA CANDELA STESSA ONDE EVITARE DI DANNEGGIARLA Unscrew and remove the four head cover fixing screws and collect the sealing O rings Rimuovere il coperchio testa completo di guarnizioni Removing the cylinder head CAUTION WHEN REMOVING THE COMPONENTS MARK THE POSITION OF EACH PART VERY CARE FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING ENG 181 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 e Unscrew and remove the screw and the was
151. ire Unscrew and remove the screw and remove the tone wheel sensor 1 CAUTION BEFORE REFITTING MAKE SURE THAT THE FAYING SURFACES BETWEEN THE SENSOR 1 AND THE SEAT ITSELF DO NOT SHOW SIGNS OF DAMAGE AND ARE COMPLETELY CLEAN ALWAYS CHECK THE DISTANCE BETWEEN THE SENSOR 1 AND THE TONE WHEEL 2 Rear brake calliper BRAK SYS 317 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Braking system Stelvio 1200 MY11 Pinza FRENO POSTERIORE Pos Descrizione Tipo Quantit Coppia Note EE Rear brake calliper fixing screw M10 2 5ONm 36 87Ibfft ru Vite fissaggio tubo olio li Nm dbff __ Vite fissaggio tubo olio Nm Ibf ft Key Rear brake calliper Screw Pads Pin calliper split pin Spring Gasket Screw Air bleed Air bleed cap O COD SOM xe JM 10 Rear brake pipe 11 Oil pipe screw BRAK SYS 318 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Braking system Front brake calliper FRONT BRAKE CALLIPERS pos Description Type Quantity Torque Notes 1 Viti TE Flang fissaggio pinze M10x55 4 50 Nm 36 88 Ibf ft BRAK SYS 319 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Braking system Stelvio 1200 MY11 Front right brake calliper Front left brake calliper Pads Air bleed Air blee
152. ite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine from vehicle Stelvio 1200 MY11 Operating from both sides undo and remove the upper engine fixing nut on the internal side of the chassis e Unscrew and remove the engine lower fixing nut and collect the washer Remove the lower bolt and collect the washer e 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 ENG VE 134 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine from vehicle 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
153. itions 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 213 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 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 005mm AS 5 944 0 002 gr SI 022 003 22 020 0 86626 0 86692 in E p T T Y Ii E lt a FEY f pz 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 Speci
154. ium clamps TABLE P 1 Clamp that has the cable harness of the left light switch and the key on the metal relay 2 Clamp that has the cable harness of the left light switch on the pipe 3 Middle clamp TABLE Q 1 Keep the cable harness outside according to the relays 2 Clamp TABLE R 1 Middle clamp 2 Position of the foglight relay connector ELE SYS 80 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system TABLE S 1 Hook the clamp on the specific hole present in the support 2 Middle clamp TABLET 1 Front plug socket adi 2 Plug socket connector 3 Correct alignment 4 Medium clamp to be placed after fitting the cap so as to avoid it can remove TABLE U 2 1 Instrument panel 2 Instrument panel connector correctly connected Central part TABLE A i i 1 Main cable harness 2 Motor main cable harness 3 Grey taping as reference that must remain be tween the two covers ELE SYS 81 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 TABLE B 1 Engine oil pressure sensor 2 Small clamp TABLE C 1 Generator 2 Sensor 3 Alternator positive TABLE D 1 Pick up cable harness 2 Medium clamp that fastens the right pick Up ca ble to the chassis TABLE E 1 Reused clamp ELE SYS 82 Revente Interdite Revendita
155. k through Navigator if the temperature indicated is the same as the engine temperature Check also that the sensor electrical characteristics are ob served replace the sensor if not OK if it is OK check the sensor connector and the Marelli control unit connector ELE SYS 106 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system 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 electrical circuit diagram Temperature sensors Location sensor on filter casing connector on the sensor Electrical characteristics AIR TEMPERATURE SENSOR RESISTANCE Specification Desc Quantity 1 Resistance at 40 C 40 F 100 950 kOhm 2 Resistance at 0 C 32 F 9 750 kOhm 3 Resistance at 10 C 50 F 5 970 kOhm 4 Resistance at 20 C 68 F 3 750 kOhm 5 Resistance at 30 C 86 F 2 420 kOhm 6 Resistance at 40 C 104 F 1 600 kOhm 7 Resistance at 90 C 194 F 0 280 kOhm Pin out PIN 1 Ground connection PIN 2 0 5 V signal NAVIGATOR PARAMETERS Air temperature In case of failure temperature is set at 25 C 77 F NAVIGATOR ERRORS air temperature sensor P0110 op
156. ky blue orange cable between the connector in question and PIN 27 of the BLUE connector if not OK restore the cable harness if OK replace the Marelli control unit Indication on Navigator 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 ECU BROWN connector pin configuration Pin Use 1 Not used 2 Not used 3 Ignition potentiometer signal 4 Not used 5 Engine temperature signal 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 7 19 Stepper motor 20 5V power supply sensors 21 Not used 22 Not used 23 Neutral sensor signal 24 Not used ELE SYS 123 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system 25 Engine revolution sensor signal 26 Not used 27 Not used 28 Left cylinder injector control 29 Ignition potentiometer negative 30 Not used 31 Not used 32 Ignition potentiometer power supply 33 Not used 34 Revolution sensor anti jamming cable 35 Engine revolution
157. leeve on the stem and set the oil seal into position with the aid of the specific tool Specific tooling 9100903 Marzocchi fork oil seal 45 mm 1 77 Insert the retainer ring in its position Fit the dust gaiter with the specific tool Specific tooling 9100903 Marzocchi fork oil seal 45 mm 1 77 Fit the pumping member pin with the cap in the spring holder sleeve and in the preload pipe SUSP 260 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Suspensions 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 10 mm 4 33 in Pour part of the fork oil into the sleeve Wait some minutes until the oil fills all the ducts Pour the remaining oil Pump out oil a few times Measure the air gap between the oil THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS level and the rim Specific tooling AP8140149 Protection for fitting operations Characteristic Oil level from sleeve rim without the spring and preloading pipe 110 mm 4 33 in Fork oil 650 cm 39 66 cu in for each stem
158. ling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics 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 ENI i RIDE PG RACING 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 ARNICA SA 32 Fork oil SAE OW ISO VG 32 AGIP GREASE SM2 Lithium grease with molybdenum for NLGI 2 bearings and other points needing lubri cation Neutral grease or petroleum jelly BATTERY POLES AGIP BRAKE 4 BRAKE 5 1 Brake fluid As an alternative for recommended flu ids use top branded fluids that meet or exceed the requirements of SAE J1703 NHTSA 116 DOT 4 ISO 4925 synthetic fluid specifications AGIP BRAKE 4 BRAKE 5 1 Clutch fluid As an alternative for recommended flu ids use top branded fluids that meet or exceed th
159. ltage 5DF7 Vehicle code 5E59 Control unit F000 CAN line D347 electric malfunction CAN line 5E11 electric malfunction 0xF01F control unit 5E5A ABS switch ERRORS Value example Unit of measure ment Braking system Notes Electrical fault in sensor or cable harness Faulty sensor or signal interference Possible tone wheel fault due to deformations or dirt possible alterations on the wheel bearing sur face In very rare cases abnormal tone wheel vibrations Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel Faulty sensor tone wheel or tone wheel with wrong number of teeth or wrong tyre size Electrical fault in sensor or cable harness Faulty sensor or signal interference Possible tone wheel fault due to deformations or dirt possible alterations on the wheel bearing sur face In very rare cases abnormal tone wheel vibrations Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel or tone wheel with wrong number of teeth Faulty sensor or missing sensor tone wheel or ex cessive distance between the sensor and the tone wheel Faulty sensor or tone wheel with wrong number of teeth or wrong tyre size Possible control unit fault Possible control unit fault Po
160. mped on the left side close to the engine oil level check cap Dimensions and mass Specification WEIGHT AND DIMENSIONS Maximum length without accessories Maximum width to handlebar Maximum width of the vehicle with accessories Minimum maximum height adjustable windshield Saddle height Minimum ground clearance Wheelbase Kerb weight Kerb weight of full house vehicle Engine Specification Type Number of cylinders Cylinder layout Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENGINE Desc Quantity 2 305 mm 90 75 in 956 mm 37 64 in 1 080 mm 42 52 in 1436 1492 mm 56 53 58 74 in 800 mm 31 5 in 185 mm 7 3 in 1 535 mm 60 43 in 281 kg 619 50 Ib 296 kg 652 57 Ib Desc Quantity Characteristics traverse mounted twin cylinder four stroke V 90 2 90 V CHAR 11 Characteristics Specification Bore stroke Engine capacity Compression ratio Ignition Engine idle speed Clutch Lubrication system Air filter Cooling Timing system diagram Values valid with control clearance between rocker and valve Transmission Stelvio 1200 MY11 Desc Quantity 95 x 81 2 mm 3 74 x 3 20 in 1151 cm 70 cu in 11 1 starter 1100 100 rpm hydraulically controlled single plate dry clutch with incorpora ted flexible coupling Pressurised circuit with regulator valves and trochoidal pump cartridge type dry filter air and oil cooled
161. n Wiederverkauf Verboten Chassis Stelvio 1200 MY11 TE flanged screw T shaped bushing Rubber ring Radiator support screw Clip sa Qo nm Removing To change the engine oil and to replace the oil fil 303 ee ter remove the oil sump guard Operating from both sides unscrew and remove the two front screws 1 Operating from both sides unscrew and remove the rear screw 2 Remove the oil sump guard Place collecting container and empty the lubrication system e Unscrew and remove the two oil pipes 4 on the radiator rali nn u m Y ar i bh ERR CHAS 300 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis Undo and remove the two radiator up per screws and collect the washer Remove the oil cooling radiator Installing Fit the oil cooling radiator on the vehi 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
162. nd PIN 18 of the instrument panel connector lf 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 ON the voltage measured ELE SYS 121 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 upstream the resistance decreases replace the instrument panel If voltage continues to be approximately 5V restore the pink cable there is a short circuit at 5V Notes If a short circuit to ground is detected at PIN 10 of the instrument panel connector the display will show a full scale air temperature indication of 60 C 140 F 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 It tells the control unit if the rider 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 u
163. nder 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 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 116 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 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
164. ng 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 353 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten A ABS 126 304 310 314 Air filter 67 Air temperature sensor 107 121 Alternator Battery 95 98 Brake 317 319 321 323 Brake calliper 317 319 Brake disc 320 Brake lever Brake pads 321 323 C Clutch 118 171 174 175 212 Coil 114 Connectors 123 Crankcase 51 211 218 Crankshaft 51 194 197 211 213 216 Cylinder 50 181 184 186 187 201 202 204 207 212 D Desmodrom
165. ng fissaggio collettori Oxygen sensor fastener Viti fissaggio protezione 10 55 Vite TE Flang fissaggio parte centrale M8x60 Vite TCEI fissaggio silenziatore a telaio EXHAUST SYSTEM Type M8 Quantity 4 N NO Torque 25 Nm 18 44 Ibf ft 38 Nm 28 03 Ibf ft 25 Nm 18 44 Ibf ft 10 Nm 7 38 Ibf ft 25 Nm 18 44 Ibf ft CHAR 26 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics ga BRAKE SYSTEM pos Description Type Quantity Torque Notes 1 Brake pipe slot screw on the pump M10 2 25 Nm 18 44 Ibf ft 2 Joint with brake pipes retainer bleeding on the M10 3 25 Nm 18 44 Ibf ft calliper 3 Brake pipes joint on the ABS hydraulic unit E 3 25 Nm 18 44 Ibf ft 4 Brake pipes joint on the ABS hydraulic unit M12 1 30 34 Nm 22 13 25 08 Ibf ft CHAR 27 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 SUPPORTO E PEDANE PILOTA pos Description Type Quantity Torque Notes 1 Viti Flang fissaggio piastrine 4 10 Nm 7 38 Ibf ft 2 Viti TCEI fissaggio supporto pedane M8x35 2 25 Nm 18 44 Ibf ft 3 Vite fissaggio supporto pedane 1 25 Nm 18 44 Ibf ft 4 Vite TCEI fissaggio supporto pedane M8x25 1 25 Nm 18 44 Ibf ft 5 Vite fissaggio supporto pedane 1 25 Nm 18 44 Ibf
166. ng gear 1 30 Nm 22 13 Ibf ft Loctite 243 D Timing cover fixing screw on the cylinder head M5x10 2 8 Nm 5 90 Ibf ft 6 Camshaft support fixing screw 6 18 Nm 13 28 Ibf ft 7 Vite fissaggio molla a tazza 1 18 Nm 13 28 Ibf ft Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten ENG 201 Engine See also Stelvio 1200 MY11 Remove the head the gasket between the head and the cylinder and the two dowel pins 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 the crankcase opening with a clean cloth Removing the cylinder head Disassembling the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS ENG 202 Remove the cylinder Cover the crankcase opening with a clean cloth Release the snap ring Remove the pin Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 O
167. ng screw on the transmission M10x35 4 50 Nm 36 87 Ibf ft housing 3 Swingarm pin on the swingarm M12 1 60 Nm 44 25 Ibf ft 4 Preloading bushing to the swingarm pin M25 1 10 Nm 7 37 Ibf ft CHAR 33 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 LUCI POSTERIORI pos Description Type Quantity Torque Notes aa Vite TBEI Flang fissaggio fanale ea 6 Nm 4 43 Ibf ft BE ru Vite TCEI fissaggio fanale ae NN CN Vite TCEI fissaggio fanale targa M5x25 6 Nm 4 43 Ibf ft MANIGLIONE E PORTAPACCHI pos Description Type Quantity Torque Notes 1 Vite TCEl fissaggio maniglione passeggero M6x25 4 10 Nm 7 38 Ibf ft 2 Vite TCEI fissaggio maniglione passeggero M8 2 25 Nm 18 44 Ibf ft 3 Vite fissaggio portatarga a maniglione M5 2 6 Nm 4 42 Ibf ft 4 Vite TBEI fissaggio supporti portapacchi M8x20 2 25 Nm 18 44 Ibf ft 5 Vite TBEI fissaggio supporti portapacchi M8x30 2 25 Nm 18 44 Ibf ft 6 Vite TSPEI fissaggio coperchio portapacchi M6x35 2 10 Nm 7 38 Ibf ft 7 Vite autofil fissaggio coperchio portapacchi 5 4 Manual CHAR 34 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics u 3 REAR WHEEL pos Description Type Quantity Torque Notes Vite TE Flang fissaggio ruota fonica 6 25Nm 18 44lbfft
168. nly 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 ELE SYS 93 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 Engine Temperature Error ECU 15 Air Temperature Error DC V DC ECU 16 Air Temperature Error DC Gnd ECU 17 Low Battery Error ECU 20 Lambda Probe Error ECU 21 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 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 Remote Error Start up 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 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
169. 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 ELE SYS 94 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Description Oil pressure failure Error code DSB 08 The instrument panel keeps all previous errors stored in its memory DELETE ERRORS This option deletes instrument panel errors only a further confirmation is requested INSTRUMENT PANEL SOFTWARE UPGRADE This function is used to program the instrument panel again with a new software through Naviga tor 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 Navigator Aprilia Moto Guzzi package to connect to the Navigator 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 necessa
170. 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 P SUPP 243 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Power supply Specification Lambda probe Left injector Right injector Fuel pump relay Left coil Right coil Idle regulator Battery voltage Starter diagnosis Engine revolution sensor Lambda heater SPEED SENSOR CAN line diagnosis RAM memory ROM memory Microprocessor Checksum EPROM SETTINGS screen page This screen page is used to adjust some control unit parameters Stelvio 1200 MY11 Desc Quantity 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 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
171. nte Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Power supply Circuit diagram key 1 Complete fuel pump unit Fuel pipe Pipe Si Jw Screws Removing Rimuovere l anello di fermo della pom 4 G pa carburante P SUPP 235 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Power supply Estrarre la pompa carburante ruotan dola progressivamente verso il basso Terminare l estrazione della pompa carburante ruotandola progressiva mente verso l alto in modo da non dan neggiare il galleggiante CAUTION ESEGUIRE LA PROCEDURA INVERSA DURANTE LA FASE DI RIMONTAGGIO Injection P SUPP 236 Stelvio 1200 MY11 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 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 237 Power supply Stelvio 1200 MY11 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
172. ntrol 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 ELE SYS 117 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 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 electrical circuit diagram Start up enabling switches Location sensor under clutch lever 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 NAVIGATOR STATUSES Clutch Example value Yes No The statuses regularly viewed are YES NO DIAGNOSIS Troubleshooting Indication on Navigator always No check the correct position of the cable terminals on the sensor and the correct
173. nut M10x1 25 4 15 Nm 11 06 Ibf ft Engine Oil Pre tightening 2 Head tightening nut M10x1 25 4 42 Nm 30 98 Ibf ft Final tightening 3 Head tightening screws chain compartment M6x120 2 10 Nm 7 37 Ibf ft 4 Plate locking screw and timing gear 1 30 Nm 22 13 Ibf ft Loctite 243 5 Timing cover fixing screw on the cylinder head M5x10 2 8 Nm 5 90 Ibf ft 6 Camshaft support fixing screw 6 18 Nm 13 28 Ibf ft 7 Vite fissaggio molla a tazza 1 18 Nm 13 28 Ibf ft CHAR 48 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Characteristics PO P TIMING SYSTEM CONTROL pos Description Type Quantity Torque Notes 1 Control timing system shaft support flange M6x14 2 8 Nm 5 90 Ibf ft fixing screw 2 Bearing fixing screw M6x16 1 10 Nm 7 37 Ibf ft Loctite 243 3 Driving gears locking nut on the crankshaft M25 1 200 Nm 147 51 Ibf ft Loctite 601 4 Timing system driven gear locking nut M18 1 25 Nm 18 44 Ibf ft Pre tightening 4 Timing system driven gear locking nut M18 1 150 Nm 110 63 Ibf ft Final tightening CHAR 49 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 GEARBOX pos Description Type Quantity Torque Notes 1 Clutch housing to gearbox fixing screw M6x55 14 13 Nm 9 59 Ibf ft 2 Neutral sensor 1 10 Nm 7 37 Ibf ft 3 Breather stud bolt 1 8
174. o 1200 MY11 Maintenance 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 screwdriver the set screw 2 until the following clearances are ob tained inlet valve 0 10 mm 0 0039 in outlet valve 0 15 mm 0 0059 in The measurement must be done using a thickness gauge 3 CAUTION IF CLEARANCE IS LARGER THAN RECOMMENDED THE TAPPET WILL BE NOISY OTHER WISE THE VALVES DO NOT CLOSE CORRECTLY WHICH CAN LEAD TO PROBLEMS SUCH AS PRESSURE DROP ENGINE OVERHEAT VALVE BURNOUT ETC Braking system Level check Brake fluid check M Rest the vehicle on its stand For the front brake turn the handlebar fully to the right For the rear brake keep the vehicle upright so that the fluid in the reservoir is at the same level with the plug 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 MAIN 69 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Maintenance Stelvio 1200 MY11 Top up Front brake Unscrew the two screws 1 of the brake fluid reservoir 2 using a P
175. ocation 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 NAVIGATOR STATUSES Side stand Example value retracted extended DIAGNOSIS Indication on Navigator always EXTENDED check the side stand sensor connector and the ECU connector se non ok ripristinare se ok scollegare i due terminali dal sensore e verifi care continuit a massa del PIN 1 grigio lato cablaggio 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 Navigator 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 Bank angle sensor if applicable ELE SYS 119 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system Function it tells the vehicle position to the control unit Operation Operating principle When the
176. on Operating principle The throttle valve position sensor works as a var lable resistance according to the throttle rotation Level in electrical circuit diagram Throttle and idle motor Location e sensor on the right cylinder throttle body connector on the potentiometer M G 0 5 30 M BiI 0 5 30 Electrical characteristics PINS A C throttle closed approx 2 5 kOhm throttle open approx 1 5 kOhm PINS A B approx 1 1 Pin out PIN A ground connection ELE SYS 103 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 PIN B supply voltage 5V PIN 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 NAVIGATOR FUEL INJECTION SYSTEM NAVIGATOR PARAMETERS Throttle Example value 4 9 NAVIGATOR STATUSES Throttle position Example value Released Pressed Full load Indicates if the throttle potentiometer is open or closed in the released position
177. onnector 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 cable harness NAVIGATOR ACTIVATION Right injector Operation for 4 ms 5 times Viene eccitato il rel iniezione secondario n 37 dello schema elettrico posizione lato sinistro anteriore del motociclo primo rel a sinistra vicino alla bobina VERIFICARE comunque l identificazione del rel con il colore dei cavi per 5 secondi e viene chiuso a massa il cavo blu rosso dell iniettore per 4 ms ogni secondo 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 dis played in case of lack of activation NAVIGATOR 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
178. ons FRONT WHEEL Stelvio 1200 MY11 pos Description Type Quantity Torque Notes 1 Viti TE Flang fissaggio dischi freno M8x20 12 25 Nm 18 44 Ibf ft 2 Nut fixing wheel 1 80 Nm 59 00 Ibf ft 3 Vite flang fissaggio sensore 1 6 Nm 4 42 Ibf ft Loct 243 4 Vite TCB fissaggio passacavo M4x6 1 3 Nm 2 21 Ibf ft 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 SUSP 246 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Suspensions Hold the vehicle front part Unscrew remove the wheel axle fixing nut and collect the sealing wash er Working from both sides loosen the screws on the wheel bolt clamps Tap the wheel axle slightly with a rubber mallet so that the hole on the opposite side is exposed Remove the wheel axle by inserting screwdriver in the holes on the pin During extraction support the wheel and then remove it Collect the spacer from the front wheel right side SUSP 247 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions Stelvio 1200 MY11 Front fork i EE p XM FRONT FORK pos Description Type Quantity Torque Notes LEM Viti piede forcella M8 141 25 Nm 18 44 Ibfft
179. ons ENG 187 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 removal and refitting AP9100838 Tool for valve pressure plate ENG 188 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 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 189 Engine Stelvio 1200 MY11 Place the
180. ooling 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 ENG 195 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 e After shimming the timing sensor prop FR erly proceed to fit it DH d e Fit the washer and tighten the timing FF CH system gear fixing nut of the service 4 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 ENG 196 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 197 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY1
181. open ing 1 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 AIR FILTER pos Description Type Quantity Torque Notes Vite fissaggio cassa filtro aria a telaio 10 Nm 7 38 Ibf ft ae Air filter box cover fastening screw SWP 5x20 3 Nm gt 21 Ibf ft MAIN 67 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Maintenance Stelvio 1200 MY11 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 IN COMPRESSION STROKE VALVES CLOSED Scollegare la pipetta candela facendo leva mediante un cacciavite attraverso la feritoia CAUTION PRESTARE ATTENZIONE A FARE LEVA SULLA GOMMA DELLA PIPETTA CANDELA E NON SULLA CANDELA STESSA ONDE EVITARE DI DANNEGGIARLA MAIN 68 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvi
182. ound connection white 4 Heater power supply white NAVIGATOR 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 sensor 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 NAVIGATOR STATUSES Lambda check Example value Open loop Closed loop 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 NAVIGATOR ELECTRICAL ERRORS Left lambda sensor P0130 Shorted to positive Error cause Excessive voltage battery voltage has been detected at PINS 32 and 22 of the BLUE connector Troubleshooting 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 measure voltage at PIN 2 cable harness side green white cable and if there is voltage restore t
183. ower fixing screw M10x60 1 30 Nm 22 13 Ibf ft GENERATOR COVER pos Description Type Quantity Torque Notes 1 Timing system cover cap fixing screw M6x20 2 10 Nm 7 37 Ibf ft Loctite 243 ENG 161 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 pos Description Type Quantity Torque Notes 2 Timing system cover fixing screw M8x55 4 25Nm 18 44lbfft Timing system cover fixing screw M6x30 12 Nm 8 85 Ibf ft Sas Generator cover fixing screw M6x16 12 Nm 8 85 Ibf ft 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 ENG 162 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Loosen the screw 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 ENG 163 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 Using a compressed air gun unscrew and remove the nut and collect the spacer Remove the lower pulley Undo and remove the eight screws
184. p the switch should be open i e the Marelli control unit should not detect voltage at PIN 27 of the BLUE connector Level in electrical circuit 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 NAVIGATOR STATUSES Run stop switch Example value Run Stop DIAGNOSIS Indication on Navigator always STOP disconnect the connector and with the switch set to RUN check if there is continuity towards the switch of both the green orange and the grey yellow 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 ELE SYS 122 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system there is continuity of the s
185. 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 CHAS 272 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis Remove the rear wheel Unscrew and remove the two screws Remove the speed sensor from the fork Unscrew and remove the 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 CHAS 273 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 Unscrew and remove the fixing nut of the connecting rod assembly and col lect the screw Loosen the ring nut Specific tooling 14 91 26 03 Hook spanner for fixing ring nut of the clutch shaft internal body 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
186. r manufacturing or commercial reasons Not all versions models 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 2011 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 MY11 This manual provides the main information to carry out regular maintenance operations on your scooter This manual is intended to Moto Guzzi Dealers and their qualified mechanics several concepts have been deliberately omitted as they are considered unnecessary As 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 scooters Without this knowledge repairing or checking the vehicle may be inefficient or even dangerous As 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 chang
187. r signal 0 5 or 1 V on the cable between pin 1 of the rear speed sensor connector and pin 12 of the ABS module connector If there is not enough voltage check cable continuity from the ABS module to the speed sensor connector and make sure that the cable is grounded insulated Solution if the cable is interrupted or grounded restore wiring If the cable harness is not damaged it means that the speed sensor is defective or the circuit between sensor and connector is interrupted replace the speed sensor FRONT REAR SPEED SENSOR COHERENCE NAVIGATOR ERROR Description of the defect the control unit detects an abnormal condition in the signals coming from the speed sensors for example disturbances signal intensity reduced speed difference between the two wheels for a certain period of time etc Checks check the correct distance between speed sensor and tone wheel Solution restore the correct distance between speed sensor and tone wheel If functioning is correct proceed to the next check Checks check the tone wheel is not distorted it should not be deformed or damaged Solution replace tone wheel If functioning is correct proceed to the next check Checks check the speed sensor position and integrity Solution position the speed sensor correctly or replace it If functioning is correct proceed to the next check ELE SYS 101 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical sy
188. rd Operating from both sides unscrew and remove the two front screws 1 Operating from both sides unscrew and remove the rear screw 2 Remove the oil sump guard Place a container with 4 000 cm 244 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 Screw and tighten the drainage plug 3 DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED OIL COLLECTION CENTRE MAIN 65 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Maintenance Stelvio 1200 MY11 Engine oil filter Replace the engine oil filter each time you change the engine oil Drain the engine oil completely Unscrew and remove the engine oil fil ter from its seat NOTE NEVER REUSE AN OLD FILTER 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 Gearbox Oil Inspection CHECKING AND TOPPING UP CAUTI
189. rts Scratches Dirt Tightening torques inspection Safety fasteners 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 Pre delivery 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 starter Engine stop via emergency stop switch and side stand Helmet compartment electrical opening switch if present Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten PRE DE 351 Pre delivery Stelvio 1200 MY11 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 N 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 UPON INSTAL
190. ry and thus program the new set of keys Electrical system In the first phase the user code must be entered and after confirming the inserted key key 1 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 entering the service code KEY CHANGE and program the new keys Battery recharge circuit ELE SYS 95 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 Checking the stator Single phase generator with regulated voltage Maximum load 40A 550W Charging voltage 14 2 14 8 V 5000 rpm Start up system check pick up input about 100 A level indicators Petrol pump Input 3 5 A 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
191. ry shaft e Remove the transmission shaft M Operate on the shaft from the grooved side Remove the shoulder washer ENG 153 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 e Remove the gear of the second gear 2h T and collect the ball bearing cage and the shoulder washer Remove the circlip Remove the gear of the sixth gear Remove the circlip and collect the shoulder washer ENG 154 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine e Remove the gear of the fourth gear and collect the ball bearing cage Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer Remove the circlip e Remove the gear of the fifth gear 1 ENG 155 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 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
192. sed Not synchronised ELE SYS 102 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system 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 0 027 0 035 in Throttle position sensor Function In charge of telling the control unit the position of the throttle valves Operati
193. 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 electrical circuit diagram Start up ena bling switches Location Sensor under the saddle right side Connector near the sensor Electrical characteristics Sensor in vertical position open circuit resistance 62 kOhm Sensor inverted closed circuit resist ance below 0 5 kOhm Pin out 1 Voltage 12V 2 Ground connection NAVIGATOR STATUSES Fall sensor Example value Normal Tip over DIAGNOSIS Indication on Navigator always Normal even when the sensor is inverted disconnect the connector 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 Navigator always Tip over disconnect the connector and check if there is continuity 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
194. 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 120 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 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 electrical circuit diagram Temperature Sensors Location sensor under the instrument panel Connector sotto al cruscotto lato sin istro Electrical characteristics Resistance at 0 C 32 F 32 5 kOhm 5 Resistance at 25 C 77 F 10 0 kOhm 5 Pin out 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 Check the sensor connector and the instrument panel connector PINS 10 and 18 If they are not 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 a
195. ssible control unit fault Possible control unit fault Possible control unit fault Voltage too low measured for 30 seconds at PIN 18 of the ABS control unit Possible control unit fault Excessive voltage measured at PIN 18 of the ABS control unit Inconsistency detected between memory coding INFO ECU Vehicle code and what is measured at cable harness identification PIN INFO ECU screen page Vehicle identification line Pins 2 15 of ABS control unit Possible control unit fault Open circuit short circuit in the ground lead or to battery of one or both wires of CAN line Possible short circuit between the two cables Open circuit short circuit in the ground lead or to battery of one or both wires of CAN line Possible short circuit between the two cables Possible control unit fault BRAK SYS 313 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Braking system SETTINGS screen page This screen page is used to adjust some control unit parameters ADJUSTMENTS Characteristic Value example Unit of Notes measure ment Coding 1 Used for re coding the control unit or coding a new one Coding 2 Vehicle identification is done according to the con nection of PINS 2 and 15 of the ABS control unit connector and is stored in the control unit memory Coding 3 The identification can be read in the INFO ECU screen page in the line Vehicle code NO
196. ssion shaft unit and extract it ENG 149 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 Once the transmission shaft unit is on a bench remove the rubber bands being careful with the group Detach the shafts and label the forks before removal Remove the forks and collect the shaft ENG 150 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine e 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 151 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 ENG 152 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine 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 seconda
197. st system components become very hot and remain hot for some time 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 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 CHAR 7 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Characteristics Stelvio 1200 MY11 BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES WHEN SERVICING THE BRAKING OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS 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 THE EYES RINSE THEM IMMEDIATELY WITH PLENTY OF COLD CLEAN WATER AND SEEK MEDICAL ADVICE KEEP OUT OF THE REACH OF CHILDREN Battery electrolyte and hydrogen gas CAUTION THE BATTERY ELECTROLYTE IS TOXIC CORROSIVE AND AS IT CONTAINS SULPHURIC ACID M
198. starts rotating While the pump is performing a rotation cycle operate and release the front brake lever until the message Navigator cycle completion is received This procedure allows the air to turn and to accumulate Once the procedure with Navigator is finished perform the REGULAR BLEEDING to remove the air from the system completely CAUTION PERFORM THE REGULAR BRAKING SYSTEM BLEEDING AS DESCRIBED AT THE END OF THE CHAPTER See also Front Rear Front If there is air in the hydraulic system it acts as a bearing absorbing a large part of the pressure from the brake pump and minimising calliper efficiency during braking The presence of air is signalled by the sponginess of the brake control and by poor braking efficiency BRAK SYS 328 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Braking system 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 REGULAR AIR BLEEDING SYST
199. stem Stelvio 1200 MY11 Checks check tyres for wear there should not be much difference between front and rear and for correct pressure Solution use tyres with the specified tyre wear condition and pressure If functioning is correct proceed to the next check Checks make sure that the failure has not been caused by using the vehicle in sport competitions Solution for example avoid prolonged rearing up on the back wheel 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 electrical circuit diagram Engine speed sensor Location Sensor Front left side of the engine under the generator Connector Under the fuel tank Electrical characteristics 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 NAVIGATOR PARAMETERS Target engine revs Example value 1100 100 rpm Parameter valid at idle setting depends especially on engine temperature the ECU unit will try to keep the engine running at this revs acting on the ignition advance NAVIGATOR STATUSES Synchronisation Example value Synchroni
200. t Specific tooling 12 91 20 00 Tool to fit the flywheel side flange together with sealing ring on the crankshaft ENG 216 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Place the flywheel side flange on the crankshaft and check if the dowel pin with the O ring is correctly placed Apply Teflon tape on the two lower fix ing screws at the back in order to pre vent oil leaks M Screw the eight flange screws on the Remove the sealing ring centring tool from the crankshaft Specific tooling 12 91 20 00 Tool to fit the flywheel side flange together with sealing ring on the crankshaft To avoid that the shim washer inside the crankcase moves out of its seat fit the two gears and the nut on the crank shaft on the generator side ENG 217 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 4 LUBRICATION SYSTEM pos Description Type Quantity Torque Notes 1 Pump outlet oil pipe nipple M14x1 5 1 40 Nm 29 50 Ibf ft 2 Slot screw for oil pipe on the cylinder head M14x1 5 2 20 Nm 14 75 Ibf ft
201. telvio 1200 MY11 Stores code 12 91 20 00 19 92 71 00 020673Y 020672Y 020674Y 020675Y 020676Y Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Description Tool to fit the flywheel side flange togeth er with sealing ring on the crankshaft Tool to fit the seal ring on the flywheel side flange Graduated dial hub Clutch spring centre and pusher Piston ring clamp Service shaft gear lock Comparator support for piston position checking Special tools S TOOLS 57 Special tools Stores code 020678Y 05 91 25 30 Stores code 14 91 26 03 AP8140190 Stores code 05 90 27 30 S TOOLS 58 Stelvio 1200 MY11 Description Tool for clutch rod checking Gearbox opening CHASSIS Description Hook spanner for fixing ring nut of the ze clutch shaft internal body fo uia V S Nae zie S T an nn FR E c Se EA A A r Tool for steering tightening A yar Se sr i N grad BEVEL GEAR SET Description Gearbox support Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Stores code 05 90 27 31 05 90 27 32 05 90 27 33 05 90 27 34 05 90 27 35 Stores code AP8140146 Special tools Description Gearbox oil seal buffer i 3 Buffer handgrip Ball joint sealing buffer I M Wrench for pinion ring nut nn ge Sx ER inc DA
202. terdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Braking system Stelvio 1200 MY11 5 Rear brake pump 6 Rear brake pedal control 7 ABS CONTROL UNIT 8 Rear brake calliper 9 Front calliper 2 callipers 10 Front brake circuit intake solenoid valve normally open 11 Humidifier 12 Rear brake circuit intake solenoid valve normally open 13 Rear brake exhaust circuit solenoid valve normally closed 14 Rear front brake circuit low pressure accumulator 15 Front brake exhaust circuit solenoid valve normally closed 16 DC electric motor 17 Double circuit hydraulic pump ABS 18 Rear brake reservoir 19 Front brake reservoir ABS OPERATION General specifications The front circuit is similar to the rear circuit The ABS inlet valve 10 12 is normally open and it is closed only when the system inter venes to avoid wheel locking The outlet valve 13 15 is normally closed and it is opened only when the system intervenes to avoid wheel locking When the system is in standby the ABS processor never stops monitoring the speed of the wheels in order to assess potential wheel slippage When in standby the system does not intervene at all when the rider brakes the braking system is the same as the one without ABS Stages in ABS cycle the following operations refer to the front circuit but are also applicable to the rear one A Brake activation the rider starts braking as he would usually do B Pressure r
203. the control panel e Himuovere la vite anteriore del serba toio Rimuovere le viti posteriori del serba toio See also Side fairings BODYW 347 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Bodywork NOTE Stelvio 1200 MY11 Scollegare il tubo carburante 1 Scollegare i tubi sfiato 2 Scollegare il connettore della pompa carburante 3 Remove the fuel tank FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER Adjustable windscreen Remove the windscreen glass Working from both sides undo and re move the windscreen top set screw and remove the knob Working from both sides unscrew and remove the lower screw BODYW 348 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Bodywork Working from both sides remove the windscreen support from the bracket Remove the four bushings from the brackets If replacing the bushings remember to place them with the larger diameter inside the brackets BODYW 349 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Carry out the listed checks before delivering the motorcycle WARNING HANDLE FUEL WITH CARE Aesthetic inspection Paintwork Fitting of Plastic Pa
204. the inter nal cable harness of the oxygen sensor TABLE Q 1 Fuel pump 2 Fuel pump connector 3 Small clamp ELE SYS 85 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Electrical system Stelvio 1200 MY11 TABLE R 1 Horn 2 Horn cable harness 3 Middle clamp TABLE 5 1 ABS control unit connector The initial position of the connector fastener lever must be as shown in the figure TABLE T Place the connector on the opposite side of the control unit and lower the driving lever until the click that signals the end of the stroke is heard TABLE U When the connector is fully inserted the distance between the connector and the ABS control unit must be 7 5 mm 0 29 in ELE SYS 86 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Electrical system TABLE V If the initial position of the connector and the pulling level is not as the one in TABLE S the connector will not hook correctly and the distance meas ured will be higher than approximately 12 mm 0 47 in In this case repeat the operation as described in TABLE T and TABLE U It is advisable to create a jig in order to check the correct connector insertion Back side TABLE 1 Main fuses 2 Filter box air temperature sensor 3 Filter box TABLE B 1 Middle clamp 2 Main cable harness ELE SYS
205. the rear brake calliper on the disc and the brake pipe on the fork CHAS 294 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis Exhaust EXHAUST SYSTEM pos Description Type Quantity Torque Notes 1 Dadi Flang fissaggio collettori M8 4 25 Nm 18 44 Ibf ft 2 Oxygen sensor fastener 2 38 Nm 28 03 Ibf ft 3 Vite TE Flang fissaggio parte centrale M10x55 1 25 Nm 18 44 Ibf ft 4 Viti fissaggio protezione 2 10 Nm 7 38 Ibf ft 5 Vite TCEI fissaggio silenziatore a telaio M8x60 1 25 Nm 18 44 Ibf ft CHAS 295 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Chassis Stelvio 1200 MY11 key Right exhaust pipe Left exhaust pipe Gasket Flanged nut Washer Gasket Clamp Central exhaust pipe ON DOF W nm 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 CHAS 296 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Chassis Undo and remove the screw and col lect the nut and the washer T A Tr mn n
206. the suitable piston ring clamp tool place the cylinder and fit the chain in the timing system plate DURING THIS OPERATION PAY ATTENTION NOT TO DAMAGE THE PISTON Specific tooling 020674Y Piston ring clamp 020716Y Connecting rod locking ENG 206 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 Stelvio 1200 MY11 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 section Shimming system Place the two dowel pins Fit the gasket with the correct thick ness between the head and the cylin der Fit the left cylinder head Fit a new O ring in the spark plug hole Fit the complete cam cap Fix the cam cap with the four nuts on the stud bolts Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine ENG 207 Engine Stelvio 1200 MY11 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
207. tions must persist within a given time BRAK SYS 309 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Braking system Stelvio 1200 MY11 If during this given time one of the conditions is missing but then it comes back the timer is reset and the system is no longer able to diagnose the error The ABS system is still inactive Example error code 5D93 requires some minutes before it is diagnosed during the given time the ABS warning light ABS keeps flashing ABS FAULTS GUIDE TO THE DIAGNOSIS 1 ABS WARNING LIGHT ON 2 CONNECT NAVIGATOR DOES NAVIGATOR COMMUNICATE NO go to 3 YES go to 4 3 PERFORM THESE CHECKS A Ground connection PIN 1 B 12V at PIN 18 e C 12V at PIN 4 with key ON 4 ARE THERE ANY ERRORS YES go to 5 NO go to 6 5 CONSULT THE ERRORS TABLE 6 ABS WARNING LIGHT ACTIVATION ACTIVE YES go to 7 NO go to 8 7 CONTACT TECHNICAL SERVICE 8 CHECK A Cable continuity between PIN 8 of the ABS control unit connector and PIN 39 of the instrument panel B Check connectors refer to the operations described in the chapter If the previous checks are OK the causes might be ABS control unit malfunction D Instrument panel malfunction Using Navigator for the abs BRAK SYS 310 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Braking system ECU INFO screen page This
208. tite 243 D Timing cover fixing screw on the cylinder head M5x10 2 8 Nm 5 90 Ibf ft 6 Camshaft support fixing screw 6 18 Nm 13 28 Ibf ft Head and timing ENG 178 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 197 9 CT EP w CA N ARE B Right cylinder head Stud bolt Cylinder head gasket Right rocking lever support Screw Pin Nut Right exhaust left intake rocking lever ae N Left exhaust right intake rocking lever 10 Set screw 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 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine ENG 179 Engine Stelvio 1200 MY11 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 49 O r
209. tity Torque Notes 1 Viti TBEI Flang fissaggio convogliatori M5x9 2 6 Nm 4 42 Ibf ft Imm c 2 Viti TBEI Flang fissaggio convogliatori Mele 6 Nm 4 42 Ibf ft Viti SWP Autofil fissaggio telaietto griglie 2 9x12 Manual BODYW 334 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Bodywork FRONT MUDGUARD pos Description Type Quantity Torque Notes 1 Viti TBEI Flang fissaggio parafango anteriore M5x12 6 6 Nm 4 42 Ibf ft COPERTURA SERBATOIO CARBURANTE pos Description Type Quantity Torque Notes 1 Vite TBEI Flang fissaggio copertura 4 5 Nm 3 69 Ibf ft BODYW 335 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Bodywork REAR BODYWORK pos Description Type Quantity Torque Notes 1 Viti SWP fissaggio piastra batteria M5x20 4 Manual 2 Viti TBEI Flang fissaggio fianchetti e para M5x9 10 6 Nm 4 42 Ibf ft spruzzi 3 Viti TE Flang fissaggio supporti valigie M6 4 10 Nm 7 38 Ibf ft 4 Viti TBEI Flang fissaggio paraspruzzi M5x12 2 6 Nm 4 43 Ibf ft 2 li JP 3 on LICENSE PLATE HOLDER pos Description Type Quantity Torque Notes 1 Viti TBEI Flang fissaggio portatarga M5 2 6Nm 443bff 2 Viti TBEI speciali 6 Nm 4 43 Ibf ft Haa mid 3 Dado autobloc flang fissaggio catadiottro M5 6 Nm 4 43 Ibf
210. tori 2 Rimuovere le fascette 3 per liberare completamente il cablaggio dei fari supplementari Svitare a rimuovere la vite 4 recuper ando il dado o in alternativa possibile rimuovere le viti 5 non compromet tendo cosi l angolo di inclinazione dei fasci luminosi Ora possibile rimuovere i fari supple mentari NOTE FOR REFITTING FOLLOW THE PROCEDURE IN THE REVERSE ORDER Headlight fairing Remove the windshield Remove the control panel BODYW 339 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Bodywork Stelvio 1200 MY11 Rimuovere le quattro viti inferiori Rimuovere le due viti di fissaggio del cupolino al telaietto in corrispondenza delle freccie anteriori Rimuovere le due viti di fissaggio del cupolino al telaietto in corrispondenza del cruscotto Scollegare i connettori dei fari e rimuovere il cupolino Rider footrest plate LEFT SIDE Undo and remove the upper screw and collect the washer and the nut BODYW 340 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Bodywork e Undo and remove the lower screw and collect the two washers and the spacer 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
211. ty 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 267 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Suspensions Shock absorbers REAR SUSPENSION Stelvio 1200 MY11 pos Description Type Quantity Torque Notes 1 Vite TE Flang fissaggio superiore ammortiz M10x80 1 50 Nm 36 88 Ibf ft zatore 2 Vite TCEI fissaggio biella doppia forcellone M10x82 1 50 Nm 36 88 Ibf ft 3 Vite TE fissaggio biella doppia ammortizza M10x47 1 40 Nm 29 50 Ibf ft 4 Vite flang fissaggio biella singola biella M10x95 1 50 Nm 36 88 Ibf ft doppia 5 Vite TE flang fissaggio biella singola al telaio M10x85 1 50 Nm 36 88 Ibf ft 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 the vehicle suspension the shock absorber has aset screw 1 to adjust the hydraulic
212. ug ENG 230 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Engine Place a new gasket between the crank case and the flange Fit the flange Fix the flange with the four screws e Fit the lubrication oil intake filter M Check that the O rings are fitted on the oil pump Fit the cooling oil intake filter ENG 231 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Engine Stelvio 1200 MY11 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 Place the oil sump Tighten the fourteen screws to the pre scribed torque Add engine oil up to the correct level ENG 232 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten INDEX OF TOPICS Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Power supply Stelvio 1200 MY11 FueL SUPPLY SYSTEM pos Description Type Quantity Torque Notes 1 Vite fissaggio protezioni corpo farfallato 6 2 10 Nm 7 38 Ibf ft THROTTLE BODY pos Description Type Quantity Torque Notes Intake pipe fixing screw 10 Nm 7 37 Ibf ft ae Flange fixing screw on the throttle body M5x12 6 Nm n 42 lbf ft P SUPP 234 Reve
213. with independent trochoidal pump and oil pressure control valve single overhead camshaft with bucket tappets and rocker op erated valves intake 0 15 mm 0 0059 in outlet 0 20 mm 0 0079 in TRANSMISSION Specification Primary drive Gearbox Gear ratios 1st gear Gear ratios 2nd gear Gear ratios 3rd gear Gear ratios 4th gear Gear ratios 5th gear Gear ratios 6th gear Final drive Ratio Capacities Desc Quantity Helical gears ratio 26 35 1 1 346 Mechanical 6 speeds with foot lever on the left hand side of the engine 1238231722353 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 with U joint 12 44 1 3 6667 CAPACITIES Specification Engine oil Gearbox oil Transmission oil Fork oil Fuel reserve included Fuel reserve Seats Maximum weight limit Electrical system 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 650 cm 39 66 cu in for each stem 32 7 04 UK gal 71 1 54 UK gal 2 495 kg 1091 29 Ib ELECTRICAL SYSTEM Specification Spark plug Electrode gap Battery Alternator permanent magnet type Main fuses Secondary fuses Front daylight running light Low high beam light halogen Turn indicators CHAR 12 Desc Quantity NGK CR8EKB long life 0 6 0 7 mm 0 024 0 028 in 12 V 18 Ampere hour 12V 550W 20 ABS version only 30 2 40A 3 10 15A 12V 5W 12
214. x 0 47 in In this case repeat the oper ation as described in the two previous points It is advisable to create a template to check the correct connector insertion Fit the protection casing Component maintenance The vehicle is fitted with a two channel ABS sys tem i e it works on both the front and the rear wheel Check periodically and each time the wheels are refitted the tone wheel 2 or the sensor 1 re placed that the wheel distance is constant at each 360 Use a thickness gauge to check the distance between sensor 1 and tone wheel 2 at three points at a 120 span The values should be be tween BRAK SYS 316 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Braking system 2 10 2 25 mm 0 083 0 088 in for the front one 1 90 2 30 mm 0 075 0 090 in for the rear one CAUTION IF A VALUE BEYOND THE TOLERANCE RANGE IS MEAS URED REPLACE THE SENSOR 1 AND OR THE TONE WHEEL 2 AND REPEAT THE CHECKS MAKE SURE THAT THE VALUES ARE WITHIN THE TOLERANCE LIM ITS TONE WHEELS 2 CLEANING It is important to check that all the tone wheels 2 are always clean Otherwise gently remove any possible dirt deposits with a cloth or metal brush Avoid using solvents abrasives and air or water jets directly on the tone wheel 2 TONE WHEEL SENSOR REPLACEMENT Disconnect the tone wheel sensor connector 1 from the main w
215. y 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 1015 mPa approximate values The sensor is inside the instrument panel 100 900 mV approximate values Signal when energised that the control unit receives from the lambda probe inversely proportional to the presence of oxygen When the control unit uses the lambda probe signal see the Lambda parameter on the Statuses screen page this value should be close to 0 km h P SUPP 241 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Power supply Stelvio 1200 MY11 Specification Desc Quantity Target engine revs 1150 rpm 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 Stepper base 70 100 approximate values Steps corresponding to the Stepper motor reference position CL Stepper 70 150 approximate values Steps set by the control unit forthe Stepper motor At idle steps so that the engine keeps the target engine revs set by the con trol unit Stepper regulator Difference between current steps of motor at idle and those at the reference position Virtual throttle angle from Stepper 0 With engine not at idle speed this value indicates the throttle de
216. ystem Stelvio 1200 MY11 Remove the pin Extract one pad at a time CAUTION AFTER REMOVING THE PADS DO NOT OPERATE THE BRAKE 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 BRAK SYS 324 Revente Interdite Revendita Vietata Resaling Forbiden Wiederverkauf Verboten Stelvio 1200 MY11 Braking system Insert the pin Position the split pin Insert the brake calliper into the disc by screwing in the two screws Abut the plungers against the pads acting on the brake pump pedal sever al times Check the brake fluid level in the res ervoir Bleeding the braking system VEHICLE PREPARATION It is important to check that there is always enough brake fluid in the reservoir Using a bleed device facilitates these operations while in the meantime the Brake fluid replacement operations are performed In this case the bleed process must be accompanied by further pedal strokes and with the bleed device connected about 5 for each wheel circuit BRAKE PUMP REPLACEMENT PRELIMINARY OPERATIONS Replace the damaged brake pump with a new one Connect the brake pipe to the new brake pump Fill the reservoir with new brake fluid BRAK SYS 325

Stelvio 1200 8V - Service Manual - 2011

Contents

Download Pdf Manuals

Related Search

Related Contents