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SERVICE STATION MANUAL
B043090
Stelvio 1200 NTX MY11

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Summary of Contents for MOTO GUZZI stelvio 1200 NTX MY11

  • Page 1 SERVICE STATION MANUAL B043090 Stelvio 1200 NTX MY11...
  • Page 2 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.
  • Page 3 In order to optimise customer satisfaction when using our vehicles, Moto Guzzi s.p.a. commits itself to continually improve its products and the relative documentation. The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International Subsidiaries.
  • Page 4 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 5 INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM BODYW ODYWORK PRE DE DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 7: Safety Rules

    Stelvio 1200 NTX 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.
  • Page 8 Stelvio 1200 NTX MY11 Characteristics 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.
  • Page 9 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.
  • Page 10: Vehicle Identification

    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.
  • Page 11 Stelvio 1200 NTX MY11 Characteristics This number consists of numbers and letters, as in the example shown below. ZGULZG000YMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LZ: model; 001: version variation; 0: free digit Y year of manufacture M: production plant (M= Mandello del Lario);...
  • Page 12 Stelvio 1200 NTX MY11 Characteristics Specification Desc./Quantity Bore / stroke 95 x 81.2 mm (3.74 x 3.20 in) Engine capacity 1151 cm³ (70 cu.in.) Compression ratio 11 : 1 Ignition starter Engine idle speed 1100 ± 100 rpm Clutch hydraulically controlled single-plate dry clutch with incorpora-...
  • Page 13 Stelvio 1200 NTX MY11 Characteristics Specification Desc./Quantity Rear daylight running light/stop light Supplementary headlamps (if fitted) 12 V/55W - H3 Dashboard lighting License plate light 12V - 5 W Turn indicator warning light Neutral gear warning light Alarm-shift warning light...
  • Page 14: Wheels And Tyres

    Stelvio 1200 NTX 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...
  • Page 15 Stelvio 1200 NTX MY11 Characteristics Front side RONT IGHTS pos. Description Type Quantity Torque Notes Horn fixing screw M6x20 15 Nm (11.06 lbf ft) Viti fissaggio freccie anteriori 3 Nm (2.21 lbf ft) Vite fissaggio superiore fanale a carozzeria 3 Nm (2.21 lbf ft)
  • Page 16 Stelvio 1200 NTX MY11 Characteristics NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Viti TCEI fissaggio sensore velocità anteriore M5x16 6 Nm (4.42 lbf ft) Viti TCEI fissaggio blocchetto avviamento M8x30 25 Nm (18.44 lbf ft) Viti autofil. fissaggio supporto cruscotto...
  • Page 17 Stelvio 1200 NTX MY11 Characteristics TEERING pos. Description Type Quantity Torque Notes Viti fissaggio piastra fermatubi 6 Nm (4.42 lbf ft) Viti fissaggio piastre M8x30 20 Nm (14.75 lbf ft) Headstock ring nut 40 Nm (29.50 lbf ft) Headstock counter-lock ring...
  • Page 18 Stelvio 1200 NTX MY11 Characteristics ARROZZERIA ANTERIORE ONVOGLIATORI pos. Description Type Quantity Torque Notes Viti TBEI Flang. fissaggio convogliatori M5x9 6 Nm (4.42 lbf ft) Viti TBEI Flang. fissaggio convogliatori 6 Nm (4.42 lbf ft) Viti SWP Autofil. fissaggio telaietto griglie 2.9x12...
  • Page 19 Stelvio 1200 NTX MY11 Characteristics ELAIETTO pos. Description Type Quantity Torque Notes Viti TCEI fissaggio telaietto M8x40 25 Nm (18.44 lbf ft) Viti TE Flang. M6x20 10 Nm (7.38 lbf ft) ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes...
  • Page 20 Stelvio 1200 NTX MY11 Characteristics pos. Description Type Quantity Torque Notes Viti TE Flangiate fissaggio cavallotti inf. man- 50 Nm (36.88 lbf ft) ubrio Vite autof. 1.5 Nm (1.11 lbf ft) Raccordo fissaggio pesi antivibranti M18x15 - Nm (-.-- lbf ft) Viti TCEI fissaggio pesi antivibranti 10 Nm (7.38 lbf ft)
  • Page 21 Stelvio 1200 NTX MY11 Characteristics LUTCH CONTROL pos. Description Type Quantity Torque Notes Viti fissaggio tubo olio 23-26 Nm (16.96-19.18 lbf Viti TE Flang. fissaggio cilindro comando fri- 10 Nm (7.38 lbf ft) zione Viti fissaggio tappo serbatoio 0.8-1.5 Nm (0.59-1.11 lbf Lever pin 5-7 Nm (3.69-5.16 lbf ft)
  • Page 22 Stelvio 1200 NTX MY11 Characteristics RONT MUDGUARD pos. Description Type Quantity Torque Notes Viti TBEI Flang. fissaggio parafango anteriore M5x12 6 Nm (4.42 lbf ft) RONT WHEEL pos. Description Type Quantity Torque Notes Viti TE Flang. fissaggio dischi freno M8x20 25 Nm (18.44 lbf ft)
  • Page 23 Stelvio 1200 NTX MY11 Characteristics pos. Description Type Quantity Torque Notes Vite TCB fissaggio passacavo M4x6 3 Nm (2.21 lbf ft) RONT BRAKE CALLIPERS pos. Description Type Quantity Torque Notes Viti TE Flang. fissaggio pinze M10x55 50 Nm (36.88 lbf ft)
  • Page 24 Stelvio 1200 NTX MY11 Characteristics AIN CABLE HARNESS pos. Description Type Quantity Torque Notes Viti TE Flang. fissaggio piastre bobine M6x20 10 Nm (7.38 lbf ft) Viti TCEI fissaggio bobine 2 Nm (1.47 lbf ft) Viti TCEI fissaggio centralina 10 Nm (7.38 lbf ft) Viti TCEI fissaggio supporto sensore temp.
  • Page 25 Stelvio 1200 NTX MY11 Characteristics OMANDO CAMBIO pos. Description Type Quantity Torque Notes Viti TCEI fissaggio leva rinvio cambio M6x20 10 Nm (7.38 lbf ft) Dadi fissaggio tirante 10 Nm (7.38 lbf ft) Vite TCEI fissaggio piolo leva freno M6x16 10 Nm (7.38 lbf ft)
  • Page 26 Stelvio 1200 NTX MY11 Characteristics EAR BRAKE LEVER pos. Description Type Quantity Torque Notes Viti te Flang. fissaggio pompa freno M6x20 10 Nm (7.38 lbf ft) Loct. 243 Dado bloccaggio asta pompa freno 10 Nm (7.38 lbf ft) Brake lever pin 15 Nm (11.06 lbf ft)
  • Page 27 Stelvio 1200 NTX MY11 Characteristics RAKE YSTEM pos. Description Type Quantity Torque Notes Brake pipe slot screw on the pump 25 Nm (18.44 lbf ft) Joint with brake pipes retainer bleeding on the 25 Nm (18.44 lbf ft) calliper Brake pipes joint on the ABS hydraulic unit 25 Nm (18.44 lbf ft)
  • Page 28 Stelvio 1200 NTX MY11 Characteristics UPPORTO E PEDANE PILOTA pos. Description Type Quantity Torque Notes Viti Flang. fissaggio piastrine 10 Nm (7.38 lbf ft) Viti TCEI fissaggio supporto pedane M8x35 25 Nm (18.44 lbf ft) Vite fissaggio supporto pedane 25 Nm (18.44 lbf ft)
  • Page 29 Stelvio 1200 NTX MY11 Characteristics UEL TANK pos. Description Type Quantity Torque Notes Vite TCEI fissaggio anteriore M6x35 10 Nm (7.38 lbf ft) Vite TE Flang. fissaggio posteriore M6x25 10 Nm (7.38 lbf ft) Viti TCEI fissaggio tappo benzina M5x15 4 Nm (2.95 lbf ft)
  • Page 30 Stelvio 1200 NTX MY11 Characteristics CHASSIS pos. Description Type Quantity Torque Notes 50 Nm (36.88 lbf ft) M12x260 50 Nm (36.88 lbf ft) Viti TCEI fissaggio anteriore motore a telaio M12x50 80 Nm (59.00 lbf ft) Screws M8x14 25 Nm (18.44 lbf ft) Viti TE Flang.
  • Page 31 Stelvio 1200 NTX MY11 Characteristics Back side EAR BODYWORK pos. Description Type Quantity Torque Notes Viti SWP fissaggio piastra batteria M5x20 Manual Viti TBEI Flang. fissaggio fianchetti e para- M5x9 6 Nm (4.42 lbf ft) spruzzi Viti TE Flang. fissaggio supporti valigie 10 Nm (7.38 lbf ft)
  • Page 32 Stelvio 1200 NTX MY11 Characteristics LICENSE PLATE HOLDER pos. Description Type Quantity Torque Notes Viti TBEI Flang. fissaggio portatarga 6 Nm (4.43 lbf ft) Viti TBEI speciali 6 Nm (4.43 lbf ft) Dado autobloc. flang. fissaggio catadiottro 6 Nm (4.43 lbf ft)
  • Page 33 Stelvio 1200 NTX MY11 Characteristics EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm clamp fixing screw on the bushing M6x25 10 Nm (7.37 lbf ft) 2 - Swingarm fixing screw on the transmission M10x35 50 Nm (36.87 lbf ft)
  • Page 34 Stelvio 1200 NTX MY11 Characteristics UCI POSTERIORI pos. Description Type Quantity Torque Notes Vite TBEI Flang. fissaggio fanale 6 Nm (4.43 lbf ft) Vite TCEI fissaggio fanale 6 Nm (4.43 lbf ft) Vite TCEI fissaggio fanale targa M5x25 6 Nm (4.43 lbf ft) ANIGLIONE E PORTAPACCHI pos.
  • Page 35 Stelvio 1200 NTX MY11 Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Vite TE Flang. fissaggio ruota fonica 25 Nm (18.44 lbf ft) Vite TE Flang. fissaggio sensore 10 Nm (7.38 lbf ft) Vite TE Flang. fissaggio sensore M12x65 110 Nm (81.13 lbf ft)
  • Page 36 Stelvio 1200 NTX MY11 Characteristics EAR SUSPENSION pos. Description Type Quantity Torque Notes Vite TE Flang. fissaggio superiore ammortiz- M10x80 50 Nm (36.88 lbf ft) zatore Vite TCEI fissaggio biella doppia/forcellone M10x82 50 Nm (36.88 lbf ft) Vite TE fissaggio biella doppia/ammortizza- M10x47 40 Nm (29.50 lbf ft)
  • Page 37 Stelvio 1200 NTX MY11 Characteristics Engine UBRICATION YSTEM pos. Description Type Quantity Torque Notes Pump outlet oil pipe nipple M14x1.5 40 Nm (29.50 lbf ft) Slot screw for oil pipe on the cylinder head M14x1.5 20 Nm (14.75 lbf ft) Nipple on the radiator and the oil pipe M16x1.5...
  • Page 38 Stelvio 1200 NTX MY11 Characteristics LTERNATOR pos. Description Type Quantity Torque Notes Generator control pulley locking nut 80 Nm (59.00 lbf ft) Loctite 243 Generator upper fixing screw 22 Nm (16.23 lbf ft) Generator lower fixing screw M10x60 30 Nm (22.13 lbf ft)
  • Page 39 Stelvio 1200 NTX MY11 Characteristics RANKCASE AND pos. Description Type Quantity Torque Notes Stud bolt M8x75 10 Nm (7.37 lbf ft) Stud bolt M8x66 10 Nm (7.37 lbf ft) Crankshaft rear support flange fixing screw M8x25 26 Nm (19.18 lbf ft) Oil cap on the crankcase 25 Nm (18.44 lbf ft)
  • Page 40 Stelvio 1200 NTX MY11 Characteristics IL SUMP COMPONENTS pos. Description Type Quantity Torque Notes Cover on the flange under the crankcase 40 Nm (29.50 lbf ft) Oil filter joint 10 Nm (7.37 lbf ft) Loctite 243 Oil sump pipe 20 Nm (14.75 lbf ft)
  • Page 41 Stelvio 1200 NTX MY11 Characteristics YLINDER HEAD COVERS pos. Description Type Quantity Torque Notes Special cylinder head fixing screw 8 Nm (5.90 lbf ft) Locked with cross sequence Spark plug cover fixing screw M5x10 8 Nm (5.90 lbf ft) ENERATOR OVER pos.
  • Page 42 Stelvio 1200 NTX MY11 Characteristics IR FILTER pos. Description Type Quantity Torque Notes Vite fissaggio cassa filtro aria a telaio 10 Nm (7.38 lbf ft) Air filter box cover fastening screw SWP 5x20 3 Nm (2.21 lbf ft) HROTTLE BODY pos.
  • Page 43 Stelvio 1200 NTX MY11 Characteristics pos. Description Type Quantity Torque Notes Flange fixing screw on the throttle body M5x12 6 Nm (4.42 lbf ft) LUTCH pos. Description Type Quantity Torque Notes Clutch to crankshaft fixing screw 42 Nm (30.98 lbf ft)
  • Page 44 Stelvio 1200 NTX MY11 Characteristics ONNECTING ROD ASSEMBLY YLINDERS pos. Description Type Quantity Torque Notes Thermal group fixing stud bolt M10x1.25 5 Nm (3.69 lbf ft) Loctite 243 Connecting rod screws 40 Nm (29.50 lbf ft) Pre-tightening Connecting rod screws 80 Nm (59.00 lbf ft)
  • Page 45 Stelvio 1200 NTX MY11 Characteristics YSTEM pos. Description Type Quantity Torque Notes Vite fissaggio distanziale vaso espansione 10 Nm (7.38 lbf ft) Blow - By a motore M5x14 Reduction joint for oil return pipe 20 Nm (14.75 lbf ft) Oil return pipe (on sump) 20 Nm (14.75 lbf ft)
  • Page 46 Stelvio 1200 NTX MY11 Characteristics TARTER MOTOR pos. Description Type Quantity Torque Notes Starter motor fixing screw 25 Nm (18.44 lbf ft) Stud bolt 10 Nm (7.37 lbf ft) Starter motor cover fixing screw M6x10 8 Nm (5.90 lbf ft) pos.
  • Page 47 Stelvio 1200 NTX MY11 Characteristics ADIATOR pos. Description Type Quantity Torque Notes Viti fissaggio radiatore a telaio M6x30 10 Nm (7.38 lbf ft) ESTA ESTRA Pos. Descrizione Tipo Quantità Coppia Note Movable chain tensioner pad fixing screw 20 Nm (14.75 lbf ft)
  • Page 48 Stelvio 1200 NTX MY11 Characteristics Pos. Descrizione Tipo Quantità Coppia Note Head tightening nut M10x1.25 15 Nm (11.06 lbf ft) Engine Oil Pre- tightening Head tightening nut M10x1.25 42 Nm (30.98 lbf ft) Final tightening Head tightening screws (chain compartment) M6x120 10 Nm (7.37 lbf ft)
  • Page 49 Stelvio 1200 NTX MY11 Characteristics IMING YSTEM ONTROL pos. Description Type Quantity Torque Notes Control, timing system, shaft support flange M6x14 8 Nm (5.90 lbf ft) fixing screw Bearing fixing screw M6x16 10 Nm (7.37 lbf ft) Loctite 243 Driving gears locking nut on the crankshaft 200 Nm (147.51 lbf ft)
  • Page 50 Stelvio 1200 NTX MY11 Characteristics EARBOX pos. Description Type Quantity Torque Notes Clutch housing to gearbox fixing screw M6x55 13 Nm (9.59 lbf ft) Neutral sensor 10 Nm (7.37 lbf ft) Breather stud bolt 8 Nm (5.90 lbf ft) Loctite 243 Gear oil magnetic drainage cap 24 Nm (17.70 lbf ft)
  • Page 51 Stelvio 1200 NTX MY11 Characteristics PIN - PISTON COUPLING Specification Desc./Quantity Pin diameter 21.998 - 21.994 mm (0.86606 - 0.86590 in) Pin hole diameter on piston 22.016 - 22.011 mm (0.86677 - 0.86657 in) Clearance between pin and holes on piston 0.013 - 0.022 mm (0.00051 - 0.00087 in)
  • Page 52 Stelvio 1200 NTX MY11 Characteristics Slot packing system • Fit both pistons on the connecting rods. • Working from both sides, fit the gasket between the crankcase and the cylin- der on the crankcase. • Fit both cylinders. • Take the left cylinder piston to TDC and lock crankshaft rotation.
  • Page 53 Stelvio 1200 NTX 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)
  • Page 54 INDEX OF TOPICS S-TOOLS PECIAL TOOLS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 55 Stelvio 1200 NTX MY11 Special tools MOTORE Stores code Description 020677Y Generator belt tensioner, lever for belt tensioning 05.91.17.30 Front cover insertion cone 020716Y Connecting rod locking 020470Y Pin snap ring fitting tool 05.92.72.30 Timing system cover sealing ring punch 01.92.91.00...
  • Page 56 Stelvio 1200 NTX MY11 Special tools Stores code Description 05.90.25.30 Gearbox support 19.92.96.00 Graduated dial to control ignition timing 12.91.18.01 Tool to lock the flywheel and the starting ring gear 12.91.36.00 Tool to remove the flywheel-side flange AP8140179 Support for valve fitting/removal...
  • Page 57 Stelvio 1200 NTX MY11 Special tools Stores code Description 12.91.20.00 Tool to fit the flywheel-side flange togeth- er with sealing ring on the crankshaft 19.92.71.00 Tool to fit the seal ring on the flywheel- side flange 020673Y Graduated dial hub...
  • Page 58 Stelvio 1200 NTX MY11 Special tools Stores code Description 020678Y Tool for clutch rod checking 05.91.25.30 Gearbox opening CHASSIS Stores code Description 14.91.26.03 Hook spanner for fixing ring nut of the clutch shaft internal body AP8140190 Tool for steering tightening...
  • Page 59 Stelvio 1200 NTX MY11 Special tools Stores code Description 05.90.27.31 Gearbox oil seal buffer 05.90.27.32 Buffer handgrip 05.90.27.33 Ball joint sealing buffer 05.90.27.34 Wrench for pinion ring nut 05.90.27.35 Pinion oil seal buffer FRONT FORK Stores code Description AP8140146 Weight...
  • Page 60 Stelvio 1200 NTX MY11 Special tools Stores code Description AP8140149 Protection for fitting operations 9100903 Marzocchi fork oil seal; ø 45 mm (1.77 in) S-TOOLS - 60 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 61 INDEX OF TOPICS MAIN AINTENANCE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 62: Maintenance Chart

    Stelvio 1200 NTX MY11 Maintenance Maintenance chart NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. Routine maintenance table I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE (1) Check and clean and adjust or replace, if necessary, before every journey.
  • Page 63: Transmission Fluid

    Stelvio 1200 NTX MY11 Maintenance km x 1,000 Brake lines (3) Clutch wear Brake pad wear (1) Transmission fluid Check • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the cap/dipstick (1). • The level is correct if the oil is close to the hole of the cap/dipstick (1).
  • Page 64: Engine Oil

    Stelvio 1200 NTX MY11 Maintenance • 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.
  • Page 65 Stelvio 1200 NTX MY11 Maintenance • Place a container with +4,000 cm³ (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).
  • Page 66: Engine Oil Filter

    Stelvio 1200 NTX MY11 Maintenance Engine oil filter Replace the engine oil filter each time you change the engine oil. • Drain the engine oil completely. • Unscrew and remove the engine oil fil- ter from its seat. NOTE NEVER REUSE AN OLD FILTER.
  • Page 67: Air Filter

    Stelvio 1200 NTX MY11 Maintenance • Place a container with suitable capacity under the drainage plug (2). • Unscrew and remove the drainage plug (2). • Unscrew and remove the filler cap (1). • Drain the oil into the container; allow several mi- nutes for oil to drain out completely.
  • Page 68: Checking The Valve Clearance

    Stelvio 1200 NTX MY11 Maintenance • 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.
  • Page 69: Braking System

    Stelvio 1200 NTX 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 a screwdriver on the set screw (2)
  • Page 70 Stelvio 1200 NTX MY11 Maintenance Top-up Front brake: • Unscrew the two screws (1) of the brake fluid reservoir (2) using a Phillips screwdriver. • Lift and remove the cover (3) and screws (1) as well. • Remove the gasket (4).
  • Page 71 Stelvio 1200 NTX MY11 Maintenance TO AN Official Moto 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...
  • Page 72 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 73 Stelvio 1200 NTX MY11 Electrical system AIN CABLE HARNESS pos. Description Type Quantity Torque Notes Viti TE Flang. fissaggio piastre bobine M6x20 10 Nm (7.38 lbf ft) Viti TCEI fissaggio bobine 2 Nm (1.47 lbf ft) Viti TCEI fissaggio centralina 10 Nm (7.38 lbf ft)
  • Page 74 Stelvio 1200 NTX MY11 Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector 5 Throttle valve potentiometer ELE SYS - 74 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 75 Stelvio 1200 NTX MY11 Electrical system 6 Fall sensor 7 Rear light 8 Main fuses 9 Oxygen sensor 10 Battery 11 Starter motor 12 Intake air temperature sensor 13 Engine revolution sensor 14 Head temperature sensor 15 Engine control unit...
  • Page 76 Stelvio 1200 NTX MY11 Electrical system • 4 Reused clamps • 7 Cable grommets • 5 Rubber clamps • 7 Cable grommets • 1 Adhesive cable grommet • 1 Cable grommet with clip Motorcycle division The wiring timing is subdivided in three essential sections, as indicated in the figure.
  • Page 77 Stelvio 1200 NTX 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.
  • Page 78 Stelvio 1200 NTX MY11 Electrical system 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 ELE SYS - 78 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 79 Stelvio 1200 NTX MY11 Electrical system TABLE G 1. Medium clamp TABLE H • No part of the cable harness must pro- trude to the inside of the support so as not to obstruct the forks TABLE I 1. Clamp that groups the cable harness of the right...
  • Page 80 Stelvio 1200 NTX MY11 Electrical system TABLE M • 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 TABLE O 1. Medium clamps TABLE P 1.
  • Page 81 Stelvio 1200 NTX MY11 Electrical system TABLE Q 1. Keep the cable harness outwards according to the relay 2. Clamp TABLE R 1. Middle clamp TABLE S 1. Hook the clamp on the specific hole present in the support. 2. Middle clamp TABLE T 1.
  • Page 82 Stelvio 1200 NTX MY11 Electrical system TABLE U 1. Instrument panel 2. Instrument panel connector correctly connected Central part TABLE A 1. Main cable harness 2 Motor main cable harness 3. Grey taping as reference that must remain be- tween the two covers TABLE B 1.
  • Page 83 Stelvio 1200 NTX MY11 Electrical system 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 TABLE F 1. Cable guide 2. Plastic cable guides TABLE G 1.
  • Page 84 Stelvio 1200 NTX MY11 Electrical system 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 TABLE L 1. Middle clamp 2.
  • Page 85 Stelvio 1200 NTX MY11 Electrical system 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 TABLE N 1. Starter motor •...
  • Page 86 Stelvio 1200 NTX MY11 Electrical system 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 •...
  • Page 87 Stelvio 1200 NTX MY11 Electrical system 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 •...
  • Page 88 Stelvio 1200 NTX MY11 Electrical system Back side TABLE 1. Main fuses 2. Filter box air temperature sensor 3. Filter box TABLE B 1. Middle clamp 2. Main cable harness TABLE C 1. Rear plug socket 2. Cable grommet 3. ECU diagnosis connector TABLE D 1.
  • Page 89 Stelvio 1200 NTX MY11 Electrical system 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 TABLE G 1. Fall sensor connector with cover TABLE H 1.
  • Page 90 Stelvio 1200 NTX MY11 Electrical system TABLE I 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 ELE SYS - 90...
  • Page 91 Stelvio 1200 NTX MY11 Electrical system General wiring diagram Key: 1. MULTIPLE CONNECTORS 2. CLUTCH SWITCH 3. START-UP RELAY 4. MAINTENANCE RELAY ELE SYS - 91 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 92 Stelvio 1200 NTX MY11 Electrical system 5. LIGHT LOGIC RELAY 6. FOG LAMP RELAY 7. Right light switch 8. LEFT LIGHT SWITCH 9. HORN 10.AMBIENT AIR TEMPERATURE SENSOR 11.INSTRUMENT PANEL 12.IMMOBILIZER AERIAL 13.IGNITION KEY 14.HEATED HANDGRIPS 15.GPS COUPLING 16.- 17.- 18.Rear right turn indicator...
  • Page 93 Stelvio 1200 NTX MY11 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...
  • Page 94 Stelvio 1200 NTX 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;...
  • Page 95 Stelvio 1200 NTX MY11 Electrical system Engine Temperature Error DC Gnd ECU 15 Air Temperature Error DC V DC ECU 16 Air Temperature Error DC Gnd ECU 17 Low Battery Error ECU 20 Lambda Probe Error ECU 21 Coil 1 Error DC V DC ECU 22...
  • Page 96 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;...
  • Page 97 Stelvio 1200 NTX MY11 Electrical system 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...
  • Page 98 Stelvio 1200 NTX MY11 Electrical system Lights list FRONT HEADLAMP Specification Desc./Quantity Front daylight running light 12V - 5W Low/high beam light (halogen) 12 V - 55 W / 60 W H4 REAR LIGHT Specification Desc./Quantity Rear daylight running light/stop light...
  • Page 99: Control Unit

    Stelvio 1200 NTX MY11 Electrical system 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).
  • Page 100: Speed Sensor

    Stelvio 1200 NTX 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...
  • Page 101 Stelvio 1200 NTX MY11 Electrical system 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.
  • Page 102 Stelvio 1200 NTX 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.
  • Page 103 Stelvio 1200 NTX MY11 Electrical system 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"...
  • Page 104 Stelvio 1200 NTX 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.
  • Page 105 Stelvio 1200 NTX MY11 Electrical system • PIN B: supply voltage +5V • PIN C: potentiometer signal THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN"...
  • Page 106 Stelvio 1200 NTX MY11 Electrical system 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.
  • Page 107 Stelvio 1200 NTX MY11 Electrical system THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN"...
  • Page 108 Stelvio 1200 NTX 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).
  • Page 109 Stelvio 1200 NTX MY11 Electrical system 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;...
  • Page 110 Stelvio 1200 NTX MY11 Electrical system Pin-out: 1. Sensor signal + (black wire) 2. Sensor signal - (grey wire) 3. Heater ground 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.
  • Page 111 Stelvio 1200 NTX MY11 Electrical system • 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;...
  • Page 112 Stelvio 1200 NTX 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.
  • Page 113 Stelvio 1200 NTX MY11 Electrical system 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-...
  • Page 114 Stelvio 1200 NTX 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 •...
  • Page 115 Stelvio 1200 NTX MY11 Electrical system between PIN 37 of the BROWN connector and the component PIN - and restore the cable harness Coil Function It controls the ignition spark plug in order to gen- erate the fuel ignition spark.
  • Page 116 Stelvio 1200 NTX 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...
  • Page 117 Stelvio 1200 NTX MY11 Electrical system 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.
  • Page 118 Stelvio 1200 NTX 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.
  • Page 119 Stelvio 1200 NTX MY11 Electrical system 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.
  • Page 120: Bank Angle Sensor

    Stelvio 1200 NTX 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...
  • Page 121 Stelvio 1200 NTX MY11 Electrical system Function it tells the vehicle position to the control unit. Operation / Operating principle When the sensor is inverted, the circuit is closed to ground: when the Marelli control unit detects this earthing, it disables the fuel pump circuit and the engine start-up circuit via the injection relay.
  • Page 122 Stelvio 1200 NTX 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...
  • Page 123 Stelvio 1200 NTX MY11 Electrical system 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)
  • Page 124 Stelvio 1200 NTX MY11 Electrical system there is continuity of the sky 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.
  • Page 125 Stelvio 1200 NTX MY11 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...
  • Page 126 Stelvio 1200 NTX MY11 Electrical system 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) (+)
  • Page 127 Stelvio 1200 NTX MY11 Electrical system 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...
  • Page 128 Stelvio 1200 NTX MY11 Electrical system 40 CONTROL - UP ABS Modulator Pin Use 1. Ground connection 2. Not used 3. Speed signal for injection ECU 4. ABS control unit power supply 5. Not used 6. Not used 7. ABS deactivation switch 8.
  • Page 129 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 130 Stelvio 1200 NTX MY11 Engine from vehicle Vehicle preparation Before removing the engine block, proceed as follows: • 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.
  • Page 131 Stelvio 1200 NTX MY11 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 breather pipe. • Disconnect the gear in neutral sensor connector.
  • Page 132 Stelvio 1200 NTX MY11 Engine from vehicle • Disconnect the horn connectors. • Operating from both sides, undo and remove the screw fixing the oil radiator to the chassis. • Loosen the clamp and slide off the oil pipe from the blow-by tank.
  • Page 133 Stelvio 1200 NTX MY11 Engine from vehicle • Working from both sides, undo and re- move the three inlet manifold screws. • Collect the gasket. • Disconnect the alternator connectors. • Disconnect the engine temperature sensor connector ENG VE - 133...
  • Page 134 Stelvio 1200 NTX 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. •...
  • Page 135 Stelvio 1200 NTX MY11 Engine from vehicle • Operating from both sides, undo and remove the upper engine fixing nut on the internal side of the chassis. • Unscrew and remove the engine lower fixing nut and collect the washer.
  • Page 136 Stelvio 1200 NTX 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.
  • Page 137 Stelvio 1200 NTX MY11 Engine from vehicle • 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.
  • Page 138 Stelvio 1200 NTX 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.
  • Page 139 Stelvio 1200 NTX MY11 Engine from vehicle • 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. ENG VE - 139...
  • Page 140 Stelvio 1200 NTX 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 - 140...
  • Page 141 Stelvio 1200 NTX MY11 Engine from vehicle • 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.
  • Page 142 INDEX OF TOPICS NGINE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 143 Stelvio 1200 NTX MY11 Engine Gearbox Diagram Key: 1. Ball bearing ENG - 143 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 144 Stelvio 1200 NTX MY11 Engine 2. Circlip 3. Thickness 4. Pin 5. Complete desmodromic 6. Ball bearing 7. Spring 8. Spacer 9. Circlip 10.Fifth wheel 11.Linking pin 12.Gear 13.Circlip 14.Thrust washer 15.Ball bearing cage 16.Gear 17.Sealing ring 18.Ball bearing 19.Gear 20.Circlip...
  • Page 145 Stelvio 1200 NTX MY11 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...
  • Page 146 Stelvio 1200 NTX 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.
  • Page 147 Stelvio 1200 NTX MY11 Engine • Undo and remove the two screws. • Undo and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts ENG - 147 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 148 Stelvio 1200 NTX 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.
  • Page 149 Stelvio 1200 NTX MY11 Engine • Slide off the rod with the two bushings. • 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 •...
  • Page 150 Stelvio 1200 NTX MY11 Engine • Remove the bearings from the gearbox if necessary. • Release the spring. • Pressing the selector, slide off the whole transmission lever. • Use rubber bands to tie down the trans- mission shaft unit and extract it.
  • Page 151 Stelvio 1200 NTX MY11 Engine • Once the transmission shaft unit is in on a bench, remove the rubber bands, being careful with the group. • Detach the shafts and label the forks before removal. • Remove the forks and collect the shaft.
  • Page 152 Stelvio 1200 NTX MY11 Engine • 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.
  • Page 153 Stelvio 1200 NTX MY11 Engine • Remove the gear of the sixth gear and collect the shoulder washer. • Remove the circlip. • Remove the gear of the third and fourth gears. • Remove the circlip and collect the shoulder washer.
  • Page 154 Stelvio 1200 NTX 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 secondary shaft • Remove the transmission shaft.
  • Page 155 Stelvio 1200 NTX MY11 Engine • Remove the gear of the second gear 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.
  • Page 156 Stelvio 1200 NTX MY11 Engine • 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.
  • Page 157 Stelvio 1200 NTX 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...
  • Page 158 Stelvio 1200 NTX 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.
  • Page 159 Stelvio 1200 NTX MY11 Engine 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...
  • Page 160 Stelvio 1200 NTX MY11 Engine Disassembling the gearbox Gear selector NTERNAL ONTROLS pos. Description Type Quantity Torque Notes Spring guide pin 24 Nm (17.70 lbf ft) Loctite 243 ENG - 160 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 161 Stelvio 1200 NTX MY11 Engine Generator Key: 1. Alternator 2. Spacer 3. Screw 4. Screw 5. Nut 6. Belt 7. Generator control pulley 8. Nut 9. Washer 10.Magneto flywheel cotter 11.Screw 12.Nut ENG - 161 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 162 Stelvio 1200 NTX MY11 Engine LTERNATOR pos. Description Type Quantity Torque Notes Generator control pulley locking nut 80 Nm (59.00 lbf ft) Loctite 243 Generator upper fixing screw 22 Nm (16.23 lbf ft) Generator lower fixing screw M10x60 30 Nm (22.13 lbf ft)
  • Page 163: Removing The Generator

    Stelvio 1200 NTX MY11 Engine pos. Description Type Quantity Torque Notes Timing system cover fixing screw M8x55 25 Nm (18.44 lbf ft) Timing system cover fixing screw M6x30 12 Nm (8.85 lbf ft) Generator cover fixing screw M6x16 12 Nm (8.85 lbf ft) Removing the generator •...
  • Page 164 Stelvio 1200 NTX 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.
  • Page 165 Stelvio 1200 NTX MY11 Engine • Using a compressed air gun, unscrew and remove the nut and collect the spacer. • Remove the lower pulley. • Undo and remove the eight screws. • Undo and remove the two screws. ENG - 165...
  • Page 166 Stelvio 1200 NTX 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.
  • Page 167 Stelvio 1200 NTX MY11 Engine • Remove the generator belt cover by lightly loosening the oil radiator. • Loosen the screw. • Loosen the nut and undo the set screw so that the alternator slides down. • Using the belt tensioning tool, tension the belt to the prescribed torque.
  • Page 168: Installing The Generator

    Stelvio 1200 NTX 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.
  • Page 169 Stelvio 1200 NTX MY11 Engine • Tighten the eight lower screws. • Operating diagonally and in stages, tighten the ten fixing screws on the al- ternator fitting. • Tighten the four screws, operating di- agonally and in stages. • Position the lower pulley and the spacer.
  • Page 170 Stelvio 1200 NTX 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.
  • Page 171: Starter Motor

    Stelvio 1200 NTX MY11 Engine • Tighten the alternator fixing screws. • Place the alternator belt cover. • Tighten the five screws operating diag- onally and in stages. Starter motor Removing the starter motor • Undo and remove the two screws and collect the washers.
  • Page 172 Stelvio 1200 NTX MY11 Engine • 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. TCEI screw 8. Clutch thrust plate...
  • Page 173 Stelvio 1200 NTX MY11 Engine 9. Ring 10.TE flanged screw 11.Conical washer 12.Bushing 13.Rod 14.Bushing 15.Intermediate body 16.Thrust bearing 17.Clutch control bowl 18.Thrust cylinder 19.Clutch control cylinder 20.TE flanged screw LUTCH pos. Description Type Quantity Torque Notes Clutch to crankshaft fixing screw 42 Nm (30.98 lbf ft)
  • Page 174 Stelvio 1200 NTX MY11 Engine • Remove the complete gearbox. • 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.
  • Page 175 Stelvio 1200 NTX MY11 Engine • 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.
  • Page 176 Stelvio 1200 NTX MY11 Engine 020678Y Tool for clutch rod checking CLUTCH CONTROL ROD SELECTION Specification Desc./Quantity Protrusion: 9.8 - 11.2 mm (0.386 - 0.441 in) Clutch control rod length (code 976593) = 183 mm (7.205 in) Protrusion: 8.3 - 9.7 mm (0.327 - 0.382 in) Clutch control rod length (code 976594) = 184.5 mm (7.264 in)
  • Page 177 Stelvio 1200 NTX MY11 Engine • 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.
  • Page 178 Stelvio 1200 NTX MY11 Engine Heads YLINDER HEAD COVERS pos. Description Type Quantity Torque Notes Special cylinder head fixing screw 8 Nm (5.90 lbf ft) Locked with cross sequence Spark plug cover fixing screw M5x10 8 Nm (5.90 lbf ft)
  • Page 179 Stelvio 1200 NTX MY11 Engine IGHT YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lbf ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lbf ft) Engine Oil Pre- tightening Head tightening nut M10x1.25...
  • Page 180 Stelvio 1200 NTX MY11 Engine Key: 1. Right cylinder head 2. Stud bolt 3. Cylinder head gasket 4. Right rocking lever support 5. Screw 6. Pin 7. Nut 8. Right exhaust, left intake rocking lever 9. Left exhaust, right intake rocking lever 10.Set screw...
  • Page 181 Stelvio 1200 NTX MY11 Engine 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...
  • Page 182: Removing The Cylinder Head

    Stelvio 1200 NTX 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...
  • Page 183 Stelvio 1200 NTX MY11 Engine • Remove the head cover. • Unscrew and remove the two screws • Remove the cap. • Unscrew and remove the screw. • Remove the timing system upper gear bulkhead. For the right head: •...
  • Page 184 Stelvio 1200 NTX MY11 Engine • Slide off the timing system gear from the chain to remove it from the cam- shaft. • Unscrew and remove the four nuts on the stud bolts. • Remove the complete cam cap. •...
  • Page 185: Cylinder Head

    Stelvio 1200 NTX MY11 Engine • 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. •...
  • Page 186 Stelvio 1200 NTX 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.
  • Page 187: Removing The Valves

    Stelvio 1200 NTX MY11 Engine • Remove the cam cap from the stud bolts. • Undo and remove the two screws. • Remove the U-bolt. • Remove the two rocking levers from the cam cap. See also Removing the cylinder head Removing the valves •...
  • Page 188: Checking The Cylinder Head

    Stelvio 1200 NTX MY11 Engine slid off the valve seats; unscrew the tool and remove it from the head. • Slide off the upper cap (2). • Remove the spring (3). • Remove the lower cap (5) and the valve guide oil seal (4), if necessary.
  • Page 189: Installing The Valves

    Stelvio 1200 NTX MY11 Engine 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.
  • Page 190 Stelvio 1200 NTX MY11 Engine • Remove the special tool Installing the rocker arms • Fit the camshaft. • Fit the two rods. WARNING MAKE SURE THAT THE NOTCH ON THE DIPSTICK BODY FACES THE ROCKING LEVER. • Place the two rocking levers in the cam tower seats.
  • Page 191 Stelvio 1200 NTX MY11 Engine • Place the U-bolt on the rocking levers making sure the two reference pins match the seats on the cam tower. • Tighten the two screws operating diag- onally and in stages. See also Installing the overhead camshaft Installing the overhead camshaft •...
  • Page 192 Stelvio 1200 NTX MY11 Engine Timing IMING YSTEM ONTROL pos. Description Type Quantity Torque Notes Control, timing system, shaft support flange M6x14 8 Nm (5.90 lbf ft) fixing screw Bearing fixing screw M6x16 10 Nm (7.37 lbf ft) Loctite 243 Driving gears locking nut on the crankshaft 200 Nm (147.51 lbf ft)
  • Page 193 Stelvio 1200 NTX MY11 Engine • Remove the timing sensor and any shim washers. • Remove the tone wheel. • Remove the cotter and shim washer from the service shaft. See also Removing the generator Service shaft removal • Remove the tone wheel.
  • Page 194 Stelvio 1200 NTX MY11 Engine Installing the service shaft • Place the service shaft bearing (if pre- viously removed) on the crankcase. • Fix it to the seat with the lock washer and screw. • Fit the timing chains according to the references marked at the removal phase.
  • Page 195 Stelvio 1200 NTX MY11 Engine • 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. •...
  • Page 196 Stelvio 1200 NTX MY11 Engine Cam timing • Fit the crankshaft and the service shaft on the crankcase. • Fit the cylinders. • Turn the crankshaft until the left cylin- der piston reaches the top dead centre (TDC). • Fit the cotter and the shim washer on the service shaft.
  • Page 197 Stelvio 1200 NTX MY11 Engine • After shimming the timing sensor prop- erly, proceed to fit it. • Fit the washer and tighten the timing system gear fixing nut of the service shaft. • Place a new gasket between the crank- case and the oil pump.
  • Page 198 Stelvio 1200 NTX 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...
  • Page 199 Stelvio 1200 NTX MY11 Engine Measuring air gap • Undo and remove the two screws and remove the sensor. • Insert a suitable plain washer on the sensor and note its thickness. • Place the sensor on the crankcase and move it until it makes contact with the tone wheel.
  • Page 200 Stelvio 1200 NTX MY11 Engine Cylinder-piston assembly Key: 1. Right cylinder 2. Piston 3. Screw 4. Top piston ring 5. Middle piston ring 6. Oil scraper piston ring 7. Pin 8. Retainer ring 9. Cylinder base gasket 10.Stud bolt 11.Pin 12.Cylinder head gasket...
  • Page 201 Stelvio 1200 NTX MY11 Engine ONNECTING ROD ASSEMBLY YLINDERS pos. Description Type Quantity Torque Notes Thermal group fixing stud bolt M10x1.25 5 Nm (3.69 lbf ft) Loctite 243 Connecting rod screws 40 Nm (29.50 lbf ft) Pre-tightening Connecting rod screws 80 Nm (59.00 lbf ft)
  • Page 202 Stelvio 1200 NTX MY11 Engine ESTA INISTRA Pos. Descrizione Tipo Quantità Coppia Note Movable chain tensioner pad fixing screw 20 Nm (14.75 lbf ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lbf ft) Engine Oil Pre- tightening Head tightening nut M10x1.25...
  • Page 203 Stelvio 1200 NTX MY11 Engine • 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.
  • Page 204 Stelvio 1200 NTX 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 ONE HEAD BUT APPLY TO BOTH HEADS.
  • Page 205 Stelvio 1200 NTX MY11 Engine • Insert the pin. • Insert the snap ring. Specific tooling 020470Y Pin snap ring fitting tool Installing the cylinder RIGHT CYLINDER • Fit the piston. • Remove the cloth used to prevent for- eign bodies from getting into the crank- case.
  • Page 206 Stelvio 1200 NTX 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.
  • Page 207 Stelvio 1200 NTX MY11 Engine • 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.
  • Page 208: Installing The Cylinder Head

    Stelvio 1200 NTX MY11 Engine Installing the cylinder head • Fit the valves in the head, if previously removed. • Take the left cylinder piston to TDC and lock crankshaft rotation. • Determine the thickness of the gasket to be fitted between the head and the cylinder as described in the section: Shimming system.
  • Page 209 Stelvio 1200 NTX MY11 Engine • Fix the head with the two screws. • Tighten nuts and screws to the prescri- bed torque operating diagonally and in stages. • Loosen the valve set screws. • Using a thin screwdriver relief oil pres- sure from the left cylinder chain ten- sioner.
  • Page 210 Stelvio 1200 NTX 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.
  • Page 211 Stelvio 1200 NTX MY11 Engine • Place the cap. • Tighten the two screws to the prescri- bed torque. • Also place the cap of the other head. • Adjust valve clearance. See also Checking the valve clearance Installing the head cover •...
  • Page 212 Stelvio 1200 NTX MY11 Engine Crankcase - crankshaft Removing the crankshaft • Remove the clutch. • Remove the tone wheel and the oil pump gear. • Working from the generator side, un- screw and remove the nut. • Remove both gears.
  • Page 213 Stelvio 1200 NTX MY11 Engine • Remove the crankshaft afterwards. • 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.
  • Page 214 Stelvio 1200 NTX 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/ Reference (1) indicates the position where the col- oured reference is applied to select diameter (B).
  • Page 215 Stelvio 1200 NTX MY11 Engine Upon replacing the bearings it may be necessary to ream the crankshaft pin. Before reaming the crankpin, measure the pin diameter (B) comparing it with the maximum wear al- lowed, as indicated in the figure; this defines what kind of undersizing the bearing should have and to which diameter the pin (B) should be reamed.
  • Page 216 Stelvio 1200 NTX 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)
  • Page 217 Stelvio 1200 NTX MY11 Engine 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.
  • Page 218 Stelvio 1200 NTX 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.
  • Page 219 Stelvio 1200 NTX MY11 Engine Refitting the crankcase halves In case the lubrication jets are removed, replace them with two new of the same type. Check that the O-ring is fitted on the jets. Do not interchange them upon refitting because they have a different length.
  • Page 220 Stelvio 1200 NTX MY11 Engine ADIATOR pos. Description Type Quantity Torque Notes Viti fissaggio radiatore a telaio M6x30 10 Nm (7.38 lbf ft) pos. Description Type Quantity Torque Notes Oil pump fixing screw M6x45 10 Nm (7.37 lbf ft) Loctite 243 Oil pump driven gear locking nut 8 Nm (5.90 lbf ft)
  • Page 221 Stelvio 1200 NTX MY11 Engine pos. Description Type Quantity Torque Notes Oil pressure valve cap 40 Nm (29.50 lbf ft) RANKCASE AND pos. Description Type Quantity Torque Notes Stud bolt M8x75 10 Nm (7.37 lbf ft) Stud bolt M8x66 10 Nm (7.37 lbf ft)
  • Page 222 Stelvio 1200 NTX MY11 Engine IL SUMP COMPONENTS pos. Description Type Quantity Torque Notes Cover on the flange under the crankcase 40 Nm (29.50 lbf ft) Oil filter joint 10 Nm (7.37 lbf ft) Loctite 243 Oil sump pipe 20 Nm (14.75 lbf ft)
  • Page 223 Stelvio 1200 NTX MY11 Engine Conceptual diagrams Key: 1. Oil cooling radiator 2. Oil delivery pipe to heads 3. Oil delivery pipe to radiator 4. Oil pump body 5. Oil pump gasket 6. Rotor for lubrication 7. Rotor for cooling 8.
  • Page 224: Oil Pump

    Stelvio 1200 NTX 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).
  • Page 225 Stelvio 1200 NTX MY11 Engine • 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.
  • Page 226 Stelvio 1200 NTX 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.
  • Page 227 Stelvio 1200 NTX 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...
  • Page 228 Stelvio 1200 NTX MY11 Engine • Fit the nipple with the gasket on the crankcase. • Tighten the nipple to the prescribed torque. Removing the oil sump NOTE TO REMOVE THE OIL SUMP, PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL.
  • Page 229 Stelvio 1200 NTX MY11 Engine • Undo and remove the four screws. • Remove the flange. • Undo and remove the two screws. • Remove both filters. ENG - 229 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 230 Stelvio 1200 NTX 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 - 230 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 231 Stelvio 1200 NTX MY11 Engine 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.
  • Page 232 Stelvio 1200 NTX MY11 Engine • Place a new gasket between the crank- case and the flange. • Fit the flange. • Fix the flange with the four screws. • Fit the lubrication oil intake filter. • Check that the O-rings are fitted on the oil pump.
  • Page 233 Stelvio 1200 NTX MY11 Engine • 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.
  • Page 234 INDEX OF TOPICS P SUPP OWER SUPPLY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 235 Stelvio 1200 NTX MY11 Power supply UPPLY YSTEM pos. Description Type Quantity Torque Notes Vite fissaggio protezioni corpo farfallato 10 Nm (7.38 lbf ft) HROTTLE BODY pos. Description Type Quantity Torque Notes Intake pipe fixing screw 10 Nm (7.37 lbf ft)
  • Page 236: Circuit Diagram

    Stelvio 1200 NTX MY11 Power supply Circuit diagram Key: 1. Complete fuel pump unit 2. Nut 3. Fuel pipe 4. Pipe 5. Screw Removing • Rimuovere l'anello di fermo della pom- pa carburante; P SUPP - 236 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 237 Stelvio 1200 NTX MY11 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.
  • Page 238 Stelvio 1200 NTX MY11 Power supply 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.
  • Page 239 Stelvio 1200 NTX MY11 Power supply 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.
  • Page 240 Stelvio 1200 NTX MY11 Power supply • 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.
  • Page 241: Injection System

    Stelvio 1200 NTX MY11 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.
  • Page 242 Stelvio 1200 NTX MY11 Power supply ECU INFO screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date INFO ECU SCREEN PAGE Specification Desc./Quantity Mapping PARAMETERS screen page...
  • Page 243 Stelvio 1200 NTX MY11 Power supply 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...
  • Page 244 Stelvio 1200 NTX MY11 Power supply ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. ACTIVATION Specification Desc./Quantity Left coil operation for 2.5 m, 5 times Right coil operation for 2.5 m, 5 times...
  • Page 245 Stelvio 1200 NTX MY11 Power supply Specification Desc./Quantity Lambda probe Possible short circuit on the earth lead, battery or open circuit or plausibility: recovery function hardly noticeable for customer. Left injector Possible short circuit in the earth lead, battery or open circuit.
  • Page 246 INDEX OF TOPICS SUSP USPENSIONS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 247: Removing The Front Wheel

    Stelvio 1200 NTX MY11 Suspensions Front RONT WHEEL pos. Description Type Quantity Torque Notes Viti TE Flang. fissaggio dischi freno M8x20 25 Nm (18.44 lbf ft) Nut fixing wheel pin 80 Nm (59.00 lbf ft) Vite flang. fissaggio sensore 6 Nm (4.42 lbf ft) Loct.
  • Page 248 Stelvio 1200 NTX MY11 Suspensions • Hold the vehicle front part. • Unscrew and remove the wheel axle fixing nut and collect the sealing wash- • 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.
  • Page 249: Front Fork

    Stelvio 1200 NTX MY11 Suspensions Front fork RONT FORK pos. Description Type Quantity Torque Notes Viti piede forcella 25 Nm (18.44 lbf ft) Viti chiusura mozzetti M6x30 10 Nm (7.38 lbf ft) Fork cap - Nm (-.- lbf ft) SUSP - 249...
  • Page 250 Stelvio 1200 NTX MY11 Suspensions Diagram Key: 1. Complete front fork 2. TCE screw 3. Washer 4. TE flanged screw 5. Stem + right wheel holder 6. Bushing 7. Stem + left wheel holder 8. Complete right pumping member 9. Nut 10.Complete left pumping member...
  • Page 251 Stelvio 1200 NTX MY11 Suspensions 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.
  • Page 252: Removing The Fork Legs

    Stelvio 1200 NTX 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-...
  • Page 253 Stelvio 1200 NTX MY11 Suspensions See also Removing the front wheel Draining oil • Lock the sleeve in a vice with the spe- cific tool (code AP8140149). • Set the minimum spring preloading. Specific tooling AP8140149 Protection for fitting operations •...
  • Page 254 Stelvio 1200 NTX MY11 Suspensions • 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;...
  • Page 255 Stelvio 1200 NTX MY11 Suspensions Disassembling the fork • Drain all the oil from the stem. • Tighten the wheel holder sleeve in a vice. • Undo the fork end bottom screw and remove it with the corresponding gas- ket.
  • Page 256 Stelvio 1200 NTX 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.
  • Page 257 Stelvio 1200 NTX MY11 Suspensions • Remove the ring and the dust guard. See also Draining oil Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1).
  • Page 258 Stelvio 1200 NTX 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.
  • Page 259 Stelvio 1200 NTX MY11 Suspensions • O-Ring on the cap. Reassembling the fork • Lock the stem in a vice without dam- aging the surface. • Protect the bearing tube end with ad- hesive tape. • Lubricate the sliding edges with fork oil or sealing grease.
  • Page 260 Stelvio 1200 NTX 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 - 260 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 261 Stelvio 1200 NTX MY11 Suspensions • Fit the dust gaiter with the specific tool. Specific tooling 9100903 Marzocchi fork oil seal; ø 45 mm (1.77 • Fit the pumping member pin with the cap in the spring holder sleeve and in the preload pipe.
  • Page 262 Stelvio 1200 NTX MY11 Suspensions • Insert the retainer ring in its position. 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.
  • Page 263 Stelvio 1200 NTX MY11 Suspensions • 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.
  • Page 264: Installing The Fork Legs

    Stelvio 1200 NTX 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 •...
  • Page 265 Stelvio 1200 NTX MY11 Suspensions • Tighten the screws on the fork plates to the prescribed torque. Steering bearing TEERING pos. Description Type Quantity Torque Notes Viti fissaggio piastra fermatubi 6 Nm (4.42 lbf ft) Viti fissaggio piastre M8x30 20 Nm (14.75 lbf ft) Headstock ring nut 40 Nm (29.50 lbf ft)
  • Page 266 Stelvio 1200 NTX MY11 Suspensions pos. Description Type Quantity Torque Notes Headstock counter-lock ring manual + 90 degrees Upper yoke fixing cap 100 Nm (73.76 lbf ft) Adjusting play • Unscrew and remove the U-bolt four fixing screws. • Remove the U-bolt.
  • Page 267 Stelvio 1200 NTX MY11 Suspensions • 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 •...
  • Page 268: Removing The Rear Wheel

    Stelvio 1200 NTX MY11 Suspensions • Fit a new safety washer. • Screw the upper ring nut manually and then slightly tighten the clamps on the plate so as to align notches on the ring nut. Specific tooling AP8140190 Tool for steering tightening •...
  • Page 269: Shock Absorbers

    Stelvio 1200 NTX MY11 Suspensions Shock absorbers EAR SUSPENSION pos. Description Type Quantity Torque Notes Vite TE Flang. fissaggio superiore ammortiz- M10x80 50 Nm (36.88 lbf ft) zatore Vite TCEI fissaggio biella doppia/forcellone M10x82 50 Nm (36.88 lbf ft) Vite TE fissaggio biella doppia/ammortizza- M10x47 40 Nm (29.50 lbf ft)
  • Page 270 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.
  • Page 271 Stelvio 1200 NTX MY11 Suspensions Removing • Park the vehicle on its centre stand. • Lock the vehicle handlebar so that the rear wheel is off the ground. • Remove the fork. • Undo and remove the shock absorber upper screw.
  • Page 272 INDEX OF TOPICS CHAS HASSIS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 273 Stelvio 1200 NTX MY11 Chassis Swinging arm EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm clamp fixing screw on the bushing M6x25 10 Nm (7.37 lbf ft) 2 - Swingarm fixing screw on the transmission M10x35 50 Nm (36.87 lbf ft)
  • Page 274 Stelvio 1200 NTX MY11 Chassis • Remove the rear wheel. • Unscrew and remove the two screws. • Remove the speed sensor from the fork. • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. •...
  • Page 275 Stelvio 1200 NTX MY11 Chassis • Loosen the two swingarm terminal screws. • 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 •...
  • Page 276 Stelvio 1200 NTX MY11 Chassis 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;...
  • Page 277 Stelvio 1200 NTX MY11 Chassis • Use the suitable box-spanner to tight- en the ring nut. Specific tooling 05.91.26.30 Tool for tightening the swingarm pin ring nut - clutch hub • Tighten the two screws of the swing- arm clamp.
  • Page 278 Stelvio 1200 NTX MY11 Chassis • Place the connecting rod assembly on the swingarm. • Insert the screw. • Tighten the fixing nut of the connecting rod assembly. • Place the speed sensor on the fork and screw the two screws.
  • Page 279 Stelvio 1200 NTX MY11 Chassis • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. • Fasten the reaction rod to the chassis with a clamp. • Undo and remove the four screws. • Remove the transmission casing slid- ing off the universal joint.
  • Page 280 Stelvio 1200 NTX MY11 Chassis Casing unit removal Remove the cover (20). Remove the plug (3) to drain out the oil. Lift the cap (10). CHAS - 280 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 281 Stelvio 1200 NTX MY11 Chassis Remove the clamps (9) and (11). Remove the cap (14). Remove the screws (16). Collect the ring (15). Remove the screws (7). Remove the casing (4). CHAS - 281 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 282 Stelvio 1200 NTX MY11 Chassis Remove the clamp (12). Remove the cap (14). Collect the ring (13). Remove the support unit (8). Casing unit fitting CHAS - 282 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 283 Stelvio 1200 NTX MY11 Chassis 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. Insert the support group in the casing.
  • Page 284 Stelvio 1200 NTX 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 - 284 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 285 Stelvio 1200 NTX MY11 Chassis 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.
  • Page 286 Stelvio 1200 NTX 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.
  • Page 287 Stelvio 1200 NTX MY11 Chassis 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...
  • Page 288 Stelvio 1200 NTX 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.
  • Page 289 Stelvio 1200 NTX MY11 Chassis Pinion unit Removal Remove the stop ring (1) from the ring nut. Unscrew the ring nut (2) with the special spanner (s4). Remove the ring nut (2) and remove the sealing ring from the ring nut.
  • Page 290 Stelvio 1200 NTX 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. Insert the stop ring (1) in the ring nut (2) in the in- dicated direction.
  • Page 291 Stelvio 1200 NTX MY11 Chassis Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT. Support unit CHAS - 291 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 292 Stelvio 1200 NTX 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.
  • Page 293 Stelvio 1200 NTX MY11 Chassis Turn the support (5) over. Assemble the ball joint (4) with the buffer and a rubber hammer. Fit the stop ring (3) in the support (5) with suitable pliers. Manually assemble the new sealing rings (2) and (7).
  • Page 294 Stelvio 1200 NTX 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.
  • Page 295 Stelvio 1200 NTX MY11 Chassis • 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.
  • Page 296 Stelvio 1200 NTX MY11 Chassis Exhaust XHAUST SYSTEM pos. Description Type Quantity Torque Notes Dadi Flang. fissaggio collettori 25 Nm (18.44 lbf ft) Oxygen sensor fastener 38 Nm (28.03 lbf ft) Vite TE Flang. fissaggio parte centrale M10x55 25 Nm (18.44 lbf ft) Viti fissaggio protezione 10 Nm (7.38 lbf ft)
  • Page 297 Stelvio 1200 NTX MY11 Chassis key: 1. Right exhaust pipe 2. Left exhaust pipe 3. Gasket 4. Flanged nut 5. Washer 6. Gasket 7. Clamp 8. Central exhaust pipe 9. TE flanged screw 10.Silent-block 11.Flanged self-locking nut 12.Lambda probe 13.Gasket 14.Clamp...
  • Page 298 Stelvio 1200 NTX MY11 Chassis • Undo and remove the screw and col- lect the nut and the washer. • Remove the exhaust end. Removing the manifold - tail pipe • Remove the exhaust end and the ex- haust manifolds.
  • Page 299 Stelvio 1200 NTX MY11 Chassis Removing the tail pipe Removing the exhaust manifold The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been switched off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.
  • Page 300 Stelvio 1200 NTX MY11 Chassis Engine oil cooler ADIATOR pos. Description Type Quantity Torque Notes Viti fissaggio radiatore a telaio M6x30 10 Nm (7.38 lbf ft) Key: 1. Complete oil radiator CHAS - 300 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 301 Stelvio 1200 NTX MY11 Chassis 2. TE flanged screw 3. T-shaped bushing 4. Rubber ring 5. Radiator support 6. TCEI screw 7. Clip Removing • Per la sostituzione dell'olio motore e del filtro olio è necessario rimuovere il paramotore in metallo svitando le quattro viti (1) che lo fissano al motore.
  • Page 302 Stelvio 1200 NTX MY11 Chassis • Undo and remove the two radiator up- per screws and collect the washer. • Remove the oil cooling radiator. See also Engine guard Installing • Fit the oil cooling radiator on the vehi- cle following the operations described in the removal chapter but in reverse order.
  • Page 303 INDEX OF TOPICS BRAK SYS RAKING SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 304 Stelvio 1200 NTX MY11 Braking system RAKE YSTEM pos. Description Type Quantity Torque Notes Brake pipe slot screw on the pump 25 Nm (18.44 lbf ft) Joint with brake pipes retainer bleeding on the 25 Nm (18.44 lbf ft) calliper Brake pipes joint on the ABS hydraulic unit 25 Nm (18.44 lbf ft)
  • Page 305 Stelvio 1200 NTX MY11 Braking system key: 1. ABS ECU control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Main relay 6. ECU 7. Instrument panel 8. K line (diagnosis) 9. Key 10.Fuses BRAK SYS - 305...
  • Page 306 Stelvio 1200 NTX MY11 Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever 4. Rear system circuit BRAK SYS - 306 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 307 Stelvio 1200 NTX MY11 Braking system 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)
  • Page 308 Stelvio 1200 NTX 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.
  • Page 309 Stelvio 1200 NTX MY11 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...
  • Page 310 Stelvio 1200 NTX 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"...
  • Page 311 Stelvio 1200 NTX MY11 Braking system 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.
  • Page 312 Stelvio 1200 NTX MY11 Braking system ECU INFO screen page This 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...
  • Page 313 Stelvio 1200 NTX MY11 Braking system ACTIVATION screen page 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 Notes measure ment...
  • Page 314 Stelvio 1200 NTX MY11 Braking system ERRORS Characteristic Value/example Unit of Notes measure ment Front speed sensor: 5D90 electric Electrical fault in sensor or cable harness malfunction Front speed sensor: 5D91 the signal Faulty sensor or signal interference works irregularly...
  • Page 315 Stelvio 1200 NTX 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.
  • Page 316 Stelvio 1200 NTX 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.
  • Page 317 Stelvio 1200 NTX MY11 Braking system • When the connector is fully inserted, 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.
  • Page 318 Stelvio 1200 NTX 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;...
  • Page 319 Stelvio 1200 NTX MY11 Braking system INZA RENO OSTERIORE Pos. Descrizione Tipo Quantità Coppia Note Rear brake calliper fixing screw 50 Nm (36.87 lbf ft) Vite fissaggio tubo olio - Nm (-.-- lbf ft) Vite fissaggio tubo olio - Nm (-.-- lbf ft) Key: 1.
  • Page 320 Stelvio 1200 NTX MY11 Braking system Front brake calliper RONT BRAKE CALLIPERS pos. Description Type Quantity Torque Notes Viti TE Flang. fissaggio pinze M10x55 50 Nm (36.88 lbf ft) Key: BRAK SYS - 320 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 321 Stelvio 1200 NTX MY11 Braking system 1. Front right brake calliper 2. Front left brake calliper 3. Pads 4. Air bleed 5. Air bleed cap 6. Pins + Calliper springs 7. Spring 8. Aluminium gasket 9. Screw Rear brake disc...
  • Page 322: Front Brake Pads

    Stelvio 1200 NTX MY11 Braking system • 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.
  • Page 323 Stelvio 1200 NTX MY11 Braking system • 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.
  • Page 324: Rear Brake Pads

    Stelvio 1200 NTX 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. • Check the brake fluid level in the res- ervoir.
  • Page 325 Stelvio 1200 NTX MY11 Braking system • 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.
  • Page 326 Stelvio 1200 NTX 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.
  • Page 327 Stelvio 1200 NTX MY11 Braking system 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.
  • Page 328 Stelvio 1200 NTX MY11 Braking system 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.
  • Page 329 Stelvio 1200 NTX MY11 Braking system • 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.
  • Page 330 Stelvio 1200 NTX 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.
  • Page 331 Stelvio 1200 NTX MY11 Braking system 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...
  • Page 332 INDEX OF TOPICS BODYW ODYWORK Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 333 Stelvio 1200 NTX MY11 Bodywork RONT IGHTS pos. Description Type Quantity Torque Notes Horn fixing screw M6x20 15 Nm (11.06 lbf ft) Viti fissaggio freccie anteriori 3 Nm (2.21 lbf ft) Vite fissaggio superiore fanale a carozzeria 3 Nm (2.21 lbf ft)
  • Page 334 Stelvio 1200 NTX MY11 Bodywork NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Viti TCEI fissaggio sensore velocità anteriore M5x16 6 Nm (4.42 lbf ft) Viti TCEI fissaggio blocchetto avviamento M8x30 25 Nm (18.44 lbf ft) Viti autofil. fissaggio supporto cruscotto...
  • Page 335 Stelvio 1200 NTX MY11 Bodywork ARROZZERIA ANTERIORE ONVOGLIATORI pos. Description Type Quantity Torque Notes Viti TBEI Flang. fissaggio convogliatori M5x9 6 Nm (4.42 lbf ft) Viti TBEI Flang. fissaggio convogliatori 6 Nm (4.42 lbf ft) Viti SWP Autofil. fissaggio telaietto griglie 2.9x12...
  • Page 336 Stelvio 1200 NTX MY11 Bodywork RONT MUDGUARD pos. Description Type Quantity Torque Notes Viti TBEI Flang. fissaggio parafango anteriore M5x12 6 Nm (4.42 lbf ft) OPERTURA SERBATOIO CARBURANTE pos. Description Type Quantity Torque Notes Vite TBEI Flang. fissaggio copertura 5 Nm (3.69 lbf ft)
  • Page 337 Stelvio 1200 NTX MY11 Bodywork EAR BODYWORK pos. Description Type Quantity Torque Notes Viti SWP fissaggio piastra batteria M5x20 Manual Viti TBEI Flang. fissaggio fianchetti e para- M5x9 6 Nm (4.42 lbf ft) spruzzi Viti TE Flang. fissaggio supporti valigie 10 Nm (7.38 lbf ft)
  • Page 338 Stelvio 1200 NTX MY11 Bodywork ANIGLIONE E PORTAPACCHI pos. Description Type Quantity Torque Notes Vite TCEI fissaggio maniglione passeggero M6x25 10 Nm (7.38 lbf ft) Vite TCEI fissaggio maniglione passeggero 25 Nm (18.44 lbf ft) Vite fissaggio portatarga a maniglione 6 Nm (4.42 lbf ft)
  • Page 339 Stelvio 1200 NTX MY11 Bodywork • Rimuovere le viti di fissaggio della co- pertura motorino avvimaneto. • Undo the screw and remove the rear brake oil reservoir. • From the left side of the vehicle, re- move the nut (1) and the correspond- ing washer.
  • Page 340 Stelvio 1200 NTX MY11 Bodywork • Rimuovere le viti di fissaggio (3) del paramotore, da entrambi i lati del mo- tociclo. • Rimuovere le viti di fissaggio (4) del paramotore, da entrambi i lati del mo- tociclo. • Rimuovere le viti di fissaggio (5) del...
  • Page 341: Instrument Panel

    Stelvio 1200 NTX MY11 Bodywork • Liberare i cablaggi dei fari supplemen- tari rimuovendo le fascette (6) e scol- legare i connettori (7) per rimuovere completamente i paramotori. Instrument panel • Rimuovere i deflettori laterali traspar- enti. • Remove the screws (1).
  • Page 342 Stelvio 1200 NTX MY11 Bodywork • 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 Additional lights • Liberare i cablaggi dei fari supplemen- tari rimuovendo le fascette (1) sul telaio e scollegare i connettori (2).
  • Page 343 Stelvio 1200 NTX MY11 Bodywork • Svitare a rimuovere la vite (4) recuper- ando il dado o in alternativa è possibile rimuovere le viti (5) non compromet- tendo cosi l'angolo di inclinazione dei fasci luminosi. • Ora è possibile rimuovere i fari supple- mentari.
  • Page 344 Stelvio 1200 NTX MY11 Bodywork • 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.
  • Page 345 Stelvio 1200 NTX MY11 Bodywork • Disconnect the gearbox rod and re- lease the spring. • Remove the left footrest holding plate. RIGHT SIDE • Undo and remove the upper screw and collect the washer and the nut. • Undo and remove the front lower screw.
  • Page 346 Stelvio 1200 NTX MY11 Bodywork • 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.
  • Page 347 Stelvio 1200 NTX MY11 Bodywork • Rimuovere la vite inferiore esterna. • Scollegare il connettore della freccia anteriore e rimuovere il fianchetto lat- erale. CAUTION ESEGUIRE LA MEDESIMA OPERAZIONE DI SMONTAGGIO ANCHE PER IL FIANCHETTO OP- POSTO Air box BODYW - 347...
  • Page 348 Stelvio 1200 NTX MY11 Bodywork IR FILTER pos. Description Type Quantity Torque Notes Vite fissaggio cassa filtro aria a telaio 10 Nm (7.38 lbf ft) Air filter box cover fastening screw SWP 5x20 3 Nm (2.21 lbf ft) • Remove the saddle.
  • Page 349 Stelvio 1200 NTX MY11 Bodywork • Release the clutch bleeding pipe from the cable guide. • Operating from both sides, undo and remove the three screws. • Remove the mudflap. • Release from its and remove the breather pipe placed on the right side of the filter casing.
  • Page 350 Stelvio 1200 NTX MY11 Bodywork • Remove the two breather pipes. • Operating from both sides, undo and remove the stud bolt. • Remove the filter casing. See also Seat Sump guard ENSURE THAT THE ENGINE AND THE THERMAL PARTS OF THE VEHICLE ARE COLD BEFORE OPERATING ACCORDING TO THE FOLLOWING INSTRUCTIONS.
  • Page 351: Fuel Tank

    Stelvio 1200 NTX MY11 Bodywork 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 the control panel.
  • Page 352 Stelvio 1200 NTX MY11 Bodywork Pannier mounting • Remove the countersunk-head screw (14) and collect the bushings (11) and nuts (16). • Remove the cross-member (9). • Remove the hexagonal-head screw (3) and collect the washers (4). • Remove the Allen screws (5) and (7).
  • Page 353 Stelvio 1200 NTX MY11 Bodywork 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.
  • Page 354 INDEX OF TOPICS PRE DE DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 355 Stelvio 1200 NTX MY11 Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit...
  • Page 356: Road Test

    Stelvio 1200 NTX MY11 Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
  • Page 357 Stelvio 1200 NTX MY11 Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up...
  • Page 358 ABS: 128, 305, 311, 315 Air filter: 67 Air temperature sensor: 108, 122 Alternator: Battery: 96, 99 Brake: 318, 320–322, 324 Brake calliper: 318, 320 Brake disc: 321 Brake lever: Brake pads: 322, 324 Clutch: 119, 172, 175, 176, 213 Coil: 115 Connectors: 124 Crankcase: 51, 212, 219...
  • Page 359 Identification: 10 Instrument panel: 122, 341 License plate holder: Maintenance: 8, 62, 317 Maintenance Table: Mudguard: Oil filter: 66 Oil pressure sensor: 117 Oil sump: 228, 231 Primary shaft: 152, 157–159 Radiator: Rear light: Rear wheel: 268 Recommended products: 53, 278 Run/Stop switch: 123 Saddle: Secondary shaft: 154, 157, 159...

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