MOTO GUZZI Stelvio 1200 4V Service Manual
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MOTO GUZZI Stelvio 1200 4V Service Manual

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SERVICE STATION MANUAL
895768
STELVIO 4V - 1200

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  • Page 1 SERVICE STATION MANUAL 895768 STELVIO 4V - 1200...
  • 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 2010- 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 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...
  • Page 6 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 7: Safety Rules

    STELVIO 4V - 1200 Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
  • Page 8 STELVIO 4V - 1200 Characteristics Brake and clutch fluid BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM- PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS.
  • Page 9 CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE: OTH- ERWISE, 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 4V - 1200 Characteristics This number consists of numbers and letters, as in the example shown below. ZGULZA000YMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LZ: model; A00: version variation; 0: free digit Y year of manufacture M: production plant (M= Mandello del Lario); XXXXXX: serial number (6 digits);...
  • Page 12 STELVIO 4V - 1200 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 Electric starter Engine idle speed 1100 ± 100 rpm Clutch hydraulically controlled single-plate dry clutch with incorpora- ted flexible coupling Lubrication system Pressure-fed, controlled by valves and trochoidal pump...
  • Page 13 STELVIO 4V - 1200 Characteristics Specification Desc./Quantity Low/high beam light (halogen) 12 V - 55 W / 60 W H4 Turn indicators 12V - 10 W Rear daylight running light/stop light 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 4V - 1200 Characteristics Wheels and tyres WHEELS AND TYRES - STELVIO (STANDARD) Wheel Model Size Tyre pressure with Tyre pressure, rider + rider only passenger Front (standard) Pirelli Scorpion Sync 2.50 x 19" 110/80 2.5 bar (250 kPa) (36.3 2.5 bar (250 kPa) (36.3 R19 - 59V PSI)
  • Page 15 STELVIO 4V - 1200 Characteristics Name Torque in Nm Timing sensor - TCEI M5x12 (2) 6 Nm (4.42 lb ft) Service shaft bearing locking screw (2) 10 Nm (7.38 lb ft) Oil pressure sensor (1) 25 Nm (18.44 lb ft) Screw fixing oil pressure sensor support - TCEI M10x20 (1) 18 Nm (13.28 lb ft) Oil cap (2)

  • Page 16: Side Stand

    STELVIO 4V - 1200 Characteristics Name Torque in Nm Gearbox to crankcase fixing nut - M8 (5) 20 Nm (14.75 lb ft) TE flanged screw fixing gearbox to crankcase - M8x45 (1) 20 Nm (14.75 lb ft) Oil cap M18x1.5 (1) 28 Nm (20.65 lb ft) Breather cap (1) 8 Nm (5.9 lb ft)

  • Page 17: Swing Arm

    STELVIO 4V - 1200 Characteristics Name Torque in Nm Stand plate to engine lower retainer 25 Nm Side stand retainer pin 10 Nm Switch fixing screw - M6x20 (1) 10 Nm (7.38 lbf ft) - Loct 243 Lock nut 30 Nm Stand cable guide to engine retainer M8 (1) 25 Nm (18.44 lbf ft) Side lever arm retainer - M6x16 (2)
  • Page 18 STELVIO 4V - 1200 Characteristics REAR BRAKING SYSTEM Name Torque in Nm Rear brake calliper retainer 50 Nm Rear brake fluid reservoir retainer 3 Nm Rear brake fluid reservoir support to plate retainer 10 Nm Rear brake rod lock nut manual Brake pump retainer - M6x20 (2) 10 Nm (7.38 lbf ft) - Loctite 243...
  • Page 19 STELVIO 4V - 1200 Characteristics REAR BODYWORK Name Torque in Nm Left - right fairings retainer - M6 (3+3) 10 Nm (7.38 lbf ft) Retroreflector to support retainer 4 Nm Retroreflector support to license plate holder retainer 4 Nm License plate holder and light reinforcing retainer - M5 (1) 4 Nm (2.95 lbf ft) Cases support retainer - M6 (2) 10 Nm (7.38 lbf ft)
  • Page 20 STELVIO 4V - 1200 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) Piston rings On each piston there are:...
  • Page 21 STELVIO 4V - 1200 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 22 STELVIO 4V - 1200 Characteristics • Repeat the same operations to determine the thickness of the left cylinder gasket between cylinder and head also for the right cylinder. CYLINDER GASKET THICKNESS - HEAD Specification Desc./Quantity Value (X) -0.56 / -0.37 mm (-0.022 / -0.0146 in) gasket thickness: 0.65 mm (0.0256 in) Value (X) -0.37 / -0.19 mm (-0.0146 / -0.0075 in) gasket thickness: 0.85 mm (0.0335 in)
  • Page 23 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 24 STELVIO 4V - 1200 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 Wrench for removing the cover on sump and filter...

  • Page 25: Special Tools

    STELVIO 4V - 1200 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 AP9100838 Tool for valve pressure plate 14.92.71.00...
  • Page 26 STELVIO 4V - 1200 Special tools Stores code Description 12.91.20.00 Tool to fit the flywheel-side flange togeth- er with seal ring on the crankshaft 19.92.71.00 Tool to fit the seal ring on the flywheel- side flange 020673Y Graduated dial hub 020672Y Clutch spring centre and pusher 020674Y...
  • Page 27 STELVIO 4V - 1200 Special tools Stores code Description 020678Y Tool for clutch rod checking 020953Y Cam shaft lock for fixing 020954Y Centring cam shaft cup spring 05.91.25.30 Gearbox opening CHASSIS Stores code Description AP8140190 Tool for steering tightening GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body S-TOOLS - 27...
  • Page 28 STELVIO 4V - 1200 Special tools BEVEL GEAR SET Stores code Description 05.90.27.30 Gearbox support 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 S-TOOLS - 28...
  • Page 29 STELVIO 4V - 1200 Special tools FRONT FORK Stores code Description AP8140146 Weight AP8140149 Protection for fitting operations 9100903 Marzocchi fork oil seal; ø 45 mm (1.77 in) S-TOOLS - 29...
  • Page 30 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 31: Scheduled Maintenance Table

    STELVIO 4V - 1200 Maintenance Scheduled maintenance table 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. NOTE THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED TO MANAGEMENT ACTIVITIES.

  • Page 32: Transmission Fluid

    STELVIO 4V - 1200 Maintenance 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 33: Engine Oil

    STELVIO 4V - 1200 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 OIL AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL.
  • Page 34 STELVIO 4V - 1200 Maintenance It is necessary to remove the oil sump guard in or- der to change the engine oil and replace the oil filter. • Operating from both sides, undo and remove the two front screws (1). •...

  • Page 35: Engine Oil Filter

    STELVIO 4V - 1200 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 36: Air Filter

    STELVIO 4V - 1200 Maintenance Replacement NOTE HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY. • Place a container with suitable capaci- ty under the drainage plug (2). • Unscrew and remove the drainage plug (2). •...

  • Page 37: Checking The Valve Clearance

    STELVIO 4V - 1200 Maintenance • Lift the filter housing cover. • Remove the air filter. • Plug the intake duct with a clean cloth to prevent any foreign objects from entering the intake manifold. DO NOT START THE ENGINE WITHOUT THE AIR FILTER. TO CLEAN THE FILTERING ELEMENT, USE A PRESSURE AIR JET FROM THE INSIDE TO THE OUTSIDE.

  • Page 38: Braking System

    STELVIO 4V - 1200 Maintenance • Loosen the nut (1). • Use a screwdriver to act on set screw (2) until the following clearances are obtained: Characteristic Values valid with control clearance between rockers and valve intake: 0.10 mm (0.0039 in) exhaust: 0.20 mm (0.0079 in) •...
  • Page 39 CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE TRAVEL OF THE BRAKE LEVER OR POOR PERFORM- ANCE OF THE BRAKING SYSTEM, TAKE YOUR VEHICLE TO AN Official Moto Guzzi Dealer, AS IT MAY BE NECES- SARY TO PURGE THE AIR IN THE SYSTEM. MAIN - 39...
  • Page 40 STELVIO 4V - 1200 Maintenance MAIN - 40...
  • Page 41 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 42 STELVIO 4V - 1200 Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector ELE SYS - 42...
  • Page 43 STELVIO 4V - 1200 Electrical system 5 Throttle valve potentiometer 6 Fall sensor 7 Rear light 8 Main fuses 9 Lambda probe 10 Battery 11 Starter motor 12 Intake air temperature sensor 13 Engine revolution sensor 14 Head temperature sensor 15 Engine control unit 16 Instrument panel air temperature sensor 17 Front headlamp...
  • Page 44 STELVIO 4V - 1200 Electrical system The wiring distribution is subdivided in three es- sential sections, as indicated in the figure. 1. Front section 2. Central section 3. Rear section Front side TABLE A 1 - Check that the ground terminals are placed on the coils TABLE B 2 - Clamps.
  • Page 45 STELVIO 4V - 1200 Electrical system TABLE D 9 - Clamp. 10 - Horn. TABLE E 11 - Clamps. 12 - Pick-Up. 13 - Antitheft. TABLE F 14 - Left fog light. 15 - GPS Connector. TABLE G 16 - Rubber clamps. ELE SYS - 45...
  • Page 46 STELVIO 4V - 1200 Electrical system TABLE H 17 - Clamps. 18 - Instrument panel air temperature thermistor. TABLE I 19 - Clamp not completely pulled. 20 - Left light switch cable harness. 21 - Key switch cable harness. 22 - Clutch switch cable harness. TABLE J 23 - Clamps.
  • Page 47 STELVIO 4V - 1200 Electrical system Central part TABLE K 25 - Main cable harness. TABLE L Main cable harness passage with output: left coil, horn, pick up, antitheft, control unit, left turn indi- cator, GPS connector and compartment lock. TABLE M Main cable harness passage with output: right coil, key, right light switch, instrument panel, secondary...
  • Page 48 STELVIO 4V - 1200 Electrical system TABLE N 26 - Clamp. 27 - Heated hand grips connectors. TABLE O 28 - Clamps. TABLE P 29 - Injectors. TABLE Q 30 - Clamp. 31 - Fall sensor. 32 - Main cable harness. ELE SYS - 48...
  • Page 49 STELVIO 4V - 1200 Electrical system TABLE R 33 - Starter motor. 34 - Positive battery cable. Back side TABLE S 35 - Adhesive cable guides. TABLE T 36 - Adhesive cable guides. 37 - U-bolt. TABLE U 38 - Clamps. ELE SYS - 49...
  • Page 50 STELVIO 4V - 1200 Electrical system TABLE V 39 - Negative battery cable. TABLE W 40 - Black cable grommet. ELE SYS - 50...
  • Page 51 STELVIO 4V - 1200 Electrical system General wiring diagram Key: 1. Multiple connectors 2. Clutch switch 3. Start-up relay 4. Start-up maintenance relay ELE SYS - 51...
  • Page 52 STELVIO 4V - 1200 Electrical system 5. Light relay 6. Fog lights relay 7. Right light switch 8. Left light switch 9. Horn 10.Instrument panel air temperature thermistor 11.Instrument panel 12.Immobilizer aerial 13.Key switch 14.Heated handgrips 15.GPS coupling 16.Glove-box compartment electric lock 17.Rear right turn indicator 18.Rear light (LED) 19.Left rear turn indicator...
  • Page 53 STELVIO 4V - 1200 Electrical system 43.Left cylinder spark plug 44.Right cylinder coil 45.Left cylinder coil 46.Right cylinder injector 47.Left cylinder injector 48.Speed sensor 49.Fall sensor 50.Flywheel pick up 51.ECU 52.Fog lights 53.Front left turn indicator 54.(Double) Front headlight 55.Tail light bulb 56.Low-beam bulb 57.High-beam bulb 58.Front right turn indicator...
  • Page 54 STELVIO 4V - 1200 Electrical system 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 55 STELVIO 4V - 1200 Electrical system Lambda Probe Error ECU 21 Coil 1 Error DC V DC ECU 22 Coil 1 Error DC Gnd ECU 23 Coil 2 Error DC V DC ECU 24 Coil 2 Error DC Gnd ECU 25 Injector 1 Error DC V DC ECU 26 Injector 1 Error DC Gnd ECU 27 Injector 2 Error DC V DC ECU 30...
  • Page 56 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 57 STELVIO 4V - 1200 Electrical system Start-up system check pick-up input about 100 A level indicators Petrol pump: Input: 3.5 A (to be measured between pins 1 and 2 with 12V voltage) Fuel level sensor: Resistance (to be measured between pins 3 and 250-300 Ohm with fuel level equal to 0 litre 100 Ohm with fuel level equal to 11.25 litres (20.43 10-20 Ohm with fuel level equal to 22.5 litres...
  • Page 58 STELVIO 4V - 1200 Electrical system REAR LIGHT Specification Desc./Quantity Rear daylight running light/stop light License plate light 12V - 5 W Fuses AUXILIARY FUSES A - Stop, horn, coil, GPS, hazard button lighting, coils, light relay, passing (15 A). B - Tail lights, starter motor (15 A).

  • Page 59: Control Unit

    STELVIO 4V - 1200 Electrical system MAIN FUSES 1 - Battery recharge (40 A). 2 - Motion main fuse (30 A). NOTE THERE IS ONE SPARE FUSE. Control unit Model: Magneti Marelli IAW 5 AM2 Battery 12 V - 18 Ampere/hour ELE SYS - 59...

  • Page 60: Speed Sensor

    STELVIO 4V - 1200 Electrical system Speed sensor Function To indicate the vehicle speed by reading the rear wheel turning speed. Operation / Operating principle HALL effect sensor: a square-wave pulse is gen- erated with voltage between 12 V and 0.3-0.4V approx.
  • Page 61 STELVIO 4V - 1200 Electrical system • Check continuity to ground of PIN 3 of the sensor. • Check continuity of the grey/white cable harness from PIN 24 of the ECU BLUE connector. • Check PIN 24 of the BLUE connector. •...
  • Page 62 STELVIO 4V - 1200 Electrical system Parameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to keep the engine running at this revs, acting on the ignition advance. NAVIGATOR: STATUSES Synchronisation Example value:Synchronised / Not synchronised Indicates if the control unit detects the revolution sensor signal correctly DIAGNOSIS Engine revolution sensor...
  • Page 63 STELVIO 4V - 1200 Electrical system • PINS A-C: throttle closed approx. 2.5 kOhm; throttle open approx. 1.5 kOhm. • PINS A-B: approx. 1.1 kOhm Pin-out: • PIN A: ground connection • PIN B: supply voltage +5V • PIN C: potentiometer signal THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS;...
  • Page 64 STELVIO 4V - 1200 Electrical system resistance. If resistance is over 2.5 kOhm, it means the red cable is shorted to positive and the cable harness should be restored • shorted to negative: disconnect the sensor connector and check the ground insulation of the red cable (from throttle sensor connector or control unit connector): if there is continuity to ground, restore the cable harness;...
  • Page 65 STELVIO 4V - 1200 Electrical system Specification Desc./Quantity Resistance at +60 °C (140 °F) 0.750 kOhm Resistance at +70 °C (158 °F) 0.530 kOhm Resistance at +80 °C (176 °F) 0.380 kOhm Resistance at +90 °C (194 °F) 0.280 kOhm Resistance at +100 °C (212 °F) 0.204 kOhm Resistance at +110 °C (230 °F)
  • Page 66 STELVIO 4V - 1200 Electrical system • If shorted to negative, check sensor correct resistance: if resistance is null, replace the sen- sor; if resistance is correct, it means that the orange cable has ground connection: restore the cable harness. NOTES No error is detected if the sensor does not work correctly or the control unit connector or sensor terminals are rusty: then check through Navigator if the temperature indicated is the same as the engine temperature.
  • Page 67 STELVIO 4V - 1200 Electrical system air temperature sensor P0110 - open circuit, shorted to positive / shorted to negative. Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 14 of the BROWN connector.
  • Page 68 STELVIO 4V - 1200 Electrical system reach a high operating temperature: that is why there is a heating circuit inside. Level in electrical circuit diagram:Oxygen sen- Location: • sensor: exhaust pipe • Connector: near the probe Electrical characteristics: Heater circuit: 12 -14 Ω at 20 °C (68 °F) Pin-out: 1.
  • Page 69 STELVIO 4V - 1200 Electrical system • shorted to positive: with the key set to ON, disconnect the sensor connector and measure voltage at PIN 1 on the cable harness side (white/yellow cable): if there is voltage (5 or 12 V), restore the cable harness;...
  • Page 70 STELVIO 4V - 1200 Electrical system Location: • on the intake manifold • connector: on injector Electrical characteristics:14.8 Ohm +/- 5% (at 20 °C) Pin-out: "+": Supply: " ": Ground connection NAVIGATOR:FUEL INJECTION SYSTEM NAVIGATOR: PARAMETERS Injection time NAVIGATOR: ACTIVATION Left injector: operation for 4 ms, 5 times The auxiliary injection relay (No.
  • Page 71 STELVIO 4V - 1200 Electrical system between PIN 28 of the BROWN connector and the component PIN - and restore the cable harness. NAVIGATOR: ACTIVATION Right injector: Operation for 4 ms, 5 times The auxiliary injection relay (No. 37 in the electrical circuit diagram, placed on the front right side of the motorcycle, in the auxiliary fuses/relays box, first relay to the left starting from the front;...
  • Page 72 STELVIO 4V - 1200 Electrical system Coil Function It controls the ignition spark plug in order to gen- erate the fuel ignition spark. Operation / Operating principle Inductive discharge system Level in electrical circuit diagram:Coils and in- jectors Location: • In front of the fuel tank, left and right side •...
  • Page 73 STELVIO 4V - 1200 Electrical system • If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 38 of the BROWN connector Troubleshooting • If short circuit to positive: disconnect the coil connector, set the key to ON, activate the coil with Navigator and check voltage at connector PIN 2: if there is voltage, restore the cable harness;...
  • Page 74 STELVIO 4V - 1200 Electrical system check the cable ground insulation (from coil connector or control unit connector). If this is not OK, restore the cable harness. Engine oil pressure sensor Function:Indicates the instrument panel if there is enough oil pressure (0.35 +/- 0.15 bar) (5.1 +/- 2.18 PSI) in the engine.
  • Page 75 STELVIO 4V - 1200 Electrical system It this error persists, use a pressure gauge to check the pressure of the oil in the engine circuit Neutral sensor Function it tells the gear position to the control unit: in neutral or in gear. Operation / Operating principle for gear in neutral, the circuit is closed to ground connection: then, via CAN, the control unit sends the signal to the instrument panel which turns on the neutral speed warning light.
  • Page 76 STELVIO 4V - 1200 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. Operation / Operating principle If the gear is engaged but the clutch is pulled, i.e.
  • Page 77 STELVIO 4V - 1200 Electrical system the sensor. If the circuit is open, it means that the brown/purple cable from PIN 1 of the sensor to PIN 33 of the BLUE connector is shorted to ground: restore the cable harness Side stand sensor Function It tells the side stand position to the control unit.

  • Page 78: Bank Angle Sensor

    STELVIO 4V - 1200 Electrical system Bank angle sensor Function it tells the vehicle position to the control unit. Operation / Operating principle When the sensor is inverted, the circuit is closed to ground: when the Marelli control unit detects this earthing, it disables the fuel pump circuit and the engine start-up circuit via the injection relay.
  • Page 79 STELVIO 4V - 1200 Electrical system Air temperature sensor - instrument panel Function It tells the ambient air temperature to the instru- ment panel. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in electrical circuit diagram:Temperature sensors Location: •...
  • Page 80 STELVIO 4V - 1200 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) Check the ground insulation of the sensor connector pink cable: if there is a connection, restore the cable harness;...
  • Page 81 STELVIO 4V - 1200 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 82 STELVIO 4V - 1200 Electrical system 25 Engine revolution sensor signal 26 Not used 27 Not used 28 Left cylinder injector control 29 Ignition potentiometer negative. 30 Not used 31 Not used 32 Ignition potentiometer power supply. 33 Not used 34 Revolution sensor anti-jamming cable 35 Engine revolution sensor signal 36 Not used...
  • Page 83 STELVIO 4V - 1200 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 Not used 32 Oxygen probe power supply 33 Clutch sensor signal 34 Not used...
  • Page 84 STELVIO 4V - 1200 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 23 REAR LEFT TURN INDICATOR ACTIVATION 24 AERIAL 1 25 LEFT HEATED HANDGRIPS ACTUATOR (OPT)
  • Page 85 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 86 STELVIO 4V - 1200 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 87 STELVIO 4V - 1200 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 88 STELVIO 4V - 1200 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 89 STELVIO 4V - 1200 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 - 89...
  • Page 90 STELVIO 4V - 1200 Engine from vehicle • Disconnect the engine oil pressure sensor connector. • Disconnect the revolution sensor con- nector. • Remove the fairing under the oil sump. • Support the vehicle with the engine service stand. • Undo and remove the screws fixing the centre stand plates.
  • Page 91 STELVIO 4V - 1200 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 92 STELVIO 4V - 1200 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 93 STELVIO 4V - 1200 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 94 STELVIO 4V - 1200 Engine from vehicle • Insert the oil breather pipe and fasten it with a new clamp. • Fit the gearbox oil breather pipe. • Fit the clutch control cylinder. • Tighten the three screws. • Connect the starter motor connectors. ENG VE - 94...
  • Page 95 STELVIO 4V - 1200 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 - 95...
  • Page 96 STELVIO 4V - 1200 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 - 96...
  • Page 97 STELVIO 4V - 1200 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 98 INDEX OF TOPICS NGINE...
  • Page 99 STELVIO 4V - 1200 Engine Gearbox Diagram key: 1. Ball bearing ENG - 99...
  • Page 100 STELVIO 4V - 1200 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.Roller cage 16.Gear 17.Seal ring 18.Ball bearing 19.Gear 20.Circlip 21.Clutch shaft 22.Ball bearing 23.Oil plug...
  • Page 101 STELVIO 4V - 1200 Engine 40.Index lever 41.Spring 42.Ball bearing 43.Gear 44.Gear 45.Roller cage 46.Thrust washer 47.Circlip 48.Gear 49.Circlip 50.Gear 51.Primary shaft 52.Transmission gear 53.Fork (5th - 1st) 54.Fork shaft 55.Fork (3rd - 4th) 56.Fork (2nd - 4th) 57.Gear 58.Gear 59.Ball bearing 60.Transmission shaft 61.Gear...
  • Page 102 STELVIO 4V - 1200 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 103 STELVIO 4V - 1200 Engine • Undo and remove the two screws. • Unscrew and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts ENG - 103...
  • Page 104 STELVIO 4V - 1200 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 105 STELVIO 4V - 1200 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 106 STELVIO 4V - 1200 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. ENG - 106...
  • Page 107 STELVIO 4V - 1200 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. ENG - 107...
  • Page 108 STELVIO 4V - 1200 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 109 STELVIO 4V - 1200 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. ENG - 109...
  • Page 110 STELVIO 4V - 1200 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 111 STELVIO 4V - 1200 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 112 STELVIO 4V - 1200 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 113 STELVIO 4V - 1200 Engine • Remove the circlip, the shoulder wash- er and remove the gear of the first gear, collect the ball bearing cage. • Remove the bearing if necessary. See also Disassembling the gearbox Checking the primary shaft Measure coaxiality of the main shaft with a dial gauge and a centring device and replace it if not complying with specifications.
  • Page 114 STELVIO 4V - 1200 Engine Checking the desmodromic drum Check gear drum for damage, scratches and wear and replace the desmodromic control rod if nec- essary. Check the desmodromic segment «3» for damage and wear and replace it if necessary. Check the desmodromic bearing «4»...
  • Page 115 STELVIO 4V - 1200 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 secondary shaft Assembling the gearbox NOTE...
  • Page 116 STELVIO 4V - 1200 Engine Disassembling the gearbox 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 - 116...

  • Page 117: Removing The Generator

    STELVIO 4V - 1200 Engine Removing the generator • Remove the fuel tank. • Remove the control unit from its seat. • Disconnect the alternator connectors. • Undo and remove the five screws and collect the bushings. • Remove the cover. •...
  • Page 118 STELVIO 4V - 1200 Engine • 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. • Using a compressed air gun, unscrew and remove the nut and collect the spacer.
  • Page 119 STELVIO 4V - 1200 Engine • Unscrew and remove the eight screws. • Undo and remove the two screws. • Undo and remove the two screws. ENG - 119...
  • Page 120 STELVIO 4V - 1200 Engine • Remove the alternator frame. • Remove the sealing ring if necessary. See also Fuel tank Tensioning the belt • Operating from both sides, undo and remove the screw fixing the oil radiator to the chassis. •...
  • Page 121 STELVIO 4V - 1200 Engine • Undo and remove the five screws fixing the alternator belt cover. • Remove the oil radiator lower support bracket and the alternator belt cover. Locking torques (N*m) Alternator belt cover screw (radiator bracket retainer) TCEI M6x40 (2) Alterna- 10 Nm (7.38 lb ft) tor belt cover screw - TCEI M6x16 (4)

  • Page 122: Installing The Generator

    STELVIO 4V - 1200 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 123 STELVIO 4V - 1200 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 124 STELVIO 4V - 1200 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 125: Starter Motor

    STELVIO 4V - 1200 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 126 STELVIO 4V - 1200 Engine • Slide off the starter motor. Clutch side Disassembling the clutch • Remove the complete gearbox. • Unscrew and remove the six screws. • Remove the start-up crown gear. • Remove the clutch housing and the friction disc.
  • Page 127 STELVIO 4V - 1200 Engine • Remove the retainer ring. • Remove the clutch pressure cap. • Undo and remove the six screws and collect the Belleville springs. • Remove the clutch plate. See also Removing the gearbox ENG - 127...
  • Page 128 STELVIO 4V - 1200 Engine key: 1. Complete clutch 2. Clutch 3. Clutch bell 4. TCEI screw 5. Clutch plate 6. Sprocket 7. TCEI screw 8. Clutch thrust plate 9. Ring 10.TE flanged screw 11.Conical washer 12.Bushing 13.Rod 14.Bushing 15.Intermediate body 16.Thrust bearing 17.Clutch control bowl 18.Thrust cylinder...
  • Page 129 STELVIO 4V - 1200 Engine Checking the clutch actuator If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod. Measure as follows: • Fit the new clutch on the crankshaft. •...
  • Page 130 STELVIO 4V - 1200 Engine • Place the clutch pressure plate. • Fit the tool to centre and compress the plate. • Fully tighten the two centring tool screws. Specific tooling 020672Y Clutch spring centre and pusher • Once the centring tool is fitted, lock the plate with the snap ring.
  • Page 131 STELVIO 4V - 1200 Engine • Place the clutch bell with the reference facing upwards. • Place the start-up crown gear with the reference facing upwards. • Tighten the six screws to the prescri- bed torque operating diagonally and in stages.
  • Page 132 STELVIO 4V - 1200 Engine 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 11.Nut 12.Rocking lever rod 13.Tappet bowl 14.Flanged screw...
  • Page 133 STELVIO 4V - 1200 Engine 40.Rocking lever rod 41.Tappet bowl 42.Flanged screw 43.Spacer 44.Camshaft 45.Pin 46.Timing system gear 47.Breather plate 48.TE flanged screw 49.O-ring 50.Complete breather cover 51.TBEI screw 52.Timing system chain 53.Chain guide slider 54.Chain tensioner pad 55.Chain tensioner screw 56.Left chain tensioner 57.Spacer Removing the head cover...

  • Page 134: Removing The Cylinder Head

    STELVIO 4V - 1200 Engine • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings. • Remove the head cover together with the gasket. Removing the cylinder head CAUTION WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CARE- FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
  • Page 135 STELVIO 4V - 1200 Engine For the left head: • Unscrew and remove the screw and the washer. • Relief oil pressure from the left chain tensioner. • Slide off the timing system gear from the chain to remove it from the cam- shaft.

  • Page 136: Cylinder Head

    STELVIO 4V - 1200 Engine • Unscrew and remove the two screws. • Remove the head. • 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.
  • Page 137 STELVIO 4V - 1200 Engine • Remove the two rocking levers from the cam cap. • Remove the two rods. • Unscrew 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 138: Removing The Valves

    STELVIO 4V - 1200 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. Removing the valves • Remove the head. •...

  • Page 139: Checking The Cylinder Head

    STELVIO 4V - 1200 Engine • Remove the lower cap (5) and the valve guide oil seal (4), if necessary. • Remove the valve (6) from inside the head. Checking the valve guides Use a punch to extract the valve guides from the heads. The valve guides should be replaced only if the clearance between them and the stem cannot be elim- inated by simply replacing the valves.

  • Page 140: Installing The Valves

    STELVIO 4V - 1200 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. - Replace the head in case of excessive wear or damage.
  • Page 141 STELVIO 4V - 1200 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 142 STELVIO 4V - 1200 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. Installing the overhead camshaft •...
  • Page 143 STELVIO 4V - 1200 Engine Removing the phonic wheel • Remove the generator and the timing system cover. • Unscrew and remove the nut and col- lect the washer. • Remove the timing system gear on the service shaft. • Remove the timing sensor and any shim washers.
  • Page 144 STELVIO 4V - 1200 Engine • Mark the timing chains so as not to in- vert the direction of rotation upon fit- ting. • Slide off the service shaft from the chains. • Remove both chains. See also Removing the phonic wheel Installing the service shaft •...
  • Page 145 STELVIO 4V - 1200 Engine • Partially fit the service shaft closing cap. • To screw the cap until it stops, use two M6 flanged screws larger than the orig- inal screws. • Tighten the two M6 flanged screws op- erating in stages until the cap stops against the crankcase.
  • Page 146 STELVIO 4V - 1200 Engine Installing the service shaft Cam timing • Fit the crankshaft and the service shaft on the crankcase. • Fit the cylinders. • Turn the crankshaft until the left cylin- der piston reaches the top dead centre (TDC).
  • Page 147 STELVIO 4V - 1200 Engine • Fit the timing system gear and align the reference with that on the crankshaft gear. Turn the crankshaft to align the two gears. • After shimming the timing sensor prop- erly, proceed to fit it. •...
  • Page 148 STELVIO 4V - 1200 Engine • Place the driving pin on the oil pump shaft. • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. •...
  • Page 149 STELVIO 4V - 1200 Engine • Tighten the screw with the washer to the prescribed torque. See also Installing the crankshaft Installing the service shaft Measuring air gap Measuring air gap • Undo and remove the two screws and remove the sensor. •...
  • Page 150 STELVIO 4V - 1200 Engine • Place the sensor on the crankcase and move it until it makes contact with the tone wheel. • Measure the clearance between the fixing plate and the crankcase with a thickness gauge. Subtract the plain washer value from this measurement to obtain the clearance between the sensor and the tone wheel.
  • Page 151 STELVIO 4V - 1200 Engine 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 13.Left cylinder 14.Washer 15.Chain tensioner cap 16.Washer 17.Left chain tensioner 18.Right chain tensioner Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY...
  • Page 152 STELVIO 4V - 1200 Engine Disassembling the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS. • Remove the cylinder. • Cover the crankcase opening with a clean cloth. • Release the snap ring. •...
  • Page 153 STELVIO 4V - 1200 Engine • Lock crankshaft rotation. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear • Fit the piston. NOTE CHECK THE ORIENTATION OF THE PISTON ACCORDING TO THE REFERENCES AT THE TOP. DO NOT ASSEMBLE PISTONS AND CYLINDERS OF DIFFERENT SELECTOR TYPES.
  • Page 154 STELVIO 4V - 1200 Engine Installing the cylinder RIGHT CYLINDER • Fit the piston. • Remove the cloth used to prevent for- eign bodies from getting into the crank- case. • Turn the rings so that the coupling ends are 120 degrees from each other. •...
  • Page 155 STELVIO 4V - 1200 Engine • Fit the movable chain slider. • Fit the upper gear. • Fit the chain tensioner and the chain tensioner cap temporarily and keep the chain taut on the service shaft. LEFT CYLINDER • Fit the piston. •...

  • Page 156: Installing The Cylinder Head

    STELVIO 4V - 1200 Engine DURING THIS OPERATION, PAY ATTENTION NOT TO DAMAGE THE PISTON. Specific tooling 020674Y Piston ring clamp 020716Y Connecting rod locking • Fit the movable chain slider. • Fit the upper gear. • Fit the chain tensioner cap temporarily and keep the chain taut on the service shaft.
  • Page 157 STELVIO 4V - 1200 Engine • Fit a new O-ring in the spark plug hole. • Fit the complete cam cap. • Fix the cam cap with the four nuts on the stud bolts. • Fix the head with the two screws. •...
  • Page 158 STELVIO 4V - 1200 Engine • Screw two screws in the threaded holes of the timing system upper gear. • Rotate the camshaft so that its pin is aimed towards the hole in the timing system chain. • Place the gear in the chain. •...
  • Page 159 STELVIO 4V - 1200 Engine • Screw two screws in the threaded holes of the timing system upper gear. • Rotate the camshaft so that its pin is aimed towards the hole in the timing system chain. • Place the gear in the chain. •...
  • Page 160 STELVIO 4V - 1200 Engine Installing the head cover • Replace the gasket and install the head cover. • Place the plastic half-cover. • Replace the four rubber rings. • Tighten the four screws to the prescri- bed torque. • Place the spark plug tube.
  • Page 161 STELVIO 4V - 1200 Engine Removing the crankshaft • Remove the clutch. • Remove the tone wheel and the oil pump gear. • Working from the generator side, un- screw and remove the nut. • Remove both gears. • Remove the connecting rods. •...
  • Page 162 STELVIO 4V - 1200 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 163 STELVIO 4V - 1200 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 164 STELVIO 4V - 1200 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 165 STELVIO 4V - 1200 Engine The connecting rods have a marked area for weight selection. The weight indicated in the chart includes screws, dowels and the bushing. CONNECTING ROD WEIGHT SELECTION Specification Desc./Quantity Connecting rod - brown 0.588 - 0.598 mm (0.02074 - 0.02109 in) Connecting rod - green 0.598 - 0.608 mm (0.02109 - 0.02145 in) Connecting rod - black...
  • Page 166 STELVIO 4V - 1200 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 167 STELVIO 4V - 1200 Engine • Place the flywheel-side flange on the crankshaft and check if the dowel pin with the O-ring is correctly placed. • Screw the eight flange screws on the flywheel side proceeding diagonally. • Remove the sealing ring centring tool from the crankshaft. Specific tooling 12.91.20.00 Tool to fit the flywheel-side flange together with seal ring on the crankshaft •...
  • Page 168 STELVIO 4V - 1200 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 169 STELVIO 4V - 1200 Engine 1. Oil 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. Rotor control shaft 9.
  • Page 170 STELVIO 4V - 1200 Engine • Remove the nipple - oil pump fitting. • Bring the left cylinder piston to the TDC in combustion phase. • Mark a reference on the oil pump con- trol gear and another on the driven gear so as to place them correctly again upon refitting.
  • Page 171 STELVIO 4V - 1200 Engine • Unscrew and remove the three screws. • Remove the oil pump. • 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.
  • Page 172 STELVIO 4V - 1200 Engine • Place the driving pin on the oil pump shaft. • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. •...
  • Page 173 STELVIO 4V - 1200 Engine • Insert the joint in the oil pump. • Fit the nipple with the gasket on the crankcase. • Tighten the nipple to the prescribed torque. Oil sump RANKCASE AND pos. Description Type Quantity Torque Notes Stud bolt M8x75...
  • Page 174 STELVIO 4V - 1200 Engine pos. Description Type Quantity Torque Notes Oil cap on the crankcase 25 Nm (18.44 lb ft) Flange fixing screw under the crankcase M6x60 10 Nm (7.37 lb ft) Flange fixing screw under the crankcase 10 Nm (7.37 lb ft) Oil sump fixing screw (filter contour) M6x35 10 Nm (7.37 lb ft)
  • Page 175 STELVIO 4V - 1200 Engine • Place the thermostatic valve. CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED. • Tighten the thermostatic valve plug. • Place a new gasket between the crank- case and the flange. ENG - 175...
  • Page 176 STELVIO 4V - 1200 Engine • Insert the flange • Fix the flange with the four screws. • Insert the lubrication oil intake filter • Check that on the oil pump are the OR rings. • Insert the cooling oil intake filter. •...
  • Page 177 STELVIO 4V - 1200 Engine • Fit a new oil filter by tightening it to the prescribed torque. • Place a new gasket between the flange and the sump. • Place the oil sump. • Tighten the fourteen screws to the pre- scribed torque.
  • Page 178 STELVIO 4V - 1200 Engine • Unscrew and remove the oil level plug and collect the O-Ring. • Undo and remove the fourteen screws fixing the oil sump to the engine crank- case. • Unscrew and remove the four screws. •...
  • Page 179 STELVIO 4V - 1200 Engine • Unscrew and remove the two screws. • Remove both side filters.. • Unscrew and remove the cap. • Remove the thermostatic valve. ENG - 179...
  • Page 180 STELVIO 4V - 1200 Engine • Unscrew and remove the overpressure valve plug. • Remove the overpressure valve ele- ments ENG - 180...
  • Page 181 INDEX OF TOPICS P SUPP OWER SUPPLY...
  • Page 182 STELVIO 4V - 1200 Power supply Circuit diagram Key: 1. Complete fuel pump unit 2. Nut 3. Fuel pipe 4. Pipe 5. Screw Injection P SUPP - 182...
  • Page 183 STELVIO 4V - 1200 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 184 STELVIO 4V - 1200 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. The shortest part of the fuel pipe connected to the throttle bodies should be placed on the right.
  • Page 185 STELVIO 4V - 1200 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 186: Injection System

    STELVIO 4V - 1200 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 187 STELVIO 4V - 1200 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 This screen page shows the parameters meas- ured by the several sensors (engine revs, engine temperature, etc.) or values set by the control unit...
  • Page 188 STELVIO 4V - 1200 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 Stepper motor Stepper base 70 - 100 (approximate values)
  • Page 189 STELVIO 4V - 1200 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 Left injector...
  • Page 190 STELVIO 4V - 1200 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. If both injectors do not work, the engine does not work Right injector Possible short circuit in the earth lead, battery or open circuit.
  • Page 191 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 192: Removing The Front Wheel

    STELVIO 4V - 1200 Suspensions Front Removing the front wheel • Working from both sides, undo and re- move the two fixing screws from the front brake callipers and remove them from their seats. • Hold the vehicle front part. •...

  • Page 193: Front Fork

    STELVIO 4V - 1200 Suspensions • Remove the wheel axle by inserting a screwdriver in the holes on the pin. • During extraction, support the wheel and then remove it. • Collect the spacer from the front wheel right side. Front fork Diagram Key:...
  • Page 194 STELVIO 4V - 1200 Suspensions 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 11.Fork upper plate 12.TCE screw 13.Base with headstock...

  • Page 195: Removing The Fork Legs

    STELVIO 4V - 1200 Suspensions Adjustment The front suspension consists of a hydraulic fork connected to the headstock by means of two plates. For adjusting the suspension set up, each stan- chion has an upper nut (1), for adjusting spring preloading, and an upper set screw (2): •...
  • Page 196 STELVIO 4V - 1200 Suspensions • Secure the rear part of the vehicle through belts in order to lift the front wheel. • Remove the mudguard. • Remove the front wheel. • Support the stanchion and loosen the screws on the upper and then the lower plate.
  • Page 197 STELVIO 4V - 1200 Suspensions • Unscrew the sleeve top cap. • Push the bushing down in order to compress the spring and then fit a tool under the pumping member lock nut and on the bushing to keep the spring compressed.
  • Page 198 STELVIO 4V - 1200 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; - lower spring guide;...
  • Page 199 STELVIO 4V - 1200 Suspensions Disassembling the fork • Drain all the oil from the stem. • Tighten the wheel holder sleeve in a vice. • Undo the bottom screw and remove it with the corresponding gasket. • Remove the pumping member pin. SUSP - 199...
  • Page 200 STELVIO 4V - 1200 Suspensions • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • During this operation, pay attention not to damage the sleeve rim. • Remove the retainer ring. • Take out the sleeve from the stem us- ing the stem as a hammer puller.
  • Page 201 STELVIO 4V - 1200 Suspensions • Remove the ring and the dust guard. See also Draining oil Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem.
  • Page 202 STELVIO 4V - 1200 Suspensions Bending limit: 0.2 mm (0.00787 in) Sleeve Check that there are no damages and/or cracks; otherwise, replace it. Spring Check the spring is in good conditions. Check that the following components are in good conditions: •...
  • Page 203 STELVIO 4V - 1200 Suspensions • dust gaiter; • 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 204 STELVIO 4V - 1200 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 - 204...
  • Page 205 STELVIO 4V - 1200 Suspensions • Get the special tool code 8140758. • Cut the tool along the longitudinal axle so as to obtain two similar half-shells to be used on forks with inverted stems. • Fit the sleeve on the stem and with the specified tool fit the oil seal into posi- tion.
  • Page 206 STELVIO 4V - 1200 Suspensions • Fit the dust guard with the specific tool. Specific tooling AP8140758 tool to fit oil seals and dust gaiter for ø 50 mm (1.97 in) stems AP8140146 Weight • Insert the pumping member in the sleeve.
  • Page 207 STELVIO 4V - 1200 Suspensions • Measure the air gap between the oil level and the rim. THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STANCHIONS. Specific tooling AP8140149 Protection for fitting operations Characteristic...
  • Page 208 STELVIO 4V - 1200 Suspensions • Fit the bushing. • Finger tight the upper cap on the pumping member stem. • Screw the upper cap on the pumping member pin. • Place the sleeve in the vice using the specified tool. •...

  • Page 209: Installing The Fork Legs

    STELVIO 4V - 1200 Suspensions • Once the operations are completed, restore the spring preloading correct value. Installing the fork legs • Insert the fork stem in position. • Insert the wheel pin so that the stems are aligned. • Tighten the screws on the fork plates to the prescribed torque.
  • Page 210 STELVIO 4V - 1200 Suspensions Steering bearing Adjusting play • Unscrew and remove the U-bolt four fixing screws. • Remove the U-bolt. • Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out. •...
  • Page 211 STELVIO 4V - 1200 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 212: Removing The Rear Wheel

    STELVIO 4V - 1200 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 213: Shock Absorbers

    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 214 STELVIO 4V - 1200 Suspensions Specification Desc./Quantity Rebound - half -load conditions 20 clicks starting from screw (1) fully tightened Rebound - maximum load conditions 18 clicks starting from screw (1) fully tightened (1) THE SETTING SHOWN IN THE TABLE MAY NEED TO BE MODIFIED ACCORDING TO THE TYRE AND ROAD TYPE.
  • Page 215 INDEX OF TOPICS CHAS HASSIS...
  • Page 216 STELVIO 4V - 1200 Chassis Swinging arm Removing • To remove the fork, first remove the footrest holding plate and the exhaust silencer. • Slide off the rear brake calliper from the disc and release the brake pipe. • Engage the first gear. •...
  • Page 217 STELVIO 4V - 1200 Chassis • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. • Fix the reaction rod to the chassis with a clamp. • Remove the clamp from the dust guard cap. • Loosen the two swingarm terminal screws.
  • Page 218 STELVIO 4V - 1200 Chassis • Loosen the ring nut. Specific tooling GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body • Helped by a second operator, remove the pin and remove the swingarm to- gether with the cardan shaft. Checking •...
  • Page 219 STELVIO 4V - 1200 Chassis Installing • Spread a thin layer of lubricating grease all along the swingarm pin. • Fit the ring nut in the swingarm pin and screw it manually. • Working from both sides, grease the cardan shaft cables with the recom- mended product from the recommen- ded products table.
  • Page 220 STELVIO 4V - 1200 Chassis • Fit the dust guard cap in the gearbox. • Lock the dust guard cap with a new clamp. • Place the reaction rod into its seat. • Insert the screw. • Screw the nut fixing the reaction rod. •...
  • Page 221 STELVIO 4V - 1200 Chassis Bevel gears Removing • Remove the rear wheel. • Unscrew and remove the two screws. • Remove the speed sensor from the fork. • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. •...
  • Page 222 STELVIO 4V - 1200 Chassis • Remove the transmission casing slid- ing off the universal joint. Checking Smontaggio gruppo scatola Casing unit removal Remove the cover (20). Remove the plug (3) to drain out the oil. CHAS - 222...
  • Page 223 STELVIO 4V - 1200 Chassis Lift the cap (10). Remove the clamps (9) and (11). Remove the cap (14). Remove the screws (16). Collect the ring (15). CHAS - 223...
  • Page 224 STELVIO 4V - 1200 Chassis Remove the screws (7). Remove the casing (4). Remove the clamp (12). Remove the cap (14). Collect the ring (13). CHAS - 224...
  • Page 225 STELVIO 4V - 1200 Chassis Remove the support unit (8). Montaggio gruppo scatola 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.
  • Page 226 STELVIO 4V - 1200 Chassis Insert the support group in the casing. Assemble the cap and the ring. Fit the cap on the support. Fit the clamp. Screw the clamp with the specific pliers. CHAS - 226...
  • Page 227 STELVIO 4V - 1200 Chassis Apply the prescribed sealant to the casing. Fit a new sealing ring using the buffer. Lubricate the sealing ring. Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture.
  • Page 228 STELVIO 4V - 1200 Chassis Assemble the fixing screws (7). Tighten the screws (7) to the prescribed torque. Remove excessive sealant. Assemble the ring to the casing. Tighten the fixing screws to the prescribed torque. Fit the cap with the washer. Screw the cap to the prescribed torque.
  • Page 229 STELVIO 4V - 1200 Chassis Fit the breather with the washer. Screw the breather to the prescribed torque. Fill the transmission with the prescribed oil. Fit the cap with the washer. Screw the cap to the prescribed torque. Assemble the cap with the clamps. Fit the cap in its seat.
  • Page 230 STELVIO 4V - 1200 Chassis Gruppo asse ruota Removal Remove the bearing from the wheel axle with a suitable extractor. Turn the unit over. Remove the bearing from the wheel axle with a suitable extractor. FITTING Heat the bearings to 100°C (212 °F). Assemble the bearings to the wheel axle.
  • Page 231 STELVIO 4V - 1200 Chassis Turn the unit over. Assemble the bearings to the wheel axle. Gruppo pignone 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 232 STELVIO 4V - 1200 Chassis Assemble the sealing ring (3) to the ring nut (2) with the buffer CA715855 (see Fig.1) and a ham- mer. Lubricate the sealing ring (3). Assemble the ring nut (2). Tighten the ring nut (2) with the special spanner (s4) to the prescribe torque.
  • Page 233 STELVIO 4V - 1200 Chassis Insert the stop ring (1) in the ring nut (2) in the in- dicated direction. Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT. Gruppo supporto CHAS - 233...
  • Page 234 STELVIO 4V - 1200 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 235 STELVIO 4V - 1200 Chassis Remove the ball joint (4) with a suitable buffer and a rubber hammer. FITTING Fit the stop ring (6) in the support (5) with suitable pliers. Turn the support (5) over. Assemble the ball joint (4) with the buffer and a rubber hammer.

  • Page 236: Troubleshooting

    STELVIO 4V - 1200 Chassis Manually assemble the new sealing rings (2) and (7). Assemble the bushing (1). Drive the bushing (1) in with a plastic hammer. Turn the support (5) over and assemble the other bushing (8). TROUBLESHOOTING Possible Cause Operation 1.
  • Page 237 STELVIO 4V - 1200 Chassis Installing • Insert the transmission casing on the swingarm making sure that the univer- sal joint engages correctly. • Tighten the four screws to the prescri- bed torque operating diagonally. • Place the reaction rod into its seat. •...
  • Page 238 STELVIO 4V - 1200 Chassis • Place the speed sensor and fasten the cable harness with the clamps. • Place the rear wheel on the fork. • Tighten the four screws with their spacers and the dust-protection ring. • Place the rear brake calliper on the disc and the brake pipe on the fork.
  • Page 239 STELVIO 4V - 1200 Chassis 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 15.Silencer 16.TCEI screw 17.Silencer fixing bushing 18.Muffler rubber ring 19.Spacer 20.Washer 21.Nut...
  • Page 240 STELVIO 4V - 1200 Chassis • Remove the exhaust end. Removing the manifold - tail pipe • Remove the exhaust end and the ex- haust manifolds. • Remove the starter motor protection in order to disconnect the lambda probe connector. •...
  • Page 241 STELVIO 4V - 1200 Chassis • Unscrew and remove the two nuts on the head exhaust stud bolts. • Retrieve the washers. • Loosen the clamp. • Remove the exhaust manifold. Engine oil cooler Key: 1. Complete oil radiator 2. TE flanged screw CHAS - 241...
  • Page 242 STELVIO 4V - 1200 Chassis 3. T-shaped bushing 4. Rubber ring 5. Radiator support 6. TCEI screw 7. Clip Removing It is necessary to remove the oil sump guard in or- der to change the engine oil and replace the oil filter.
  • Page 243 STELVIO 4V - 1200 Chassis • Undo and remove the two radiator up- per screws and collect the washer. • Remove the oil cooling radiator. Installing • Fit the oil cooling radiator on the vehi- cle following the operations described in the removal chapter but in reverse order.
  • Page 244 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 245 STELVIO 4V - 1200 Braking system Rear brake calliper Key: 1. Rear brake calliper 2. Screw 3. Pads 4. Pin + calliper split pin 5. Spring 6. Gasket 7. Screw 8. Air bleed 9. Air bleed cap 10.Rear brake pipe 11.Oil pipe screw BRAK SYS - 245...
  • Page 246 STELVIO 4V - 1200 Braking system Front brake calliper Key: 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 Front brake pads BRAK SYS - 246...
  • Page 247 STELVIO 4V - 1200 Braking system Removal • Undo and remove the two screws. • Slide off the brake calliper from the disc. • Turn the pins and remove both cotter pins. • Remove both pins. • Remove the vibration-damping plate. BRAK SYS - 247...
  • Page 248 STELVIO 4V - 1200 Braking system • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS. Installing •...

  • Page 249: Rear Brake Pads

    STELVIO 4V - 1200 Braking system Rear brake pads Removal • Undo and remove the two screws. • Remove the brake calliper from the disc. • Turn the pin and pull out the cotter pin. • Remove the cotter pin. •...
  • Page 250 STELVIO 4V - 1200 Braking system • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS. Installing •...
  • Page 251 STELVIO 4V - 1200 Braking system Bleeding the braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper. The presence of air is signalled by the "sponginess"...
  • Page 252 STELVIO 4V - 1200 Braking system • Repeat the procedure for both callip- ers. • Screw the bleeding valve and remove the pipe. • Top-up the reservoir until the correct brake fluid level is obtained. • Refit and block the front brake oil reservoir cap. •...
  • Page 253 STELVIO 4V - 1200 Braking system • Close the bleed again before reaching the lever end of the stroke and repeat the operation until there is no air. • Screw the bleeding valve and remove the pipe. • Top-up the reservoir until the correct brake fluid level is obtained. •...
  • Page 254 INDEX OF TOPICS BODYW ODYWORK...

  • Page 255: Instrument Panel

    STELVIO 4V - 1200 Bodywork Seat • Rest the vehicle on its stand. • Insert the key in the saddle lock. • Turn the key clockwise, pressing lightly in the middle of the rear passenger saddle seat to help pin release. •...
  • Page 256 STELVIO 4V - 1200 Bodywork Rider footrest plate LEFT SIDE • Undo and remove the upper screw and collect the washer and the nut. • Undo and remove the lower screw and collect the two washers and the spacer. • Undo and remove the lower screw and collect the washer and the spacer.
  • Page 257 STELVIO 4V - 1200 Bodywork RIGHT SIDE • Undo and remove the upper screw and collect the washer and the nut. • Undo and remove the front lower screw. • Undo and remove the three screws. • Remove the right under seat fairing. •...
  • Page 258 STELVIO 4V - 1200 Bodywork • Undo and remove the two rear lower screws; collect the washers and the spacer. • Unscrew and remove the screw. • Detach the rear brake fluid reservoir but keep it connected to the pipe. •...
  • Page 259 STELVIO 4V - 1200 Bodywork • Working from both sides, unscrew and remove the screw. • Working from both sides, unscrew and remove the screw. • Detach the fairing. • Disconnect the glove-box compart- ment opening cable. • Unscrew and remove the two front screws.
  • Page 260 STELVIO 4V - 1200 Bodywork • Operating from both sides, undo and remove the internal screw and collect the washer and the nut. • Unscrew and remove the two screws. • Unscrew and remove the four screws. • Remove the headlight lower cover. •...
  • Page 261 STELVIO 4V - 1200 Bodywork • Operating from both sides, disconnect the turn indicator connector. • Slightly detach the fairing. • Disconnect the front headlight connec- tors releasing the cable harness from the clamps. • Remove the fairing together with the front headlight.
  • Page 262 STELVIO 4V - 1200 Bodywork • Disconnect the air temperature sensor connector. • Slide off and remove the main fuse box from its holder. • Disconnect the rear light connectors • Release the clutch bleeding pipe from the cable guide. BODYW - 262...
  • Page 263 STELVIO 4V - 1200 Bodywork • Operating from both sides, undo and remove the three screws. • Remove the mudflap. • Release from its and remove the breather pipe placed on the right side of the filter casing. • Operating on both sides, loosen the clamp.
  • Page 264 STELVIO 4V - 1200 Bodywork • Operating from both sides, undo and remove the stud bolt. • Remove the filter casing. See also Seat Fuel tank FUEL TANK CAP REMOVAL • Open the fuel tank cap. • Cover the tank fill opening with a clean cloth so that no foreign bodies can come in.
  • Page 265 STELVIO 4V - 1200 Bodywork FUEL TANK UPPER FAIRING • Remove the fuel tank cap. • Undo and remove the four screws. • Remove the fuel tank cover. • Working from both sides, undo and re- move the screw. • Unscrew and remove the front screw fixing the tank.
  • Page 266 STELVIO 4V - 1200 Bodywork • Lift the rear part of the fuel tank fairing. • Disconnect the pipes. • Remove the fuel tank fairing. See also Seat FUEL TANK • Remove the tank side fairings. • Disconnect the glove-box opening control connector.
  • Page 267 STELVIO 4V - 1200 Bodywork • Lift the tank and disconnect the fuel pipe. • Disconnect the fuel pump connector. • Remove the fuel tank. See also Side fairings Adjustable windscreen • Remove the windscreen glass. • Working from both sides, undo and re- move the windscreen top set screw and remove the knob.
  • Page 268 STELVIO 4V - 1200 Bodywork • Working from both sides, remove the windscreen support from the bracket. • Remove the four bushings from the brackets If replacing the bushings remember to place them with the larger diameter inside the brackets. BODYW - 268...
  • Page 269 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 270 STELVIO 4V - 1200 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 front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...

  • Page 271: Road Test

    STELVIO 4V - 1200 Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
  • Page 272 STELVIO 4V - 1200 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 - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering...
  • Page 273 Air filter: 36 Air temperature sensor: 66, 79 Alternator: Battery: 56, 59 Brake: 245, 246, 249 Brake calliper: 245, 246 Brake pads: 246, 249 Clutch: 76, 126, 129, 162 Coil: 72 Connectors: 81 Crankcase: 20, 160, 168 Crankshaft: 20, 145, 149, 160, 161, 163, 166 Cylinder: 19, 134, 136, 139, 151, 154, 156, 162 Desmodromic drum: 114 Diagnostics: 186...
  • Page 274 Identification: 10 Instrument panel: 79, 255 Maintenance: 8, 31 Maintenance Table: Oil filter: 35 Oil pressure sensor: 74 Oil sump: 173, 174, 177 Primary shaft: 108, 113–115 Radiator: Rear light: Rear wheel: 212 Recommended products: 22, 220 Run/Stop switch: 80 Scheduled maintenance: 31 Secondary shaft: 110, 113, 115 Shock absorber:...

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