MOTO GUZZI STELVIO 4V - 1200 ABS Service Station Manual
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MOTO GUZZI STELVIO 4V - 1200 ABS Service Station Manual

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SERVICE STATION MANUAL
895790
STELVIO 4V - 1200 ABS

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  • Page 1 SERVICE STATION MANUAL 895790 STELVIO 4V - 1200 ABS...
  • Page 2 Not all versions shown in this publication are available in all countries. The availability of individual versions should be checked with the official Moto Guzzi sales network. © Copyright 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 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 4V - 1200 ABS 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 ABS Characteristics 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 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 4V - 1200 ABS 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);...
  • Page 12 STELVIO 4V - 1200 ABS 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 electric Idle speed 1100 ± 100 rpm Clutch hydraulic single plate dry clutch with integrated flexible coupling...
  • Page 13 STELVIO 4V - 1200 ABS Characteristics Specification Desc./Quantity Rear daylight running lights /stop light Supplementary headlamps (if fitted) 12 V/55W - H3 Instrument panel lighting License plate light 12V - 5 W Turn indicator warning light Neutral gear warning light...

  • Page 14: Wheels And Tyres

    STELVIO 4V - 1200 ABS 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...

  • Page 15: Oil Sump

    STELVIO 4V - 1200 ABS Characteristics Name Torque in Nm Timing sensor - TCEI M5x12 (2) 6 Nm (4.42 lbf ft) Service shaft bearing locking screw (2) 10 Nm (7.38 lbf ft) Oil pressure sensor (1) 25 Nm (18.44 lbf ft) Screw fixing oil pressure sensor support - TCEI M10x20 (1) 18 Nm (13.28 lbf ft)

  • Page 16: Side Stand

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

  • Page 17: Front Suspension

    STELVIO 4V - 1200 ABS 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...
  • Page 18 STELVIO 4V - 1200 ABS 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...
  • Page 19 STELVIO 4V - 1200 ABS 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)
  • Page 20 STELVIO 4V - 1200 ABS 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 21 STELVIO 4V - 1200 ABS 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. •...
  • Page 22 STELVIO 4V - 1200 ABS 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 23 INDEX OF TOPICS S-TOOLS PECIAL TOOLS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 24 STELVIO 4V - 1200 ABS Special tools MOTORE Stores code Description 020677Y Alternator belt tensioner, Belt tensioning lever 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 25 STELVIO 4V - 1200 ABS 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 26 STELVIO 4V - 1200 ABS 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 sealing ring on the flywheel- side flange 020673Y Graduated dial hub...
  • Page 27 STELVIO 4V - 1200 ABS 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 28 STELVIO 4V - 1200 ABS 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...
  • Page 29 STELVIO 4V - 1200 ABS Special tools Stores code Description AP8140149 Protection for fitting operations 9100903 Marzocchi fork oil seal; ø 45 mm (1.77 in) 020886Y Spacer / pumping member pin splitting plate S-TOOLS - 29 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 30 INDEX OF TOPICS MAIN AINTENANCE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 31: Maintenance Chart

    STELVIO 4V - 1200 ABS Maintenance Maintenance chart NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VEHICLE IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTING APPLICATIONS. OUTINE MAINTENANCE TABLE I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Check and clean, adjust or replace if necessary before every ride.
  • Page 32 STELVIO 4V - 1200 ABS Maintenance 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 ABS Maintenance Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM (10 miles).

  • Page 34: Engine Oil Filter

    STELVIO 4V - 1200 ABS 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 35: Gearbox Oil

    STELVIO 4V - 1200 ABS Maintenance Gearbox Oil Inspection CHECKING AND TOPPING UP CAUTION ENGINE MUST BE WARM TO CHECK GEARBOX OIL LEVEL. NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL.

  • Page 36: Air Filter

    STELVIO 4V - 1200 ABS Maintenance • Pour in new oil until it reaches the dipstick open- ing (1). • Tighten the filler cap (1). CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL- EMENT, MAKE SURE IT IS PERFECTLY CLEAN.

  • Page 37: Braking System

    STELVIO 4V - 1200 ABS Maintenance • Disconnect both spark plug tubes. • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings. • Remove the head cover together with the gasket. • Loosen the nut (1).
  • Page 38 STELVIO 4V - 1200 ABS Maintenance • For the front brake, turn the handlebar fully to the right. • For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the same level with the plug.
  • 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 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 41 STELVIO 4V - 1200 ABS Electrical system Components arrangement Key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector ELE SYS - 41 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 42 STELVIO 4V - 1200 ABS 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...
  • Page 43 STELVIO 4V - 1200 ABS Electrical system Front side TABLE A 1 - Check that the ground terminals are placed on the coils TABLE B 2 - Clamps. 3 - Auxiliary fuses. 4 - Instrument panel cable harness. 5 - Relays.
  • Page 44 STELVIO 4V - 1200 ABS Electrical system TABLE C 7 - Marelli control unit. 8 - Left coil. TABLE D 9 - Clamp. 10 - Horn. TABLE E 11 - Clamps. 12 - Pick-Up. 13 - Antitheft. TABLE F 14 - Left fog light.
  • Page 45 STELVIO 4V - 1200 ABS 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.
  • Page 46 STELVIO 4V - 1200 ABS Electrical system TABLE J1 A - Black cable grommet. B - Pipe lock clamp. C - Front ABS sensor. TABLE J2 D - Black cable grommet. ELE SYS - 46 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 47 STELVIO 4V - 1200 ABS 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.
  • Page 48 STELVIO 4V - 1200 ABS Electrical system TABLE N 26 - Clamp. 27 - Heated hand grips connectors. TABLE O 28 - Clamps. TABLE O1 - Connect the ABS connector by fully inserting the cap in its housing. - Slide out the cables and connectors of: speed sensor, light switch and ignition switch assembly.
  • Page 49 STELVIO 4V - 1200 ABS Electrical system TABLE O4 - Place the connector in the control unit counter part and lower the pulling lever until you hear the "click" of end of stroke. TABLE O5 CORRECT ASSEMBLY - When the connector is fully inserted, the distance measured between this and the ABS control unit must be of 7.5 mm (0.29 in).
  • Page 50 STELVIO 4V - 1200 ABS Electrical system TABLE O 28 - Clamps. TABLE P 29 - Injectors. TABLE Q 30 - Clamp. 31 - Fall sensor. 32 - Main cable harness. ELE SYS - 50 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 51 STELVIO 4V - 1200 ABS 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.
  • Page 52 STELVIO 4V - 1200 ABS Electrical system TABLE V 39 - Negative battery cable. TABLE W 40 - Black cable grommet. ELE SYS - 52 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 53 STELVIO 4V - 1200 ABS Electrical system General wiring diagram key: 1. MULTIPLE CONNECTORS 2. CLUTCH SWITCH 3. START-UP RELAY 4. MAINTENANCE RELAY ELE SYS - 53 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 54 STELVIO 4V - 1200 ABS Electrical system 5. LIGHT LOGIC RELAY 6. FOG LIGHTS RELAY (OPTIONAL EQUIPMENT) 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.GLOVE-BOX COMPARTMENT OPENING RELAY...
  • Page 55 STELVIO 4V - 1200 ABS 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 55.PICK-UP...
  • Page 56 STELVIO 4V - 1200 ABS Electrical system 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 57 STELVIO 4V - 1200 ABS Electrical system Air Temperature Error DC Gnd ECU 17 Low Battery Error ECU 20 Lambda Probe Error ECU 21 Coil 1 Error DC V DC ECU 22 Coil 1 Error DC Gnd ECU 23 Coil 2 Error DC V DC ECU 24...
  • Page 58 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 59 STELVIO 4V - 1200 ABS 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 60 STELVIO 4V - 1200 ABS Electrical system Lights list FRONT HEADLAMP Specification Desc./Quantity Front daylight running light 12V - 5W Low/high beam headlight (halogen) 12 V - 55 W / 60 W H4 REAR LIGHT Specification Desc./Quantity Rear daylight running lights /stop light...

  • Page 61: Control Unit

    STELVIO 4V - 1200 ABS Electrical system D - Lambda burner, secondary injection relay coil, start-up relay coil (15 A). F- Permanent positive, ECU power supply (3A). NOTE THERE ARE TWO SPARE FUSES. MAIN FUSES 1 - Battery recharge (40 A).

  • Page 62: Speed Sensor

    STELVIO 4V - 1200 ABS 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 63 STELVIO 4V - 1200 ABS 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 64 STELVIO 4V - 1200 ABS 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 65 STELVIO 4V - 1200 ABS 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 66 STELVIO 4V - 1200 ABS 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 67 STELVIO 4V - 1200 ABS Electrical system • 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 68 STELVIO 4V - 1200 ABS Electrical system 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 69 STELVIO 4V - 1200 ABS Electrical system THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE "MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT. CAUTION BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROU- BLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
  • Page 70 STELVIO 4V - 1200 ABS 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 71 STELVIO 4V - 1200 ABS Electrical system of the BROWN connector and PIN 2 of sensor: restore cable harness if there is not continuity; if it is OK, reconnect the control unit connector and, with key set to key ON, check the continuity between the sensor connector PIN 1 and the vehicle ground connection: if there is not continuity, restore the cable harness;...
  • Page 72 STELVIO 4V - 1200 ABS Electrical system 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 73 STELVIO 4V - 1200 ABS Electrical system • shorted to positive: disconnect the probe connector and check the sensor correct resistance: replace the sensor if not OK; if it is OK, restore the cable harness. • circuit is open, shorted to negative: check the continuity from probe connector (PIN 3 and 4) towards the probe: if not OK, replace the probe;...
  • Page 74 STELVIO 4V - 1200 ABS Electrical system Left 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; CHECK, how- ever, the identification of the relay with the colour of the cables) is energised for 5 seconds and the grey/ red cable of the injector is closed to ground for 4 ms per second.
  • Page 75 STELVIO 4V - 1200 ABS Electrical system • If shorted to positive: excessive voltage has been detected at PIN 37 of the BROWN con- nector. • If shorted to negative: no voltage has been detected. • If the circuit is open: an interruption has been detected Troubleshooting •...
  • Page 76 STELVIO 4V - 1200 ABS Electrical system 1. Power supply + Vbatt 2. Circuit ground NAVIGATOR: PARAMETERS Left coil ignition advance. NAVIGATOR: ACTIVATION Left coil: 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 77 STELVIO 4V - 1200 ABS Electrical system of the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary for correct activation: no error indications are displayed in case of lack of activation NAVIGATOR: ERRORS Right coil P0352 - shorted to positive / open circuit, shorted to negative.
  • Page 78 STELVIO 4V - 1200 ABS Electrical system • An oil sensor failure is signalled when, with engine off, it is detected that the sensor circuit is open. The test is performed only once when the key is set to ON. This error is signalled by the bulb icon and the general warning light turns on as well.
  • Page 79 STELVIO 4V - 1200 ABS Electrical system Gear in neutral Example value:yes/no DIAGNOSIS • Indication on the instrument panel always gear engaged: check the control unit connector and the sensor connector: if they are not OK, restore the cable harness; if OK, disconnect...
  • Page 80 STELVIO 4V - 1200 ABS Electrical system Example value:Yes/No The statuses regularly viewed are YES / NO DIAGNOSIS Troubleshooting: • Indication on Navigator always No: check the correct position of the cable terminals on the sensor and the correct connection of the cables on the terminals. If they are not correct, restore the cable harness;...

  • Page 81: Bank Angle Sensor

    STELVIO 4V - 1200 ABS Electrical system • Indication on Navigator always EXTENDED: check the side stand sensor connector and the ECU connector: if they are not OK, restore; if OK, disconnect both terminals from the sensor and check continuity to ground of PIN 1 (blue/green, cable harness side): if there is not continuity, restore the cable harness;...
  • Page 82 STELVIO 4V - 1200 ABS Electrical system • Indication on Navigator always Normal, even when the sensor is inverted: disconnect the connector and, with sensor inverted, check if there is continuity between the two PINS of the sensor: if there is no continuity, replace the sensor; if there is, check the connector. If not OK, restore the cable harness;...
  • Page 83 STELVIO 4V - 1200 ABS Electrical system • An oil sensor failure is signalled when it is detected that the sensor circuit is open or shorted to positive Troubleshooting • Check the sensor connector and the instrument panel connector (PINS 10 and 18): If they are not OK, restore.
  • Page 84 STELVIO 4V - 1200 ABS Electrical system • sky blue/orange cable: 0V if engine kill in STOP; 12V if engine kill in RUN • red/black cable: Voltage 12V NAVIGATOR: STATUSES Run / stop switch Example value:Run/Stop DIAGNOSIS • Indication on Navigator always STOP: disconnect the connector and, with the switch set to RUN, check if there is continuity towards the switch of both the green/orange and the grey/ yellow cables (sensor side): if there is not continuity, replace the sensor;...
  • Page 85 STELVIO 4V - 1200 ABS Electrical system 11 Not used 12 Not used 13 Not used 14 Air temperature signal 15 Not used 16 Not used 17 Stepper motor (+) 18 Stepper motor (-) 19 Stepper motor (-) 20 5V power supply (NTC sensors)
  • Page 86 STELVIO 4V - 1200 ABS Electrical system 9 Not used 10 Not used 11 Oxygen probe negative control 12 Not used 13 Not used 14 Not used 15 Not used 16 K line (diagnosis) 17 Power supply from main relay...
  • Page 87 STELVIO 4V - 1200 ABS Electrical system Dashboard The pin configuration of the GREY-bodied con- nector is as follows: PIN USE 1 + KEY 2 RIGHT TURN INDICATOR CONTROL 3 HIGH-BEAM LIGHT INPUT 5 FOG LIGHTS ON (OPT) 6 K LINE...
  • Page 88 STELVIO 4V - 1200 ABS Electrical system 32 FRONT RIGHT TURN INDICATOR ACTIVATION 33 REAR RIGHT TURN INDICATOR ACTIVATION 34 AERIAL 2 35 RIGHT HEATED HANDGRIPS ACTUATOR (OPT) 36 CAN L 37 HAZARD CONTROL 38 - 39 ABS 40 CONTROL - UP...
  • Page 89 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 90 STELVIO 4V - 1200 ABS 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. •...
  • Page 91 STELVIO 4V - 1200 ABS Engine from vehicle • Disconnect the starter motor connec- tors. • Disconnect the stand sensor connec- tor and release it from the clamps. • Slide off the gearbox oil breather pipe. • Disconnect the neutral sensor connec- tor.
  • Page 92 STELVIO 4V - 1200 ABS 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 93 STELVIO 4V - 1200 ABS 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 - 93...
  • Page 94 STELVIO 4V - 1200 ABS 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 95 STELVIO 4V - 1200 ABS 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 96 STELVIO 4V - 1200 ABS 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. •...
  • Page 97 STELVIO 4V - 1200 ABS 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 98 STELVIO 4V - 1200 ABS 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. •...
  • Page 99 STELVIO 4V - 1200 ABS 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 - 99...
  • Page 100 STELVIO 4V - 1200 ABS 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 - 100...
  • Page 101 STELVIO 4V - 1200 ABS 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 102 INDEX OF TOPICS NGINE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 103 STELVIO 4V - 1200 ABS Engine Gearbox Diagram Key: 1. Ball bearing ENG - 103 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 104 STELVIO 4V - 1200 ABS 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...
  • Page 105 STELVIO 4V - 1200 ABS 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...
  • Page 106 STELVIO 4V - 1200 ABS 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 fitting on the sump.
  • Page 107 STELVIO 4V - 1200 ABS 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 - 107 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 108 STELVIO 4V - 1200 ABS 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 109 STELVIO 4V - 1200 ABS 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 110 STELVIO 4V - 1200 ABS 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 111 STELVIO 4V - 1200 ABS 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 112 STELVIO 4V - 1200 ABS 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 113 STELVIO 4V - 1200 ABS 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 114 STELVIO 4V - 1200 ABS 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 115 STELVIO 4V - 1200 ABS 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 116 STELVIO 4V - 1200 ABS 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 117 STELVIO 4V - 1200 ABS 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 118 STELVIO 4V - 1200 ABS 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 119 STELVIO 4V - 1200 ABS Engine Removing the primary shaft Fitting the secondary shaft NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED.
  • Page 120 STELVIO 4V - 1200 ABS 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 - 120 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 121: Removing The Generator

    STELVIO 4V - 1200 ABS 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 122 STELVIO 4V - 1200 ABS 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 123 STELVIO 4V - 1200 ABS Engine • Undo and remove the eight screws. • Undo and remove the two screws. • Undo and remove the two screws. ENG - 123 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 124 STELVIO 4V - 1200 ABS 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 125 STELVIO 4V - 1200 ABS 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...

  • Page 126: Installing The Generator

    STELVIO 4V - 1200 ABS 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 •...
  • Page 127 STELVIO 4V - 1200 ABS 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. •...
  • Page 128 STELVIO 4V - 1200 ABS 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. •...

  • Page 129: Starter Motor

    STELVIO 4V - 1200 ABS 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 130 STELVIO 4V - 1200 ABS Engine • Slide off the starter motor. Clutch side Disassembling the clutch • Remove the complete gearbox. • Undo and remove the six screws. • Remove the start-up crown gear. • Remove the clutch bell and the friction disc.
  • Page 131 STELVIO 4V - 1200 ABS Engine • Remove the Seeger ring. • Remove the clutch pressure plate. • Undo and remove the six screws and collect the belleville springs. • Remove the clutch disc. See also Removing the gearbox ENG - 131...
  • Page 132 STELVIO 4V - 1200 ABS Engine Key: 1. Complete clutch 2. Clutch 3. Clutch bell 4. TCEI screw 5. Clutch disc 6. Crown 7. TCEI screw 8. Clutch pressure plate 9. Ring 10.TE flanged screw 11.Conical washer 12.Bushing 13.Rod 14.Bushing 15.Intermediate body...
  • Page 133 STELVIO 4V - 1200 ABS 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 134 STELVIO 4V - 1200 ABS 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 135 STELVIO 4V - 1200 ABS 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 136 STELVIO 4V - 1200 ABS 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...
  • Page 137 STELVIO 4V - 1200 ABS 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...

  • Page 138: Removing The Cylinder Head

    STELVIO 4V - 1200 ABS 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 139 STELVIO 4V - 1200 ABS 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 140: Cylinder Head

    STELVIO 4V - 1200 ABS 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 141 STELVIO 4V - 1200 ABS Engine • Remove the two rocking levers from the cam cap. • Remove the two rods. • 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 142: Removing The Valves

    STELVIO 4V - 1200 ABS Engine WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CARE- FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING. • Remove the cam cap from the stud bolts. •...
  • Page 143 STELVIO 4V - 1200 ABS Engine • Tighten the tool screw until fitted, and then hit the tool head (where the upper cap works) with a mallet so that the two cotters (1) get detached from the upper cap (2).

  • Page 144: Checking The Cylinder Head

    STELVIO 4V - 1200 ABS Engine Checking the cylinder head Check that: • the faying surfaces with the cover and the cylinder are not scored or damaged, jeopardising a perfect sealing. • Check that the tolerance between the valve guide holes and the valve stems is within the prescribed limits.
  • Page 145 STELVIO 4V - 1200 ABS Engine • Place the valve guide oil seal (4) in the head. • Place the lower cap (5). • Place the valve (6) inside the head. • Place the spring (3). • Fit the upper cap (2).
  • Page 146 STELVIO 4V - 1200 ABS Engine • Place the two rocking levers in the cam tower seats. • 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.
  • Page 147 STELVIO 4V - 1200 ABS Engine • Place the camshaft with the gear seat on the dowel side. • Place the U-bolt on the camshaft mak- ing sure the two reference pins match the seats on the cam tower. •...
  • Page 148 STELVIO 4V - 1200 ABS Engine Removing the generator Service shaft removal • Remove the tone wheel. • Remove both cylinders. • Undo and remove the two screws. • Remove the service shaft closing cap. • Mark the timing chains so as not to in- vert the direction of rotation upon fit- ting.
  • Page 149 STELVIO 4V - 1200 ABS Engine • Fit the timing chains according to the references marked at the removal phase. • Lubricate the service shaft. • Insert the service shaft in its crankcase seat by sliding it through the two chains.
  • Page 150 STELVIO 4V - 1200 ABS Engine Installing sliders • Fit the crankshaft and the service shaft on the crankcase. • Fit the fixed chain sliders and tighten the fixing screws. • Tighten the chain caps with O-rings. • The operations related to the movable chain sliders are described in the cyl- inder fitting section.
  • Page 151 STELVIO 4V - 1200 ABS Engine • Lock crankshaft rotation. • Unscrew and remove the nut fixing the crankshaft gear. • Remove the oil pump control gear. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear •...
  • Page 152 STELVIO 4V - 1200 ABS Engine • Place a new gasket between the crank- case and the oil pump. • Place the oil pump. • Tighten the three screws fixing the oil pump. • Place the driving pin on the oil pump shaft.
  • Page 153 STELVIO 4V - 1200 ABS Engine • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear.
  • Page 154 STELVIO 4V - 1200 ABS 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 155 STELVIO 4V - 1200 ABS 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. Snap ring 9. Cylinder base gasket 10.Stud bolt 11.Pin...
  • Page 156 STELVIO 4V - 1200 ABS Engine Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Remove the head, the gasket between the head and the cylinder and the two dowel pins.
  • Page 157 STELVIO 4V - 1200 ABS 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 158 STELVIO 4V - 1200 ABS 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 159 STELVIO 4V - 1200 ABS 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. •...
  • Page 160 STELVIO 4V - 1200 ABS 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 161: Installing The Cylinder Head

    STELVIO 4V - 1200 ABS 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 162 STELVIO 4V - 1200 ABS 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 163 STELVIO 4V - 1200 ABS 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 164 STELVIO 4V - 1200 ABS 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 165 STELVIO 4V - 1200 ABS 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 166 STELVIO 4V - 1200 ABS 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 167 STELVIO 4V - 1200 ABS 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 168 STELVIO 4V - 1200 ABS 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 169 STELVIO 4V - 1200 ABS 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 170 STELVIO 4V - 1200 ABS 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 171 STELVIO 4V - 1200 ABS Engine • Place the flywheel-side flange on the crankshaft and check if the dowel pin with the O-ring is correctly placed. • When fitting the flange on the crank- case, make sure that the three dowel pins match the seats on the crankcase.
  • Page 172 STELVIO 4V - 1200 ABS 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 173 STELVIO 4V - 1200 ABS Engine 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. Rotor control shaft 9.
  • Page 174 STELVIO 4V - 1200 ABS 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 175 STELVIO 4V - 1200 ABS Engine • Undo and remove the three screws. • Remove the oil pump. • Remove the gasket between the crankcase and the oil pump. See also Replacement Removing the generator Installing • Place a new gasket between the crank- case and the oil pump.
  • Page 176 STELVIO 4V - 1200 ABS 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 177 STELVIO 4V - 1200 ABS Engine • Insert the joint in the oil pump. • Fit the nipple with the gasket on the crankcase. • Tighten the nipple to the prescribed torque. Removing the oil sump NOTE TO REMOVE THE OIL SUMP, PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL.
  • Page 178 STELVIO 4V - 1200 ABS Engine • Undo and remove the fourteen screws fixing the oil sump to the engine crank- case. • Undo and remove the four screws. • Remove the flange. ENG - 178 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 179 STELVIO 4V - 1200 ABS Engine • Undo and remove the two screws. • Remove both filters. • Unscrew and remove the plug. • Remove the thermostatic valve. • Unscrew and remove the pressure re- lief valve plug. • Remove the pressure relief valve com-...
  • Page 180 STELVIO 4V - 1200 ABS 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 181 STELVIO 4V - 1200 ABS Engine • Tighten the thermostatic valve plug. • 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.
  • Page 182 STELVIO 4V - 1200 ABS Engine • Check that the O-rings are fitted on the oil pump. • Fit the cooling oil intake filter. • Fix both filters and tighten the two screws to the prescribed torque. • Fit a new oil filter and tighten it to the prescribed torque.
  • Page 183 STELVIO 4V - 1200 ABS Engine • Place the oil sump. • Tighten the fourteen screws to the pre- scribed torque. • Add engine oil up to the correct level. ENG - 183 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 184 INDEX OF TOPICS P SUPP OWER SUPPLY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 185: Circuit Diagram

    STELVIO 4V - 1200 ABS Power supply Circuit diagram Key: 1. Complete fuel pump unit 2. Nut 3. Fuel pipe 4. Pipe 5. Screw Injection P SUPP - 185 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 186 STELVIO 4V - 1200 ABS 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 187 STELVIO 4V - 1200 ABS 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 188 STELVIO 4V - 1200 ABS 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 189: Injection System

    STELVIO 4V - 1200 ABS 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"...
  • Page 190 STELVIO 4V - 1200 ABS 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 191 STELVIO 4V - 1200 ABS 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 192 STELVIO 4V - 1200 ABS 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 193 STELVIO 4V - 1200 ABS 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 194 INDEX OF TOPICS SUSP USPENSIONS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 195: Removing The Front Wheel

    STELVIO 4V - 1200 ABS 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 196: Front Fork

    STELVIO 4V - 1200 ABS 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.
  • Page 197 STELVIO 4V - 1200 ABS 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...
  • Page 198 STELVIO 4V - 1200 ABS Suspensions Adjustment The front suspension consists of a hydraulic fork connected to the headstock by means of two plates. To set the vehicle suspension, each fork stem fea- tures an upper nut (1), to adjust spring preloading, and an upper set screw (2): •...

  • Page 199: Removing The Fork Legs

    STELVIO 4V - 1200 ABS Suspensions Removing the fork legs • Rest the vehicle on its centre stand. • Secure the rear part of the vehicle through belts in order to lift the front wheel. • Remove the mudguard. •...
  • Page 200 STELVIO 4V - 1200 ABS Suspensions • Unscrew the sleeve top cap. • Push the bushing down in order to compress the spring and then fit the appropriate tool under the pumping member pin lock nut and on the bush- ing to keep the spring compressed.
  • Page 201 STELVIO 4V - 1200 ABS 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 the preload pipe and the spring holder cap.
  • Page 202 STELVIO 4V - 1200 ABS Suspensions • Push the bushing down in order to compress the spring and then fit the appropriate tool under the pumping member pin lock nut and on the bush- ing to keep the spring compressed.
  • Page 203 STELVIO 4V - 1200 ABS Suspensions • Pour the oil into the container. • Remove the preload pipe and the spring holder cap. Disassembling the fork • Drain all the oil from the stem. • Tighten the wheel holder sleeve in a vice.
  • Page 204 STELVIO 4V - 1200 ABS Suspensions • Remove the pumping member pin. • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • During this operation, pay attention not to damage the sleeve rim. •...
  • Page 205 STELVIO 4V - 1200 ABS Suspensions • From the stem remove the fixed fitted bushing, the movable bushing, the ring and the oil seal. • Remove the ring and the dust guard. See also Draining oil Checking the components Stem...
  • Page 206 STELVIO 4V - 1200 ABS Suspensions Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1). If the scorings are deep, replace the stem. Use a dial gauge to check that the stem bending is below the limit value.
  • Page 207 STELVIO 4V - 1200 ABS Suspensions Replace the following components with new ones: • sealing ring; • dust guard; • O-Ring on the cap. Reassembling the fork • Lock the stem in a vice without dam- aging the surface. •...
  • Page 208 STELVIO 4V - 1200 ABS 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 - 208...
  • Page 209 STELVIO 4V - 1200 ABS 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 210 STELVIO 4V - 1200 ABS Suspensions • Tighten the screw fixing the pumping member on the fork end to the prescri- bed torque. • Fit the sleeve on the stem and set the oil seal into position with the aid of the specific tool.
  • Page 211 STELVIO 4V - 1200 ABS Suspensions • Measure the air gap between the oil level and the rim. THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS.

  • Page 212: Installing The Fork Legs

    STELVIO 4V - 1200 ABS Suspensions • Screw the upper cap on the pumping member pin. • Remove the tool to compress the spring. • Place the sleeve in the vice using the specified tool. • Screw the upper cover, tightening it to the prescribed torque.
  • Page 213 STELVIO 4V - 1200 ABS Suspensions • Tighten the screws on the fork plates to the prescribed torque. 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 214 STELVIO 4V - 1200 ABS Suspensions • Unscrew and remove the fork upper plate cover; collect the shim. • Lift the fork upper plate sliding it off from the stems. • Rivet the safety washer on the head- stock. UPON REFITTING, REPLACE THE SAFETY WASHER WITH A NEW ONE •...
  • Page 215 STELVIO 4V - 1200 ABS Suspensions • Remove the safety washer. • Using the suitable special tool, set the preloading of the steering bearings. Specific tooling AP8140190 Tool for steering tightening • 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.

  • Page 216: Removing The Rear Wheel

    STELVIO 4V - 1200 ABS Suspensions Removing the rear wheel • Support the vehicle rear part using a suitable stand. • Engage the first gear. • Undo and remove the four screws, col- lect the spacers and the dust-protec- tion ring.
  • Page 217 THE VEHICLE USE CONDITIONS. IF THE SPRING PRELOADING IS INCREASED, IT IS NECES- SARY TO INCREASE THE REBOUND DAMPING ACCORDINGLY TO AVOID SUDDEN JERKS WHEN RIDING. IF NECESSARY, CONTACT AN Official Moto Guzzi Dealer. TRY RIDING THE VE- HICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED.
  • Page 218 STELVIO 4V - 1200 ABS 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 219 INDEX OF TOPICS CHAS HASSIS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 220 STELVIO 4V - 1200 ABS 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. •...
  • Page 221 STELVIO 4V - 1200 ABS 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.
  • Page 222 STELVIO 4V - 1200 ABS Chassis • Loosen the ring nut. Specific tooling 14.91.26.03 Hook spanner for fixing ring nut of the clutch shaft internal body • Helped by a second operator, remove the pin and remove the swingarm to- gether with the cardan shaft.
  • Page 223 STELVIO 4V - 1200 ABS 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...
  • Page 224 STELVIO 4V - 1200 ABS 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 225 STELVIO 4V - 1200 ABS 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. •...
  • Page 226 STELVIO 4V - 1200 ABS Chassis • Remove the transmission casing slid- ing off the universal joint. Checking Smontaggio gruppo scatola Remove the cover (20). Remove the plug (3) to drain out the oil. CHAS - 226 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 227 STELVIO 4V - 1200 ABS Chassis Lift the cap (10). Remove the clamps (9) and (11). Remove the cap (14). Remove the screws (16). Collect the ring (15). CHAS - 227 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 228 STELVIO 4V - 1200 ABS Chassis Remove the screws (7). Remove the casing (4). Remove the clamp (12). Remove the cap (14). Collect the ring (13). CHAS - 228 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 229 STELVIO 4V - 1200 ABS Chassis Remove the support unit (8). Montaggio gruppo scatola 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.
  • Page 230 STELVIO 4V - 1200 ABS 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 - 230 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 231 STELVIO 4V - 1200 ABS 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 232 STELVIO 4V - 1200 ABS 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.
  • Page 233 STELVIO 4V - 1200 ABS 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.
  • Page 234 STELVIO 4V - 1200 ABS Chassis 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).
  • Page 235 STELVIO 4V - 1200 ABS Chassis Turn the unit over. Assemble the bearings to the wheel axle. Gruppo pignone 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 236 STELVIO 4V - 1200 ABS 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 237 STELVIO 4V - 1200 ABS 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...
  • Page 238 STELVIO 4V - 1200 ABS Chassis 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 239 STELVIO 4V - 1200 ABS 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 240: Troubleshooting

    STELVIO 4V - 1200 ABS 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...
  • Page 241 STELVIO 4V - 1200 ABS 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 242 STELVIO 4V - 1200 ABS 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. •...
  • Page 243 STELVIO 4V - 1200 ABS 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...
  • Page 244 STELVIO 4V - 1200 ABS 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 245 STELVIO 4V - 1200 ABS 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.
  • Page 246 STELVIO 4V - 1200 ABS Chassis 3. T-shaped bushing 4. Rubber ring 5. Radiator support 6. TCEI screw 7. Clip Removing To change the engine oil and to replace the oil fil- ter, remove the oil sump guard. • Operating from both sides, unscrew and remove the two front screws (1).
  • Page 247 STELVIO 4V - 1200 ABS 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 248 INDEX OF TOPICS BRAK SYS RAKING SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 249 STELVIO 4V - 1200 ABS Braking system Interventions rules CAUTION THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM. key: 1. ABS ECU control unit 2. Front ABS sensor 3. Rear ABS sensor 4.
  • Page 250 STELVIO 4V - 1200 ABS Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever control 4. Rear system circuit BRAK SYS - 250 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 251 STELVIO 4V - 1200 ABS 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 252 STELVIO 4V - 1200 ABS 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 253 STELVIO 4V - 1200 ABS 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 254 STELVIO 4V - 1200 ABS Braking system light (5) on the instrument panel (4) turns off. 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 255 STELVIO 4V - 1200 ABS 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 256 STELVIO 4V - 1200 ABS 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...
  • Page 257 STELVIO 4V - 1200 ABS 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...
  • Page 258 STELVIO 4V - 1200 ABS 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 259 STELVIO 4V - 1200 ABS 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 260 STELVIO 4V - 1200 ABS 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 261 STELVIO 4V - 1200 ABS 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 262 STELVIO 4V - 1200 ABS 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 263 STELVIO 4V - 1200 ABS Braking system 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...
  • Page 264 STELVIO 4V - 1200 ABS Braking system 8. Aluminium gasket 9. Screw Rear brake disc Disc Inspection CAUTION THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECI- FICATIONS OF THE SYSTEM. • The following operations are to be car- ried out with brake disc fitted on the wheel.

  • Page 265: Front Brake Pads

    STELVIO 4V - 1200 ABS Braking system • Using a dial gauge, check that the max- imum oscillation of the disc does not exceed the tolerance; otherwise, re- place it. Disc oscillation tolerance: 0.15 mm (0.0059 in) Front brake pads Removal •...
  • Page 266 STELVIO 4V - 1200 ABS Braking system • 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 267: Rear Brake Pads

    STELVIO 4V - 1200 ABS Braking system Rear brake pads Removal • Undo and remove the two screws. • Remove the brake calliper from the disc. • Turn the pin and pull out the split pin. • Remove the split pin.
  • Page 268 STELVIO 4V - 1200 ABS Braking system • Remove the pin. • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS.
  • Page 269 STELVIO 4V - 1200 ABS Braking system Bleeding the braking system VEHICLE PREPARATION • It is important to check that there is always enough brake fluid in the reservoir. • Using a bleed device facilitates these operations while, in the meantime, the "Brake fluid replacement"...
  • Page 270 STELVIO 4V - 1200 ABS Braking system • Detach the bleed hoses and close the bleed screws again to the correct tightening torque. See also Front Rear REPLACE THE ABS CONTROL UNIT VEHICLE PREPARATION • Connect the bleed bottle to the bleed screws of the front and rear callipers and open it.
  • Page 271 STELVIO 4V - 1200 ABS 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. •...
  • Page 272 STELVIO 4V - 1200 ABS Braking system • If, after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in the braking system and if everything is ok, continue bleeding operations using Navigator as described.
  • Page 273 STELVIO 4V - 1200 ABS Braking system OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR. REGULAR AIR BLEEDING SYSTEM • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in...
  • Page 274 STELVIO 4V - 1200 ABS Braking system • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the rear brake calliper bleed valve and insert the other end of this pipe into a container to collect the fluid.
  • Page 275 INDEX OF TOPICS BODYW ODYWORK Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

  • Page 276: Instrument Panel

    STELVIO 4V - 1200 ABS 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 277 STELVIO 4V - 1200 ABS 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.
  • Page 278 STELVIO 4V - 1200 ABS 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 279 STELVIO 4V - 1200 ABS 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 280 STELVIO 4V - 1200 ABS Bodywork • Working from both sides, undo and re- move the screw. • Working from both sides, undo and re- move the screw. • Detach the fairing. • Disconnect the glove-box compart- ment opening cable.
  • Page 281 STELVIO 4V - 1200 ABS Bodywork • Operating from both sides, undo and remove the internal screw and collect the washer and the nut. • Unscrew and remove the two screws. • Undo and remove the four screws. • Remove the headlight lower cover.
  • Page 282 STELVIO 4V - 1200 ABS 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 283 STELVIO 4V - 1200 ABS 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.
  • Page 284 STELVIO 4V - 1200 ABS 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. •...
  • Page 285 STELVIO 4V - 1200 ABS 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 286 STELVIO 4V - 1200 ABS 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.
  • Page 287 STELVIO 4V - 1200 ABS 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 288 STELVIO 4V - 1200 ABS 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 289 STELVIO 4V - 1200 ABS 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.
  • Page 290 INDEX OF TOPICS PRE DE DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
  • Page 291 STELVIO 4V - 1200 ABS Pre-delivery Carry out the listed checks before delivering the vehicle. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety locks:...

  • Page 292: Road Test

    STELVIO 4V - 1200 ABS 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 293 STELVIO 4V - 1200 ABS 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 294 ABS: 88, 249, 255, 259 Air filter: 36 Battery: 58, 61 Brake: 262–265, 267 Clutch: 79, 130, 133, 166 Clutch lever: 79 Engine oil: 33, 77, 245 Fork: 196, 199, 203, 207, 212 Forks: 118 Fuel: 90, 124, 260, 285 Fuses: 60 Gearbox oil: 35 Identification: 10...
  • Page 295 Transmission: 12, 31 Tyres: 14 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

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