MOTO GUZZI Stelvio 1200 NTX 2011 Service Station Manual
  1. Manuals
  2. Brands
  3. MOTO GUZZI Manuals
  4. Motorcycle
  5. Stelvio 1200 NTX 2011
  6. Service station manual

MOTO GUZZI Stelvio 1200 NTX 2011 Service Station Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

SERVICE STATION MANUAL
B043090
Stelvio 1200 NTX MY11

Advertisement

Table of Contents
loading

Related Manuals for MOTO GUZZI Stelvio 1200 NTX 2011

Summary of Contents for MOTO GUZZI Stelvio 1200 NTX 2011

  • Page 1 SERVICE STATION MANUAL B043090 Stelvio 1200 NTX MY11...
  • Page 2 Not all versions/models shown in this publication are available in all countries. The availability of individual versions should be checked with the Official Moto Guzzi sales network. © Copyright 2011- Moto Guzzi. All rights reserved. Reproduction of this publication in whole or in part is prohibited. Moto Guzzi - After sales service.
  • Page 3 In order to optimise customer satisfaction when using our vehicles, Moto Guzzi s.p.a. commits itself to continually improve its products and the relative documentation. The main technical modifications and changes in repair procedures are communicated to all Moto Guzzi Sales Outlets and its International Subsidiaries.
  • Page 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 1200 NTX MY11 Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never 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 1200 NTX MY11 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 1200 NTX MY11 Characteristics This number consists of numbers and letters, as in the example shown below. ZGULZG000YMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LZ: model; 001: version variation; 0: free digit Y year of manufacture M: production plant (M= Mandello del Lario); XXXXXX: serial number (6 digits);...
  • Page 12 Stelvio 1200 NTX MY11 Characteristics Specification Desc./Quantity Bore / stroke 95 x 81.2 mm (3.74 x 3.20 in) Engine capacity 1151 cm³ (70 cu.in) Compression ratio 11 : 1 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 1200 NTX MY11 Characteristics Specification Desc./Quantity Rear daylight running light/stop light Supplementary headlamps (if fitted) 12 V/55W - H3 Dashboard lighting License plate light 12V - 5 W Turn indicator warning light Neutral gear warning light Alarm-shift warning light Side stand down warning light Low fuel warning light High beam warning light...

  • Page 14: Wheels And Tyres

    Stelvio 1200 NTX MY11 Characteristics Wheels and tyres WHEELS AND TYRES Wheel Model Wheel rim Measure Tyre pressure with Tyre pressure, rider + ment rider only passenger Front (standard) H SPECIFIC Pirelli 2.50 x 19" 110/80 2.5 bar (250 kPa) (36.3 2.5 bar (250 kPa) (36.3 Scorpion Trail R19 - 59V...
  • Page 15 Stelvio 1200 NTX MY11 Characteristics Front side RONT IGHTS pos. Description Type Quantity Torque Notes Horn fixing screw M6x20 15 Nm (11.06 lbf ft) Viti fissaggio freccie anteriori 3 Nm (2.21 lbf ft) Vite fissaggio superiore fanale a carozzeria 3 Nm (2.21 lbf ft) Viti fissaggio fanale a carozzeria M4x25 3 Nm (2.21 lbf ft)
  • Page 16 Stelvio 1200 NTX MY11 Characteristics NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Viti TCEI fissaggio sensore velocità anteriore M5x16 6 Nm (4.42 lbf ft) Viti TCEI fissaggio blocchetto avviamento M8x30 25 Nm (18.44 lbf ft) Viti autofil. fissaggio supporto cruscotto 5x14 Manual Viti autofil.
  • Page 17 Stelvio 1200 NTX MY11 Characteristics TEERING pos. Description Type Quantity Torque Notes Viti fissaggio piastra fermatubi 6 Nm (4.42 lbf ft) Viti fissaggio piastre M8x30 20 Nm (14.75 lbf ft) Headstock ring nut 40 Nm (29.50 lbf ft) Headstock counter-lock ring manual + 90 degrees Upper yoke fixing cap 100 Nm (73.76 lbf ft)
  • Page 18 Stelvio 1200 NTX MY11 Characteristics ARROZZERIA ANTERIORE ONVOGLIATORI pos. Description Type Quantity Torque Notes Viti TBEI Flang. fissaggio convogliatori M5x9 6 Nm (4.42 lbf ft) Viti TBEI Flang. fissaggio convogliatori 6 Nm (4.42 lbf ft) Viti SWP Autofil. fissaggio telaietto griglie 2.9x12 Manual ARROZZERIA ANTERIORE...
  • Page 19 Stelvio 1200 NTX MY11 Characteristics RAME pos. Description Type Quantity Torque Notes TCEI frame fixing screws M8x40 25 Nm (18.44 lb ft) TE Screws Flang. M6x20 10 Nm (7.38 lb ft) ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes TCC handlebar upper U-bolt fixing screws M8x30 25 Nm (18.44 lb ft)
  • Page 20 Stelvio 1200 NTX MY11 Characteristics pos. Description Type Quantity Torque Notes TE handlebar lower U-bolt flanged fixing 50 Nm (36.88 lb ft) Loct. 243 screws Self-tapp. screw 1.5 Nm (1.11 lb ft) Anti-vibration counterweight fastener connec- M18x15 - Nm (-.-- lb ft) tion TCEI anti-vibration counterweight fastener 10 Nm (7.38 lb ft)
  • Page 21 Stelvio 1200 NTX MY11 Characteristics LUTCH CONTROL pos. Description Type Quantity Torque Notes Viti fissaggio tubo olio 23-26 Nm (16.96-19.18 lbf Viti TE Flang. fissaggio cilindro comando fri- 10 Nm (7.38 lbf ft) zione Viti fissaggio tappo serbatoio 0.8-1.5 Nm (0.59-1.11 lbf Lever pin 5-7 Nm (3.69-5.16 lbf ft) Dado perno leva...
  • Page 22 Stelvio 1200 NTX MY11 Characteristics RONT MUDGUARD pos. Description Type Quantity Torque Notes Viti TBEI Flang. fissaggio parafango anteriore M5x12 6 Nm (4.42 lbf ft) RONT WHEEL pos. Description Type Quantity Torque Notes Viti TE Flang. fissaggio dischi freno M8x20 25 Nm (18.44 lbf ft) Nut fixing wheel pin 80 Nm (59.00 lbf ft)
  • Page 23 Stelvio 1200 NTX MY11 Characteristics pos. Description Type Quantity Torque Notes Vite TCB fissaggio passacavo M4x6 3 Nm (2.21 lbf ft) RONT BRAKE CALLIPERS pos. Description Type Quantity Torque Notes Viti TE Flang. fissaggio pinze M10x55 50 Nm (36.88 lbf ft) Central part CHAR - 23...
  • Page 24 Stelvio 1200 NTX MY11 Characteristics AIN CABLE HARNESS pos. Description Type Quantity Torque Notes Viti TE Flang. fissaggio piastre bobine M6x20 10 Nm (7.38 lbf ft) Viti TCEI fissaggio bobine 2 Nm (1.47 lbf ft) Viti TCEI fissaggio centralina 10 Nm (7.38 lbf ft) Viti TCEI fissaggio supporto sensore temp.
  • Page 25 Stelvio 1200 NTX MY11 Characteristics OMANDO CAMBIO pos. Description Type Quantity Torque Notes Viti TCEI fissaggio leva rinvio cambio M6x20 10 Nm (7.38 lbf ft) Dadi fissaggio tirante 10 Nm (7.38 lbf ft) Vite TCEI fissaggio piolo leva freno M6x16 10 Nm (7.38 lbf ft) Brake lever pin 15 Nm (11.06 lbf ft)
  • Page 26 Stelvio 1200 NTX MY11 Characteristics EAR BRAKE LEVER pos. Description Type Quantity Torque Notes Viti te Flang. fissaggio pompa freno M6x20 10 Nm (7.38 lbf ft) Loct. 243 Dado bloccaggio asta pompa freno 10 Nm (7.38 lbf ft) Brake lever pin 15 Nm (11.06 lbf ft) Loct.
  • Page 27 Stelvio 1200 NTX MY11 Characteristics RAKE YSTEM pos. Description Type Quantity Torque Notes Brake pipe slot screw on the pump 25 Nm (18.44 lbf ft) Joint with brake pipes retainer bleeding on the 25 Nm (18.44 lbf ft) calliper Brake pipes joint on the ABS hydraulic unit 25 Nm (18.44 lbf ft) Brake pipes joint on the ABS hydraulic unit 30-34 Nm (22.13-25.08 lbf...
  • Page 28 Stelvio 1200 NTX MY11 Characteristics UPPORTO E PEDANE PILOTA pos. Description Type Quantity Torque Notes Viti Flang. fissaggio piastrine 10 Nm (7.38 lbf ft) Viti TCEI fissaggio supporto pedane M8x35 25 Nm (18.44 lbf ft) Vite fissaggio supporto pedane 25 Nm (18.44 lbf ft) Vite TCEI fissaggio supporto pedane M8x25 25 Nm (18.44 lbf ft)
  • Page 29 Stelvio 1200 NTX MY11 Characteristics UEL TANK pos. Description Type Quantity Torque Notes Vite TCEI fissaggio anteriore M6x35 10 Nm (7.38 lbf ft) Vite TE Flang. fissaggio posteriore M6x25 10 Nm (7.38 lbf ft) Viti TCEI fissaggio tappo benzina M5x15 4 Nm (2.95 lbf ft) OPERTURA SERBATOIO CARBURANTE pos.
  • Page 30 Stelvio 1200 NTX MY11 Characteristics CHASSIS pos. Description Type Quantity Torque Notes 50 Nm (36.88 lbf ft) M12x260 50 Nm (36.88 lbf ft) Viti TCEI fissaggio anteriore motore a telaio M12x50 80 Nm (59.00 lbf ft) Screws M8x14 25 Nm (18.44 lbf ft) Viti TE Flang.
  • Page 31 Stelvio 1200 NTX MY11 Characteristics Back side EAR BODYWORK pos. Description Type Quantity Torque Notes Viti SWP fissaggio piastra batteria M5x20 Manual Viti TBEI Flang. fissaggio fianchetti e para- M5x9 6 Nm (4.42 lbf ft) spruzzi Viti TE Flang. fissaggio supporti valigie 10 Nm (7.38 lbf ft) Viti TBEI Flang.
  • Page 32 Stelvio 1200 NTX MY11 Characteristics LICENSE PLATE HOLDER pos. Description Type Quantity Torque Notes Viti TBEI Flang. fissaggio portatarga 6 Nm (4.43 lbf ft) Viti TBEI speciali 6 Nm (4.43 lbf ft) Dado autobloc. flang. fissaggio catadiottro 6 Nm (4.43 lbf ft) RANSMISSION CONNECTION NGINE pos.
  • Page 33 Stelvio 1200 NTX MY11 Characteristics EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm clamp fixing screw on the bushing M6x25 10 Nm (7.37 lbf ft) 2 - Swingarm fixing screw on the transmission M10x35 50 Nm (36.87 lbf ft) housing Swingarm pin on the swingarm 60 Nm (44.25 lbf ft)
  • Page 34 Stelvio 1200 NTX MY11 Characteristics UCI POSTERIORI pos. Description Type Quantity Torque Notes Vite TBEI Flang. fissaggio fanale 6 Nm (4.43 lbf ft) Vite TCEI fissaggio fanale 6 Nm (4.43 lbf ft) Vite TCEI fissaggio fanale targa M5x25 6 Nm (4.43 lbf ft) ANIGLIONE E PORTAPACCHI pos.
  • Page 35 Stelvio 1200 NTX MY11 Characteristics EAR WHEEL pos. Description Type Quantity Torque Notes Vite TE Flang. fissaggio ruota fonica 25 Nm (18.44 lbf ft) Vite TE Flang. fissaggio sensore 10 Nm (7.38 lbf ft) Vite TE Flang. fissaggio sensore M12x65 110 Nm (81.13 lbf ft) CHAR - 35...
  • Page 36 Stelvio 1200 NTX MY11 Characteristics EAR SUSPENSION pos. Description Type Quantity Torque Notes Vite TE Flang. fissaggio superiore ammortiz- M10x80 50 Nm (36.88 lbf ft) zatore Vite TCEI fissaggio biella doppia/forcellone M10x82 50 Nm (36.88 lbf ft) Vite TE fissaggio biella doppia/ammortizza- M10x47 40 Nm (29.50 lbf ft) tore...
  • Page 37 Stelvio 1200 NTX MY11 Characteristics Engine UBRICATION YSTEM pos. Description Type Quantity Torque Notes Pump outlet oil pipe nipple M14x1.5 40 Nm (29.50 lb ft) Slot screw for oil pipe on the cylinder head M14x1.5 20 Nm (14.75 lb ft) Nipple on the radiator and the oil pipe M16x1.5 20 Nm (14.75 lb ft)
  • Page 38 Stelvio 1200 NTX MY11 Characteristics LTERNATOR pos. Description Type Quantity Torque Notes Generator control pulley locking nut 100 Nm (73.76 lb ft) Loctite 243 Generator upper fixing screw 22 Nm (16.23 lb ft) Generator lower fixing screw M10x60 30 Nm (22.13 lb ft) CHAR - 38...
  • Page 39 Stelvio 1200 NTX MY11 Characteristics NTERNAL ONTROLS pos. Description Type Quantity Torque Notes Spring guide pin 24 Nm (17.70 lb ft) Loctite 243 RANKCASE AND pos. Description Type Quantity Torque Notes Stud bolt M8x75 10 Nm (7.37 lb ft) Stud bolt M8x66 10 Nm (7.37 lb ft) Crankshaft rear support flange fixing screw...
  • Page 40 Stelvio 1200 NTX MY11 Characteristics IL SUMP COMPONENTS pos. Description Type Quantity Torque Notes Cover on the flange under the crankcase 40 Nm (29.50 lb ft) Oil filter joint 10 Nm (7.37 lb ft) Loctite 243 Oil sump pipe 20 Nm (14.75 lb ft) Loctite 648 Oil filter 15 Nm (11.06 lb ft)
  • Page 41 Stelvio 1200 NTX MY11 Characteristics YLINDER HEAD COVERS pos. Description Type Quantity Torque Notes Special cylinder head fixing screw 8 Nm (5.90 lb ft) Locked with cross sequence Spark plug cover fixing screw M5x10 8 Nm (5.90 lb ft) ENERATOR OVER pos.
  • Page 42 Stelvio 1200 NTX MY11 Characteristics IR FILTER pos. Description Type Quantity Torque Notes Air filter box fastening screw to frame 10 Nm (7.38 lb ft) Air filter box cover fastening screw SWP 5x20 3 Nm (2.21 lb ft) HROTTLE BODY pos.
  • Page 43 Stelvio 1200 NTX MY11 Characteristics pos. Description Type Quantity Torque Notes Flange fixing screw on the throttle body M5x12 6 Nm (4.42 lb ft) LUTCH pos. Description Type Quantity Torque Notes Clutch to crankshaft fixing screw 42 Nm (30.98 lb ft) Tighten with cross sequence Clutch external flange fixing screw on flywheel...
  • Page 44 Stelvio 1200 NTX MY11 Characteristics ONNECTING ROD ASSEMBLY YLINDERS pos. Description Type Quantity Torque Notes Thermal group fixing stud bolt M10x1.25 5 Nm (3.69 lb ft) Loctite 243 Connecting rod screws 40 Nm (29.50 lb ft) Pre-tightening Connecting rod screws 80 Nm (59.00 lb ft) Final tightening Right hydraulic tensioner cover...
  • Page 45 Stelvio 1200 NTX MY11 Characteristics YSTEM pos. Description Type Quantity Torque Notes Vite fissaggio distanziale vaso espansione 10 Nm (7.38 lbf ft) Blow - By a motore M5x14 Reduction joint for oil return pipe 20 Nm (14.75 lbf ft) Oil return pipe (on sump) 20 Nm (14.75 lbf ft) Vaseline oil CHAR - 45...
  • Page 46 Stelvio 1200 NTX MY11 Characteristics TARTER MOTOR pos. Description Type Quantity Torque Notes Starter motor fixing screw 25 Nm (18.44 lbf ft) Stud bolt 10 Nm (7.37 lbf ft) Starter motor cover fixing screw M6x10 8 Nm (5.90 lbf ft) pos.
  • Page 47 Stelvio 1200 NTX MY11 Characteristics ADIATOR pos. Description Type Quantity Torque Notes Screws fixing radiator to chassis M6x30 10 Nm (7.38 lb ft) IGHT YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lb ft) Loctite 243 CHAR - 47...
  • Page 48 Stelvio 1200 NTX MY11 Characteristics pos. Description Type Quantity Torque Notes Head tightening nut M10x1.25 15 Nm (11.06 lb ft) Engine Oil Pre- tightening Head tightening nut M10x1.25 42 Nm (30.98 lb ft) Final tightening Head tightening screws (chain compartment) M6x120 10 Nm (7.37 lb ft) Plate locking screw and timing gear...
  • Page 49 Stelvio 1200 NTX MY11 Characteristics IMING YSTEM ONTROL pos. Description Type Quantity Torque Notes Control, timing system, shaft support flange M6x14 8 Nm (5.90 lb ft) fixing screw Bearing fixing screw M6x16 10 Nm (7.37 lb ft) Loctite 243 Driving gears locking nut on the crankshaft 200 Nm (147.51 lb ft) Loctite 601 Timing system driven gear locking nut...
  • Page 50 Stelvio 1200 NTX MY11 Characteristics EARBOX pos. Description Type Quantity Torque Notes Clutch housing to gearbox fixing screw M6x55 13 Nm (9.59 lbf ft) Neutral sensor 10 Nm (7.37 lbf ft) Breather stud bolt 8 Nm (5.90 lbf ft) Loctite 243 Gear oil magnetic drainage cap 24 Nm (17.70 lbf ft) Oil filler cap...
  • Page 51 Stelvio 1200 NTX MY11 Characteristics PIN - PISTON COUPLING Specification Desc./Quantity Pin diameter 21.998 - 21.994 mm (0.86606 - 0.86590 in) Pin hole diameter on piston 22.016 - 22.011 mm (0.86677 - 0.86657 in) Clearance between pin and holes on piston 0.013 - 0.022 mm (0.00051 - 0.00087 in) Piston rings On each piston there are:...
  • Page 52 Stelvio 1200 NTX MY11 Characteristics Slot packing system • Fit both pistons on the connecting rods. • Working from both sides, fit the gasket between the crankcase and the cylin- der on the crankcase. • Fit both cylinders. • Take the left cylinder piston to TDC and lock crankshaft rotation.
  • Page 53 Stelvio 1200 NTX MY11 Characteristics • Repeat the same operations to determine the thickness of the left cylinder gasket between cylinder and head also for the right cylinder. CYLINDER GASKET THICKNESS - HEAD Specification Desc./Quantity Value (X) -0.56 / -0.37 mm (-0.022 / -0.0146 in) gasket thickness: 0.65 mm (0.0256 in) Value (X) -0.37 / -0.19 mm (-0.0146 / -0.0075 in) gasket thickness: 0.85 mm (0.0335 in)
  • Page 54 INDEX OF TOPICS S-TOOLS PECIAL TOOLS...
  • Page 55 Stelvio 1200 NTX MY11 Special tools MOTORE Stores code Description 020677Y Generator belt tensioner, lever for belt tensioning 05.91.17.30 Front cover insertion cone 020716Y Connecting rod locking 020470Y Pin snap ring fitting tool 05.92.72.30 Timing system cover sealing ring punch 01.92.91.00 Wrench for removing the cover on sump and filter...
  • Page 56 Stelvio 1200 NTX MY11 Special tools Stores code Description 05.90.25.30 Gearbox support 19.92.96.00 Graduated dial to control ignition timing 12.91.18.01 Tool to lock the flywheel and the starting ring gear 12.91.36.00 Tool to remove the flywheel-side flange AP8140179 Support for valve fitting/removal AP9100838 Tool for valve pressure plate 14.92.71.00...
  • Page 57 Stelvio 1200 NTX MY11 Special tools Stores code Description 12.91.20.00 Tool to fit the flywheel-side flange togeth- er with 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 58 Stelvio 1200 NTX MY11 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 - 58...
  • Page 59 Stelvio 1200 NTX MY11 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 - 59...
  • Page 60 Stelvio 1200 NTX MY11 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 - 60...
  • Page 61 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 62: Scheduled Maintenance Table

    Stelvio 1200 NTX MY11 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 63: Transmission Fluid

    Stelvio 1200 NTX MY11 Maintenance km x 1.000 (mi x 1.000) (0.9) (6.2) (12.4) (18.6) (28.4) (31.1) (37.3) (43.5) (49.7) Footrests joint (5) Suspension and setting Engine oil pressure warning light (4) Empty oil drain pipe from the filter housing Fuel lines (3) Brake lines (3) Clutch wear...

  • Page 64: Engine Oil

    Stelvio 1200 NTX MY11 Maintenance CAUTION DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN. • Screw and tighten the caps (1 - 2). Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL.
  • Page 65 Stelvio 1200 NTX MY11 Maintenance • Operating from both sides, unscrew and remove both screws (1). • Remove the oil sump guard. • Place a container with +4,000 cm³ (244 cu in) capacity under the drainage plug (3). • Unscrew and remove the drainage plug (3).

  • Page 66: Engine Oil Filter

    Stelvio 1200 NTX MY11 Maintenance Engine oil filter Replace the engine oil filter each time you change the engine oil. • Drain the engine oil completely. • Unscrew and remove the engine oil fil- ter from its seat. NOTE NEVER REUSE AN OLD FILTER. •...
  • Page 67 Stelvio 1200 NTX MY11 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 68: Air Filter

    Stelvio 1200 NTX MY11 Maintenance Air filter IR FILTER pos. Description Type Quantity Torque Notes Air filter box fastening screw to frame 10 Nm (7.38 lb ft) Air filter box cover fastening screw SWP 5x20 3 Nm (2.21 lb ft) •...

  • Page 69: Checking The Valve Clearance

    Stelvio 1200 NTX MY11 Maintenance • 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 70 Stelvio 1200 NTX MY11 Maintenance • The measurement must be taken using a special thickness gauge. CAUTION IF CLEARANCE IS LARGER THAN RECOMMENDED, THE TAPPETS WILL BE NOISY. OTHERWISE, THE VALVES DO NOT CLOSE CORRECTLY, WHICH CAN LEAD TO PROB- LEMS SUCH AS: •...
  • Page 71 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 - 71...
  • Page 72 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 73 Stelvio 1200 NTX MY11 Electrical system AIN CABLE HARNESS pos. Description Type Quantity Torque Notes Viti TE Flang. fissaggio piastre bobine M6x20 10 Nm (7.38 lbf ft) Viti TCEI fissaggio bobine 2 Nm (1.47 lbf ft) Viti TCEI fissaggio centralina 10 Nm (7.38 lbf ft) Viti TCEI fissaggio supporto sensore temp.
  • Page 74 Stelvio 1200 NTX MY11 Electrical system Components arrangement key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector 5 Throttle valve potentiometer ELE SYS - 74...
  • Page 75 Stelvio 1200 NTX MY11 Electrical system 6 Fall sensor (optional equipment) 7 Rear light 8 Main fuses 9 Oxygen sensor 10 Battery 11 Starter motor 12 Intake air temperature sensor 13 Engine revolution sensor 14 Head temperature sensor 15 Engine control unit 16 Instrument panel air temperature sensor 17 Front headlamp 18 Alternator...
  • Page 76 Stelvio 1200 NTX MY11 Electrical system • 4 Reused clamps • 7 Cable grommets • 5 Rubber clamps • 7 Cable grommets • 1 Adhesive cable grommet • 1 Cable grommet with clip Motorcycle division The wiring timing is subdivided in three essential sections, as indicated in the figure.
  • Page 77 Stelvio 1200 NTX MY11 Electrical system Front side TABLE A 1. Front headlamp 2. Small clamps 3. Cable grommet 4. Headlamp cable harness TABLE B 1. Rubber clamps TABLE C 1. Front brake switch 2. Faston • Check the faston are connected up to the end.
  • Page 78 Stelvio 1200 NTX MY11 Electrical system TABLE E 1. Main cable harness 2. Small clamp 3. Middle clamp TABLE F 1. Middle clamp 2. Clamp already present on the cable harness ELE SYS - 78...
  • Page 79 Stelvio 1200 NTX MY11 Electrical system TABLE G 1. Medium clamp TABLE H • No part of the cable harness must pro- trude to the inside of the support so as not to obstruct the forks TABLE I 1. Clamp that groups the cable harness of the right light switch, the front stop switch, the front ABS sensor and the key TABLE L...
  • Page 80 Stelvio 1200 NTX MY11 Electrical system TABLE M • Check correct closure of the secondary fuses housing cover TABLE N 1. Middle clamp 2. Ground lead oriented as in the photo 3. Small clamp 4. Cable grommet TABLE O 1. Medium clamps TABLE P 1.
  • Page 81 Stelvio 1200 NTX MY11 Electrical system TABLE Q 1. Keep the cable harness outside according to the relays 2. Clamp TABLE R 1. Middle clamp TABLE S 1. Hook the clamp on the specific hole present in the support. 2. Middle clamp TABLE T 1.
  • Page 82 Stelvio 1200 NTX MY11 Electrical system TABLE U 1. Instrument panel 2. Instrument panel connector correctly connected Central part TABLE A 1. Main cable harness 2 Motor main cable harness 3. Grey taping as reference that must remain be- tween the two covers TABLE B 1.
  • Page 83 Stelvio 1200 NTX MY11 Electrical system TABLE D 1. Pick up cable harness 2. Medium clamp that fastens the right pick-Up ca- ble to the chassis TABLE E 1. Reused clamp TABLE F 1. Cable guide 2. Plastic cable guides TABLE G 1.
  • Page 84 Stelvio 1200 NTX MY11 Electrical system TABLE H • Correct laying of cables for the injec- tors TABLE I 1. Left injector 2. Right injector • Check that the steel clip is correctly placed after the connection TABLE L 1. Middle clamp 2.
  • Page 85 Stelvio 1200 NTX MY11 Electrical system TABLE M 1. Ground cable harness 2. Battery ground lead 3. Left lambda sensor. 4. Clamp to keep the starter motor cable harness far from the throttle bodies control pin TABLE N 1. Starter motor •...
  • Page 86 Stelvio 1200 NTX MY11 Electrical system TABLE O 1. Starter motor cover 2. Cable grommet • If the cable grommet is correctly fitted, it will be hidden by the cover. TABLE P 1. Oxygen sensor cable harness 2. Cable grommet •...
  • Page 87 Stelvio 1200 NTX MY11 Electrical system TABLE T • Place the connector on the opposite side of the control unit and lower the driving lever until the "click" that signals the end of the stroke is heard. TABLE U • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5...
  • Page 88 Stelvio 1200 NTX MY11 Electrical system Back side TABLE A 1. Main fuses 2. Filter box air temperature sensor 3. Filter box 4. Secondary fuse protection injection system. TABLE B 1. Medium clamp 2. Main cable harness TABLE C 1. Rear plug socket 2.
  • Page 89 Stelvio 1200 NTX MY11 Electrical system TABLE E 1. Plastic cable guides TABLE F 1. Medium clamp that groups the oxygen sensor leads, the rear stop and the rear taillight cable har- ness TABLE G 1. Fall sensor connector with cover TABLE H 1.
  • Page 90 Stelvio 1200 NTX MY11 Electrical system TABLE I 1. Cable grommet 2. Lambda leads TABLE L 1. Reused clamps 2. Small clamp that has the lambda and the rear stop cable together with the pipes group General wiring diagram OPTION 01 ELE SYS - 90...
  • Page 91 Stelvio 1200 NTX MY11 Electrical system key: 1. MULTIPLE CONNECTORS 2. CLUTCH SWITCH 3. START-UP RELAY 4. MAINTENANCE RELAY 5. LIGHT LOGIC RELAY 6. FOG LAMP RELAY ELE SYS - 91...
  • Page 92 Stelvio 1200 NTX MY11 Electrical system 7. RIGHT LIGHT SWITCH 8. LEFT LIGHT SWITCH 9. HORN 10.AMBIENT AIR TEMPERATURE SENSOR 11.INSTRUMENT PANEL 12.IMMOBILIZER AERIAL 13.IGNITION KEY 14.HEATED HANDGRIPS 15.GPS COUPLING 16.- 17.- 18.REAR RIGHT TURN INDICATOR 19.TAILLIGHT ASSEMBLY 20.REAR LEFT TURN INDICATOR 21.LICENSE PLATE LIGHT BULB 22.REAR STOP SWITCH 23.FRONT STOP SWITCH...
  • Page 93 Stelvio 1200 NTX MY11 Electrical system 45.ENGINE TEMPERATURE SENSOR 46.IDLE MOTOR 47.THROTTLE POSITION SENSOR 48.RIGHT CYLINDER COIL 49.LEFT CYLINDER COIL 50.RIGHT SPARK PLUG 51.LEFT SPARK PLUG 52.RIGHT CYLINDER INJECTOR 53.LEFT CYLINDER INJECTOR 54.FALL SENSOR (OPTIONAL EQUIPMENT) 55.PICK-UP 56.ECU 57.FOG LIGHTS 58.FRONT LEFT TURN INDICATOR 59.COMPLETE HEADLAMP 60.TAIL LIGHT BULB...
  • Page 94 Stelvio 1200 NTX MY11 Electrical system key: 1. MULTIPLE CONNECTORS 2. CLUTCH SWITCH 3. START-UP RELAY 4. MAINTENANCE RELAY 5. LIGHT LOGIC RELAY 6. FOG LAMP RELAY ELE SYS - 94...
  • Page 95 Stelvio 1200 NTX MY11 Electrical system 7. RIGHT LIGHT SWITCH 8. LEFT LIGHT SWITCH 9. HORN 10.AMBIENT AIR TEMPERATURE SENSOR 11.INSTRUMENT PANEL 12.IMMOBILIZER AERIAL 13.IGNITION SWITCH 14.HEATED HANDGRIPS 15.GPS COUPLING 16.- 17.- 18.REAR RIGHT TURN INDICATOR 19.TAILLIGHT ASSEMBLY 20.REAR LEFT TURN INDICATOR 21.LICENSE PLATE LIGHT BULB 22.REAR STOP SWITCH 23.FRONT STOP SWITCH...
  • Page 96 Stelvio 1200 NTX MY11 Electrical system 45.ENGINE TEMPERATURE SENSOR 46.IDLE MOTOR 47.THROTTLE POSITION SENSOR 48.RIGHT CYLINDER COIL 49.LEFT CYLINDER COIL 50.RIGHT SPARK PLUG 51.LEFT SPARK PLUG 52.RIGHT CYLINDER INJECTOR 53.LEFT CYLINDER INJECTOR 54.FALL SENSOR (OPTIONAL EQUIPMENT) 55.PICK-UP 56.ECU 57.FOG LIGHTS 58.FRONT LEFT TURN INDICATOR 59.COMPLETE HEADLAMP 60.TAIL LIGHT BULB...
  • Page 97 Stelvio 1200 NTX MY11 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 98 Stelvio 1200 NTX MY11 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 Coil 2 Error DC Gnd ECU 25 Injector 1 Error DC V DC ECU 26 Injector 1 Error DC Gnd ECU 27...
  • Page 99 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 100 Stelvio 1200 NTX MY11 Electrical system Checking the stator Single-phase generator with regulated voltage Maximum load 40A (550W) Charging voltage 14.2 - 14.8 V (5000 rpm) Start-up system check pick-up input about 100 A level indicators Petrol pump: Input: 3.5 A (to be measured between pins 1 and 2 with 12V voltage) Fuel level sensor: Resistance (to be measured between pins 3 and...
  • Page 101 Stelvio 1200 NTX MY11 Electrical system Lights list FRONT HEADLAMP Specification Desc./Quantity Front daylight running lights 12V - 5W Low/high beam light (halogen) 12 V - 55 W / 60 W H4 REAR LIGHT Specification Desc./Quantity Rear daylight running light/stop light License plate light 12V - 5 W Fuses...

  • Page 102: Control Unit

    Stelvio 1200 NTX MY11 Electrical system D - Fuel pump, coils, injectors (15 A). D - Lambda burner, secondary injection relay coil, start-up relay coil (15 A). F- Permanent positive, ECU power supply, starter relay (3A). G - Plug socket (5A). NOTE THREE OF THE FUSES ARE SPARES (H).

  • Page 103: Speed Sensor

    Stelvio 1200 NTX MY11 Electrical system Battery 12 V - 18 Ampere/hour Speed sensor FRONT FUNCTION:To indicate the vehicle speed by read- ing the front wheel turning speed. OPERATION / OPERATING PRINCIPLE:Magne- toresistive sensor: a square-wave pulse is gener- ated with voltage approx. between 11.55 V and 11.25 V WIRING DIAGRAM Level in wiring diagram: ABS.
  • Page 104 Stelvio 1200 NTX MY11 Electrical system PIN 2 of the sensor on the cable harness side, with the sensor disconnected and key set to ON, must have 12V voltage approximately: if there is no voltage, check PIN 2 for continuity with the vehicle ground connection: if it is grounded, restore the cable harness.
  • Page 105 Stelvio 1200 NTX MY11 Electrical system OK, check that the tyre pressure is the correct one. If it is not OK, restore it; if it is OK, replace the speed sensor. REAR FUNCTION: It is used by the ABS module, and then by the ECU and the instrument panel.
  • Page 106 Stelvio 1200 NTX MY11 Electrical system Description of the defect: the control unit detects an abnormal condition in the signals coming from the speed sensors: for example, disturbances, signal intensity reduced, speed difference between the two wheels for a certain period of time, etc. Checks:check the correct distance between speed sensor and tone wheel.
  • Page 107 Stelvio 1200 NTX MY11 Electrical system PIN: 1. Engine revolution sensor positive signal. 2. Engine revolution sensor negative signal. 3. Revolution sensor anti-jamming cable. NAVIGATOR: PARAMETERS Target engine revs Example value:1100 +/- 100 rpm Parameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to keep the engine running at this revs, acting on the ignition advance.
  • Page 108 Stelvio 1200 NTX MY11 Electrical system Throttle position sensor Function In charge of telling the control unit the position of the throttle valves. Operation / Operating principle The throttle valve position sensor works as a var- iable resistance according to the throttle rotation. Level in electrical circuit diagram:Throttle and idle motor Location:...
  • Page 109 Stelvio 1200 NTX MY11 Electrical system Throttle actuator position sensor P0120 Example value:open circuit, shorted to positive / shorted to negative. Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 3 of connector A (BROWN).
  • Page 110 Stelvio 1200 NTX MY11 Electrical system Engine temperature sensor Function tells the engine temperature to the control unit so as to optimise its operation. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in electrical circuit diagram:Temperature sensors Location: •...
  • Page 111 Stelvio 1200 NTX MY11 Electrical system In case of recovery, this value is set by the control unit. NAVIGATOR: ERRORS engine temperature sensor P0115 - open circuit, shorted to positive / shorted to negative. Error cause • If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 5 of connector A (BROWN).
  • Page 112 Stelvio 1200 NTX MY11 Electrical system Air temperature sensor Function It tells the control unit the intake air temperature in order to calculate oxygen presence so as to opti- mise the petrol quantity necessary for correct com- bustion. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature).
  • Page 113 Stelvio 1200 NTX MY11 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 114 Stelvio 1200 NTX MY11 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 115 Stelvio 1200 NTX MY11 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 116 Stelvio 1200 NTX MY11 Electrical system • If shorted to positive: excessive voltage has been detected at PIN 1 of the BLUE connector. • If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 1 of the BLUE connector.
  • Page 117 Stelvio 1200 NTX MY11 Electrical system Injector Function To supply the correct amount of petrol at the right timing. Operation / Operating principle Injector coil is excited for the petrol passage to open. Level in electrical circuit diagram:Coils and in- jectors Location: •...
  • Page 118 Stelvio 1200 NTX MY11 Electrical system • If short circuit to positive: disconnect the injector connector, take the key to ON and check if there is voltage on the grey/red cable: if there is voltage, restore the cable harness. If there is no voltage, replace the injector •...
  • Page 119 Stelvio 1200 NTX MY11 Electrical system between PIN 37 of the BROWN connector and the component PIN - and restore the cable harness Coil Function It controls the ignition spark plug in order to gen- erate the fuel ignition spark. Operation / Operating principle Inductive discharge system Level in electrical circuit diagram:Coils and in-...
  • Page 120 Stelvio 1200 NTX MY11 Electrical system • If shorted to positive: excessive voltage has been detected at PIN 38 of the BROWN con- nector. • If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 38 of the BROWN connector Troubleshooting •...
  • Page 121 Stelvio 1200 NTX MY11 Electrical system continuity, restore the cable harness; if there is cable continuity, with the key set to KEY ON, check the cable ground insulation (from coil connector or control unit connector). If this is not OK, restore the cable harness. Engine oil pressure sensor Function:Indicates the instrument panel if there is enough oil pressure (0.35 +/- 0.15 bar) (5.1 +/-...
  • Page 122 Stelvio 1200 NTX MY11 Electrical system It this error persists, use a pressure gauge to check the pressure of the oil in the engine circuit Neutral sensor Function it tells the gear position to the control unit: in neutral or in gear. 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 123 Stelvio 1200 NTX MY11 Electrical system that the grey/black cable from PIN 1 of the sensor to PIN 23 of the BROWN connector is shorted to ground: restore the cable harness. Clutch lever sensor Function It tells the clutch lever position to the control unit. Operation / Operating principle If the gear is engaged but the clutch is pulled, i.e.

  • Page 124: Bank Angle Sensor

    Stelvio 1200 NTX MY11 Electrical system the sensor. If the circuit is open, it means that the brown/purple cable from PIN 1 of the sensor to PIN 33 of the BLUE connector is shorted to ground: restore the cable harness Side stand sensor Function It tells the side stand position to the control unit.
  • Page 125 Stelvio 1200 NTX MY11 Electrical system Function it tells the vehicle position to the control unit. Operation / Operating principle When the sensor is inverted, the circuit is closed to ground: when the Marelli control unit detects this earthing, it disables the fuel pump circuit and the engine start-up circuit via the injection relay.
  • Page 126 Stelvio 1200 NTX MY11 Electrical system Air temperature sensor - instrument panel Function It tells the ambient air temperature to the instru- ment panel. Operation / Operating principle NTC type sensor (resistance sensor, inversely variable with temperature). Level in electrical circuit diagram:Temperature sensors Location: •...
  • Page 127 Stelvio 1200 NTX MY11 Electrical system upstream the resistance decreases, replace the instrument panel. If voltage continues to be approximately 5V, restore the pink cable (there is a short circuit at + 5V). Notes If a short circuit to ground is detected at PIN 10 of the instrument panel connector, the display will show a full scale air temperature indication of 60 °C (140 °F) Check the ground insulation of the sensor connector pink cable: if there is a connection, restore the cable harness;...
  • Page 128 Stelvio 1200 NTX MY11 Electrical system there is continuity of the sky blue/orange cable between the connector in question and PIN 27 of the BLUE connector: if not OK, restore the cable harness; if OK, replace the Marelli control unit. •...
  • Page 129 Stelvio 1200 NTX MY11 Electrical system 25 Engine revolution sensor signal 26 Not used 27 Not used 28 Left cylinder injector control 29 Ignition potentiometer negative. 30 Not used 31 Not used 32 Ignition potentiometer power supply. 33 Not used 34 Revolution sensor anti-jamming cable 35 Engine revolution sensor signal 36 Not used...
  • Page 130 Stelvio 1200 NTX MY11 Electrical system 23 Not used 24 Vehicle speed signal input 25 Not used 26 Not used 27 "Engine stop" signal input 28 Ignition signal input 29 CAN - L line (ccm/instrument panel) 30 Not used 31 Ingresso sensore Lambda 2 (destra) (+) 32 Ingresso sensore Lambda 1 (sinistra) (-) 33 Clutch sensor signal 34 Not used...
  • Page 131 Stelvio 1200 NTX MY11 Electrical system 17 OIL PRESSURE SENSOR INTAKE 18 SENSORS EARTH CONNECTION 19 GENERAL GROUND (OPTIONAL) 20 GENERAL GROUND (OPTIONAL) The pin configuration of the BLACK-bodied connector is as follows: PIN USE 21 + BATTERY 22 FRONT LEFT TURN INDICATOR ACTIVATION 23 REAR LEFT TURN INDICATOR ACTIVATION 24 AERIAL 1 25 LEFT HEATED HANDGRIPS ACTUATOR (OPT)
  • Page 132 Stelvio 1200 NTX MY11 Electrical system 40 CONTROL - UP ABS Modulator Pin Use 1. Ground connection 2. Not used 3. Speed signal for injection ECU 4. ABS control unit power supply 5. Not used 6. Not used 7. ABS deactivation switch 8.
  • Page 133 INDEX OF TOPICS ENG VE NGINE FROM VEHICLE...
  • Page 134 Stelvio 1200 NTX MY11 Engine from vehicle Vehicle preparation Before removing the engine block, proceed as follows: • Rest the vehicle on its centre stand. • From the back, secure the vehicle with belts attached to a hoist. • From the front, secure the vehicle with belts attached to the handlebar and fixed to the work bench.
  • Page 135 Stelvio 1200 NTX MY11 Engine from vehicle • Disconnect the connectors of the start- er motor. • Disconnect the stand sensor connec- tor and release it from the clamps. • Slide off the gearbox oil breather pipe. • Disconnect the gear in neutral sensor connector.
  • Page 136 Stelvio 1200 NTX MY11 Engine from vehicle • Disconnect the horn connectors. • Operating from both sides, undo and remove the screw fixing the oil radiator to the chassis. • Loosen the clamp and slide off the oil pipe from the blow-by tank. •...
  • Page 137 Stelvio 1200 NTX MY11 Engine from vehicle • Working from both sides, undo and re- move the three inlet manifold screws. • Collect the gasket. • Disconnect the alternator connectors. • Disconnect the engine temperature sensor connector ENG VE - 137...
  • Page 138 Stelvio 1200 NTX MY11 Engine from vehicle • Disconnect the engine oil pressure sensor connector. • Disconnect the revolution sensor con- nector. • Remove the fairing under the oil sump. • Support the vehicle with the engine service stand. • Undo and remove the screws fixing the centre stand plates.
  • Page 139 Stelvio 1200 NTX MY11 Engine from vehicle • Operating from both sides, undo and remove the upper engine fixing nut on the internal side of the chassis. • Unscrew and remove the engine lower fixing nut and collect the washer. •...
  • Page 140 Stelvio 1200 NTX MY11 Engine from vehicle Installing the engine to the vehicle • Place the vehicle chassis over the en- gine with the gear. • From the back, secure the chassis with belts attached to a hoist. • From the front, secure the vehicle with belts attached to the handlebar and fixed to the work bench.
  • Page 141 Stelvio 1200 NTX MY11 Engine from vehicle • Operating from both sides, tighten the upper engine fixing nut on the internal side of the chassis. • Fit the centre stand. • Operating from both sides, tighten the screws fixing the centre stand plates. •...
  • Page 142 Stelvio 1200 NTX MY11 Engine from vehicle • Insert the oil breather pipe and fasten it with a new clamp. • Fit the gearbox oil breather pipe. • Fit the clutch control cylinder. • Tighten the three screws. • Connect the starter motor connectors. ENG VE - 142...
  • Page 143 Stelvio 1200 NTX MY11 Engine from vehicle • Connect the ground leads and tighten the stud bolt. • Fit the starter motor cover. • Tighten the screws. • Connect the neutral sensor connector. • Connect the alternator connectors. ENG VE - 143...
  • Page 144 Stelvio 1200 NTX MY11 Engine from vehicle • Connect the revolution sensor connec- tor. • Connect the horn connectors. • Connect the engine temperature sen- sor connector. • Place the oil radiator. • Tighten the two screws. ENG VE - 144...
  • Page 145 Stelvio 1200 NTX MY11 Engine from vehicle • Place the fork with cardan shaft and the rear wheel. • Working on both sides, connect the in- jector connectors. • Adjust the throttle grip cable clearance. • Working from both sides, connect the spark plug tube.
  • Page 146 INDEX OF TOPICS NGINE...
  • Page 147 Stelvio 1200 NTX MY11 Engine Gearbox Diagram key: 1. Ball bearing ENG - 147...
  • Page 148 Stelvio 1200 NTX MY11 Engine 2. Circlip 3. Thickness 4. Pin 5. Complete desmodromic 6. Ball bearing 7. Spring 8. Spacer 9. Circlip 10.Fifth wheel 11.Linking pin 12.Gear 13.Circlip 14.Thrust washer 15.Roller cage 16.Gear 17.Seal ring 18.Ball bearing 19.Gear 20.Circlip 21.Clutch shaft 22.Ball bearing 23.Oil plug...
  • Page 149 Stelvio 1200 NTX MY11 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 150 Stelvio 1200 NTX MY11 Engine • Unscrew and remove the gearbox oil filler cap. • Place a container of suitable capacity under it, unscrew and remove the cap and then bleed all gearbox oil. • Loosen and turn the oil pipe joint on the sump.
  • Page 151 Stelvio 1200 NTX MY11 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 - 151...
  • Page 152 Stelvio 1200 NTX MY11 Engine Disassembling the gearbox • Remove the gearbox. • Unscrew and slide off the odometer gear and collect the abutment washer that is inside the gearbox. • From the outside, slide off the thrust cylinder and collect the O-Ring and the washer.
  • Page 153 Stelvio 1200 NTX MY11 Engine • Slide off the rod with the two bushings. • Undo and remove the five external screws. • Place the gearbox on the specific gearbox support tool and on a vice. Specific tooling 05.90.25.30 Gearbox support •...
  • Page 154 Stelvio 1200 NTX MY11 Engine • Remove the bearings from the gearbox if necessary. • Release the spring. • Pressing the selector, slide off the whole transmission lever. • Use rubber bands to tie down the trans- mission shaft unit and extract it. ENG - 154...
  • Page 155 Stelvio 1200 NTX MY11 Engine • Once the transmission shaft unit is in on a bench, remove the rubber bands, being careful with the group. • Detach the shafts and label the forks before removal. • Remove the forks and collect the shaft. ENG - 155...
  • Page 156 Stelvio 1200 NTX MY11 Engine • Replace bearings if necessary and re- move the clutch shaft. See also Removing the gearbox Removing the primary shaft • Remove the main shaft. • Operate on the main shaft from the second gear side. •...
  • Page 157 Stelvio 1200 NTX MY11 Engine • Remove the gear of the sixth gear and collect the shoulder washer. • Remove the circlip. • Remove the gear of the third and fourth gears. • Remove the circlip and collect the shoulder washer. ENG - 157...
  • Page 158 Stelvio 1200 NTX MY11 Engine • Remove the gear of the fifth gear and collect the ball bearing cage. • Heat the shaft with a specific heater and remove the helical transmission gear. Removing the secondary shaft • Remove the transmission shaft. •...
  • Page 159 Stelvio 1200 NTX MY11 Engine • Remove the gear of the second gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. • Remove the gear of the sixth gear. • Remove the circlip and collect the shoulder washer.
  • Page 160 Stelvio 1200 NTX MY11 Engine • Remove the gear of the fourth gear and collect the ball bearing cage. • Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. •...
  • Page 161 Stelvio 1200 NTX MY11 Engine • Remove the circlip, the shoulder wash- er and remove the gear of the first gear, collect the ball bearing cage. • Remove the bearing if necessary. See also Disassembling the gearbox Checking the primary shaft Measure coaxiality of the main shaft with a dial gauge and a centring device and replace it if not complying with specifications.
  • Page 162 Stelvio 1200 NTX MY11 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 163 Stelvio 1200 NTX MY11 Engine primary shaft Fitting the secondary shaft NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED. See also Removing the secondary shaft Assembling the gearbox NOTE...
  • Page 164 Stelvio 1200 NTX MY11 Engine Disassembling the gearbox Gear selector NTERNAL ONTROLS pos. Description Type Quantity Torque Notes Spring guide pin 24 Nm (17.70 lb ft) Loctite 243 ENG - 164...
  • Page 165 Stelvio 1200 NTX MY11 Engine Generator key: 1. Alternator 2. Spacer 3. Screw 4. Screw 5. Nut 6. Belt 7. Generator control pulley 8. Nut 9. Washer 10.Magneto flywheel cotter 11.Screw 12.Nut ENG - 165...
  • Page 166 Stelvio 1200 NTX MY11 Engine LTERNATOR pos. Description Type Quantity Torque Notes Generator control pulley locking nut 100 Nm (73.76 lb ft) Loctite 243 Generator upper fixing screw 22 Nm (16.23 lb ft) Generator lower fixing screw M10x60 30 Nm (22.13 lb ft) ENERATOR OVER pos.

  • Page 167: Removing The Generator

    Stelvio 1200 NTX MY11 Engine pos. Description Type Quantity Torque Notes Timing system cover fixing screw M8x55 25 Nm (18.44 lb ft) Timing system cover fixing screw M6x30 12 Nm (8.85 lb ft) Generator cover fixing screw M6x16 12 Nm (8.85 lb ft) Removing the generator •...
  • Page 168 Stelvio 1200 NTX MY11 Engine • Loosen the screw. • Loosen the nut and undo the set screw so that the alternator slides down. • Completely loosen and remove the screw. • Remove the belt and the alternator with pulley. ENG - 168...
  • Page 169 Stelvio 1200 NTX MY11 Engine • Using a compressed air gun, unscrew and remove the nut and collect the spacer. • Remove the lower pulley. • Unscrew and remove the eight screws. • Undo and remove the two screws. ENG - 169...
  • Page 170 Stelvio 1200 NTX MY11 Engine • Undo and remove the two screws. • Remove the alternator frame. • Remove the sealing ring if necessary. See also Fuel tank Tensioning the belt • Remove the left fairing lug. • Undo and remove the two front fixing screws of the oil radiator.
  • Page 171 Stelvio 1200 NTX MY11 Engine • Remove the generator belt cover by lightly loosening the oil radiator. • Loosen the screw. • Loosen the nut and undo the set screw so that the alternator slides down. • Using the belt tensioning tool, tension the belt to the prescribed torque.

  • Page 172: Installing The Generator

    Stelvio 1200 NTX MY11 Engine Installing the generator • If the sealing ring has been previously removed, replace it using the punch of the timing system cover sealing ring. Specific tooling 05.92.72.30 Timing system cover sealing ring punch • Place the bolt and the pin in the gen- erator cover.
  • Page 173 Stelvio 1200 NTX MY11 Engine • Tighten the eight lower screws. • Operating diagonally and in stages, tighten the ten fixing screws on the al- ternator fitting. • Tighten the four screws, operating di- agonally and in stages. • Position the lower pulley and the spacer.
  • Page 174 Stelvio 1200 NTX MY11 Engine • Position the screw and pre-tighten it. • Position the screw and tighten the nut. • Using the belt tensioning tool, tension the belt to the prescribed torque and tighten the set screw. • Remove the belt tensioning tool. •...

  • Page 175: Starter Motor

    Stelvio 1200 NTX MY11 Engine • Tighten the alternator fixing screws. • Place the alternator belt cover. • Tighten the five screws operating diag- onally and in stages. Starter motor Removing the starter motor • Undo and remove the two screws and collect the washers.
  • Page 176 Stelvio 1200 NTX MY11 Engine • Slide off the starter motor. Clutch side Disassembling the clutch key: 1. Complete clutch 2. Clutch 3. Clutch bell 4. TCEI screw 5. Clutch plate 6. Sprocket 7. TCEI screw 8. Clutch thrust plate ENG - 176...
  • Page 177 Stelvio 1200 NTX MY11 Engine 9. Ring 10.TE flanged screw 11.Conical washer 12.Bushing 13.Rod 14.Bushing 15.Intermediate body 16.Thrust bearing 17.Clutch control bowl 18.Thrust cylinder 19.Clutch control cylinder 20.TE flanged screw LUTCH pos. Description Type Quantity Torque Notes Clutch to crankshaft fixing screw 42 Nm (30.98 lb ft) Tighten with cross sequence...
  • Page 178 Stelvio 1200 NTX MY11 Engine • Remove the complete gearbox. • Unscrew and remove the six screws. • Remove the start-up crown gear. • Remove the clutch housing and the friction disc. • Remove the retainer ring. • Remove the clutch pressure cap. ENG - 178...
  • Page 179 Stelvio 1200 NTX MY11 Engine • Undo and remove the six screws and collect the Belleville springs. • Remove the clutch plate. See also Removing the gearbox Checking the clutch actuator If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod.
  • Page 180 Stelvio 1200 NTX MY11 Engine 020678Y Tool for clutch rod checking CLUTCH CONTROL ROD SELECTION Specification Desc./Quantity Protrusion: 9.8 - 11.2 mm (0.386 - 0.441 in) Clutch control rod length (code 976593) = 183 mm (7.205 in) Protrusion: 8.3 - 9.7 mm (0.327 - 0.382 in) Clutch control rod length (code 976594) = 184.5 mm (7.264 in) Protrusion: 6.8 - 8.2 mm (0.268 - 0.323 in) Clutch control rod length (code 976595) = 186 mm (7.323 in)
  • Page 181 Stelvio 1200 NTX MY11 Engine • Once the centring tool is fitted, lock the plate with the snap ring. • Undo and remove the two screws fixing the tool. • Remove the special tool. • Place the friction disc; centre it. •...
  • Page 182 Stelvio 1200 NTX MY11 Engine Heads YLINDER HEAD COVERS pos. Description Type Quantity Torque Notes Special cylinder head fixing screw 8 Nm (5.90 lb ft) Locked with cross sequence Spark plug cover fixing screw M5x10 8 Nm (5.90 lb ft) OPTION 01 - TRADITIONAL TIMING SYSTEM ENG - 182...
  • Page 183 Stelvio 1200 NTX MY11 Engine IGHT YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lb ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lb ft) Engine Oil Pre- tightening Head tightening nut M10x1.25 42 Nm (30.98 lb ft) Final tightening...
  • Page 184 Stelvio 1200 NTX MY11 Engine IGHT YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lb ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lb ft) Engine Oil Pre- tightening Head tightening nut M10x1.25 42 Nm (30.98 lb ft) Final tightening...
  • Page 185 Stelvio 1200 NTX MY11 Engine YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lb ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lb ft) Engine Oil Pre- tightening Head tightening nut M10x1.25 42 Nm (30.98 lb ft) Final tightening...
  • Page 186 Stelvio 1200 NTX MY11 Engine key: 1. Right cylinder head 2. Stud bolt 3. Cylinder head gasket 4. Right rocking lever support 5. Screw 6. Pin 7. Nut 8. Right exhaust, left intake rocking lever 9. Left exhaust, right intake rocking lever 10.Set screw 11.Nut 12.Rocking lever rod...
  • Page 187 Stelvio 1200 NTX MY11 Engine 22.Complete breather cover 23.TBEI screw 24.Timing system chain 25.Chain guide slider 26.Chain tensioner pad 27.Chain tensioner screw 28.Right chain tensioner 29.Left cylinder head 30.Stud bolt 31.Cylinder head gasket 32.Left rocking lever support 33.Screw 34.Pin 35.Nut 36.Right exhaust, left intake rocking lever 37.Left exhaust, right intake rocking lever 38.Set screw...
  • Page 188 Stelvio 1200 NTX MY11 Engine key: 1. Pad 2. Hydraulic tappet 3. Right rocker axle support 4. Pin D. 2.5 5. Screw M8x30 6. Threaded cap M6x10 7. Camshaft 8. Pin 9. Intake and exhaust com. rockers 10.Rocker adjustment nut 11.Adjustment screw 12.Intake and exhaust com.
  • Page 189 Stelvio 1200 NTX MY11 Engine 22.Nut M10x1.25 6H 23.Flanged screw M6x120 24.Flat washer 12x6.1x2 25.Timing system gear 26.Breather plate 27.Flanged screw 28.Seal ring 2.62x46.52 29.Timing chain 30.Chain guide slider 31.Chain tensioner pad 32.Spacer screw M8 Removing the head cover NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY TO BOTH HEADS.

  • Page 190: Removing The Cylinder Head

    Stelvio 1200 NTX MY11 Engine • Remove the head cover together with the gaskets. Removing the cylinder head OPTION 01 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 191 Stelvio 1200 NTX MY11 Engine For the right head: • Unscrew and remove the chain ten- sioner cap. • Remove the right chain tensioner. For the left head: • Unscrew and remove the screw and the washer. • Relief oil pressure from the left chain tensioner.
  • Page 192 Stelvio 1200 NTX MY11 Engine • Unscrew and remove the four nuts on the stud bolts. • Remove the complete cam cap. • Unscrew and remove the two screws. • Remove the head. • Fit the timing system upper gear back to the chain.
  • Page 193 Stelvio 1200 NTX MY11 Engine • Remove the head cover. • Unscrew and remove the two screws in the points indicated in the figure. • Remove the blow-by spout. • Undo and remove the centrifugal sep- arator fixing screw. • Remove the spacer as shown in the figure.
  • Page 194 Stelvio 1200 NTX MY11 Engine For the right head: • Unscrew and remove the chain ten- sioner cap. • Remove the right chain tensioner. For the left head: • Unscrew and remove the screw and the washer. • Relief oil pressure from the left chain tensioner.

  • Page 195: Cylinder Head

    Stelvio 1200 NTX MY11 Engine • Unscrew and remove the four nuts on the stud bolts. • Remove the complete cam cap. • Unscrew and remove the two screws. • Remove the head. • Fit the timing system upper gear back to the chain.
  • Page 196 Stelvio 1200 NTX MY11 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. OPTION 01 - TRADITIONAL TIMING SYSTEM • Remove the two rocking levers from the cam cap.
  • Page 197 Stelvio 1200 NTX MY11 Engine • Unscrew and remove the four screws. • Remove the U-bolt. • Remove the camshaft. • Remove the roller hydraulic tappets from the cam tower, marking the posi- tion to not invert when refitting. Removing the rocker arms CAUTION WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CARE- FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
  • Page 198 Stelvio 1200 NTX MY11 Engine • Remove the cam cap from the stud bolts. • Undo and remove the two screws. • Remove the U-bolt. • Remove the two rocking levers from the cam cap. OPTION 02 - ROLLER TIMING SYSTEM •...

  • Page 199: Removing The Valves

    Stelvio 1200 NTX MY11 Engine Removing the valves • Remove the head. • Place the special tool on the upper cap and at the centre of the head of the valve to be removed. Specific tooling 10.90.72.00 Tool for valve removal and refitting AP9100838 Tool for valve pressure plate •...

  • Page 200: Checking The Cylinder Head

    Stelvio 1200 NTX MY11 Engine • Use a reamer to bore the holes the valve stems slide through so that the inside diameter is at the prescribed value. The interference between the seat on the head and the valve guide must be 0.046 - 0.075 mm (0.0018 - 0.0030 in) VALVE GUIDE COUPLING - VALVES (INLET) Specification...

  • Page 201: Installing The Valves

    Stelvio 1200 NTX MY11 Engine - Replace the head in case of excessive wear or damage. Installing the valves NOTE THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Place the valve guide oil seal (4) in the head.
  • Page 202 Stelvio 1200 NTX MY11 Engine WARNING MAKE SURE THAT THE NOTCH ON THE DIPSTICK BODY FACES THE ROCKING LEVER. • 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.
  • Page 203 Stelvio 1200 NTX MY11 Engine • Place the half spheres (1) into the ap- propriate seats (2) of the rocker. • Place the two rocking levers in the cam tower seats. • Position the U-bolt on the rockers. • Position the ground plate and tighten the two screws.
  • Page 204 Stelvio 1200 NTX MY11 Engine • Place the camshaft with the gear seat on the dowel side. • Insert and tighten the shim washer. • Place the U-bolt on the camshaft mak- ing sure the two reference pins match the seats on the cam tower. •...
  • Page 205 Stelvio 1200 NTX MY11 Engine • Position the cam shaft paying attention to the direction. • Position the U-bolt on the camshaft matching up the reference pins. • Tighten the four fixing screws to the prescribed torque, proceeding diago- nally. •...
  • Page 206 Stelvio 1200 NTX MY11 Engine • Tighten the camshaft fixing screw. • Between the two washers, there is a cup spring which recovers the axial clearance of the shaft. The spring must necessarily be centred using the ap- propriate tool. Specific tooling 020954Y Centring cam shaft cup spring Timing...
  • Page 207 Stelvio 1200 NTX MY11 Engine pos. Description Type Quantity Torque Notes Driving gears locking nut on the crankshaft 200 Nm (147.51 lb ft) Loctite 601 Timing system driven gear locking nut 25 Nm (18.44 lb ft) Pre-tightening Timing system driven gear locking nut 150 Nm (110.63 lb ft) Final tightening Removing the phonic wheel...
  • Page 208 Stelvio 1200 NTX MY11 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 209 Stelvio 1200 NTX MY11 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 210 Stelvio 1200 NTX MY11 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 211 Stelvio 1200 NTX MY11 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 212 Stelvio 1200 NTX MY11 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 213 Stelvio 1200 NTX MY11 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 214 Stelvio 1200 NTX MY11 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 215 Stelvio 1200 NTX MY11 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 ONNECTING ROD ASSEMBLY YLINDERS pos.
  • Page 216 Stelvio 1200 NTX MY11 Engine YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lb ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lb ft) Engine Oil Pre- tightening Head tightening nut M10x1.25 42 Nm (30.98 lb ft) Final tightening...
  • Page 217 Stelvio 1200 NTX MY11 Engine IGHT YLINDER pos. Description Type Quantity Torque Notes Movable chain tensioner pad fixing screw 20 Nm (14.75 lb ft) Loctite 243 Head tightening nut M10x1.25 15 Nm (11.06 lb ft) Engine Oil Pre- tightening Head tightening nut M10x1.25 42 Nm (30.98 lb ft) Final tightening...
  • Page 218 Stelvio 1200 NTX MY11 Engine • Remove the two dowel pins on the stud bolts. • Remove the two gaskets between the crankcase and the cylinder. • Cover the crankcase opening with a clean cloth. See also Removing the cylinder head Disassembling the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO ONE HEAD REMOVING ONLY BUT APPLY...
  • Page 219 Stelvio 1200 NTX MY11 Engine • The reference on the piston ring must be facing the piston crown. • Fit the piston rings on the piston: - the oil scraper in the lower slot; - the thicker smooth ring in the intermediate slot; - the less thick smooth ring in the upper slot.
  • Page 220 Stelvio 1200 NTX MY11 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 221 Stelvio 1200 NTX MY11 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 222: Installing The Cylinder Head

    Stelvio 1200 NTX MY11 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 223 Stelvio 1200 NTX MY11 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 224 Stelvio 1200 NTX MY11 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 225 Stelvio 1200 NTX MY11 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 226 Stelvio 1200 NTX MY11 Engine • 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 227 Stelvio 1200 NTX MY11 Engine • Fix the head with the two screws. • Tighten nuts and screws to the prescri- bed torque operating diagonally and in stages. • Loosen the valve set screws. • Using a thin screwdriver relief oil pres- sure from the left cylinder chain ten- sioner.
  • Page 228 Stelvio 1200 NTX MY11 Engine • Fit the gasket with the correct thick- ness between the head and the cylin- der. • Fit the right cylinder head. • Unscrew and remove the right chain tensioner cap. • Screw two screws in the threaded holes of the timing system upper gear.
  • Page 229 Stelvio 1200 NTX MY11 Engine • Also place the centrifugal separator of the other head. • 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 230 Stelvio 1200 NTX MY11 Engine • Place the spark plug tube. 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. •...
  • Page 231 Stelvio 1200 NTX MY11 Engine • Hold the crankshaft during flange re- moval. • With the suitable special tool, hold the flange under slight tension by tighten- ing the central screw of the tool itself, simultaneously heating the outer part of the flange for about twenty minutes.
  • Page 232 Stelvio 1200 NTX MY11 Engine Disassembling the connecting rod • Remove both heads. • Remove the cylinders and the pistons. • Remove the oil sump. • Undo the coupling screws (A) inside the crankcase and remove the con- necting rods (B). See also Removing the flywheel Disassembling the piston...
  • Page 233 Stelvio 1200 NTX MY11 Engine BALANCING SELECTION COLOURS (2) Specification Desc./Quantity Crankshaft selection colour (2) brown Type 1 to be used with brown connecting rods. Balance with a 1558 g (54.96 oz) +/- 0.25% weight fitted on the crankpin (B). Maximum imbalance allowed for each shoulder: 2 g (0.07 oz).
  • Page 234 Stelvio 1200 NTX MY11 Engine CONNECTING ROD BEARING THICKNESS Specification Desc./Quantity Regular 'Blue' connecting rod bearing (production) 1.539 - 1.544 mm (0.06059 - 0.06079 in) Regular 'Red' connecting rod bearing (production) 1.535 - 1.540 mm (0.06043 - 0.06063 in) CRANKPIN DIAMETER (B) Specification Desc./Quantity 'Blue' bushing half-shell regular production...
  • Page 235 Stelvio 1200 NTX MY11 Engine Assembling the connecting rod • Lubricate the crankpin on which the connecting rods are to be fixed. • If the connecting rods are not replaced, be careful not to interchange the right connecting rod with the left one and vice versa.
  • Page 236 Stelvio 1200 NTX MY11 Engine Installing the crankshaft • Fit the shim washer inside the crank- case with the chamfered side facing the generator side. • Lubricate the crankshaft bushing on the crankcase, generator side. • Use the sealing ring fitting tool on the flywheel-side flange to fit the sealing ring on the flange. Specific tooling 19.92.71.00 Tool to fit the seal ring on the flywheel-side flange •...
  • Page 237 Stelvio 1200 NTX MY11 Engine • Place the flywheel-side flange on the crankshaft and check if the dowel pin with the O-ring is correctly placed. • 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 238 Stelvio 1200 NTX MY11 Engine Refitting the crankcase halves In case the lubrication jets are removed, replace them with two new of the same type. Check that the O-ring is fitted on the jets. Do not interchange them upon refitting because they have a different length.
  • Page 239 Stelvio 1200 NTX MY11 Engine ADIATOR pos. Description Type Quantity Torque Notes Screws fixing radiator to chassis M6x30 10 Nm (7.38 lb ft) pos. Description Type Quantity Torque Notes Oil pump fixing screw M6x45 10 Nm (7.37 lb ft) Loctite 243 Oil pump driven gear locking nut 8 Nm (5.90 lb ft) Loctite 243...
  • Page 240 Stelvio 1200 NTX MY11 Engine pos. Description Type Quantity Torque Notes Oil pressure valve cap 40 Nm (29.50 lb ft) RANKCASE AND pos. Description Type Quantity Torque Notes Stud bolt M8x75 10 Nm (7.37 lb ft) Stud bolt M8x66 10 Nm (7.37 lb ft) Crankshaft rear support flange fixing screw M8x25 26 Nm (19.18 lb ft)
  • Page 241 Stelvio 1200 NTX MY11 Engine IL SUMP COMPONENTS pos. Description Type Quantity Torque Notes Cover on the flange under the crankcase 40 Nm (29.50 lb ft) Oil filter joint 10 Nm (7.37 lb ft) Loctite 243 Oil sump pipe 20 Nm (14.75 lb ft) Loctite 648 Oil filter 15 Nm (11.06 lb ft)
  • Page 242 Stelvio 1200 NTX MY11 Engine Conceptual diagrams key: 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 243: Oil Pump

    Stelvio 1200 NTX MY11 Engine The oil pump is operated by the gear (10) which receives the motion directly from the crankshaft. The gear (10) is mounted on the shaft (8), on which two rotors are fitted: one for engine cooling (7) and another for lubrication (6).
  • Page 244 Stelvio 1200 NTX MY11 Engine • Bring the left cylinder piston to the TDC in combustion phase. • Mark a reference on the oil pump con- trol gear and another on the driven gear so as to place them correctly again upon refitting.
  • Page 245 Stelvio 1200 NTX MY11 Engine • Remove the gasket between the crankcase and the oil pump. See also Removing the generator Installing • Place a new gasket between the crank- case and the oil pump. • Fit the oil pump. •...
  • Page 246 Stelvio 1200 NTX MY11 Engine • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear.

  • Page 247: Oil Sump

    Stelvio 1200 NTX MY11 Engine • 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 10 Nm (7.37 lb ft) Stud bolt M8x66 10 Nm (7.37 lb ft)
  • Page 248 Stelvio 1200 NTX MY11 Engine IL SUMP COMPONENTS pos. Description Type Quantity Torque Notes Cover on the flange under the crankcase 40 Nm (29.50 lb ft) Oil filter joint 10 Nm (7.37 lb ft) Loctite 243 Oil sump pipe 20 Nm (14.75 lb ft) Loctite 648 Oil filter 15 Nm (11.06 lb ft)
  • Page 249 Stelvio 1200 NTX MY11 Engine • Undo and remove the fourteen screws fixing the oil sump to the engine crank- case. • Unscrew and remove the four screws. • Remove the flange. ENG - 249...
  • Page 250 Stelvio 1200 NTX MY11 Engine • Unscrew and remove the two screws. • Remove both side filters.. • Unscrew and remove the cap. • Remove the thermostatic valve. • Unscrew and remove the overpressure valve plug. • Remove the overpressure valve ele- ments ENG - 250...
  • Page 251 Stelvio 1200 NTX MY11 Engine Refitting the oil sump • Place the overpressure valve elements correctly. • Tighten the overpressure valve plug. • Place the thermostatic valve. CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED. ENG - 251...
  • Page 252 Stelvio 1200 NTX MY11 Engine • Tighten the thermostatic valve plug. • Place a new gasket between the crank- case and the flange. • Insert the flange • Fix the flange with the four screws. • Insert the lubrication oil intake filter ENG - 252...
  • Page 253 Stelvio 1200 NTX MY11 Engine • Check that on the oil pump are the OR rings. • Insert the cooling oil intake filter. • Fix both filters by tightening the two screws to the prescribed torque. • Fit a new oil filter by tightening it to the prescribed torque.
  • Page 254 Stelvio 1200 NTX MY11 Engine • Place the oil sump. • Tighten the fourteen screws to the pre- scribed torque. • Add engine oil up to the correct level. ENG - 254...
  • Page 255 INDEX OF TOPICS P SUPP OWER SUPPLY...
  • Page 256 Stelvio 1200 NTX MY11 Power supply UPPLY YSTEM pos. Description Type Quantity Torque Notes Vite fissaggio protezioni corpo farfallato 10 Nm (7.38 lbf ft) HROTTLE BODY pos. Description Type Quantity Torque Notes Intake pipe fixing screw 10 Nm (7.37 lb ft) Flange fixing screw on the throttle body M5x12 6 Nm (4.42 lb ft)
  • Page 257 Stelvio 1200 NTX MY11 Power supply Circuit diagram Key: 1. Complete fuel pump unit 2. Nut 3. Fuel pipe 4. Pipe 5. Screw Removing • Rimuovere l'anello di fermo della pom- pa carburante; P SUPP - 257...
  • Page 258 Stelvio 1200 NTX MY11 Power supply • Estrarre la pompa carburante ruotan- dola progressivamente verso il basso; • Terminare l'estrazione della pompa carburante ruotandola progressiva- mente verso l'alto in modo da non dan- neggiare il galleggiante. CAUTION ESEGUIRE LA PROCEDURA INVERSA DURANTE LA FASE DI RIMONTAGGIO.
  • Page 259 Stelvio 1200 NTX MY11 Power supply Diagram Key: 1 Control unit 2 Ignition switch 3 Battery 4 Fuel pump 5 Coils 6 Instrument panel 7 Air temperature sensor 8. Throttle valve position sensor 9 Injectors 10 Engine temperature sensor 11 Crankshaft position sensor 12.
  • Page 260 Stelvio 1200 NTX MY11 Power supply 13 Lambda probe 14 Fall sensor THROTTLE BODY PIPES LAYING Pipes from the throttle body to the idle motor should be laid so that the shaped part is inserted in the air filter casing. The shortest part of the fuel pipe connected to the throttle bodies should be placed on the right.
  • Page 261 Stelvio 1200 NTX MY11 Power supply • Make sure there are no errors in the control unit; otherwise, solve them and repeat the procedure. • Make sure the left throttle is fully in. DO NOT TOUCH THE THROTTLE ABUTMENT SCREW OR THE THROTTLE BODY MUST BE REPLACED.

  • Page 262: Injection System

    Stelvio 1200 NTX MY11 Power supply If there is a larger difference: • act on the set screw of the throttle body connecting rod to reduce the pressure difference in the two pipes. • Repeat the procedure "Throttle posi- tion self-acquisition" as explained above.
  • Page 263 Stelvio 1200 NTX MY11 Power supply ECU INFO screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date INFO ECU SCREEN PAGE Specification Desc./Quantity Mapping PARAMETERS screen page 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 264 Stelvio 1200 NTX MY11 Power supply Specification Desc./Quantity Target engine revs 1150 rpm (approximate values) Parameter valid at idle, setting depends especially on the en- gine temperature: the control unit will try to keep the engine running at this revs, acting on the ignition advance and the Stepper motor Stepper base 70 - 100 (approximate values)
  • Page 265 Stelvio 1200 NTX MY11 Power supply ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. ACTIVATION Specification Desc./Quantity Left coil operation for 2.5 m, 5 times Right coil operation for 2.5 m, 5 times Left injector...
  • Page 266 Stelvio 1200 NTX MY11 Power supply Specification Desc./Quantity Lambda probe Possible short circuit on the earth lead, battery or open circuit or plausibility: recovery function hardly noticeable for customer. Left injector Possible short circuit in the earth lead, battery or open circuit. 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 267 INDEX OF TOPICS SUSP USPENSIONS...

  • Page 268: Removing The Front Wheel

    Stelvio 1200 NTX MY11 Suspensions Front RONT WHEEL pos. Description Type Quantity Torque Notes Viti TE Flang. fissaggio dischi freno M8x20 25 Nm (18.44 lbf ft) Nut fixing wheel pin 80 Nm (59.00 lbf ft) Vite flang. fissaggio sensore 6 Nm (4.42 lbf ft) Loct.
  • Page 269 Stelvio 1200 NTX MY11 Suspensions • Hold the vehicle front part. • Unscrew and remove the wheel axle fixing nut and collect the sealing wash- • Working from both sides, loosen the screws on the wheel bolt clamps. • Tap the wheel axle slightly with a rubber mallet so that the hole on the opposite side is exposed.
  • Page 270 Stelvio 1200 NTX MY11 Suspensions Handlebar ANDLEBAR AND CONTROLS pos. Description Type Quantity Torque Notes TCC handlebar upper U-bolt fixing screws M8x30 25 Nm (18.44 lb ft) TE handlebar lower U-bolt flanged fixing 50 Nm (36.88 lb ft) Loct. 243 screws Self-tapp.

  • Page 271: Front Fork

    Stelvio 1200 NTX MY11 Suspensions • Operating from below the front head- light assembly, using an extension, in- tercept the screws and insert the bushing making sure that it is com- pletely and orthogonally inserted re- garding its head. CAUTION A WRONG DIAMETER OF THE BUSHING COULD REDUCE THE EFFECTIVE CLOSING TORQUE DUE TO THE FRIC- TION EFFECT BETWEEN BUSHING AND THE SEAT ON...
  • Page 272 Stelvio 1200 NTX MY11 Suspensions RONT FORK pos. Description Type Quantity Torque Notes Viti piede forcella 25 Nm (18.44 lbf ft) Viti chiusura mozzetti M6x30 10 Nm (7.38 lbf ft) Fork cap - Nm (-.- lbf ft) Diagram Key: 1. Complete front fork 2.
  • Page 273 Stelvio 1200 NTX MY11 Suspensions 15.Left sleeve cap 16.O-ring 17.O-ring 18.Washer 19.Snap ring 20.O-ring 21.Complete sleeve 22.Spring holder cap 23.Spring guide 24.Preloading pipe 25.Spring guide 26.Spring 27.Bushing 28.Dust guard 29.Snap ring 30.Sealing ring 31.Cap 32.Bushing Adjustment The front suspension consists of a hydraulic fork connected to the headstock by means of two plates.

  • Page 274: Removing The Fork Legs

    Stelvio 1200 NTX MY11 Suspensions Normal load adjustments are the standard settings by manufacturer: FORK SETTINGS Specification Desc./Quantity Spring preloading, nut (1) - regular load conditions tighten (clockwise) 8 turns from fully open Spring preloading, nut (1) - half-load conditions tighten (clockwise) 9 turns from fully open Spring preloading, nut (1) - maximum load conditions tighten (clockwise) 9 turns from fully open...
  • Page 275 Stelvio 1200 NTX MY11 Suspensions • Remove the ABS sensor. • Remove the stanchion. See also Removing the front wheel Draining oil • Lock the sleeve in a vice with the spe- cific tool (code AP8140149). • Set the minimum spring preloading. Specific tooling AP8140149 Protection for fitting operations •...
  • Page 276 Stelvio 1200 NTX MY11 Suspensions • Remove the complete cap. • Remove the spring. Let the oil depos- ited on the spring turns fully drip into the sleeve. • Pour the oil into the container. • Remove in order: - upper spring guide; - preload pipe;...
  • Page 277 Stelvio 1200 NTX MY11 Suspensions Disassembling the fork • Drain all the oil from the stem. • Tighten the wheel holder sleeve in a vice. • Undo the fork end bottom screw and remove it with the corresponding gas- ket. SUSP - 277...
  • Page 278 Stelvio 1200 NTX MY11 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. • Remove the retainer ring. •...
  • Page 279 Stelvio 1200 NTX MY11 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 SUSP - 279...
  • Page 280 Stelvio 1200 NTX MY11 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. If over the value, replace the stem.
  • Page 281 Stelvio 1200 NTX MY11 Suspensions Replace the following components with new ones: • seal ring; • 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.
  • Page 282 Stelvio 1200 NTX MY11 Suspensions • The sealing ring must be placed with the stamped part facing the dust gaiter. • Fit the ring, the movable bushing and, after removing the tape, fit the fixed bushing. SUSP - 282...
  • Page 283 Stelvio 1200 NTX MY11 Suspensions • Fit the dust gaiter with the specific tool. Specific tooling 9100903 Marzocchi fork oil seal; ø 45 mm (1.77 • Fit the pumping member pin with the cap in the spring holder sleeve and in the preload pipe.
  • Page 284 Stelvio 1200 NTX MY11 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 285 Stelvio 1200 NTX MY11 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 286: Installing The Fork Legs

    Stelvio 1200 NTX MY11 Suspensions • Tighten the nut completely. • Support the pumping member pin in order to screw the upper cover. • Screw the upper cap on the pumping member pin. • Place the sleeve in the vice using the specified tool.
  • Page 287 Stelvio 1200 NTX MY11 Suspensions • Insert the wheel pin so that the stems are aligned. • Tighten the screws on the fork plates to the prescribed torque. SUSP - 287...
  • Page 288 Stelvio 1200 NTX MY11 Suspensions Steering bearing TEERING pos. Description Type Quantity Torque Notes Viti fissaggio piastra fermatubi 6 Nm (4.42 lbf ft) Viti fissaggio piastre M8x30 20 Nm (14.75 lbf ft) Headstock ring nut 40 Nm (29.50 lbf ft) Headstock counter-lock ring manual + 90 degrees Upper yoke fixing cap...
  • Page 289 Stelvio 1200 NTX MY11 Suspensions • Working on both sides, unscrew and remove the upper plate fixing screw on the fork stems. • Unscrew and remove the fork upper plate cover; collect the shim. • Lift the fork upper plate sliding it off from the stems.
  • Page 290 Stelvio 1200 NTX MY11 Suspensions • Using the suitable special tool, un- screw and remove the upper ring nut. Specific tooling AP8140190 Tool for steering tightening • Remove the safety washer. • Using the suitable special tool, set the preloading of the steering bearings. Specific tooling AP8140190 Tool for steering tightening •...

  • Page 291: Removing The Rear Wheel

    Stelvio 1200 NTX MY11 Suspensions • Rivet the tongues of the new safety washer. • Fit the fork upper plate on the stems. Rear Removing the rear wheel • Support the vehicle rear part using a suitable stand. • Engage the first gear. •...

  • Page 292: Shock Absorbers

    Stelvio 1200 NTX MY11 Suspensions Shock absorbers EAR SUSPENSION pos. Description Type Quantity Torque Notes Vite TE Flang. fissaggio superiore ammortiz- M10x80 50 Nm (36.88 lbf ft) zatore Vite TCEI fissaggio biella doppia/forcellone M10x82 50 Nm (36.88 lbf ft) Vite TE fissaggio biella doppia/ammortizza- M10x47 40 Nm (29.50 lbf ft) tore...
  • Page 293 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 294 Stelvio 1200 NTX MY11 Suspensions Removing • Park the vehicle on its centre stand. • Lock the vehicle handlebar so that the rear wheel is off the ground. • Remove the fork. • Undo and remove the shock absorber upper screw. •...
  • Page 295 INDEX OF TOPICS CHAS HASSIS...
  • Page 296 Stelvio 1200 NTX MY11 Chassis Swinging arm EAR SWINGARM pos. Description Type Quantity Torque Notes Swingarm clamp fixing screw on the bushing M6x25 10 Nm (7.37 lbf ft) 2 - Swingarm fixing screw on the transmission M10x35 50 Nm (36.87 lbf ft) housing Swingarm pin on the swingarm 60 Nm (44.25 lbf ft)
  • Page 297 Stelvio 1200 NTX MY11 Chassis • Remove the rear wheel. • Unscrew and remove the two screws. • Remove the speed sensor from the fork. • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. • Fix the reaction rod to the chassis with a clamp.
  • Page 298 Stelvio 1200 NTX MY11 Chassis • Loosen the two swingarm terminal screws. • Unscrew and remove the fixing nut of the connecting rod assembly and col- lect the screw. • Loosen the ring nut. Specific tooling GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body •...
  • Page 299 Stelvio 1200 NTX MY11 Chassis Checking • Check that the universal joint is not damaged, the gear teeth inserting in the sleeve grooves and the grooves on the joint are not deformed or damaged; otherwise, replace the joint. • Check that the rubber bellows are not cut or pierced;...
  • Page 300 Stelvio 1200 NTX MY11 Chassis • Use the suitable box-spanner to tight- en the ring nut. Specific tooling GU14912603 Hook spanner for fixing ring nut of the clutch shaft internal body • Tighten the two screws of the swing- arm clamp. •...
  • Page 301 Stelvio 1200 NTX MY11 Chassis • Place the connecting rod assembly on the swingarm. • Insert the screw. • Tighten the fixing nut of the connecting rod assembly. • Place the speed sensor on the fork and screw the two screws. •...
  • Page 302 Stelvio 1200 NTX MY11 Chassis • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. • Fasten the reaction rod to the chassis with a clamp. • Undo and remove the four screws. • Remove the transmission casing slid- ing off the universal joint.
  • Page 303 Stelvio 1200 NTX MY11 Chassis Casing unit removal Remove the cover (20). Remove the plug (3) to drain out the oil. Lift the cap (10). CHAS - 303...
  • Page 304 Stelvio 1200 NTX MY11 Chassis Remove the clamps (9) and (11). Remove the cap (14). Remove the screws (16). Collect the ring (15). Remove the screws (7). Remove the casing (4). CHAS - 304...
  • Page 305 Stelvio 1200 NTX MY11 Chassis Remove the clamp (12). Remove the cap (14). Collect the ring (13). Remove the support unit (8). Casing unit fitting CHAS - 305...
  • Page 306 Stelvio 1200 NTX MY11 Chassis Casing unit fitting Assemble the dowel pins to the casing with the buffer and a hammer. Assemble the casing to the special fastening tool. Clean the casing faying surfaces carefully. Heat the casing. Insert the support group in the casing. CHAS - 306...
  • Page 307 Stelvio 1200 NTX MY11 Chassis Assemble the cap and the ring. Fit the cap on the support. Fit the clamp. Screw the clamp with the specific pliers. Apply the prescribed sealant to the casing. CHAS - 307...
  • Page 308 Stelvio 1200 NTX MY11 Chassis Fit a new sealing ring using the buffer. Lubricate the sealing ring. Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture. Fit the casing. Remove the two dowel pins.
  • Page 309 Stelvio 1200 NTX MY11 Chassis Assemble the ring to the casing. Tighten the fixing screws to the prescribed torque. Fit the cap with the washer. Screw the cap to the prescribed torque. Fit the breather with the washer. Screw the breather to the prescribed torque. CHAS - 309...
  • Page 310 Stelvio 1200 NTX MY11 Chassis Fill the transmission with the prescribed oil. Fit the cap with the washer. Screw the cap to the prescribed torque. Assemble the cap with the clamps. Fit the cap in its seat. Wheel axle unit Gruppo asse ruota Removal Remove the bearing from the wheel axle with a...
  • Page 311 Stelvio 1200 NTX MY11 Chassis Turn the unit over. Remove the bearing from the wheel axle with a suitable extractor. FITTING Heat the bearings to 100°C (212 °F). Assemble the bearings to the wheel axle. Turn the unit over. Assemble the bearings to the wheel axle. Pinion unit CHAS - 311...
  • Page 312 Stelvio 1200 NTX MY11 Chassis Pinion unit Removal Remove the stop ring (1) from the ring nut. Unscrew the ring nut (2) with the special spanner (s4). Remove the ring nut (2) and remove the sealing ring from the ring nut. NOTE THIS OPERATION DESTROYS THE SEALING RING.
  • Page 313 Stelvio 1200 NTX MY11 Chassis Lubricate the sealing ring (3). Assemble the ring nut (2). Tighten the ring nut (2) with the special spanner (s4) to the prescribe torque. Insert the stop ring (1) in the ring nut (2) in the in- dicated direction.
  • Page 314 Stelvio 1200 NTX MY11 Chassis Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT. Support unit CHAS - 314...
  • Page 315 Stelvio 1200 NTX MY11 Chassis Support unit Removal Remove the bushing (1) with a punch. Turn the support (5) over and remove the other bushing (8). Remove the sealing rings (2) and (7) with a screw- driver. Remove the stop rings (3) and (6) from the support (5) with suitable pliers.
  • Page 316 Stelvio 1200 NTX MY11 Chassis Turn the support (5) over. Assemble the ball joint (4) with the buffer and a rubber hammer. Fit the stop ring (3) in the support (5) with suitable pliers. Manually assemble the new sealing rings (2) and (7).
  • Page 317 Stelvio 1200 NTX MY11 Chassis Possible Cause Operation 1. Casing not sealed 2. Closing screws of the casing shells not 1. Open the casing shells, clean the surfaces, seal and reas- tightened to the prescribed torque semble the casing shells 2.
  • Page 318 Stelvio 1200 NTX MY11 Chassis • Place the dust-protection ring between the rim and the cardan shaft taking care to mount it with the collar facing the transmission unit. • Place the speed sensor and fasten the cable harness with the clamps. •...
  • Page 319 Stelvio 1200 NTX MY11 Chassis Exhaust XHAUST SYSTEM pos. Description Type Quantity Torque Notes Dadi Flang. fissaggio collettori 25 Nm (18.44 lbf ft) Oxygen sensor fastener 38 Nm (28.03 lbf ft) Vite TE Flang. fissaggio parte centrale M10x55 25 Nm (18.44 lbf ft) Viti fissaggio protezione 10 Nm (7.38 lbf ft) Vite TCEI fissaggio silenziatore a telaio...
  • Page 320 Stelvio 1200 NTX MY11 Chassis key: 1. Right exhaust pipe 2. Left exhaust pipe 3. Gasket 4. Flanged nut 5. Washer 6. Gasket 7. Clamp 8. Central exhaust pipe 9. TE flanged screw 10.Silent-block 11.Flanged self-locking nut 12.Lambda probe 13.Gasket 14.Clamp 15.Silencer 16.TCEI screw...
  • Page 321 Stelvio 1200 NTX MY11 Chassis • Undo and remove the screw and col- lect the nut and the washer. • Remove the exhaust end. Removing the manifold - tail pipe • Remove the exhaust end and the ex- haust manifolds. •...
  • Page 322 Stelvio 1200 NTX MY11 Chassis Removing the tail pipe Removing the exhaust manifold The engine and the exhaust system components get very hot and remain in this condition for a certain time interval after the engine has been switched off. Before handling these components, make sure that you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.
  • Page 323 Stelvio 1200 NTX MY11 Chassis Engine oil cooler ADIATOR pos. Description Type Quantity Torque Notes Screws fixing radiator to chassis M6x30 10 Nm (7.38 lb ft) Key: 1. Complete oil radiator CHAS - 323...
  • Page 324 Stelvio 1200 NTX MY11 Chassis 2. TE flanged screw 3. T-shaped bushing 4. Rubber ring 5. Radiator support 6. TCEI screw 7. Clip Removing • Per la sostituzione dell'olio motore e del filtro olio è necessario rimuovere il paramotore in metallo svitando le quattro viti (1) che lo fissano al motore.
  • Page 325 Stelvio 1200 NTX MY11 Chassis • Undo and remove the two radiator up- per screws and collect the washer. • Remove the oil cooling radiator. See also Engine guard Installing • Fit the oil cooling radiator on the vehi- cle following the operations described in the removal chapter but in reverse order.
  • Page 326 INDEX OF TOPICS BRAK SYS RAKING SYSTEM...
  • Page 327 Stelvio 1200 NTX MY11 Braking system RAKE YSTEM pos. Description Type Quantity Torque Notes Brake pipe slot screw on the pump 25 Nm (18.44 lbf ft) Joint with brake pipes retainer bleeding on the 25 Nm (18.44 lbf ft) calliper Brake pipes joint on the ABS hydraulic unit 25 Nm (18.44 lbf ft) Interventions rules...
  • Page 328 Stelvio 1200 NTX MY11 Braking system key: 1. ABS ECU control unit 2. Front ABS sensor 3. Rear ABS sensor 4. Battery 5. Main relay 6. ECU 7. Instrument panel 8. K line (diagnosis) 9. Key 10.Fuses BRAK SYS - 328...
  • Page 329 Stelvio 1200 NTX MY11 Braking system Operating diagram ABS functional diagram key 1. Front system circuit 2. Front brake pump 3. Front brake lever 4. Rear system circuit BRAK SYS - 329...
  • Page 330 Stelvio 1200 NTX MY11 Braking system 5. Rear brake pump 6. Rear brake pedal control 7. ABS control unit 8. Rear brake calliper 9. Front calliper (2 callipers) 10.Front brake circuit intake solenoid valve (normally open) 11.Humidifier 12.Rear brake circuit intake solenoid valve (normally open) 13.Rear brake exhaust circuit solenoid valve (normally closed) 14.Rear/front brake circuit low pressure accumulator 15.Front brake exhaust circuit solenoid valve (normally closed)
  • Page 331 Stelvio 1200 NTX MY11 Braking system D - Pressure restored: by opening the inlet valve (10-12) momentarily, the pressure of the callipers (8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the braking back to the rider. E - If the wheel does not reach complete grip, the system continues operating as before until complete grip is obtained or until the vehicle stops.
  • Page 332 Stelvio 1200 NTX MY11 Braking system Riding with an active ABS system • At engine starter, the ABS warning light (5) on the instrument panel (4) flashes until the vehicle exceeds 5 km/h (3.1 mph). If the ABS warning light remains on when the vehicle is running, it means that a fault has been detected and the ABS system has been automatically deactivated.
  • Page 333 Stelvio 1200 NTX MY11 Braking system light (5) on the instrument panel (4) turns off. CAUTION IF THE ABS SWITCH IS PRESSED FOR MORE THAN TEN SECONDS, THE SYSTEM DETECTS A FAILURE. TO ACTI- VATE THE ABS SYSTEM AGAIN TURN THE IGNITION SWITCH TO "OFF"...
  • Page 334 Stelvio 1200 NTX MY11 Braking system If during this given time one of the conditions is missing but then it comes back, the timer is reset and the system is no longer able to diagnose the error. The ABS system continues to be inactive. Example: - error code 5D93 requires some minutes before it is diagnosed during the given time: the ABS warning light ABS keeps flashing.
  • Page 335 Stelvio 1200 NTX MY11 Braking system ECU INFO screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date INFO ECU SCREEN PAGE Characteristic Value/example Unit of Notes measure ment Vehicle manufacturing date Frame number...
  • Page 336 Stelvio 1200 NTX MY11 Braking system ACTIVATION screen page This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. ACTIVATION Characteristic Value/example Unit of Notes measure ment Front brake bleeding procedure Useful in case of lever sponginess although the bleeding has been done as in a regular braking...
  • Page 337 Stelvio 1200 NTX MY11 Braking system ERRORS Characteristic Value/example Unit of Notes measure ment Front speed sensor: 5D90 electric Electrical fault in sensor or cable harness malfunction Front speed sensor: 5D91 the signal Faulty sensor or signal interference works irregularly Front speed sensor: 5D92 the signal Possible tone wheel fault due to deformations or decreases periodically...
  • Page 338 Stelvio 1200 NTX MY11 Braking system SETTINGS screen page This screen page is used to adjust some control unit parameters. ADJUSTMENTS Characteristic Value/example Unit of Notes measure ment Coding (1) Used for re-coding the control unit or coding a new one.
  • Page 339 Stelvio 1200 NTX MY11 Braking system • With a felt-tip pen, mark a reference on the pipes and on the ABS control unit to avoid inverting them when refitting. • Protect with a clean cloth the plastic materials near the ABS control unit. •...
  • Page 340 Stelvio 1200 NTX MY11 Braking system • When the connector is fully inserted, the distance between the connector and the ABS control unit must be 7.5 mm (0.29 in). • If the initial position of the connector and the driving lever is not that shown in fig.
  • Page 341 Stelvio 1200 NTX MY11 Braking system 2.10 - 2.25 mm (0.083 - 0.088 in) for the front one; 1.90 - 2.30 mm (0.075 - 0.090 in) for the rear one; CAUTION IF A VALUE BEYOND THE TOLERANCE RANGE IS MEAS- URED, REPLACE THE SENSOR (1) AND/OR THE TONE WHEEL (2) AND REPEAT THE CHECKS;...
  • Page 342 Stelvio 1200 NTX MY11 Braking system INZA RENO OSTERIORE Pos. Descrizione Tipo Quantità Coppia Note Rear brake calliper fixing screw 50 Nm (36.87 lbf ft) Vite fissaggio tubo olio - Nm (-.-- lbf ft) Vite fissaggio tubo olio - Nm (-.-- lbf ft) Key: 1.
  • Page 343 Stelvio 1200 NTX MY11 Braking system Front brake calliper RONT BRAKE CALLIPERS pos. Description Type Quantity Torque Notes Viti TE Flang. fissaggio pinze M10x55 50 Nm (36.88 lbf ft) Key: BRAK SYS - 343...
  • Page 344 Stelvio 1200 NTX MY11 Braking system 1. Front right brake calliper 2. Front left brake calliper 3. Pads 4. Air bleed 5. Air bleed cap 6. Pins + Calliper springs 7. Spring 8. Aluminium gasket 9. Screw Rear brake disc Disc Inspection CAUTION THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECI-...

  • Page 345: Front Brake Pads

    Stelvio 1200 NTX MY11 Braking system • The following operations are to be car- ried out with brake disc fitted on the wheel. • Check the disc for wear by measuring the minimum thickness with a micro- meter in different points. If the mini- mum thickness, even in a single point of the disc, is less than the minimum value, replace the disc.
  • Page 346 Stelvio 1200 NTX MY11 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 - 346...
  • Page 347 Stelvio 1200 NTX MY11 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 348: Rear Brake Pads

    Stelvio 1200 NTX MY11 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 349 Stelvio 1200 NTX MY11 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 350 Stelvio 1200 NTX MY11 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 351 Stelvio 1200 NTX MY11 Braking system REPLACE THE ABS CONTROL UNIT VEHICLE PREPARATION • Connect the bleed bottle to the bleed screws of the front and rear callipers and open it. • Fully press down the lever and the brake pedal and fix them into position with the respective locking devices.
  • Page 352 Stelvio 1200 NTX MY11 Braking system • Check the stroke and the sensitivity of both the lever and the brake pedal. • If, after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in the braking system and if everything is ok, continue bleeding operations using Navigator as described.
  • Page 353 Stelvio 1200 NTX MY11 Braking system BLEEDING SYSTEM WITH NAVIGATOR This type of bleeding has to be carried out if after all the checks the brake lever and the pedal are still spongy. The operations described here are valid for both systems even though the description refers to the front system.
  • Page 354 Stelvio 1200 NTX MY11 Braking system • Remove the rubber protection cover from the bleed valve. • Insert the transparent plastic pipe in the front brake calliper bleed valve and slide the other end of this pipe in a con- tainer to collect the fluid.
  • Page 355 Stelvio 1200 NTX MY11 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 356 INDEX OF TOPICS BODYW ODYWORK...
  • Page 357 Stelvio 1200 NTX MY11 Bodywork RONT IGHTS pos. Description Type Quantity Torque Notes Horn fixing screw M6x20 15 Nm (11.06 lbf ft) Viti fissaggio freccie anteriori 3 Nm (2.21 lbf ft) Vite fissaggio superiore fanale a carozzeria 3 Nm (2.21 lbf ft) Viti fissaggio fanale a carozzeria M4x25 3 Nm (2.21 lbf ft)
  • Page 358 Stelvio 1200 NTX MY11 Bodywork NSTRUMENT PANEL pos. Description Type Quantity Torque Notes Viti TCEI fissaggio sensore velocità anteriore M5x16 6 Nm (4.42 lbf ft) Viti TCEI fissaggio blocchetto avviamento M8x30 25 Nm (18.44 lbf ft) Viti autofil. fissaggio supporto cruscotto 5x14 Manual Viti autofil.
  • Page 359 Stelvio 1200 NTX MY11 Bodywork ARROZZERIA ANTERIORE ONVOGLIATORI pos. Description Type Quantity Torque Notes Viti TBEI Flang. fissaggio convogliatori M5x9 6 Nm (4.42 lbf ft) Viti TBEI Flang. fissaggio convogliatori 6 Nm (4.42 lbf ft) Viti SWP Autofil. fissaggio telaietto griglie 2.9x12 Manual BODYW - 359...
  • Page 360 Stelvio 1200 NTX MY11 Bodywork RONT MUDGUARD pos. Description Type Quantity Torque Notes Viti TBEI Flang. fissaggio parafango anteriore M5x12 6 Nm (4.42 lbf ft) OPERTURA SERBATOIO CARBURANTE pos. Description Type Quantity Torque Notes Vite TBEI Flang. fissaggio copertura 5 Nm (3.69 lbf ft) BODYW - 360...
  • Page 361 Stelvio 1200 NTX MY11 Bodywork EAR BODYWORK pos. Description Type Quantity Torque Notes Viti SWP fissaggio piastra batteria M5x20 Manual Viti TBEI Flang. fissaggio fianchetti e para- M5x9 6 Nm (4.42 lbf ft) spruzzi Viti TE Flang. fissaggio supporti valigie 10 Nm (7.38 lbf ft) Viti TBEI Flang.
  • Page 362 Stelvio 1200 NTX MY11 Bodywork ANIGLIONE E PORTAPACCHI pos. Description Type Quantity Torque Notes Vite TCEI fissaggio maniglione passeggero M6x25 10 Nm (7.38 lbf ft) Vite TCEI fissaggio maniglione passeggero 25 Nm (18.44 lbf ft) Vite fissaggio portatarga a maniglione 6 Nm (4.42 lbf ft) Vite TBEI fissaggio supporti portapacchi M8x20...
  • Page 363 Stelvio 1200 NTX MY11 Bodywork • Rimuovere le viti di fissaggio della co- pertura motorino avvimaneto. • Undo the screw and remove the rear brake oil reservoir. • From the left side of the vehicle, re- move the nut (1) and the correspond- ing washer.
  • Page 364 Stelvio 1200 NTX MY11 Bodywork • Rimuovere le viti di fissaggio (3) del paramotore, da entrambi i lati del mo- tociclo. • Rimuovere le viti di fissaggio (4) del paramotore, da entrambi i lati del mo- tociclo. • Rimuovere le viti di fissaggio (5) del paramotore, da entrambi i lati del mo- tociclo prestando attenzione a recu- perare la guida in gomma.

  • Page 365: Instrument Panel

    Stelvio 1200 NTX MY11 Bodywork • Liberare i cablaggi dei fari supplemen- tari rimuovendo le fascette (6) e scol- legare i connettori (7) per rimuovere completamente i paramotori. Instrument panel • Rimuovere i deflettori laterali traspar- enti. • Remove the screws (1). •...
  • Page 366 Stelvio 1200 NTX MY11 Bodywork • Scollegare il connettore cruscotto (2) e il connettore della presa di corrente (3) • Remove the instrument panel. NOTE FOR REFITTING, FOLLOW THE PROCEDURE IN THE REVERSE ORDER Additional lights • Liberare i cablaggi dei fari supplemen- tari rimuovendo le fascette (1) sul telaio e scollegare i connettori (2).
  • Page 367 Stelvio 1200 NTX MY11 Bodywork • Svitare a rimuovere la vite (4) recuper- ando il dado o in alternativa è possibile rimuovere le viti (5) non compromet- tendo cosi l'angolo di inclinazione dei fasci luminosi. • Ora è possibile rimuovere i fari supple- mentari.
  • Page 368 Stelvio 1200 NTX MY11 Bodywork • Rimuovere le due viti di fissaggio del cupolino al telaietto in corrispondenza del cruscotto. • Scollegare i connettori dei fari e rimuovere il cupolino. Rider footrest plate LEFT SIDE • Undo and remove the upper screw and collect the washer and the nut.
  • Page 369 Stelvio 1200 NTX MY11 Bodywork • Disconnect the gearbox rod and re- lease the spring. • Remove the left footrest holding plate. RIGHT SIDE • Undo and remove the upper screw and collect the washer and the nut. • Undo and remove the front lower screw.
  • Page 370 Stelvio 1200 NTX MY11 Bodywork • Disconnect the connectors of the rear brake lever switch and the speed sen- sor. • Release the cable harness from the clamps. • Undo and remove the two rear lower screws; collect the washers and the spacer.
  • Page 371 Stelvio 1200 NTX MY11 Bodywork • Rimuovere la vite inferiore esterna. • Scollegare il connettore della freccia anteriore e rimuovere il fianchetto lat- erale. CAUTION ESEGUIRE LA MEDESIMA OPERAZIONE DI SMONTAGGIO ANCHE PER IL FIANCHETTO OP- POSTO Air box BODYW - 371...
  • Page 372 Stelvio 1200 NTX MY11 Bodywork IR FILTER pos. Description Type Quantity Torque Notes Air filter box fastening screw to frame 10 Nm (7.38 lb ft) Air filter box cover fastening screw SWP 5x20 3 Nm (2.21 lb ft) • Remove the saddle. •...
  • Page 373 Stelvio 1200 NTX MY11 Bodywork • Release the clutch bleeding pipe from the cable guide. • Operating from both sides, undo and remove the three screws. • Remove the mudflap. • Release from its and remove the breather pipe placed on the right side of the filter casing.
  • Page 374 Stelvio 1200 NTX MY11 Bodywork • Remove the two breather pipes. • Operating from both sides, undo and remove the stud bolt. • Remove the filter casing. See also Seat Sump guard ENSURE THAT THE ENGINE AND THE THERMAL PARTS OF THE VEHICLE ARE COLD BEFORE OPERATING ACCORDING TO THE FOLLOWING INSTRUCTIONS.

  • Page 375: Fuel Tank

    Stelvio 1200 NTX MY11 Bodywork Fuel tank RIMOZIONE COPRI SERBATOIO CARBURANTE • Rimuovere le viti (1) dal lato destro del motociclo. • Rimuovere le viti (2) dal lato destro del motociclo. • Remove the side fairings. • Remove the control panel. •...
  • Page 376 Stelvio 1200 NTX MY11 Bodywork Pannier mounting • Remove the countersunk-head screw (14) and collect the bushings (11) and nuts (16). • Remove the cross-member (9). • Remove the hexagonal-head screw (3) and collect the washers (4). • Remove the Allen screws (5) and (7). •...
  • Page 377 Stelvio 1200 NTX MY11 Bodywork Adjustable windscreen • Remove the windscreen glass. • Working from both sides, undo and re- move the windscreen top set screw and remove the knob. • Working from both sides, unscrew and remove the lower screw. •...
  • Page 378 INDEX OF TOPICS PRE DE DELIVERY...
  • Page 379 Stelvio 1200 NTX MY11 Pre-delivery Carry out the listed checks before delivering the motorcycle. WARNING HANDLE FUEL WITH CARE. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety fasteners: front and rear suspension unit front and rear brake calliper retainer unit front and rear wheel unit engine - chassis retainers...

  • Page 380: Road Test

    Stelvio 1200 NTX MY11 Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation. CAUTION TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
  • Page 381 Stelvio 1200 NTX MY11 Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up - Starter operation (if present) - Minimum holding (turning the handlebar) - Uniform turning of the steering...
  • Page 382 Stelvio 1200 NTX MY11 Pre-delivery Specific operations for the vehicle • Remove the saddle from its housing by turning the key clockwise. • Loosen the two screws (A) and remove the bracket (B) with the plug socket. • Temporarily position the antitheft de- vice in the helmet compartment plastic seat, insert the cable into the appropri- ate seat.
  • Page 383 Stelvio 1200 NTX MY11 Pre-delivery • Position the sponge (2) with the adhe- sive under the antitheft device (1), cut off the excess parts. • Position the antitheft device in the seat of the plastic and move the clamps into the holes made.
  • Page 384 ABS: 132, 328, 334, 338 Air filter: 68 Air temperature sensor: 112, 126 Alternator: Battery: 99, 103 Brake: 341, 343–345, 348 Brake calliper: 341, 343 Brake disc: 344, 345 Brake lever: Brake pads: 345, 348 Clutch: 123, 176, 179, 180, 231 Coil: 119 Connectors: 128 Crankcase: 51, 230, 238...
  • Page 385 Headlight: 367 Identification: 10 Instrument panel: 126, 365 License plate holder: Maintenance: 8, 62, 340 Maintenance Table: Mudguard: Oil filter: 66 Oil pressure sensor: 121 Oil sump: 247, 248, 251 Primary shaft: 156, 161–163 Radiator: Rear light: Rear wheel: 291 Recommended products: 53, 301 Run/Stop switch: 127 Saddle:...

This manual is also suitable for:

Stelvio 1200 my11 2011

Table of Contents