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

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SERVICE STATION MANUAL
981063
STELVIO 4V - 1200

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  • Page 1 SERVICE STATION MANUAL 981063 STELVIO 4V - 1200...
  • Page 2 Not all versions shown in this publication are available in all Countries. The availability of individual versions should be checked with the Official Moto Guzzi sales network. © Copyright 2008- 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 MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM NGINE P SUPP OWER SUPPLY CHAS HASSIS...
  • Page 7 INDEX OF TOPICS CHAR HARACTERISTICS...

  • Page 8: Safety Rules

    STELVIO 4V - 1200 Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running in order to carry out any procedure, please ensure that you do so in an open or very well ventilated area. Never let the engine run in an enclosed area. If you do work in an enclosed area, make sure to use a smoke-extraction system.
  • Page 9 STELVIO 4V - 1200 Characteristics THE BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SUR- FACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THE SYSTEMS.
  • Page 10 CAUTION BEARINGS MUST BE ABLE TO ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTH- ERWISE THEY NEED REPLACING. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables usage guidelines. • Lubricate parts (whenever possible) before reassembling them.
  • Page 11 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 12 STELVIO 4V - 1200 Characteristics Specification Desc./Quantity 4th gear ratios 26/29 = 1:1.1154 5th gear ratios 31/30 = 1:0.9677 6th gear ratios 29/25 = 1:0.8621 Final drive cardan shaft Ratio 12/44 = 1:3.6667 Supply FUEL SUPPLY Specification Desc./Quantity FUEL SUPPLY Electronic injection (Weber .
  • Page 13 STELVIO 4V - 1200 Characteristics PIN - PISTON COUPLING Specification Desc./Quantity Pin diameter 21.998 - 21.994 mm (0.86606 - 0.86590 in) Pin hole diameter on piston 22.016 - 22.011 mm (0.86677 - 0.86657 in) Clearance between pin and holes on piston 0.013 - 0.022 mm (0.00051 - 0.00087 in)
  • Page 14 STELVIO 4V - 1200 Characteristics CRANKSHAFT SEAT (CLUTCH SIDE) Specification Desc./Quantity Diameter of crankshaft main journal, clutch side 53.97 - 53.961 mm (2.12480 - 2.12444 in) Inside diameter of crankshaft bushing on clutch- 54.019 - 54.0 mm (2.12673 - 2.12598 in)
  • Page 15 STELVIO 4V - 1200 Characteristics • Take note of the measurement and, according to the values found, consult the chart at the bottom of the page to decide the thickness of the gasket to be fitted between the cylinder and the head.
  • Page 16 STELVIO 4V - 1200 Characteristics CHAR - 10...
  • Page 17 INDEX OF TOPICS MAIN AINTENANCE...

  • Page 18: Transmission Fluid

    STELVIO 4V - 1200 Maintenance Transmission fluid Gearbox Oil Checking the valve clearance If the timing system is very noisy, check the clearance between the valves and the rocking levers. NOTE ADJUST WITH COLD ENGINE, WITH PISTON AT TOP DEAD CENTRE (TDC) IN COMPRESSION STROKE (VALVES CLOSED).
  • Page 19 STELVIO 4V - 1200 Maintenance RECTLY, WHICH CAN LEAD TO PROBLEMS SUCH AS: • PRESSURE DROP; • ENGINE OVERHEAT; • VALVE BURNOUT, ETC. MAIN - 3...
  • Page 20 STELVIO 4V - 1200 Maintenance MAIN - 4...
  • Page 21 INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM...
  • Page 22 STELVIO 4V - 1200 Electrical system Checks and inspections Battery recharge circuit 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...
  • Page 23 STELVIO 4V - 1200 Electrical system Engine rpm sensor Measures the engine revolution speed and each cylinder timing in relation to the TDC Inductive type sensor, with three-way connector: • positive voltage pin; • negative voltage pin: resistance from 650 to 720 Ohm (to be measured be- tween pins 1 and 2);...
  • Page 24 STELVIO 4V - 1200 Electrical system Specification Desc./Quantity Resistance at +80 °C (176 °F) 0.380 kOhm Resistance at +90 °C (194 °F) 0.280 kOhm Resistance at +100 °C (212 °F) 0.204 kOhm Resistance at +110 °C (230 °F) 0.153 kOhm Resistance at +120 °C (257 °F)
  • Page 25 STELVIO 4V - 1200 Electrical system Lambda sensor Oxygen sensor with heater. Sensor voltage between 0 and 0.9 V (to be meas- ured between pins 1 and 2). Heater resistance 12.8 Ohm (to be measured be- tween pins 3 and 4 at 20°C - 68°F).

  • Page 26: Bank Angle Sensor

    STELVIO 4V - 1200 Electrical system Engine oil pressure sensor An oil pressure sensor anomaly is signalled by the lighting of the "bulb" icon which should remain lit even with the engine running. There is an oil pressure anomaly when, with en-...
  • Page 27 INDEX OF TOPICS NGINE...
  • Page 28 STELVIO 4V - 1200 Engine Gearbox Diagram Key: 1. Ball bearing ENG - 2...

  • Page 29: Spring

    STELVIO 4V - 1200 Engine 2. Circlip 3. Thickness 4. Pin 5. Complete desmodromic 6. Ball bearing 7. Spring 8. Spacer 9. Circlip 10.Fifth wheel 11.Linking pin 12.Gear 13.Circlip 14.Thrust washer 15.Ball bearing cage 16.Gear 17.Sealing ring 18.Ball bearing 19.Gear 20.Circlip...

  • Page 30: Table Of Contents

    STELVIO 4V - 1200 Engine 40.Index lever 41.Spring 42.Ball bearing 43.Gear 44.Gear 45.Ball bearing cage 46.Thrust washer 47.Circlip 48.Gear 49.Circlip 50.Gear 51.Main shaft 52.Transmission gear 53.Fork (5th - 1st) 54.Fork shaft 55.Fork (3rd - 4th) 56.Fork (2nd - 4th) 57.Gear 58.Gear...
  • Page 31 STELVIO 4V - 1200 Engine • Unscrew and remove the gearbox oil filler cap. • Place a container of suitable capacity under it, unscrew and remove the cap and then bleed all gearbox oil. • Loosen and turn the oil pipe fitting on the sump.
  • Page 32 STELVIO 4V - 1200 Engine • Undo and remove the two screws. • Undo and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts ENG - 6...
  • Page 33 STELVIO 4V - 1200 Engine Disassembling the gearbox • Remove the gearbox. • Unscrew and slide off the odometer gear and collect the abutment washer that is inside the gearbox. • From the outside, slide off the thrust cylinder and collect the O-Ring and the washer.
  • Page 34 STELVIO 4V - 1200 Engine • Slide off the rod with the two bushings. • Undo and remove the five external screws. • Place the gearbox on the specific gearbox support tool and on a vice. Specific tooling 05.90.25.30 Gearbox support •...
  • Page 35 STELVIO 4V - 1200 Engine • Remove the bearings from the gearbox if necessary. • Release the spring. • Pressing the selector, slide off the whole transmission lever. • Use rubber bands to tie down the trans- mission shaft unit and extract it.
  • Page 36 STELVIO 4V - 1200 Engine • Remove the forks and collect the shaft. ENG - 10...

  • Page 37: Ball Bearing

    STELVIO 4V - 1200 Engine • Replace bearings if necessary and re- move the clutch shaft. See also Removing the gearbox Removing the primary shaft • Remove the main shaft. • Operate on the main shaft from the second gear side.

  • Page 38: Gear

    STELVIO 4V - 1200 Engine • Remove the circlip. • Remove the gear of the third and fourth gears. • Remove the circlip and collect the shoulder washer. • Remove the gear of the fifth gear and collect the ball bearing cage.
  • Page 39 STELVIO 4V - 1200 Engine • Heat the shaft with a specific heater and remove the helical transmission gear. Removing the secondary shaft • Remove the transmission shaft. • Operate on the shaft from the grooved side. • Remove the shoulder washer.

  • Page 40: Ball Bearing Cage

    STELVIO 4V - 1200 Engine • Remove the circlip. • Remove the gear of the sixth gear. • Remove the circlip and collect the shoulder washer. • Remove the gear of the fourth gear and collect the ball bearing cage.

  • Page 41: Circlip

    STELVIO 4V - 1200 Engine • Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. • Remove the gear of the fifth gear. • Remove the circlip, the shoulder wash- er and remove the gear of the first gear, collect the ball bearing cage.
  • Page 42 STELVIO 4V - 1200 Engine Checking the primary shaft Measure coaxiality of the main shaft with a dial gauge and a centring device and replace it if not complying with specifications. Characteristic Shaft coaxiality limit 0.08 mm (0.0031 in) Check transmission gears for signs of pitting and wear and replace damaged gears if necessary.
  • Page 43 STELVIO 4V - 1200 Engine Checking the forks NOTE THE FOLLOWING PROCEDURE IS VALID FOR ALL TRANSMISSION FORKS. • Check the transmission fork cam roller «1» and the transmission fork tooth «2» for damage, deformation and wear. • Replace the transmission fork if nec- essary.

  • Page 44: Gear

    STELVIO 4V - 1200 Engine TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED. If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod.
  • Page 45 STELVIO 4V - 1200 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 - 19...

  • Page 46: Removing The Generator

    STELVIO 4V - 1200 Engine Removing the generator • Remove the fuel tank. • Remove the control unit from its seat. • Disconnect the alternator connectors. • Undo and remove the five screws and collect the bushings. • Remove the cover.
  • Page 47 STELVIO 4V - 1200 Engine • Loosen the nut and undo the set screw so that the alternator slides down. • Completely loosen and remove the screw. • Remove the belt and the alternator with pulley. • Using a compressed air gun, unscrew and remove the nut and collect the spacer.
  • Page 48 STELVIO 4V - 1200 Engine • Undo and remove the eight screws. • Undo and remove the two screws. • Undo and remove the two screws. ENG - 22...
  • Page 49 STELVIO 4V - 1200 Engine • Remove the alternator frame. • Remove the sealing ring if necessary. See also Fuel tank Tensioning the belt • Remove both fuel tank side fairings. • Remove the right exhaust manifold. • Remove the control unit.

  • Page 50: Installing The Generator

    STELVIO 4V - 1200 Engine • Utilizzando l'attrezzo di tensionamento della cinghia, tensionare la cinghia alla coppia prestabilita. • Avvitare il registro. • Serrare il controdado. Specific tooling 020677Y Tenditore cinghia alternatore Installing the generator • If the sealing ring has been previously removed, replace it using the punch of the timing system cover sealing ring.
  • Page 51 STELVIO 4V - 1200 Engine • Place the bolt and the pin in the gen- erator cover. • Replace the gasket and place the al- ternator frame using the front cover in- sertion cone. • Remove the insertion cone afterwards.
  • Page 52 STELVIO 4V - 1200 Engine • Tighten the four screws, operating di- agonally and in stages. • Position the lower pulley and the spacer. • Tighten the nut to the prescribed tor- que. • Position the alternator and the timing system belt.
  • Page 53 STELVIO 4V - 1200 Engine • Position the screw and tighten the nut. • Utilizzando l'attrezzo di tensionamento della cinghia, tensionare la cinghia alla coppia prestabilita e avvitare il registro. • Rimuovere l'attrezzo di tensionamento della cinghia. • Bloccare il registro in posizione serran- do il controdado.

  • Page 54: Starter Motor

    STELVIO 4V - 1200 Engine • Position the timing system cover. • Tighten the five screws, operating in oblique direction and in stages. Starter motor Removing the starter motor • Undo and remove the two screws and collect the washers.
  • Page 55 STELVIO 4V - 1200 Engine Clutch side Disassembling the clutch Key: 1. Complete clutch 2. Clutch 3. Clutch bell 4. TCEI screw 5. Clutch disc 6. Crown 7. TCEI screw 8. Clutch pressure plate 9. Ring 10.TE flanged screw 11.Conical washer 12.Bushing...

  • Page 56: Gear

    STELVIO 4V - 1200 Engine 18.Thrust cylinder 19.Clutch control cylinder 20.TE flanged screw • Remove the complete gearbox. • Undo and remove the six screws. • Remove the start-up crown gear. • Remove the clutch bell and the friction disc.
  • Page 57 STELVIO 4V - 1200 Engine • Undo and remove the six screws and collect the belleville springs. • Remove the clutch disc. 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 58 STELVIO 4V - 1200 Engine CLUTCH CONTROL ROD SELECTION Specification Desc./Quantity Clutch control rod (code 976593) 183 mm (7.205 in) Clutch control rod (code 976594) 184.5 mm (7.264 in) Clutch control rod (code 976595) 186 mm (7.323 in) Clutch control rod (code 976596) 187.5 mm (7.382 in)
  • Page 59 STELVIO 4V - 1200 Engine • Lock the plate with a snap ring. • Centre the plate. • Place the friction disc; centre it. • Place the clutch bell with the reference facing upwards. • Place the start-up crown gear with the reference facing upwards.

  • Page 60: Spacer

    STELVIO 4V - 1200 Engine Head and timing Key: 1. Right cylinder head 2. Stud bolt 3. Cylinder head gasket 4. Right rocking lever support 5. Screw 6. Pin 7. Nut 8. Right exhaust, left intake rocking lever 9. Left exhaust, right intake rocking lever 10.Set screw...
  • Page 61 STELVIO 4V - 1200 Engine 20.TE flanged screw 21.O-ring 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...

  • Page 62: Removing The Cylinder Head

    STELVIO 4V - 1200 Engine Removing the head cover NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Disconnect the spark plug tube. • Undo and remove the four head cover fixing screws and collect the sealing O- rings.
  • Page 63 STELVIO 4V - 1200 Engine • Undo and remove the screw. • Remove the timing system upper gear bulkhead. For the right head: • Unscrew and remove the chain ten- sioner cap. • Remove the right chain tensioner. For the left head: •...
  • Page 64 STELVIO 4V - 1200 Engine • Slide off the timing system gear from the chain to remove it from the cam- shaft. • Unscrew and remove the four nuts on the stud bolts. • Remove the complete cam cap. •...

  • Page 65: Cylinder Head

    STELVIO 4V - 1200 Engine • Collect the two head dowel pins. • Collect the gasket between the head and the cylinder. See also Removing the head cover Cylinder head Removing the overhead camshaft CAUTION WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CARE- FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
  • Page 66 STELVIO 4V - 1200 Engine • Remove the camshaft. • Remove the bowls from the cam cap, and mark their position so as not inter- change them when refitting. See also Removing the rocker arms Removing the rocker arms CAUTION WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CARE- FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.

  • Page 67: Removing The Valves

    STELVIO 4V - 1200 Engine • Remove the two rocking levers from the cam cap. See also Removing the cylinder head Removing the valves • Rimuovere la testa. • Posizionare l'attrezzo speciale sul piat- tello superiore e al centro del fungo della valvola che si vuole rimuovere.

  • Page 68: Checking The Cylinder Head

    STELVIO 4V - 1200 Engine Checking the valve guides Use a punch to extract the valve guides from the heads. The valve guides should be replaced only if the clearance between them and the stem cannot be elim- inated by simply replacing the valves.

  • Page 69: Installing The Valves

    STELVIO 4V - 1200 Engine INLET VALVE SEAT DETAIL DRAWING OUTLET VALVE SEAT DETAIL DRAWING - If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45° mill and then grind.
  • Page 70 STELVIO 4V - 1200 Engine • Remove the special tool Installing the rocker arms • Fit the camshaft. • Fit the two rods. • Place the two rocking levers in the cam cap seats. • Place the U-bolt on the rocking levers making sure the two reference pins match the seats on the cam cap.
  • Page 71 STELVIO 4V - 1200 Engine Installing the overhead camshaft • Place the bowls in the cam cap, if those previously removed are refitted be careful not to interchange them. • Place the camshaft with the gear seat on the dowel side.
  • Page 72 STELVIO 4V - 1200 Engine Removing the phonic wheel • Remove the generator and the timing system cover. • Unscrew and remove the nut and col- lect the washer. • Remove the timing system gear on the service shaft. •...
  • Page 73 STELVIO 4V - 1200 Engine • Mark the timing chains so as not to in- vert the direction of rotation upon fit- ting. • Slide off the service shaft from the chains. • Remove both chains. See also Removing the phonic wheel Installing the service shaft •...
  • Page 74 STELVIO 4V - 1200 Engine • Partially fit the service shaft closing cap. • To screw the cap until it stops, use two M6 flanged screws larger than the orig- inal screws. • Tighten the two M6 flanged screws op- erating in stages until the cap stops against the crankcase.
  • Page 75 STELVIO 4V - 1200 Engine Cam timing • Fit the crankshaft and the service shaft on the crankcase. • Fit the cylinders. • Turn the crankshaft until the left cylin- der piston reaches the top dead centre (TDC). • Fit the cotter and the shim washer on the service shaft.
  • Page 76 STELVIO 4V - 1200 Engine • After shimming the timing sensor prop- erly, proceed to fit it. • Fit the washer and tighten the timing system gear fixing nut of the service shaft. • Place a new gasket between the crank- case and the oil pump.
  • Page 77 STELVIO 4V - 1200 Engine • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the...
  • Page 78 STELVIO 4V - 1200 Engine Measuring air gap • Undo and remove the two screws and remove the sensor. • Insert a suitable plain washer on the sensor and note its thickness. • Place the sensor on the crankcase and move it until it makes contact with the tone wheel.
  • Page 79 STELVIO 4V - 1200 Engine Cylinder-piston assembly Key: 1. Right cylinder 2. Piston 3. Screw 4. Top piston ring 5. Middle piston ring 6. Oil scraper piston ring 7. Pin 8. Snap ring 9. Cylinder base gasket 10.Stud bolt 11.Pin 12.Cylinder head gasket...
  • Page 80 STELVIO 4V - 1200 Engine Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Remove the head, the gasket between the head and the cylinder and the two dowel pins.
  • Page 81 STELVIO 4V - 1200 Engine • Mark the piston crown on the outlet side to remember its position when re- fitting. • Remove the piston. Fitting the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.
  • Page 82 STELVIO 4V - 1200 Engine • Insert the pin. • Inserire il fermo dello spinotto. Specific tooling 020470Y Pin snap ring fitting tool Installing the cylinder RIGHT CYLINDER • Fit the piston. • Remove the cloth used to prevent for- eign bodies from getting into the crank- case.
  • Page 83 STELVIO 4V - 1200 Engine 020674Y Stringifasce 020716Y Connecting rod locking • Rimuovere l'attrezzo stringifasce e completare il posizionamento del cilin- dro. Specific tooling 020674Y Stringifasce • Fit the movable chain slider. • Fit the upper gear. • Fit the chain tensioner and the chain tensioner cap temporarily and keep the chain taut on the service shaft.
  • Page 84 STELVIO 4V - 1200 Engine • Check that the oil in the left cylinder chain tensioner has been drained off by compressing it. If the operation is difficult, use a pin drive to push the central hole so that the oil is drained off from the circuit.

  • Page 85: Installing The Cylinder Head

    STELVIO 4V - 1200 Engine Installing the cylinder head • Fit the valves in the head, if previously removed. • Take the left cylinder piston to TDC and lock crankshaft rotation. • Determine the thickness of the gasket to be fitted between the head and the cylinder as described in the section: Shimming system.
  • Page 86 STELVIO 4V - 1200 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 87 STELVIO 4V - 1200 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 88 STELVIO 4V - 1200 Engine • Place the cap. • Tighten the two screws to the prescri- bed torque. • Also place the cap of the other head. • Adjust valve clearance. See also Checking the valve clearance Installing the head cover •...
  • Page 89 STELVIO 4V - 1200 Engine Crankcase - crankshaft Removing the crankshaft • Remove the clutch. • Remove the tone wheel and the oil pump gear. • Working from the generator side, un- screw and remove the nut. • Remove both gears.
  • Page 90 STELVIO 4V - 1200 Engine • Remove the crankshaft afterwards. • Collect the shim washer from inside the crankcase. See also Disassembling the clutch Removing the phonic wheel Disassembling the connecting rod • Remove both heads. • Remove the cylinders and the pistons.
  • Page 91 STELVIO 4V - 1200 Engine Inspecting the crankshaft components Check the surfaces of the main journals; if they are scored or oval-shaped, reface them (observing the undersize charts), and replace the main bushing/ Reference (1) indicates the position where the col- oured reference is applied to select diameter (B).
  • Page 92 STELVIO 4V - 1200 Engine Checking the connecting rod When examining the connecting rods, check that: • Bushing conditions and bushings-pins clearance; • Shaft parallelism; • Connecting rod bearings. These are thin shell bearings, anti-friction alloy that does not allow for any adaptation; replace them immediately if seizing or wear marks are found.
  • Page 93 STELVIO 4V - 1200 Engine CRANKPIN DIAMETER (B) Specification Desc./Quantity 'Blue' bushing half-shell regular production 44.008 ÷ 44.014 mm (1.73259 ÷ 1.73283 in) 'Red' bushing half-shell regular production 44.014 ÷ 44.020 mm (1.73283 ÷ 1.73307 in) PIN-BUSHING COUPLING DATA Specification Desc./Quantity...
  • Page 94 STELVIO 4V - 1200 Engine • Place the connecting rods and the caps (B) on the crankshaft and fasten them with new screws (A). • Remember these recommendations: • The screws fixing the connecting rods to the crankshaft must be replaced with new ones at the following refitting as they are subject to high loads and stress;...
  • Page 95 STELVIO 4V - 1200 Engine • 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 sealing ring on the flywheel-side flange • Fit a new gasket between the crankcase and the crankshaft flange, flywheel side.
  • Page 96 STELVIO 4V - 1200 Engine • To avoid that the shim washer inside the crankcase moves out of its seat, fit the two gears and the nut on the crank- shaft on the generator side. Refitting the crankcase halves In case the lubrication jets are removed, replace them with two new of the same type.
  • Page 97 STELVIO 4V - 1200 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 98: Oil Pump

    STELVIO 4V - 1200 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 99 STELVIO 4V - 1200 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 100 STELVIO 4V - 1200 Engine • Remove the gasket between the crankcase and the oil pump. See also Replacement Removing the generator Installing • Place a new gasket between the crank- case and the oil pump. • Place the oil pump.
  • Page 101 STELVIO 4V - 1200 Engine • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the...
  • Page 102 STELVIO 4V - 1200 Engine • Fit the nipple with the gasket on the crankcase. • Tighten the nipple to the prescribed torque. Removing the oil sump NOTE TO REMOVE THE OIL SUMP, PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL.
  • Page 103 STELVIO 4V - 1200 Engine • Undo and remove the four screws. • Remove the flange. • Undo and remove the two screws. • Remove both filters. ENG - 77...
  • Page 104 STELVIO 4V - 1200 Engine • Unscrew and remove the plug. • Remove the thermostatic valve. • Unscrew and remove the pressure re- lief valve plug. • Remove the pressure relief valve com- ponents ENG - 78...
  • Page 105 STELVIO 4V - 1200 Engine Refitting the oil sump • Place the pressure relief valve compo- nents correctly. • Screw the pressure relief valve plug. • Place the thermostatic valve. CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED.
  • Page 106 STELVIO 4V - 1200 Engine • Place a new gasket between the crank- case and the flange. • Fit the flange. • Fix the flange with the four screws. • Fit the lubrication oil intake filter. • Check that the O-rings are fitted on the oil pump.
  • Page 107 STELVIO 4V - 1200 Engine • Fix both filters and tighten the two screws to the prescribed torque. • Fit a new oil filter and tighten it to the prescribed torque. • Place a new gasket between the flange and the sump.
  • Page 108 STELVIO 4V - 1200 Engine ENG - 82...
  • Page 109 INDEX OF TOPICS P SUPP OWER SUPPLY...
  • Page 110 STELVIO 4V - 1200 Power supply Injection 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...
  • Page 111 STELVIO 4V - 1200 Power supply 11 Crankshaft position sensor 12. Side stand 13 Lambda probe 14 Fall sensor PASSAGGIO TUBAZIONI CORPO FARFALLA- La tubazione che và dal corpo farfallato al motor- ino del minimo deve essere installata in modo che la parte sagomata sia inserita nella cassa filtro aria.
  • Page 112 STELVIO 4V - 1200 Power supply • Turn on the scanner. • Screw the joints connecting the vacu- ometer pipes on the inlet pipe holes. • Connect the vacuometer pipes to the relative joints. • Set the key to ON.
  • Page 113 STELVIO 4V - 1200 Power supply • take the engine back to idle and check the depression values so that they are aligned between the two cylinders. Otherwise, open only the screw with higher depression, using the by-pass screws, to compensate.
  • Page 114 STELVIO 4V - 1200 Power supply Iso screen page This display shows general data regarding the control unit, for example software type, mapping, control unit programming date ISO DISPLAY Specification Desc./Quantity Mapping Engine parameter reading screen page ENGINE PARAMETER READING...
  • Page 115 STELVIO 4V - 1200 Power supply Specification Desc./Quantity The sensor is inside the instrument panel Lambda probe 100 - 900 mV (approximate values) Signal when energised that the control unit re- ceives from the lambda probe: inversely propor- tional to the presence of oxygen...
  • Page 116 STELVIO 4V - 1200 Power supply Specification Desc./Quantity indicates if the control unit consents engine start- RUN / STOP switch Run / stop indicates the position of the safety switch Clutch No / Yes indicates the clutch sensor status Gear engaged...
  • Page 117 STELVIO 4V - 1200 Power supply Errors display screen page ERRORS DISPLAY This screen page shows potential errors detected in the vehicle (ATT) or stored in the control unit (MEM) and it is possible to check error deletion (STO) ERRORS DISPLAY Specification Desc./Quantity...
  • Page 118 STELVIO 4V - 1200 Power supply Specification Desc./Quantity Lambda heater Possible short circuit in the earth lead, battery or lambda probe heating circuit open. SPEED SENSOR Possible short circuit in the earth lead, battery or speed sensor circuit open: also possible lack of...
  • Page 119 INDEX OF TOPICS CHAS HASSIS...
  • Page 120 STELVIO 4V - 1200 Chassis Bevel gears Checking Smontaggio gruppo scatola Remove the cover (20). Remove the plug (3) to drain out the oil. Lift the cap (10). CHAS - 2...
  • Page 121 STELVIO 4V - 1200 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 - 3...
  • Page 122 STELVIO 4V - 1200 Chassis Remove the clamp (12). Remove the cap (14). Collect the ring (13). Remove the support unit (8). Montaggio gruppo scatola CHAS - 4...
  • Page 123 STELVIO 4V - 1200 Chassis Assemble the dowel pins to the casing with the buffer and a hammer. Assemble the casing to the special fastening tool. Clean the casing faying surfaces carefully. Heat the casing. Insert the support group in the casing.
  • Page 124 STELVIO 4V - 1200 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 - 6...
  • Page 125 STELVIO 4V - 1200 Chassis Fit a new sealing ring using the buffer. Lubricate the sealing ring. Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture. Fit the casing.
  • Page 126 STELVIO 4V - 1200 Chassis Assemble the ring to the casing. Tighten the fixing screws to the prescribed torque. Fit the cap with the washer. Screw the cap to the prescribed torque. Fit the breather with the washer. Screw the breather to the prescribed torque.
  • Page 127 STELVIO 4V - 1200 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. Gruppo asse ruota...
  • Page 128 STELVIO 4V - 1200 Chassis Turn the unit over. Remove the bearing from the wheel axle with a suitable extractor. FITTING Heat the bearings to 100°C (212 °F). Assemble the bearings to the wheel axle. Turn the unit over. Assemble the bearings to the wheel axle.
  • Page 129 STELVIO 4V - 1200 Chassis 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 130 STELVIO 4V - 1200 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 131 STELVIO 4V - 1200 Chassis Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT. Gruppo supporto CHAS - 13...
  • Page 132 STELVIO 4V - 1200 Chassis REMOVAL Remove the bushing (1) with a punch. Turn the support (5) over and remove the other bushing (8). Remove the sealing rings (2) and (7) with a screw- driver. Remove the stop rings (3) and (6) from the support (5) with suitable pliers.
  • Page 133 STELVIO 4V - 1200 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 134 STELVIO 4V - 1200 Chassis Installing • Insert the transmission casing on the fork making sure that the universal joint engages correctly. • Tighten the four screws to the prescri- bed torque operating diagonally. • Place the reaction rod into its seat.
  • Page 135 STELVIO 4V - 1200 Chassis • Posizionare il sensore velocità e fer- mare il cablaggio tramite fascette. • Posizionare sul forcellone la ruota pos- teriore. • Serrare le quattro viti complete di dis- tanziali e anello antipolvere. • Posizionare sul disco la pinza freno posteriore e il tubo freno sul forcellone.

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