Page 1 SERVICE STATION MANUAL 981127 STELVIO 1200 NTX...
Page 2: The Value Of Service
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 4 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 5: Index Of Topics
INDEX OF TOPICS CHAR HARACTERISTICS S-TOOLS PECIAL TOOLS MAIN AINTENANCE ELE SYS LECTRICAL SYSTEM ENG VE NGINE FROM VEHICLE NGINE P SUPP OWER SUPPLY SUSP USPENSIONS CHAS HASSIS BRAK SYS RAKING SYSTEM BODYW ODYWORK PRE DE DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 6 INDEX OF TOPICS CHAR HARACTERISTICS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 7: Safety Rules
STELVIO 1200 NTX 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: Maintenance Rules
STELVIO 1200 NTX Characteristics BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COM- PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR EYES.
Page 9: Electric Connectors
REASSEMBLING COMPONENTS CAUTION BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY NEED TO BE REPLACED. • Only use ORIGINAL Moto Guzzi SPARE PARTS. • Comply with lubricant and consumables use guidelines. • Lubricate parts (whenever possible) before reassembling them.
Page 10: Vehicle Identification
That is to permit the adequate adjustment of the pad friction material to the brake discs. AFTER THE SPECIFIED MILEAGE, TAKE THE VEHICLE TO AN OFFICIAL Moto Guzzi DEALER FOR THE CHECKS INDICATED IN THE "AFTER RUN-IN" TABLE IN THE SCHEDULED MAINTE- NANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHI- CLE.
Page 11: Chassis Number
STELVIO 1200 NTX Characteristics This number consists of numbers and letters, as in the example shown below. ZGULZB000YMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LZ: model; B00: version variation; 0: digit free Y year of manufacture M: production plant (M= Mandello del Lario);...
Page 12: Electrical System
STELVIO 1200 NTX 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 Idle speed 1100 ± 100 rpm Clutch hydraulic single plate dry clutch with integrated flexible coupling...
Page 13 STELVIO 1200 NTX Characteristics Specification Desc./Quantity Low/high beam headlight (halogen) 12 V - 55 W / 60 W H4 Turn indicators 12V - 10 W Tail light/stop light Supplementary headlamps (if fitted) 12 V/55W - H3 Instrument panel lighting License plate light...
Page 14: Fuel System
STELVIO 1200 NTX Characteristics Wheels and tyres WHEELS AND TYRES - STELVIO NTX Wheel Model Wheel rim Measure Tyre pressure with Tyre pressure, rider + ment rider only passenger Front (standard) Metzeler Tourance 2.50 x 19" 110/80 2.4 bar (240 kPa) (34.8 2.5 bar (250 kPa) (36.3...
Page 15: Timing System
STELVIO 1200 NTX Characteristics Name Torque in Nm Head covers fixing screws (8) 8 Nm (5.9 lbf ft) Spark plug (2) 15 Nm (11.06 lbf ft) - Molykote CRANKCASE Name Torque in Nm Crankcase stud bolt - cylinder (8) 25 Nm (18.44 lbf ft) Transmission side flange stud bolt - M8x66 (3) 35 Nm (25.81 lbf ft)
Page 16: Oil Radiator
STELVIO 1200 NTX Characteristics ALTERNATOR Name Torque in Nm Alternator fixing screw - TCEI M8x45 (1) 22 Nm (16.23 lbf ft) Alternator fixing nut - M10x1.5 (1) 30 Nm (22.13 lbf ft) Alternator pulley nut on crankshaft - M16 (1)
Page 17: Side Stand
STELVIO 1200 NTX Characteristics FOOTRESTS AND LEVERS Name Torque in Nm Footrest rubber retainer 10 Nm Rider footrest sliding pin - M8 25 Nm Passenger footrest support to lateral plates retainer 38 Nm Rider heelrest to plates retainer 6 Nm...
Page 18: Front Wheel
STELVIO 1200 NTX Characteristics Name Torque in Nm Clamps retainer - M8 (3) 20 Nm (14.75 lbf ft) FRONT WHEEL Name Torque in Nm Wheel pin nut 80 Nm REAR WHEEL Name Torque in Nm Disc retainer 25 Nm Rear wheel retainer 10.9...
Page 19: Engine Cover
STELVIO 1200 NTX Characteristics ENGINE COVER Name Torque in Nm Right cover plate retainer - M10x20 (2) 40 Nm (29.5 lbf ft) Left cover plate retainer - M10 (1) 40 Nm (29.5 lbf ft) Front engine guard retainer - M8x40 (4) 15 Nm (11.06 lbf ft)
Page 20: Piston Rings
STELVIO 1200 NTX Characteristics Specification Desc./Quantity Piston diameter - selection F 94.955 - 94.965 mm (3.73837 - 3.73877 in) Cylinder diameter - selection F 95.020 - 95.030 mm (3.74093 - 3.74133 in) PIN - PISTON COUPLING Specification Desc./Quantity Pin diameter 21.998 - 21.994 mm (0.86606 - 0.86590 in)
Page 21 STELVIO 1200 NTX Characteristics Crankcase - crankshaft - connecting rod CRANKSHAFT SEAT (TIMING SYSTEM SIDE) Specification Desc./Quantity Diameter of crankshaft main journal, timing system side 37.975 - 37.959 mm (1.49507 - 1.49444 in) Inside diameter of crankshaft bushing, timing system side 38.016 - 38.0 mm (1.49669 - 1.49606 in)
Page 22 STELVIO 1200 NTX Characteristics • Reset the micrometer on the cylinder rim. • Move the tool so that the micrometer feeler reaches the top point of the piston crown. • 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 cylinder and head.
Page 23: Index Of Topics
INDEX OF TOPICS S-TOOLS PECIAL TOOLS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 24 STELVIO 1200 NTX Special tools ENGINE Stores code Description 020677Y Alternator belt tensioner, Belt tensioning lever 05.91.17.30 Front cover insertion cone 020716Y Connecting rod locking 020470Y Pin snap ring fitting tool 05.92.72.30 Timing system cover sealing ring punch 01.92.91.00 Wrench for removing the cover on sump...
Page 25 STELVIO 1200 NTX Special tools Stores code Description 05.90.25.30 Gearbox support 19.92.96.00 Graduated dial to control ignition timing 17.94.75.60 Arrow 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...
Page 26 STELVIO 1200 NTX Special tools Stores code Description 14.92.71.00 Tool to fit the sealing ring on the flywheel- side flange 12.91.20.00 Tool to fit the flywheel-side flange togeth- er with sealing ring on the crankshaft 19.92.71.00 Tool to fit the sealing ring on the flywheel-...
Page 27 STELVIO 1200 NTX Special tools Stores code Description 020676Y Comparator support for piston position checking 020678Y Tool for clutch rod checking 05.91.25.30 Gearbox opening CHASSIS Stores code Description 05.91.26.30 Tool for tightening the swingarm pin ring nut - clutch hub...
Page 28 STELVIO 1200 NTX Special tools BEVEL GEAR PAIR 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 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 29: Front Fork
STELVIO 1200 NTX Special tools Stores code Description 05.90.27.36 Bevel gear pair support FRONT FORK Stores code Description AP8140146 Weight AP8140149 Protection for fitting operations AP8140758 tool to fit oil seals and dust guards for ø 50 mm (1.97 in) stems...
Page 30: Maintenance
INDEX OF TOPICS MAIN AINTENANCE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 31: Maintenance Chart
STELVIO 1200 NTX Maintenance Maintenance chart NOTE CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE- HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK USE. OUTINE MAINTENANCE TABLE I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE * Check and clean, adjust or replace if necessary before every ride.
Page 32 STELVIO 1200 NTX Maintenance Check • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the cap/dipstick (1). • The level is correct if the oil is close to the hole of the cap/dipstick (1).
Page 33: Engine Oil
STELVIO 1200 NTX Maintenance Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM (10 miles).
Page 34: Engine Oil Filter
STELVIO 1200 NTX Maintenance • Place a container with +4,000 cm³ (244 cu in) capacity under the drainage plug (3). • Unscrew and remove the drainage plug (3). • Pull out the oil filler plug / engine oil level dipstick (4).
Page 35: Checking And Topping Up
STELVIO 1200 NTX Maintenance Gearbox Oil Inspection CHECKING AND TOPPING UP CAUTION ENGINE MUST BE WARM TO CHECK GEARBOX OIL LEVEL. NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM (10 miles).
Page 36: Air Filter
STELVIO 1200 NTX Maintenance • Pour in new oil until it reaches the dipstick open- ing (1). • Tighten the filler cap (1). CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL- EMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Page 37: Braking System
STELVIO 1200 NTX Maintenance • Disconnect both spark plug tubes. • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings. • Remove the head cover together with the gasket. • Loosen the nut (1). •...
Page 38 STELVIO 1200 NTX Maintenance • For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the same level with the plug. • Make sure that the fluid level in the reservoir is above the "MIN" reference mark:...
Page 39 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 40: Electrical System
INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 41 STELVIO 1200 NTX Electrical system Components arrangement key: 1 Coil 2 Instrument panel 3 Fuel pump 4 Injector Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ELE SYS - 41...
Page 42: Electrical System Installation
STELVIO 1200 NTX Electrical system 5 Throttle valve potentiometer 6 Fall sensor 7 Rear light 8 Main fuses 9 Lambda probe 10 Battery 11 Starter motor 12 Intake air temperature sensor 13 Engine revolution sensor 14 Head temperature sensor 15 Engine control unit...
Page 43 STELVIO 1200 NTX Electrical system • Clamp the clutch pipes with the clutch switch and the left light switch, making sure that the fixing part of the lower clamp faces the inside, to avoid that by turning the steering the instrument panel is damaged and the clamp gets unhooked.
Page 44 STELVIO 1200 NTX Electrical system • Clamp the left headlight cable (3), the left turn indicator (4) and the TOM TOM cable (5). • Clamp the heated handgrips cable. Central part CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPE-...
Page 45: Central Section
STELVIO 1200 NTX Electrical system CENTRAL SECTION TABLE A - CORRECT FITTING OF THE ALTER- NATOR CABLE • The red cable of the alternator must be in upright position. TABLE B - RED CLAMP STARTING POINT IN THE ELECTRICAL SYSTEM •...
Page 46 STELVIO 1200 NTX Electrical system TABLE C - POSITION OF THE FUEL PUMP CA- BLE HARNESS • Clamp the cable at the front to obtain the correct position. • The connection must be between the chassis and the air filter.
Page 47: Back Side
STELVIO 1200 NTX Electrical system TABLE E - BATTERY COMPARTMENT HOUS- • The battery housing must be free of any connections or pipes, in order to allow perfect fitting. Back side CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPE-...
Page 48 STELVIO 1200 NTX Electrical system REAR SECTION TABLE C - REAR SYSTEM RETAINER • Pay attention to the position of the U- bolt adhesive cable grommets for the system. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 49: General Wiring Diagram
STELVIO 1200 NTX Electrical system General wiring diagram Key: 1. Multiple connectors 2. Clutch switch 3. Start-up relay 4. Start-up maintenance relay Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ELE SYS - 49...
Page 50 STELVIO 1200 NTX Electrical system 5. Light relay 6. Fog lights relay 7. Right light switch 8. Left light switch 9. Horn 10.Instrument panel air temperature thermistor 11.Instrument panel 12.Immobilizer aerial 13.Key switch 14.Heated handgrips 15.GPS coupling 16.Glove-box compartment electric lock 17.Rear right turn indicator...
Page 51: Checks And Inspections
STELVIO 1200 NTX Electrical system 43.Left cylinder spark plug 44.Right cylinder coil 45.Left cylinder coil 46.Right cylinder injector 47.Left cylinder injector 48.Speed sensor 49.Fall sensor 50.Flywheel pick up 51.ECU 52.Fog lights 53.Front left turn indicator 54.(Double) Front headlight 55.Tail light bulb 56.Low-beam bulb...
Page 52: Enter New Code
STELVIO 1200 NTX Electrical system Dashboard Diagnosis Changing the CODE If you know the code, just enter it and then a new code that will be automatically stored in the memory. If the vehicle is new, the user code is: 00000 Resetting the CODE This function is used to set a new code when the old one is not available;...
Page 53 STELVIO 1200 NTX Electrical system Lambda Probe Error ECU 21 Coil 1 Error DC V DC ECU 22 Coil 1 Error DC Gnd ECU 23 Coil 2 Error DC V DC ECU 24 Coil 2 Error DC Gnd ECU 25...
Page 54: Checking The Stator
Use the Ditech connector in the Axone 2000 Apri- lia-Moto Guzzi package to connect to the Axone cable. KEY CHANGE FUNCTION This function can be used: 1) if one key is lost;...
Page 55: Front Headlamp
STELVIO 1200 NTX Electrical system Start-up system check pick-up input about 100 A level indicators Petrol pump: Input: 3.5 A (to be measured between pins 1 and 2 with 12V voltage) Fuel level sensor: Resistance (to be measured between pins 3 and 250-300 Ohm with fuel level equal to 0 litre 100 Ohm with fuel level equal to 11.25 litres (20.43...
Page 56: Rear Light
STELVIO 1200 NTX Electrical system REAR LIGHT Specification Desc./Quantity Tail light/stop light License plate light 12V - 5 W DDITIONAL HEADLAMPS Specification Desc./Quantity Additional headlamp bulbs 12V/55W - H3 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 57: Auxiliary Fuses
STELVIO 1200 NTX Electrical system Fuses AUXILIARY FUSES A - Stop, horn, coil, GPS, hazard button lighting, coils, light relay, passing (15 A). B - Tail lights, starter motor (15 A). C - Free D - Fuel pump, coils, injectors (15 A).
Page 58 STELVIO 1200 NTX Electrical system 6 Not used 7 Not used 8 Not used 9 Stepper motor (+) 10 Right cylinder coil control 11 Not used 12 Not used 13 Not used 14 Air temperature signal 15 Not used 16 Not used...
Page 59 STELVIO 1200 NTX Electrical system 4 Power supply protected from instrument panel 5 Not used 6 Pin 86 auxiliary relay control 7 Immobilizer line 8 Pin 85 ignition relay control 9 Not used 10 Not used 11 Oxygen probe negative control...
Page 60: Speed Sensor
STELVIO 1200 NTX Electrical system Battery 12 V - 18 Ampere/hour Speed sensor Function To indicate the vehicle speed by reading the rear wheel turning speed. Operation / Operating principle HALL effect sensor: a square-wave pulse is gen- erated with voltage between 12 V and 0.3-0.4V approx.
Page 61: Engine Rpm Sensor
STELVIO 1200 NTX Electrical system • Error signal if a speed below the default value set by the manufacturer for the running vehicle is detected. Possibly shorted to ground, battery or speed sensor circuit open: lack of supply from the control unit also possible.
Page 62 STELVIO 1200 NTX Electrical system • Winding resistance 650 Ohm +/- 15% • Output alternating voltage, value range: minimum: 0.5 V - maximum: 5 V PIN: 1. Engine revolution sensor positive signal. 2. Engine revolution sensor negative signal. 3. Revolution sensor anti-jamming cable.
Page 63: Throttle Position Sensor
STELVIO 1200 NTX 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.
Page 64: Engine Temperature Sensor
STELVIO 1200 NTX Electrical system 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). • If shorted to negative: voltage equal to zero has been detected.
Page 65 STELVIO 1200 NTX Electrical system • sensor: inside the "V" • connector: on the sensor Electrical characteristics: NGINE TEMPERATURE SENSOR RESISTANCE Specification Desc./Quantity Resistance at -40 °C (-40 °F) 100.950 kOhm Resistance at -30 °C (-22 °F) 53.100 kOhm Resistance at -20 °C (-4 °F) 29.120 kOhm...
Page 66: Air Temperature Sensor
STELVIO 1200 NTX Electrical system • If the circuit is open, shorted to positive: check the sensor connector and the Marelli control unit connector. If they are not OK, restore the cable harness; if OK, check the continuity of the sensor; if it is not OK, replace the sensor; if it is OK, check continuity between PIN 5 of the BROWN connector and PIN 2 of sensor: restore cable harness if there is not continuity;...
Page 67 STELVIO 1200 NTX Electrical system Specification Desc./Quantity Resistance at 0 °C (32 °F) 9.750 kOhm Resistance at 10 °C (50 °F) 5.970 kOhm Resistance at 20 °C (68 °F) 3.750 kOhm Resistance at 30 °C (86 °F) 2.420 kOhm Resistance at 40 °C (104 °F) 1.600 kOhm...
Page 68: Lambda Sensor
STELVIO 1200 NTX Electrical system Lambda sensor Function It tells the control unit whether combustion is lean or rich. Operation / Operating principle The Marelli injection control unit reads and inter- prets a voltage generated by the difference in oxy- gen content between the exhaust fumes and the ambient.
Page 69 STELVIO 1200 NTX Electrical system Closed loop indicates that the control unit is using the lambda probe signal to keep the combustion as close as possible to the stoichiometric value. AXONE: ELECTRICAL ERRORS Lambda probe P0130 - shorted to positive.
Page 70 STELVIO 1200 NTX 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 wiring diagram:Coils and injectors Location: •...
Page 71 STELVIO 1200 NTX Electrical system • Shorted 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 72 STELVIO 1200 NTX 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...
Page 73 STELVIO 1200 NTX Electrical system • If shorted to positive: excessive voltage has been detected at PIN 38 of the BROWN con- nector. • If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 38...
Page 74: Engine Oil Pressure Sensor
STELVIO 1200 NTX Electrical system continuity, restore the cable harness; if there is cable continuity, with the key set to KEY ON, check the cable ground insulation (from coil connector or control unit connector). If this is not OK, restore the cable harness.
Page 75 STELVIO 1200 NTX Electrical system It this error persists, use a pressure gauge to check the pressure of the oil in the engine circuit Neutral sensor Function it tells the gear position to the control unit: in neutral or in gear.
Page 76 STELVIO 1200 NTX Electrical system that the grey/black cable from PIN 1 of the sensor to PIN 23 of the BROWN connector is shorted to ground: restore the cable harness. Clutch lever sensor Function It tells the clutch lever position to the control unit.
Page 77 STELVIO 1200 NTX Electrical system the sensor. If the circuit is open, it means that the brown/purple cable from PIN 1 of the sensor to PIN 33 of the BLUE connector is shorted to ground: restore the cable harness Side stand sensor Function It tells the side stand position to the control unit.
Page 78: Bank Angle Sensor
STELVIO 1200 NTX Electrical system Bank angle sensor Function it tells the vehicle position to the control unit. Operation / Operating principle When the sensor is inverted, the circuit is closed to ground: when the Marelli control unit detects this earthing, it disables the fuel pump circuit and the engine start-up circuit via the injection relay.
Page 79 STELVIO 1200 NTX 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 wiring diagram:Temperature sensors Location: •...
Page 80: Run/Stop Switch
STELVIO 1200 NTX Electrical system If a short circuit to ground is detected at PIN 10 of the instrument panel connector, the display will show a full scale temperature indication of 60°C Check the ground insulation of the sensor connector pink cable: if there is a connection, restore the cable harness;...
Page 81 STELVIO 1200 NTX Electrical system 27 of the BLUE connector: if not OK, restore the cable harness; if OK, replace the Marelli control unit. • Indication on Axone always RUN: disconnect the connector and, with the switch set to STOP, check if there is continuity between the two cables of the switch (sensor side): if there is continuity, replace the switch;...
Page 82 STELVIO 1200 NTX Electrical system 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...
Page 83: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 84: Vehicle Preparation
STELVIO 1200 NTX Engine from vehicle Vehicle preparation Before removing the engine block, proceed as follows: • Park 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 85 STELVIO 1200 NTX Engine from vehicle • Remove the starter motor cover. • Unscrew and remove the stud bolt. • Disconnect the ground leads. • Disconnect the starter motor connec- tors. • Disconnect the stand sensor connec- tor and release it from the clamps.
Page 86 STELVIO 1200 NTX Engine from vehicle • Disconnect the neutral sensor connec- tor. • 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 87 STELVIO 1200 NTX Engine from vehicle • Working on both sides disconnect the injector connectors. • Working from both sides, undo and re- move the three inlet manifold screws. • Collect the gasket. • Disconnect the alternator connectors. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 88 STELVIO 1200 NTX Engine from vehicle • Disconnect the engine temperature sensor connector • Disconnect the engine oil pressure sensor connector. • Disconnect the revolution sensor con- nector. • Remove the fairing under the oil sump. • Support the vehicle with the engine service stand.
Page 89 STELVIO 1200 NTX Engine from vehicle • Working on both sides, unscrew and remove the front screw and collect the washer. • Operating from both sides, undo and remove the upper engine fixing nut on the internal side of the chassis.
Page 90 STELVIO 1200 NTX 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 91 STELVIO 1200 NTX 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 92 STELVIO 1200 NTX Engine from vehicle • Insert the oil breather pipe and fasten it with a new clamp. • Fit the gearbox oil breather pipe. • Fit the clutch control cylinder. • Tighten the three screws. • Connect the starter motor connectors.
Page 93 STELVIO 1200 NTX 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 94 STELVIO 1200 NTX 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 95 STELVIO 1200 NTX 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 96: Index Of Topics
INDEX OF TOPICS NGINE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 97 STELVIO 1200 NTX Engine Gearbox Diagram Key: 1. Ball bearing Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG - 97...
Page 98 STELVIO 1200 NTX 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 21.Clutch shaft...
Page 99: Removing The Gearbox
STELVIO 1200 NTX 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 59.Ball bearing...
Page 100 STELVIO 1200 NTX 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 101: Gearbox Shafts
STELVIO 1200 NTX Engine • Undo and remove the two screws. • Undo and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 102 STELVIO 1200 NTX 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 103 STELVIO 1200 NTX 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 104 STELVIO 1200 NTX 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 105 STELVIO 1200 NTX Engine • Once the transmission shaft unit is in on a bench, remove the rubber bands, being careful with the group. • Detach the shafts and label the forks before removal. • Remove the forks and collect the shaft.
Page 106 STELVIO 1200 NTX 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 107 STELVIO 1200 NTX Engine • Remove the gear of the sixth gear and collect the shoulder washer. • Remove the circlip. • Remove the gear of the third and fourth gears. • Remove the circlip and collect the shoulder washer.
Page 108 STELVIO 1200 NTX 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 109 STELVIO 1200 NTX 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 110 STELVIO 1200 NTX 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 111: Checking The Secondary Shaft
STELVIO 1200 NTX Engine • Remove the circlip, the shoulder wash- er and remove the gear of the first gear, collect the ball bearing cage. • Remove the bearing if necessary. See also Disassembling the gearbox Checking the primary shaft...
Page 112 STELVIO 1200 NTX Engine Checking the desmodromic drum Check gear drum for damage, scratches and wear and replace the desmodromic if necessary. Check the desmodromic segment «3» for damage and wear and replace it if necessary. Check the desmodromic bearing «4» for damage and cracks and replace it if necessary.
Page 113: Assembling The Gearbox
STELVIO 1200 NTX Engine Removing the primary shaft Fitting the secondary shaft NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED. See also...
Page 114 STELVIO 1200 NTX 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 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 115: Removing The Generator
STELVIO 1200 NTX 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 116 STELVIO 1200 NTX 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 117 STELVIO 1200 NTX Engine • Undo and remove the eight screws. • Undo and remove the two screws. • Undo and remove the two screws. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG - 117...
Page 118: Tensioning The Belt
STELVIO 1200 NTX Engine • Remove the alternator frame. • Remove the sealing ring if necessary. See also Fuel tank Tensioning the belt • Operating from both sides, undo and remove the screw fixing the oil radiator to the chassis.
Page 119 STELVIO 1200 NTX Engine • Undo and remove the five screws fixing the alternator belt cover. • Remove the oil radiator lower support bracket and the alternator belt cover. Locking torques (N*m) Alternator belt cover screw (radiator bracket retainer) TCEI M6x40 (2) Alter- 10 Nm (7.38 lbf ft)
Page 120: Installing The Generator
STELVIO 1200 NTX 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 121 STELVIO 1200 NTX 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 122 STELVIO 1200 NTX 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 123: Starter Motor
STELVIO 1200 NTX 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 124: Disassembling The Clutch
STELVIO 1200 NTX 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 disc 6. Crown 7. TCEI screw 8. Clutch pressure plate Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 125 STELVIO 1200 NTX 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 • Remove the complete gearbox. • Undo and remove the six screws.
Page 126 STELVIO 1200 NTX Engine • Remove the Seeger ring. • Remove the clutch pressure plate. • Undo and remove the six screws and collect the belleville springs. • Remove the clutch disc. See also Removing the gearbox 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 127: Specific Tooling
STELVIO 1200 NTX Engine • Fit the gearbox on the engine block. • Fit the tool in the gearbox to determine the clutch control rod length. • Measure rod protrusion using a depth gauge (see picture). • According to the value found, select...
Page 128 STELVIO 1200 NTX 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 129 STELVIO 1200 NTX Engine • Place the start-up crown gear with the reference facing upwards. • Tighten the six screws to the prescri- bed torque operating diagonally and in stages. Head and timing Key: 1. Right cylinder head 2. Stud bolt 3.
Page 130 STELVIO 1200 NTX Engine 11.Nut 12.Rocking lever rod 13.Tappet bowl 14.Flanged screw 15.Spacer 16.Camshaft 17.Pin 18.Timing system gear 19.Breather plate 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...
Page 131: Removing The Head Cover
STELVIO 1200 NTX Engine 49.O-ring 50.Complete breather cover 51.TBEI screw 52.Timing system chain 53.Chain guide slider 54.Chain tensioner pad 55.Chain tensioner screw 56.Left chain tensioner 57.Spacer Removing the head cover NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.
Page 132 STELVIO 1200 NTX Engine • Remove the head cover. • Unscrew and remove the two screws • Remove the cap. • Unscrew and remove the screw. • Remove the timing system upper gear bulkhead. For the right head: • Unscrew and remove the chain ten- sioner cap.
Page 133 STELVIO 1200 NTX 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. • Unscrew and remove the two screws.
Page 134: Cylinder Head
STELVIO 1200 NTX Engine • Fit the timing system upper gear back to the chain. • Fit the chain tensioner cap temporarily and keep the chain taut on the service shaft. • Collect the two head dowel pins. • Collect the gasket between the head and the cylinder.
Page 135 STELVIO 1200 NTX Engine • Undo and remove the four screws. • Remove the U-bolt. • Remove the camshaft. • Remove the bowls from the cam cap, and mark their position so as not inter- change them when refitting. See also...
Page 136: Removing The Valves
STELVIO 1200 NTX Engine • Remove the cam cap from the stud bolts. • Undo and remove the two screws. • Remove the U-bolt. • Remove the two rocking levers from the cam cap. See also Removing the cylinder head Removing the valves •...
Page 137: Checking The Valve Guides
STELVIO 1200 NTX Engine • Slide off the upper cap (2). • Remove the spring (3). • Remove the lower cap (5) and the valve guide oil seal (4), if necessary. • Remove the valve (6) from inside the head.
Page 138: Installing The Valves
STELVIO 1200 NTX Engine INLET VALVE SEAT DETAIL DRAWING OUTLET VALVE SEAT DETAIL DRAWING - If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45° milling cutter and then grind.
Page 139 STELVIO 1200 NTX Engine • Remove the special tool Installing the rocker arms • Fit the camshaft. • Fit the two rods. WARNING MAKE SURE THAT THE NOTCH ON THE DIPSTICK BODY FACES THE ROCKING LEVER. • Place the two rocking levers in the cam tower seats.
Page 140 STELVIO 1200 NTX Engine • Place the U-bolt on the rocking levers making sure the two reference pins match the seats on the cam tower. • Tighten the two screws operating diag- onally and in stages. See also Installing the overhead camshaft Installing the overhead camshaft •...
Page 141 STELVIO 1200 NTX Engine Timing 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 142 STELVIO 1200 NTX 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 143 STELVIO 1200 NTX 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 144: Cam Timing
STELVIO 1200 NTX 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 145 STELVIO 1200 NTX 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 146 STELVIO 1200 NTX 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 147 STELVIO 1200 NTX 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 148 STELVIO 1200 NTX 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 13.Left cylinder...
Page 149: Removing The Cylinder
STELVIO 1200 NTX 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 150: Fitting The Piston
STELVIO 1200 NTX Engine • Mark the piston crown on the exhaust side so as to remember the refitting po- sition. • Remove the piston. Fitting the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.
Page 151: Installing The Cylinder
STELVIO 1200 NTX Engine • Insert the pin. • Insert the snap ring. Specific tooling 020470Y Pin snap ring fitting tool Installing the cylinder RIGHT CYLINDER • Fit the piston. • Remove the cloth used to prevent for- eign bodies from getting into the crank- case.
Page 152 STELVIO 1200 NTX Engine 020716Y Connecting rod locking • Remove the piston ring clamp tool and finish positioning the cylinder. Specific tooling 020674Y Piston ring clamp • Fit the movable chain slider. • Fit the upper gear. • Fit the chain tensioner and the chain tensioner cap temporarily and keep the chain taut on the service shaft.
Page 153 STELVIO 1200 NTX 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 154: Installing The Cylinder Head
STELVIO 1200 NTX 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 155 STELVIO 1200 NTX 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 156 STELVIO 1200 NTX 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 157 STELVIO 1200 NTX 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 158: Crankcase - Crankshaft
STELVIO 1200 NTX 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 159 STELVIO 1200 NTX 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 160 STELVIO 1200 NTX 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 161 STELVIO 1200 NTX Engine Upon replacing the bearings it may be necessary to ream the crankshaft pin. Before reaming the crankpin, measure the pin diameter (B) comparing it with the maximum wear al- lowed, as indicated in the figure; this defines what kind of undersizing the bearing should have and to which diameter the pin (B) should be reamed.
Page 162 STELVIO 1200 NTX Engine The connecting rods have a marked area for weight selection. The weight indicated in the chart includes screws, dowels and the bushing. CONNECTING ROD WEIGHT SELECTION Specification Desc./Quantity Connecting rod - brown 0.588 - 0.598 mm (0.02074 - 0.02109 in) Connecting rod - green 0.598 - 0.608 mm (0.02109 - 0.02145 in)
Page 163: Installing The Crankshaft
STELVIO 1200 NTX Engine PAY ATTENTION TO CRANKSHAFT ROTATION WHEN ONLY THE CONNECTING RODS ARE FITTED BECAUSE IT COULD HIT THE TWO LUBRICATION JETS INSIDE THE CRANKCASE. Installing the crankshaft • Fit the shim washer inside the crank- case with the chamfered side facing the generator side.
Page 164 STELVIO 1200 NTX Engine • Place the flywheel-side flange on the crankshaft and check if the dowel pin with the O-ring is correctly placed. • When fitting the flange on the crank- case, make sure that the three dowel pins match the seats on the crankcase.
Page 165 STELVIO 1200 NTX 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 166: Oil Pump
STELVIO 1200 NTX Engine 1. Oil cooling radiator 2. Oil delivery pipe to heads 3. Oil delivery pipe to radiator 4. Oil pump body 5. Oil pump gasket 6. Rotor for lubrication 7. Rotor for cooling 8. Rotor control shaft 9.
Page 167 STELVIO 1200 NTX Engine • Remove the nipple - oil pump fitting. • Bring the left cylinder piston to the TDC in combustion phase. • Mark a reference on the oil pump con- trol gear and another on the driven gear so as to place them correctly again upon refitting.
Page 168 STELVIO 1200 NTX Engine • Undo and remove the three screws. • Remove the oil pump. • Remove the gasket between the crankcase and the oil pump. See also Replacement Removing the generator Installing • Place a new gasket between the crank- case and the oil pump.
Page 169 STELVIO 1200 NTX 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 170 STELVIO 1200 NTX Engine • Insert the joint in the oil pump. • Fit the nipple with the gasket on the crankcase. • Tighten the nipple to the prescribed torque. Removing the oil sump NOTE TO REMOVE THE OIL SUMP, PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL.
Page 171 STELVIO 1200 NTX Engine • Undo and remove the fourteen screws fixing the oil sump to the engine crank- case. • Undo and remove the four screws. • Remove the flange. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 172 STELVIO 1200 NTX Engine • Undo and remove the two screws. • Remove both filters. • Unscrew and remove the plug. • Remove the thermostatic valve. • Unscrew and remove the pressure re- lief valve plug. • Remove the pressure relief valve com-...
Page 173 STELVIO 1200 NTX 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 174 STELVIO 1200 NTX Engine • Tighten the thermostatic valve plug. • Place a new gasket between the crank- case and the flange. • Fit the flange. • Fix the flange with the four screws. • Fit the lubrication oil intake filter.
Page 175 STELVIO 1200 NTX Engine • Check that the O-rings are fitted on the oil pump. • Fit the cooling oil intake filter. • Fix both filters and tighten the two screws to the prescribed torque. • Fit a new oil filter and tighten it to the prescribed torque.
Page 176 STELVIO 1200 NTX Engine • Place the oil sump. • Tighten the fourteen screws to the pre- scribed torque. • Add engine oil up to the correct level. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG - 176...
Page 177: Index Of Topics
INDEX OF TOPICS P SUPP OWER SUPPLY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 178: Circuit Diagram
STELVIO 1200 NTX Power supply Circuit diagram Key: 1. Complete fuel pump unit 2. Nut 3. Fuel pipe 4. Pipe 5. Screw Injection Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten P SUPP - 178...
Page 179 STELVIO 1200 NTX 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 180 STELVIO 1200 NTX 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 181 STELVIO 1200 NTX 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 182: Recovery Function
STELVIO 1200 NTX 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-learning" as explained above.
Page 183 STELVIO 1200 NTX Power supply Iso screen page This screen page shows general data regarding the control unit, for example software type, map- ping, control unit programming date ISO DISPLAY Specification Desc./Quantity Mapping Engine parameter reading screen page ENGINE PARAMETER READING...
Page 184: Device Status
STELVIO 1200 NTX Power supply Specification Desc./Quantity Target engine revs 1150 rpm (approximate values) Parameter valid at idle, setting depends especially on the en- gine temperature: the control unit will try to keep the engine running at this revs, acting on the ignition advance and the...
Page 185: Errors Display
STELVIO 1200 NTX Power supply Devices activation screen page DEVICES ACTIVATION This screen page is used to delete errors in the control unit memory and to activate some systems controlled by the control unit. DEVICES ACTIVATION Specification Desc./Quantity Left coil operation for 2.5 m, 5 times...
Page 186: Adjustable Parameters
STELVIO 1200 NTX Power supply Specification Desc./Quantity Right injector Possible short circuit in the earth lead, battery or open circuit. If both injectors do not work, the engine does not work Fuel pump relay Possible short circuit in the earth lead, battery or open circuit: the engine does not start.
Page 187 INDEX OF TOPICS SUSP USPENSIONS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 188: Removing The Front Wheel
STELVIO 1200 NTX Suspensions Front Removing the front wheel • Working from both sides, undo and re- move the two fixing screws from the front brake callipers and remove them from their seats. • Support the front part of the vehicle.
Page 189 STELVIO 1200 NTX Suspensions • Take out the wheel bolt by inserting a screwdriver in the bolt holes. • Upon extracting the wheel, hold it and then remove it. • Collect the spacer from the front wheel right side. Front fork...
Page 190 STELVIO 1200 NTX Suspensions 1. Complete front fork 2. TCE screw 3. Washer 4. TE flanged screw 5. Stem + right wheel holder 6. Bushing 7. Stem + left wheel holder 8. Complete right pumping member 9. Nut 10.Complete left pumping member 11.Fork upper plate...
Page 191 STELVIO 1200 NTX Suspensions Adjustment The front suspension consists of a hydraulic fork connected to the headstock by means of two plates. To set the vehicle suspension, each fork stem fea- tures an upper nut (1), to adjust spring preloading, and an upper set screw (2): •...
Page 192: Removing The Fork Legs
STELVIO 1200 NTX Suspensions Removing the fork legs • Rest the vehicle on its centre stand. • Secure the rear part of the vehicle through belts in order to lift the front wheel. • Remove the mudguard. • Remove the front wheel.
Page 193 STELVIO 1200 NTX Suspensions • Unscrew the sleeve upper cap. • Push the bushing down in order to compress the spring and then fit a tool under the pumping member lock nut and on the bushing to keep the spring compressed.
Page 194 STELVIO 1200 NTX Suspensions • Remove the spring. Let the oil depos- ited on the spring turns fully drip into the sleeve. • Pour the oil into the container. • Remove in order: - upper spring guide; - preload pipe;...
Page 195: Disassembling The Fork
STELVIO 1200 NTX Suspensions Disassembling the fork • Drain out all the oil in the stem. • Block the wheel holder sleeve with a vice. • Unscrew the bottom screw and remove it together with its gasket. • Remove the pumping member.
Page 196 STELVIO 1200 NTX Suspensions • Slide off the dust scraper from the sleeve using a screwdriver as a lever. • Do not damage the sleeve edge while doing this. • Remove the snap ring. • Take out the sleeve from the stem us- ing the stem as a hammer puller.
Page 197: Checking The Components
STELVIO 1200 NTX Suspensions • Remove the ring and the dust guard. See also Draining oil Checking the components Stem Check the sliding surface for scorings and/or scratches. These scorings can be eliminated by rubbing them with wet sandpaper (grain 1).
Page 198 STELVIO 1200 NTX Suspensions Bending limit: 0.2 mm (0.00787 in) Sleeve Check that there are no damages and/or cracks; otherwise, replace it. Spring Check the spring is in good conditions. Check that the following components are in good conditions: •...
Page 199 STELVIO 1200 NTX Suspensions • dust guard; • O-Ring on the cap. Reassembling the fork • Lock the stem in a vice without dam- aging the surface. • Protect the bearing tube end with ad- hesive tape. • Lubricate the sliding edges with fork oil or sealing grease.
Page 200 STELVIO 1200 NTX 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. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 201 STELVIO 1200 NTX Suspensions • Get the special tool code 8140758. • Cut the tool along the longitudinal axle so as to obtain two similar half-shells to be used on forks with inverted stems. • Fit the sleeve on the stem and with the specified tool fit the oil seal into posi- tion.
Page 202: Filling Oil
STELVIO 1200 NTX Suspensions • Fit the dust guard with the specific tool. Specific tooling AP8140758 tool to fit oil seals and dust guards for ø 50 mm (1.97 in) stems AP8140146 Weight • Insert the pumping member in the sleeve.
Page 203 STELVIO 1200 NTX Suspensions • Measure the air gap between the oil level and the rim. THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS.
Page 204 STELVIO 1200 NTX Suspensions • Fit the bushing. • Finger tight the upper cap on the pumping member stem. • Compress the spring and then fit a tool under the pumping member lock nut to keep the spring compressed. •...
Page 205: Installing The Fork Legs
STELVIO 1200 NTX Suspensions • Once the operations are completed, restore the spring preloading correct value. Installing the fork legs • Insert the fork stem in position. • Insert the wheel pin so that the stems are aligned. • Tighten the screws on the fork plates to the prescribed torque.
Page 206: Steering Bearing
STELVIO 1200 NTX Suspensions Steering bearing Adjusting play • Unscrew and remove the U-bolt four fixing screws. • Remove the U-bolt. • Remove the handlebar and place it paying attention that oil in the clutch and front brake tanks does not spill out.
Page 207 STELVIO 1200 NTX Suspensions • Rivet the safety washer on the head- stock. UPON REFITTING, REPLACE THE SAFETY WASHER WITH A NEW ONE • Using the suitable special tool, un- screw and remove the upper ring nut. Specific tooling AP8140190 Tool for steering tightening •...
Page 208: Removing The Rear Wheel
STELVIO 1200 NTX Suspensions • Fit a new safety washer. • Screw the upper ring nut manually and then slightly tighten the clamps on the plate so as to align notches on the ring nut. Specific tooling AP8140190 Tool for steering tightening •...
Page 209: Rear Shock Absorber Adjustment
THE VEHICLE USE CONDITIONS. IF THE SPRING PRELOADING IS INCREASED, IT IS NECES- SARY TO INCREASE THE REBOUND DAMPING ACCORDINGLY TO AVOID SUDDEN JERKS WHEN RIDING. IF NECESSARY, CONTACT AN Official Moto Guzzi Dealer. TRY RIDING THE VE- HICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED.
Page 210 STELVIO 1200 NTX Suspensions Specification Desc./Quantity Rebound - half -load conditions 20 clicks starting from screw (1) fully tightened Rebound - maximum load conditions 18 clicks starting from screw (1) fully tightened (1) THE SETTING SHOWN IN THE TABLE MAY NEED TO BE MODIFIED ACCORDING TO THE TYRE AND ROAD TYPE.
Page 211: Index Of Topics
INDEX OF TOPICS CHAS HASSIS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 212: Swinging Arm
STELVIO 1200 NTX Chassis Swinging arm Removing • To remove the fork, first remove the footrest holding plate and the exhaust silencer. • Slide off the rear brake calliper from the disc and release the brake pipe. • Engage the first gear.
Page 213 STELVIO 1200 NTX Chassis • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. • Fix the reaction rod to the chassis with a clamp. • Remove the clamp from the dust guard cap. • Loosen the two swingarm terminal screws.
Page 214 STELVIO 1200 NTX Chassis • Loosen the ring nut. Specific tooling 05.91.26.30 Tool for tightening the swingarm pin ring nut - clutch hub • Helped by a second operator, remove the pin and remove the swingarm to- gether with the cardan shaft.
Page 215 STELVIO 1200 NTX Chassis Installing • Spread a thin layer of lubricating grease all along the swingarm pin. • Fit the ring nut in the swingarm pin and screw it manually. • Working from both sides, grease the cardan shaft cables with the recom- mended product from the recommen- ded products table.
Page 216 STELVIO 1200 NTX Chassis • Fit the dust guard cap in the gearbox. • Lock the dust guard cap with a new clamp. • Place the reaction rod into its seat. • Insert the screw. • Screw the nut fixing the reaction rod.
Page 217 STELVIO 1200 NTX Chassis Bevel gears Removing • Remove the rear wheel. • Unscrew and remove the two screws. • Remove the speed sensor from the fork. • Unscrew and remove the nut fixing the reaction rod. • Remove the screw.
Page 218 STELVIO 1200 NTX Chassis • Remove the transmission casing slid- ing off the universal joint. Checking Casing unit removal Remove the cover (20). Remove the plug (3) to drain out the oil. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 219 STELVIO 1200 NTX Chassis Lift the cap (10). Remove the clamps (9) and (11). Remove the cap (14). Remove the screws (16). Collect the ring (15). Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 219...
Page 220 STELVIO 1200 NTX Chassis Remove the screws (7). Remove the casing (4). Remove the clamp (12). Remove the cap (14). Collect the ring (13). Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten CHAS - 220...
Page 221 STELVIO 1200 NTX Chassis Remove the support unit (8). Casing unit fitting Assemble the dowel pins to the casing with the buffer and a hammer. Assemble the casing to the special fastening tool. Clean the casing faying surfaces carefully. Heat the casing.
Page 222 STELVIO 1200 NTX Chassis Insert the support group in the casing. Assemble the cap and the ring. Fit the cap on the support. Fit the clamp. Screw the clamp with the specific pliers. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 223 STELVIO 1200 NTX Chassis Apply the prescribed sealant to the casing. Fit a new sealing ring using the buffer. Lubricate the sealing ring. Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture.
Page 224 STELVIO 1200 NTX Chassis Assemble the fixing screws (7). Tighten the screws (7) to the prescribed torque. Remove excessive sealant. Assemble the ring to the casing. Tighten the fixing screws to the prescribed torque. Fit the cap with the washer.
Page 225 STELVIO 1200 NTX Chassis Fit the breather with the washer. Screw the breather to the prescribed torque. Fill the transmission with the prescribed oil. Fit the cap with the washer. Screw the cap to the prescribed torque. Assemble the cap with the clamps.
Page 226 STELVIO 1200 NTX Chassis REMOVAL Remove the bearing from the wheel axle with a suitable extractor. Turn the unit over. Remove the bearing from the wheel axle with a suitable extractor. FITTING Heat the bearings to 100°C (212 °F). Assemble the bearings to the wheel axle.
Page 227 STELVIO 1200 NTX Chassis Turn the unit over. Assemble the bearings to the wheel axle. Pinion unit REMOVAL Remove the stop ring (1) from the ring nut. Unscrew the ring nut (2) with the special spanner (s4). Remove the ring nut (2) and remove the sealing ring from the ring nut.
Page 228 STELVIO 1200 NTX Chassis Assemble the sealing ring (3) to the ring nut (2) with the buffer CA715855 (see Fig.1) and a ham- mer. Lubricate the sealing ring (3). Assemble the ring nut (2). Tighten the ring nut (2) with the special spanner (s4) to the prescribe torque.
Page 229 STELVIO 1200 NTX Chassis Insert the stop ring (1) in the ring nut (2) in the in- dicated direction. Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT. Support unit Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 230 STELVIO 1200 NTX 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 231 STELVIO 1200 NTX Chassis Remove the ball joint (4) with a suitable buffer and a rubber hammer. FITTING Fit the stop ring (6) in the support (5) with suitable pliers. Turn the support (5) over. Assemble the ball joint (4) with the buffer and a rubber hammer.
Page 232: Troubleshooting
STELVIO 1200 NTX Chassis Manually assemble the new sealing rings (2) and (7). Assemble the bushing (1). Drive the bushing (1) in with a plastic hammer. Turn the support (5) over and assemble the other bushing (8). TROUBLESHOOTING Possible Cause Operation 1.
Page 233 STELVIO 1200 NTX Chassis Installing • Insert the transmission casing on the swingarm making sure that the univer- sal joint engages correctly. • Tighten the four screws to the prescri- bed torque operating diagonally. • Place the reaction rod into its seat.
Page 234 STELVIO 1200 NTX Chassis • Place the speed sensor and fasten the cable harness with the clamps. • Place the rear wheel on the fork. • Tighten the four screws with their spacers and the dust-protection ring. • Place the rear brake calliper on the disc and the brake pipe on the fork.
Page 235 STELVIO 1200 NTX Chassis 3. Gasket 4. Flanged nut 5. Washer 6. Gasket 7. Clamp 8. Central exhaust pipe 9. TE flanged screw 10.Silent-block 11.Flanged self-locking nut 12.Lambda probe 13.Gasket 14.Clamp 15.Silencer 16.TCEI screw 17.Silencer fixing bushing 18.Muffler rubber ring 19.Spacer...
Page 236: Removing The Exhaust Manifold
STELVIO 1200 NTX Chassis • Remove the exhaust end. Removing the manifold - tail pipe • Remove the exhaust end and the ex- haust manifolds. • Remove the starter motor protection in order to disconnect the lambda probe connector. •...
Page 237: Engine Oil Cooler
STELVIO 1200 NTX Chassis • Unscrew and remove the two nuts on the head exhaust stud bolts. • Retrieve the washers. • Loosen the clamp. • Remove the exhaust manifold. Engine oil cooler Key: 1. Complete oil radiator 2. TE flanged screw...
Page 238 STELVIO 1200 NTX Chassis 3. T-shaped bushing 4. Rubber ring 5. Radiator support 6. TCEI screw 7. Clip Removing It is necessary to remove the metal oil sump guard in order to change the engine oil and replace the oil filter: •...
Page 239 STELVIO 1200 NTX Chassis • Undo and remove the two radiator up- per screws and collect the washer. • Remove the oil cooling radiator. Installing • Fit the oil cooling radiator on the vehi- cle following the operations described in the removal chapter but in reverse order.
Page 240: Index Of Topics
INDEX OF TOPICS BRAK SYS RAKING SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 241: Rear Brake Calliper
STELVIO 1200 NTX Braking system Rear brake calliper Key: 1. Rear brake calliper 2. Screw 3. Pads 4. Pin + calliper split pin 5. Spring 6. Gasket 7. Screw 8. Air bleed 9. Air bleed cap 10.Rear brake pipe 11.Oil pipe screw...
Page 242: Front Brake Calliper
STELVIO 1200 NTX Braking system Front brake calliper Key: 1. Front right brake calliper 2. Front left brake calliper 3. Pads 4. Air bleed 5. Air bleed cap 6. Pins + Calliper springs 7. Spring 8. Aluminium gasket 9. Screw...
Page 243 STELVIO 1200 NTX Braking system Removal • Unscrew and remove the two screws. • Slide off the brake calliper from the disc. • Turn the pins and remove both split pins. • Remove both pins. • Remove the vibration-damping plate.
Page 244 STELVIO 1200 NTX Braking system • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS. Installing •...
Page 245: Rear Brake Pads
STELVIO 1200 NTX Braking system Rear brake pads Removal • Undo and remove the two screws. • Remove the brake calliper from the disc. • Turn the pin and pull out the split pin. • Remove the split pin. •...
Page 246 STELVIO 1200 NTX Braking system • Extract one pad at a time. CAUTION AFTER REMOVING THE PADS, DO NOT OPERATE THE BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID LEAKS. Installing •...
Page 247 STELVIO 1200 NTX Braking system Bleeding the braking system Front Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by the brake pump and minimising the braking power of the calliper. Air in the system causes a "spongy" feeling in the brake control and poor braking efficiency.
Page 248 STELVIO 1200 NTX Braking system • Repeat the procedure for both callip- ers. • Screw the bleed valve and remove the pipe. • Top-up the reservoir until the right brake fluid level is obtained. • Refit and block the front brake fluid reservoir cap.
Page 249 STELVIO 1200 NTX Braking system then repeat the operation until air no longer escapes. • Screw the bleed valve and remove the pipe. • Top-up the reservoir until the right brake fluid level is obtained. • Refit and lock the rear brake fluid reservoir cap.
Page 250 INDEX OF TOPICS BODYW ODYWORK Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 251: Engine Guard
STELVIO 1200 NTX Bodywork Seat • Rest the vehicle on its stand. • Insert the key in the saddle lock. • Turn the key clockwise and slightly press the centre of the passenger seat rear part to facilitate releasing the pin.
Page 252 STELVIO 1200 NTX Bodywork • Remove the TCEI screw (3) (M10x35) on the upper side. • Remove both TCEI screws (4) (M8x40) in the lower part of the engine guard. • Remove the TCEI screw (5) (M8x60) in the engine guard front section with the corresponding washer.
Page 253: Instrument Panel
STELVIO 1200 NTX Bodywork • Remove the TCEI screws (8) (M10x35) on the upper side. • Remove the TCEI screw (9) (M8x60) and the corresponding washer. • Remove the TCEI screws (10) (M8x40) in the lower part of the engine guard.
Page 254 STELVIO 1200 NTX Bodywork • Disconnect the instrument panel con- nector. Supplementary light mount ENSURE THAT THE ENGINE AND THE THERMAL PARTS OF THE VEHICLE ARE COLD BEFORE OPERATING ACCORDING TO THE FOLLOWING INSTRUCTIONS. PARK THE VEHICLE ON STAND ON FIRM AND LEVEL GROUND.
Page 255: Left Side
STELVIO 1200 NTX Bodywork Additional lights • Disconnect the additional headlamps connectors. • Slide off the cables from the opening near the arrows between the side fair- ings and fairings. • Remove the screw (M8x20) and be careful to collect the washer and the nut.
Page 256: Right Side
STELVIO 1200 NTX Bodywork • Undo and remove the lower screw and collect the two washers and the spacer. • Undo and remove the lower screw and collect the washer and the spacer. • Disconnect the gearbox rod and re- lease the spring.
Page 257 STELVIO 1200 NTX Bodywork • Undo and remove the front lower screw. • Undo and remove the three screws. • Remove the right under seat fairing. • Disconnect the connectors of the rear brake lever switch and the speed sen- sor.
Page 258: Side Fairings
STELVIO 1200 NTX Bodywork • Unscrew and remove the screw. • Detach the rear brake fluid reservoir but keep it connected to the pipe. • Remove the right footrest plate, keeping the brake fluid reservoir in vertical position. Side fairings •...
Page 259 STELVIO 1200 NTX Bodywork • Detach the fairing. • Disconnect the glove-box compart- ment opening cable. • Undo and remove the two front screws. • Operating from both sides, undo and remove the internal screw and collect the washer and the nut.
Page 260 STELVIO 1200 NTX Bodywork • Undo and remove the four screws. • Remove the headlight lower cover. • Unscrew and remove the two screws. • Operating from both sides, disconnect the turn indicator connector. • Slightly detach the fairing. •...
Page 261 STELVIO 1200 NTX Bodywork Air box • Remove the saddle. • Remove the passenger grab handle. • Undo and remove the two screws and collect the cable guide. • Disconnect the air temperature sensor connector. • Slide off and remove the main fuse box from its holder.
Page 262 STELVIO 1200 NTX Bodywork • Disconnect the rear light connectors • 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 263: Sump Guard
STELVIO 1200 NTX 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 AC- CORDING TO THE FOLLOWING INSTRUCTIONS.
Page 264: Fuel Tank Cover
STELVIO 1200 NTX Bodywork • Remove the four TCEI 8x40 screws (1) (two on each side) • Be careful to collect the four spacer bushings inside the sump guard. NOTE FOR REFITTING, FOLLOW THE PROCEDURE IN THE REVERSE ORDER Fuel tank FUEL TANK CAP REMOVAL •...
Page 265 STELVIO 1200 NTX Bodywork FUEL TANK UPPER FAIRING • Remove the fuel tank cap. • Undo and remove the four screws. • Remove the fuel tank cover. • Working from both sides, undo and re- move the screw. • Unscrew and remove the front screw fixing the tank.
Page 266 STELVIO 1200 NTX Bodywork • Lift the rear part of the fuel tank fairing. • Disconnect the pipes. • Remove the fuel tank fairing. See also Seat FUEL TANK • Remove the tank side fairings. • Disconnect the glove-box opening control connector.
Page 267 STELVIO 1200 NTX Bodywork • Lift the tank and disconnect the fuel pipe. • Disconnect the fuel pump connector. • Remove the fuel tank. See also Side fairings Pannier mounting • Remove the countersunk-head screw (14) and collect the bushings (11) and nuts (16).
Page 268 STELVIO 1200 NTX Bodywork • Remove the spacers (6) and (8). • Remove the components (11) to (16) from both supports. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten BODYW - 268...
Page 269 INDEX OF TOPICS PRE DE DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 270 STELVIO 1200 NTX Pre-delivery Carry out the listed checks before delivering the vehicle. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety locks: front and rear suspension unit...
Page 271: Road Test
STELVIO 1200 NTX Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
Page 272: Static Test
STELVIO 1200 NTX Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up...
Page 273 Air filter: 36 Battery: 54, 60 Brake: 241, 242, 245 Clutch: 76, 124, 126, 127, 159 Clutch lever: 76 Display: 185 Engine oil: 33, 74, 237 Fork: 189, 192, 195, 199, 205 Forks: 112 Fuel: 84, 118, 264 Fuses: 57 Gearbox oil: 35 Identification: 10 Instrument panel: 79, 253...
Page 274 Tank: 84, 118, 264 Transmission: 12, 31 Tyres: 14 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

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