Page 1 SERVICE STATION MANUAL 981138 Stelvio 1200 NTX ABS...
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 2009 - 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 ABS Characteristics Rules Safety rules Carbon monoxide If you need to keep the engine running while working on the vehicle, please ensure that you do so in an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an enclosed area, make sure to use a fume extraction system.
Page 8: Maintenance Rules
Stelvio 1200 NTX ABS Characteristics BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES. WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COM- PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING THESE SYSTEMS.
Page 9: 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 ABS Characteristics This number consists of numbers and letters, as in the example shown below. ZGULZB010YMXXXXXX KEY: ZGU: WMI (World manufacturer identifier) code; LZ: model; B01: version variation; 0: free digit Y year of manufacture M: production plant (M= Mandello del Lario);...
Page 12: Electrical System
Stelvio 1200 NTX ABS Characteristics Specification Desc./Quantity Bore / stroke 95 x 81.2 mm (3.74 x 3.20 in) Engine capacity 1151 cm³ (70 cu.in) Compression ratio 11: 1 Electric starter Idle speed 1100 ± 100 rpm Clutch hydraulic single plate dry clutch with integrated flexible coupling...
Page 13 Stelvio 1200 NTX ABS 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 Instrument panel lighting License plate light 12V - 5 W Turn indicator warning light...
Page 14: Fuel System
Stelvio 1200 NTX ABS 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 ABS 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)
Page 16: Oil Radiator
Stelvio 1200 NTX ABS 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 ABS Characteristics Name Torque in Nm Front speed sensor screws retainer 6 Nm (4.42 lbf ft) + Loc. 243 ABS control unit screws retainer (2) 10 Nm (7.37 lbf ft) Rear speed sensor screws retainer 10 Nm (7.37 lbf ft)
Page 18: Front Wheel
Stelvio 1200 NTX ABS Characteristics Name Torque in Nm Silencer to chassis connecting pipe retainer 25 Nm Muffler to chassis retainer - M8x45 (1) 25 Nm (18.44 lbf ft) Heat guard retainer - M6 (3) 10 Nm (7.38 lbf ft)
Page 19: Engine Cover
Stelvio 1200 NTX ABS Characteristics Name Torque in Nm Tank to chassis front retainer 10 Nm 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)
Page 20: Piston Rings
Stelvio 1200 NTX ABS Characteristics Specification Desc./Quantity Piston diameter - selection E 94.945 - 94.955 mm (3.73798 - 3.73837 in) Cylinder diameter - selection E 95.010 - 95.020 mm (3.74054 - 3.74093 in) 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)
Page 21 Stelvio 1200 NTX ABS 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 ABS 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 Stelvio 1200 NTX ABS Characteristics Product Description Specifications exceed the requirements of SAE J1703, NHTSA 116 DOT 4, ISO 4925 synthetic fluid specifications. AGIP BRAKE 4 / BRAKE 5.1 Clutch fluid As an alternative for recommended flu- ids, use top branded fluids that meet or...
Page 24: Index Of Topics
INDEX OF TOPICS S-TOOLS PECIAL TOOLS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 25 Stelvio 1200 NTX ABS 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...
Page 26 Stelvio 1200 NTX ABS 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 27 Stelvio 1200 NTX ABS 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 28 Stelvio 1200 NTX ABS 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 29 Stelvio 1200 NTX ABS 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 30: Front Fork
Stelvio 1200 NTX ABS 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 31: Maintenance
INDEX OF TOPICS MAIN AINTENANCE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 32: Maintenance Chart
Stelvio 1200 NTX ABS 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 33 Stelvio 1200 NTX ABS Maintenance Check • Keep the vehicle upright with both wheels on the ground. • Unscrew and remove the cap/dipstick (1). • The level is correct if the oil is close to the hole of the cap/dipstick (1).
Page 34: Engine Oil
Stelvio 1200 NTX ABS Maintenance Engine oil Check CAUTION ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM (10 miles).
Page 35: Engine Oil Filter
Stelvio 1200 NTX ABS Maintenance • Place a container with +4,000 cm³ (244 cu in) capacity under the drainage plug (3). • Unscrew and remove the drainage plug (3). • Pull out the oil filler plug / engine oil level dipstick (4).
Page 36: Checking And Topping Up
Stelvio 1200 NTX ABS Maintenance Gearbox Oil Inspection CHECKING AND TOPPING UP CAUTION ENGINE MUST BE WARM TO CHECK GEARBOX OIL LEVEL. NOTE DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER RUNNING FOR ABOUT 15 KM (10 miles).
Page 37: Air Filter
Stelvio 1200 NTX ABS Maintenance • Pour in new oil until it reaches the dipstick open- ing (1). • Tighten the filler cap (1). CAUTION DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL OR ANY OTHER EL- EMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Page 38: Braking System
Stelvio 1200 NTX ABS Maintenance • Disconnect both spark plug tubes. • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings. • Remove the head cover together with the gasket. • Loosen the nut (1).
Page 39 Stelvio 1200 NTX ABS 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 40 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 41: Electrical System
INDEX OF TOPICS ELE SYS LECTRICAL SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 42 Stelvio 1200 NTX ABS 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 - 42...
Page 43: Electrical System Installation
Stelvio 1200 NTX ABS Electrical system 5 Throttle valve potentiometer 6 Fall sensor 7 Rear light 8 Main fuses 9 Lambda probe 10 Battery 11 Starter motor 12 Intake air temperature sensor 13 Engine revolution sensor 14 Head temperature sensor...
Page 44: Front Section
Stelvio 1200 NTX ABS Electrical system FRONT SECTION TABLE A • Clamp the brake pipes with the throttle grip transmission and right light switch properly. • Clamp the clutch pipes with the clutch switch and the left light switch, making...
Page 45 Stelvio 1200 NTX ABS Electrical system • Clamp the left headlight cable (3), the left turn indicator (4) and the TOM TOM cable (5). • Clamp the heated handgrips cable. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 46: Central Section
Stelvio 1200 NTX ABS Electrical system TABLE D - ABS SENSOR SYSTEM CLAMPS • Clamp in the indicated points. Central part CAUTION ONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED AND CLAMPS AND RETAINERS RESTORED, CARRY OUT THE CHECKS INDICATED UNDER "SPE- CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES"...
Page 47: The Electrical System
Stelvio 1200 NTX ABS Electrical system TABLE B - RED CLAMP STARTING POINT IN THE ELECTRICAL SYSTEM • The red clamp must start from the point indicated. • The cable of heated handgrips must come out under the beam and be clam- ped.
Page 48: Back Side
Stelvio 1200 NTX ABS Electrical system • The connection must be between the chassis and the air filter. TABLE D - LAMBDA PROBE SYSTEM CLAMP- • Clamp the stand system with the return pipes in sump and leave the lambda probe system free •...
Page 49: Rear Section
Stelvio 1200 NTX ABS Electrical system CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELEC- TRICAL SYSTEM INSTALLATION" SECTION. REAR SECTION TABLE A - CORRECT FITTING OF THE ODOM- ETER CLAMP • The clamp fixing the odometer cable must be placed ahead of the brake pipe guide clamp.
Page 50 Stelvio 1200 NTX ABS Electrical system Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ELE SYS - 50...
Page 51: General Wiring Diagram
Stelvio 1200 NTX ABS 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 - 51...
Page 52 Stelvio 1200 NTX ABS 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 53: Abs Control Unit
Stelvio 1200 NTX ABS Electrical system 43.Left cylinder spark plug 44.Right cylinder coil 45.Left cylinder coil 46.Right cylinder injector 47.Left cylinder injector 48.--- 49.Fall sensor 50.Flywheel pick-up 51.ECU 52.Fog lights 53.Front left turn indicator 54.(Double) Front headlight 55.Front daylight running light bulb (2) 56.High-beam bulb...
Page 54: Enter New Code
Stelvio 1200 NTX ABS Electrical system Vi purple Checks and inspections Dashboard Diagnosis Changing the CODE If you know the code, just enter it and then a new code that will be automatically stored in the memory. If the vehicle is new, the user code is: 00000 Resetting the CODE This function is used to set a new code when the old one is not available;...
Page 55 Stelvio 1200 NTX ABS Electrical system Engine Temperature Error DC Gnd ECU 15 Air Temperature Error DC V DC ECU 16 Air Temperature Error DC Gnd ECU 17 Low Battery Error ECU 20 Lambda Probe Error ECU 21 Coil 1 Error DC V DC ECU 22...
Page 56 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 57: Checking The Stator
Stelvio 1200 NTX ABS Electrical system Checking the stator Single-phase generator with regulated voltage Maximum load 40A (550W) Charging voltage 14.2 - 14.8 V (5000 rpm) Start-up system check pick-up input about 100 A level indicators Petrol pump: Input: 3.5 A (to be measured between pins 1 and...
Page 58: Front Headlamp
Stelvio 1200 NTX ABS Electrical system Lights list FRONT HEADLAMP Specification Desc./Quantity Front daylight running light 12V - 5W Low/high beam headlight (halogen) 12 V - 55 W / 60 W H4 REAR LIGHT Specification Desc./Quantity Tail light/stop light License plate light...
Page 59: Main Fuses
Stelvio 1200 NTX ABS Electrical system Fuses MAIN FUSES 1 - Battery recharge (40 A). 2 - Motion main fuse (30 A). NOTE THERE IS ONE SPARE FUSE. ABS MAIN FUSES 3 - ABS main fuse (40 A). 4 - ABS main fuse (25 A).
Page 60: Control Unit
Stelvio 1200 NTX ABS Electrical system Control unit Model: Magneti Marelli IAW 5 AM2 BROWN connector pin configuration Pin Use 1 Not used 2 Not used 3 Ignition potentiometer signal 4 Not used 5 Engine temperature signal 6 Not used...
Page 61 Stelvio 1200 NTX ABS Electrical system 27 Not used 28 Left cylinder injector control 29 Ignition potentiometer power supply 30 Not used 31 Not used 32 Ignition potentiometer negative 33 Not used 34 Revolution sensor anti-jamming cable 35 Engine revolution sensor signal...
Page 62 Stelvio 1200 NTX ABS Electrical system 25 Not used 26 Not used 27 "Engine stop" signal input 28 Ignition signal input 29 CAN - L line (ccm/instrument panel) 30 Not used 31 Not used 32 Oxygen probe power supply 33 Clutch sensor signal...
Page 63: Engine Rpm Sensor
Stelvio 1200 NTX ABS Electrical system 23 Not used 24 Not used 25 ABS pump supply 26 Not used 27 ABS deactivation switch 28 Not used 29 Not used 30 Not used 31 Rear (ABS) speed sensor (signal / ground)
Page 64 Stelvio 1200 NTX ABS Electrical system Location: • Sensor: Front left side of the engine, under the generator. • Connector: Under the fuel tank. Electrical characteristics: • Winding resistance 650 Ohm +/- 15% • Output alternating voltage, value range: minimum: 0.5 V - maximum: 5 V PIN: 1.
Page 65: Throttle Position Sensor
Stelvio 1200 NTX ABS 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 66: Engine Temperature Sensor
Stelvio 1200 NTX ABS 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). •...
Page 67 Stelvio 1200 NTX ABS 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)
Page 68: Air Temperature Sensor
Stelvio 1200 NTX ABS 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;...
Page 69 Stelvio 1200 NTX ABS 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)
Page 70: Lambda Sensor
Stelvio 1200 NTX ABS 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 71 Stelvio 1200 NTX ABS 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 72 Stelvio 1200 NTX ABS 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 73 Stelvio 1200 NTX ABS 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 74 Stelvio 1200 NTX ABS 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.
Page 75 Stelvio 1200 NTX ABS 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 76: Engine Oil Pressure Sensor
Stelvio 1200 NTX ABS 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 77 Stelvio 1200 NTX ABS 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 78 Stelvio 1200 NTX ABS 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 79 Stelvio 1200 NTX ABS 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...
Page 80: Bank Angle Sensor
Stelvio 1200 NTX ABS 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 81 Stelvio 1200 NTX ABS 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 82: Run/Stop Switch
Stelvio 1200 NTX ABS 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 83 Stelvio 1200 NTX ABS 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 84 Stelvio 1200 NTX ABS 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 85: Index Of Topics
INDEX OF TOPICS ENG VE NGINE FROM VEHICLE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 86: Vehicle Preparation
Stelvio 1200 NTX ABS 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 87 Stelvio 1200 NTX ABS 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 88 Stelvio 1200 NTX ABS 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 89 Stelvio 1200 NTX ABS 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 90 Stelvio 1200 NTX ABS 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 91 Stelvio 1200 NTX ABS 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 92 Stelvio 1200 NTX ABS Engine from vehicle Installing the engine to the vehicle • Place the vehicle chassis over the en- gine with the gear. • From the back, secure the chassis with belts attached to a hoist. • From the front, secure the vehicle with belts attached to the handlebar and fixed to the work bench.
Page 93 Stelvio 1200 NTX ABS Engine from vehicle • Operating from both sides, tighten the upper engine fixing nut on the internal side of the chassis. • Fit the centre stand. • Operating from both sides, tighten the screws fixing the centre stand plates.
Page 94 Stelvio 1200 NTX ABS Engine from vehicle • Insert the oil breather pipe and fasten it with a new clamp. • Fit the gearbox oil breather pipe. • Fit the clutch control cylinder. • Tighten the three screws. • Connect the starter motor connectors.
Page 95 Stelvio 1200 NTX ABS Engine from vehicle • Connect the ground leads and tighten the stud bolt. • Fit the starter motor cover. • Tighten the screws. • Connect the neutral sensor connector. • Connect the alternator connectors. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 96 Stelvio 1200 NTX ABS Engine from vehicle • Connect the revolution sensor connec- tor. • Connect the horn connectors. • Connect the engine temperature sen- sor connector. • Place the oil radiator. • Tighten the two screws. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 97 Stelvio 1200 NTX ABS Engine from vehicle • Place the fork with cardan shaft and the rear wheel. • Working on both sides, connect the in- jector connectors. • Adjust the throttle grip cable clearance. • Working from both sides, connect the spark plug tube.
Page 98: Index Of Topics
INDEX OF TOPICS NGINE Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 99 Stelvio 1200 NTX ABS Engine Gearbox Diagram Key: 1. Ball bearing Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten ENG - 99...
Page 100 Stelvio 1200 NTX ABS Engine 2. Circlip 3. Thickness 4. Pin 5. Complete desmodromic 6. Ball bearing 7. Spring 8. Spacer 9. Circlip 10.Fifth wheel 11.Linking pin 12.Gear 13.Circlip 14.Thrust washer 15.Ball bearing cage 16.Gear 17.Sealing ring 18.Ball bearing 19.Gear 20.Circlip...
Page 101: Removing The Gearbox
Stelvio 1200 NTX ABS Engine 40.Index lever 41.Spring 42.Ball bearing 43.Gear 44.Gear 45.Ball bearing cage 46.Thrust washer 47.Circlip 48.Gear 49.Circlip 50.Gear 51.Main shaft 52.Transmission gear 53.Fork (5th - 1st) 54.Fork shaft 55.Fork (3rd - 4th) 56.Fork (2nd - 4th) 57.Gear 58.Gear...
Page 102 Stelvio 1200 NTX ABS Engine • Unscrew and remove the gearbox oil filler cap. • Place a container of suitable capacity under it, unscrew and remove the cap and then bleed all gearbox oil. • Loosen and turn the oil pipe fitting on the sump.
Page 103: Gearbox Shafts
Stelvio 1200 NTX ABS Engine • Undo and remove the two screws. • Undo and remove the screw. • Remove the gearbox. See also Removing the starter motor Replacement Gearbox shafts Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 104 Stelvio 1200 NTX ABS Engine Disassembling the gearbox • Remove the gearbox. • Unscrew and slide off the odometer gear and collect the abutment washer that is inside the gearbox. • From the outside, slide off the thrust cylinder and collect the O-Ring and the washer.
Page 105 Stelvio 1200 NTX ABS Engine • Slide off the rod with the two bushings. • Undo and remove the five external screws. • Place the gearbox on the specific gearbox support tool and on a vice. Specific tooling 05.90.25.30 Gearbox support •...
Page 106 Stelvio 1200 NTX ABS Engine • Remove the bearings from the gearbox if necessary. • Release the spring. • Pressing the selector, slide off the whole transmission lever. • Use rubber bands to tie down the trans- mission shaft unit and extract it.
Page 107 Stelvio 1200 NTX ABS Engine • Once the transmission shaft unit is in on a bench, remove the rubber bands, being careful with the group. • Detach the shafts and label the forks before removal. • Remove the forks and collect the shaft.
Page 108 Stelvio 1200 NTX ABS Engine • Replace bearings if necessary and re- move the clutch shaft. See also Removing the gearbox Removing the primary shaft • Remove the main shaft. • Operate on the main shaft from the second gear side.
Page 109 Stelvio 1200 NTX ABS Engine • Remove the gear of the sixth gear and collect the shoulder washer. • Remove the circlip. • Remove the gear of the third and fourth gears. • Remove the circlip and collect the shoulder washer.
Page 110 Stelvio 1200 NTX ABS Engine • Remove the gear of the fifth gear and collect the ball bearing cage. • Heat the shaft with a specific heater and remove the helical transmission gear. Removing the secondary shaft • Remove the transmission shaft.
Page 111 Stelvio 1200 NTX ABS Engine • Remove the gear of the second gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip. • Remove the gear of the sixth gear. • Remove the circlip and collect the shoulder washer.
Page 112 Stelvio 1200 NTX ABS Engine • Remove the gear of the fourth gear and collect the ball bearing cage. • Remove the gear of the third gear and collect the ball bearing cage and the shoulder washer. • Remove the circlip.
Page 113: Checking The Secondary Shaft
Stelvio 1200 NTX ABS Engine • Remove the circlip, the shoulder wash- er and remove the gear of the first gear, collect the ball bearing cage. • Remove the bearing if necessary. See also Disassembling the gearbox Checking the primary shaft...
Page 114 Stelvio 1200 NTX ABS Engine Checking the desmodromic drum Check gear drum for damage, scratches and wear and replace the desmodromic if necessary. Check the desmodromic segment «3» for damage and wear and replace it if necessary. Check the desmodromic bearing «4» for damage and cracks and replace it if necessary.
Page 115: Assembling The Gearbox
Stelvio 1200 NTX ABS Engine Removing the primary shaft Fitting the secondary shaft NOTE TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER. REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY REMOVED. See also...
Page 116 Stelvio 1200 NTX ABS Engine Generator Key: 1. Alternator 2. Spacer 3. Screw 4. Screw 5. Nut 6. Belt 7. Generator control pulley 8. Nut 9. Washer 10.Magneto flywheel cotter 11.Screw 12.Nut Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 117: Removing The Generator
Stelvio 1200 NTX ABS Engine Removing the generator • Remove the fuel tank. • Remove the control unit from its seat. • Disconnect the alternator connectors. • Undo and remove the five screws and collect the bushings. • Remove the cover.
Page 118 Stelvio 1200 NTX ABS Engine • Loosen the nut and undo the set screw so that the alternator slides down. • Completely loosen and remove the screw. • Remove the belt and the alternator with pulley. • Using a compressed air gun, unscrew and remove the nut and collect the spacer.
Page 119 Stelvio 1200 NTX ABS 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 - 119...
Page 120: Tensioning The Belt
Stelvio 1200 NTX ABS Engine • Remove the alternator frame. • Remove the sealing ring if necessary. See also Fuel tank Tensioning the belt • Operating from both sides, undo and remove the screw fixing the oil radiator to the chassis.
Page 121 Stelvio 1200 NTX ABS Engine • Undo and remove the five screws fixing the alternator belt cover. • Remove the oil radiator lower support bracket and the alternator belt cover. Locking torques (N*m) Alternator belt cover screw (radiator bracket retainer) TCEI M6x40 (2) Alter- 10 Nm (7.38 lbf ft)
Page 122: Installing The Generator
Stelvio 1200 NTX ABS Engine Installing the generator • If the sealing ring has been previously removed, replace it using the punch of the timing system cover sealing ring. Specific tooling 05.92.72.30 Timing system cover sealing ring punch • Place the bolt and the pin in the gen- erator cover.
Page 123 Stelvio 1200 NTX ABS Engine • Tighten the eight lower screws. • Operating diagonally and in stages, tighten the ten fixing screws on the al- ternator fitting. • Tighten the four screws, operating di- agonally and in stages. • Position the lower pulley and the spacer.
Page 124 Stelvio 1200 NTX ABS Engine • Position the screw and pre-tighten it. • Position the screw and tighten the nut. • Using the belt tensioning tool, tension the belt to the prescribed torque and tighten the set screw. • Remove the belt tensioning tool.
Page 125: Starter Motor
Stelvio 1200 NTX ABS Engine • Tighten the alternator fixing screws. • Place the alternator belt cover. • Tighten the five screws operating diag- onally and in stages. Starter motor Removing the starter motor • Undo and remove the two screws and collect the washers.
Page 126 Stelvio 1200 NTX ABS Engine • Slide off the starter motor. Clutch side Disassembling the clutch • Remove the complete gearbox. • Undo and remove the six screws. • Remove the start-up crown gear. • Remove the clutch bell and the friction disc.
Page 127 Stelvio 1200 NTX ABS Engine • Remove the Seeger ring. • Remove the clutch pressure plate. • Undo and remove the six screws and collect the belleville springs. • Remove the clutch disc. See also Removing the gearbox Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 128 Stelvio 1200 NTX ABS Engine Key: 1. Complete clutch 2. Clutch 3. Clutch bell 4. TCEI screw 5. Clutch disc 6. Crown 7. TCEI screw 8. Clutch pressure plate 9. Ring 10.TE flanged screw 11.Conical washer 12.Bushing 13.Rod 14.Bushing 15.Intermediate body 16.Thrust bearing...
Page 129: Specific Tooling
Stelvio 1200 NTX ABS Engine Checking the clutch actuator If the clutch is replaced, measure the length of the clutch control rod in order to use the correct rod. Measure as follows: • Fit the new clutch on the crankshaft.
Page 130 Stelvio 1200 NTX ABS Engine • Place the clutch pressure plate. • Fit the tool to centre and compress the plate. • Fully tighten the two centring tool screws. Specific tooling 020672Y Clutch spring centre and pusher • Once the centring tool is fitted, lock the plate with the snap ring.
Page 131 Stelvio 1200 NTX ABS Engine • Place the clutch bell with the reference facing upwards. • Place the start-up crown gear with the reference facing upwards. • Tighten the six screws to the prescri- bed torque operating diagonally and in stages.
Page 132 Stelvio 1200 NTX ABS Engine 2. Stud bolt 3. Cylinder head gasket 4. Right rocking lever support 5. Screw 6. Pin 7. Nut 8. Right exhaust, left intake rocking lever 9. Left exhaust, right intake rocking lever 10.Set screw 11.Nut 12.Rocking lever rod...
Page 133: Removing The Head Cover
Stelvio 1200 NTX ABS Engine 40.Rocking lever rod 41.Tappet bowl 42.Flanged screw 43.Spacer 44.Camshaft 45.Pin 46.Timing system gear 47.Breather plate 48.TE flanged screw 49.O-ring 50.Complete breather cover 51.TBEI screw 52.Timing system chain 53.Chain guide slider 54.Chain tensioner pad 55.Chain tensioner screw 56.Left chain tensioner...
Page 134: Removing The Cylinder Head
Stelvio 1200 NTX ABS Engine • Unscrew and remove the four head cover fixing screws and collect the sealing O-rings. • Remove the head cover together with the gasket. Removing the cylinder head CAUTION WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CARE- FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
Page 135 Stelvio 1200 NTX ABS Engine For the left head: • Unscrew and remove the screw and the washer. • Relief oil pressure from the left chain tensioner. • Slide off the timing system gear from the chain to remove it from the cam- shaft.
Page 136: Cylinder Head
Stelvio 1200 NTX ABS Engine • Unscrew and remove the two screws. • Remove the head. • Fit the timing system upper gear back to the chain. • Fit the chain tensioner cap temporarily and keep the chain taut on the service shaft.
Page 137 Stelvio 1200 NTX ABS Engine • Remove the two rocking levers from the cam cap. • Remove the two rods. • Undo and remove the four screws. • Remove the U-bolt. • Remove the camshaft. • Remove the bowls from the cam cap, and mark their position so as not inter- change them when refitting.
Page 138: Removing The Valves
Stelvio 1200 NTX ABS Engine WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CARE- FULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING. • Remove the cam cap from the stud bolts. • Undo and remove the two screws.
Page 139: Checking The Valve Guides
Stelvio 1200 NTX ABS Engine • Tighten the tool screw until fitted, and then hit the tool head (where the upper cap works) with a mallet so that the two cotters (1) get detached from the upper cap (2). •...
Page 140: Checking The Cylinder Head
Stelvio 1200 NTX ABS Engine Checking the cylinder head Check that: • the faying surfaces with the cover and the cylinder are not scored or damaged, jeopardising a perfect sealing. • Check that the tolerance between the valve guide holes and the valve stems is within the prescribed limits.
Page 141 Stelvio 1200 NTX ABS Engine • Place the valve guide oil seal (4) in the head. • Place the lower cap (5). • Place the valve (6) inside the head. • Place the spring (3). • Fit the upper cap (2).
Page 142 Stelvio 1200 NTX ABS Engine • Place the two rocking levers in the cam tower seats. • Place the U-bolt on the rocking levers making sure the two reference pins match the seats on the cam tower. • Tighten the two screws operating diag- onally and in stages.
Page 143 Stelvio 1200 NTX ABS Engine • Place the camshaft with the gear seat on the dowel side. • Place the U-bolt on the camshaft mak- ing sure the two reference pins match the seats on the cam tower. • Tighten the four screws operating di- agonally and in stages.
Page 144 Stelvio 1200 NTX ABS Engine Removing the generator Service shaft removal • Remove the tone wheel. • Remove both cylinders. • Undo and remove the two screws. • Remove the service shaft closing cap. • Mark the timing chains so as not to in- vert the direction of rotation upon fit- ting.
Page 145 Stelvio 1200 NTX ABS Engine • Fit the timing chains according to the references marked at the removal phase. • Lubricate the service shaft. • Insert the service shaft in its crankcase seat by sliding it through the two chains.
Page 146: Cam Timing
Stelvio 1200 NTX ABS Engine Installing sliders • Fit the crankshaft and the service shaft on the crankcase. • Fit the fixed chain sliders and tighten the fixing screws. • Tighten the chain caps with O-rings. • The operations related to the movable chain sliders are described in the cyl- inder fitting section.
Page 147 Stelvio 1200 NTX ABS Engine • Lock crankshaft rotation. • Unscrew and remove the nut fixing the crankshaft gear. • Remove the oil pump control gear. Specific tooling 12.91.18.01 Tool to lock the flywheel and the starting ring gear •...
Page 148 Stelvio 1200 NTX ABS Engine • Place a new gasket between the crank- case and the oil pump. • Place the oil pump. • Tighten the three screws fixing the oil pump. • Place the driving pin on the oil pump shaft.
Page 149 Stelvio 1200 NTX ABS Engine • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque. • Place the oil pump control gear on the crankshaft and align its reference with that marked during the removal phase on the oil pump driven gear.
Page 150 Stelvio 1200 NTX ABS Engine Measuring air gap • Undo and remove the two screws and remove the sensor. • Insert a suitable plain washer on the sensor and note its thickness. • Place the sensor on the crankcase and move it until it makes contact with the tone wheel.
Page 151 Stelvio 1200 NTX ABS Engine Cylinder-piston assembly Key: 1. Right cylinder 2. Piston 3. Screw 4. Top piston ring 5. Middle piston ring 6. Oil scraper piston ring 7. Pin 8. Snap ring 9. Cylinder base gasket 10.Stud bolt 11.Pin 12.Cylinder head gasket...
Page 152: Removing The Cylinder
Stelvio 1200 NTX ABS Engine Removing the cylinder NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS. • Remove the head, the gasket between the head and the cylinder and the two dowel pins.
Page 153: Fitting The Piston
Stelvio 1200 NTX ABS Engine • Mark the piston crown on the exhaust side so as to remember the refitting po- sition. • Remove the piston. Fitting the piston NOTE THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH HEADS.
Page 154: Installing The Cylinder
Stelvio 1200 NTX ABS Engine • Insert the pin. • Insert the snap ring. Specific tooling 020470Y Pin snap ring fitting tool Installing the cylinder RIGHT CYLINDER • Fit the piston. • Remove the cloth used to prevent for- eign bodies from getting into the crank- case.
Page 155 Stelvio 1200 NTX ABS Engine 020716Y Connecting rod locking • Remove the piston ring clamp tool and finish positioning the cylinder. Specific tooling 020674Y Piston ring clamp • Fit the movable chain slider. • Fit the upper gear. • Fit the chain tensioner and the chain tensioner cap temporarily and keep the chain taut on the service shaft.
Page 156 Stelvio 1200 NTX ABS Engine • Check that the oil in the left cylinder chain tensioner has been drained off by compressing it. If the operation is difficult, use a pin drive to push the central hole so that the oil is drained off from the circuit.
Page 157: Installing The Cylinder Head
Stelvio 1200 NTX ABS Engine Installing the cylinder head • Fit the valves in the head, if previously removed. • Take the left cylinder piston to TDC and lock crankshaft rotation. • Determine the thickness of the gasket to be fitted between the head and the cylinder as described in the section: Shimming system.
Page 158 Stelvio 1200 NTX ABS Engine • Fix the head with the two screws. • Tighten nuts and screws to the prescri- bed torque operating diagonally and in stages. • Loosen the valve set screws. • Using a thin screwdriver relief oil pres- sure from the left cylinder chain ten- sioner.
Page 159 Stelvio 1200 NTX ABS Engine • Fit the gasket with the correct thick- ness between the head and the cylin- der. • Fit the right cylinder head. • Unscrew and remove the right chain tensioner cap. • Screw two screws in the threaded holes of the timing system upper gear.
Page 160 Stelvio 1200 NTX ABS Engine • Place the cap. • Tighten the two screws to the prescri- bed torque. • Also place the cap of the other head. • Adjust valve clearance. See also Checking the valve clearance Installing the head cover •...
Page 161: Crankcase - Crankshaft
Stelvio 1200 NTX ABS Engine Crankcase - crankshaft Removing the crankshaft • Remove the clutch. • Remove the tone wheel and the oil pump gear. • Working from the generator side, un- screw and remove the nut. • Remove both gears.
Page 162 Stelvio 1200 NTX ABS Engine • Remove the crankshaft afterwards. • Collect the shim washer from inside the crankcase. See also Disassembling the clutch Removing the phonic wheel Disassembling the connecting rod • Remove both heads. • Remove the cylinders and the pistons.
Page 163 Stelvio 1200 NTX ABS Engine Inspecting the crankshaft components Check the surfaces of the main journals; if they are scored or oval-shaped, reface them (observing the undersize charts), and replace the main bushing/ Reference (1) indicates the position where the col- oured reference is applied to select diameter (B).
Page 164 Stelvio 1200 NTX ABS Engine Upon replacing the bearings it may be necessary to ream the crankshaft pin. Before reaming the crankpin, measure the pin diameter (B) comparing it with the maximum wear al- lowed, as indicated in the figure; this defines what kind of undersizing the bearing should have and to which diameter the pin (B) should be reamed.
Page 165 Stelvio 1200 NTX ABS Engine The connecting rods have a marked area for weight selection. The weight indicated in the chart includes screws, dowels and the bushing. CONNECTING ROD WEIGHT SELECTION Specification Desc./Quantity Connecting rod - brown 0.588 - 0.598 mm (0.02074 - 0.02109 in) Connecting rod - green 0.598 - 0.608 mm (0.02109 - 0.02145 in)
Page 166: Installing The Crankshaft
Stelvio 1200 NTX ABS Engine PAY ATTENTION TO CRANKSHAFT ROTATION WHEN ONLY THE CONNECTING RODS ARE FITTED BECAUSE IT COULD HIT THE TWO LUBRICATION JETS INSIDE THE CRANKCASE. Installing the crankshaft • Fit the shim washer inside the crank- case with the chamfered side facing the generator side.
Page 167 Stelvio 1200 NTX ABS Engine • Place the flywheel-side flange on the crankshaft and check if the dowel pin with the O-ring is correctly placed. • When fitting the flange on the crank- case, make sure that the three dowel pins match the seats on the crankcase.
Page 168 Stelvio 1200 NTX ABS Engine Refitting the crankcase halves In case the lubrication jets are removed, replace them with two new of the same type. Check that the O-ring is fitted on the jets. Do not interchange them upon refitting because they have a different length.
Page 169: Oil Pump
Stelvio 1200 NTX ABS Engine 1. Oil cooling radiator 2. Oil delivery pipe to heads 3. Oil delivery pipe to radiator 4. Oil pump body 5. Oil pump gasket 6. Rotor for lubrication 7. Rotor for cooling 8. Rotor control shaft 9.
Page 170 Stelvio 1200 NTX ABS Engine • Remove the nipple - oil pump fitting. • Bring the left cylinder piston to the TDC in combustion phase. • Mark a reference on the oil pump con- trol gear and another on the driven gear so as to place them correctly again upon refitting.
Page 171 Stelvio 1200 NTX ABS Engine • Undo and remove the three screws. • Remove the oil pump. • Remove the gasket between the crankcase and the oil pump. See also Replacement Removing the generator Installing • Place a new gasket between the crank- case and the oil pump.
Page 172 Stelvio 1200 NTX ABS Engine • Place the driving pin on the oil pump shaft. • Place the gear on the oil pump shaft. • Place the washer on the oil pump shaft. • Tighten the nut to the specified torque.
Page 173 Stelvio 1200 NTX ABS Engine • Insert the joint in the oil pump. • Fit the nipple with the gasket on the crankcase. • Tighten the nipple to the prescribed torque. Removing the oil sump NOTE TO REMOVE THE OIL SUMP, PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE USED OIL AND DRAIN OUT ALL OIL.
Page 174 Stelvio 1200 NTX ABS Engine • Undo and remove the fourteen screws fixing the oil sump to the engine crank- case. • Undo and remove the four screws. • Remove the flange. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 175 Stelvio 1200 NTX ABS Engine • Undo and remove the two screws. • Remove both filters. • Unscrew and remove the plug. • Remove the thermostatic valve. • Unscrew and remove the pressure re- lief valve plug. • Remove the pressure relief valve com-...
Page 176 Stelvio 1200 NTX ABS Engine Refitting the oil sump • Place the pressure relief valve compo- nents correctly. • Screw the pressure relief valve plug. • Place the thermostatic valve. CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT CLOGGED.
Page 177 Stelvio 1200 NTX ABS Engine • Tighten the thermostatic valve plug. • Place a new gasket between the crank- case and the flange. • Fit the flange. • Fix the flange with the four screws. • Fit the lubrication oil intake filter.
Page 178 Stelvio 1200 NTX ABS Engine • Check that the O-rings are fitted on the oil pump. • Fit the cooling oil intake filter. • Fix both filters and tighten the two screws to the prescribed torque. • Fit a new oil filter and tighten it to the prescribed torque.
Page 179 Stelvio 1200 NTX ABS 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...
Page 180: Index Of Topics
INDEX OF TOPICS P SUPP OWER SUPPLY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 181: Circuit Diagram
Stelvio 1200 NTX ABS 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 - 181...
Page 182 Stelvio 1200 NTX ABS Power supply Diagram Key: 1 Control unit 2 Ignition switch 3 Battery 4 Fuel pump 5 Coils 6 Instrument panel 7 Air temperature sensor 8. Throttle valve position sensor 9 Injectors 10 Engine temperature sensor 11 Crankshaft position sensor 12.
Page 183 Stelvio 1200 NTX ABS Power supply 13 Lambda probe 14 Fall sensor THROTTLE BODY PIPES LAYING Pipes from the throttle body to the idle motor should be laid so that the shaped part is inserted in the air filter casing.
Page 184 Stelvio 1200 NTX ABS Power supply • Make sure there are no errors in the control unit; otherwise, solve them and repeat the procedure. • Make sure the left throttle is fully in. DO NOT TOUCH THE THROTTLE ABUTMENT SCREW OR THE THROTTLE BODY MUST BE REPLACED.
Page 185: Recovery Function
Stelvio 1200 NTX ABS Power supply If there is a larger difference: • act on the set screw of the throttle body connecting rod to reduce the pressure difference in the two pipes. • Repeat the procedure "Throttle posi- tion self-learning" as explained above.
Page 186 Stelvio 1200 NTX ABS 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 187: Device Status
Stelvio 1200 NTX ABS Power supply Specification Desc./Quantity Target engine revs 1150 rpm (approximate values) Parameter valid at idle, setting depends especially on the en- gine temperature: the control unit will try to keep the engine running at this revs, acting on the ignition advance and the...
Page 188: Errors Display
Stelvio 1200 NTX ABS 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 189: Adjustable Parameters
Stelvio 1200 NTX ABS 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 190 INDEX OF TOPICS SUSP USPENSIONS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 191: Removing The Front Wheel
Stelvio 1200 NTX ABS Suspensions Front Removing the front wheel • Working from both sides, undo and re- move the two fixing screws from the front brake callipers and remove them from their seats. • Support the front part of the vehicle.
Page 192 Stelvio 1200 NTX ABS 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.
Page 193 Stelvio 1200 NTX ABS Suspensions 1. Complete front fork 2. TCE screw 3. Washer 4. TE flanged screw 5. Stem + right wheel holder 6. Bushing 7. Stem + left wheel holder 8. Complete right pumping member 9. Nut 10.Complete left pumping member 11.Fork upper plate...
Page 194 Stelvio 1200 NTX ABS Suspensions Adjustment The front suspension consists of a hydraulic fork connected to the headstock by means of two plates. To set the vehicle suspension, each fork stem fea- tures an upper nut (1), to adjust spring preloading, and an upper set screw (2): •...
Page 195: Removing The Fork Legs
Stelvio 1200 NTX ABS Suspensions Removing the fork legs • Rest the vehicle on its centre stand. • Secure the rear part of the vehicle through belts in order to lift the front wheel. • Remove the mudguard. • Remove the front wheel.
Page 196 Stelvio 1200 NTX ABS 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 197 Stelvio 1200 NTX ABS Suspensions • Remove the spring. Let the oil depos- ited on the spring turns fully drip into the sleeve. • Pour the oil into the container. • Remove in order: - upper spring guide; - preload pipe;...
Page 198: Disassembling The Fork
Stelvio 1200 NTX ABS 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 199 Stelvio 1200 NTX ABS 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 200: Checking The Components
Stelvio 1200 NTX ABS 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 201 Stelvio 1200 NTX ABS 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 202 Stelvio 1200 NTX ABS 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 203 Stelvio 1200 NTX ABS Suspensions • The sealing ring must be placed with the stamped part facing the dust gaiter. • Fit the ring, the movable bushing and, after removing the tape, fit the fixed bushing. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 204 Stelvio 1200 NTX ABS 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 205: Filling Oil
Stelvio 1200 NTX ABS 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 206 Stelvio 1200 NTX ABS Suspensions • Measure the air gap between the oil level and the rim. THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL MUST BE THE SAME IN BOTH STEMS.
Page 207 Stelvio 1200 NTX ABS 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 208: Installing The Fork Legs
Stelvio 1200 NTX ABS 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. •...
Page 209: Steering Bearing
Stelvio 1200 NTX ABS 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 210 Stelvio 1200 NTX ABS 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 211: Removing The Rear Wheel
Stelvio 1200 NTX ABS 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 212: 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 213 Stelvio 1200 NTX ABS 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 214: Index Of Topics
INDEX OF TOPICS CHAS HASSIS Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 215: Swinging Arm
Stelvio 1200 NTX ABS Chassis Swinging arm Removing • To remove the fork, first remove the footrest holding plate and the exhaust silencer. • Slide off the rear brake calliper from the disc and release the brake pipe. • Engage the first gear.
Page 216 Stelvio 1200 NTX ABS Chassis • Unscrew and remove the nut fixing the reaction rod. • Remove the screw. • Fix the reaction rod to the chassis with a clamp. • Remove the clamp from the dust guard cap. •...
Page 217 Stelvio 1200 NTX ABS 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 218 Stelvio 1200 NTX ABS Chassis Installing • Spread a thin layer of lubricating grease all along the swingarm pin. • Fit the ring nut in the swingarm pin and screw it manually. • Working from both sides, grease the cardan shaft cables with the recom- mended product from the recommen- ded products table.
Page 219 Stelvio 1200 NTX ABS Chassis • Fit the dust guard cap in the gearbox. • Lock the dust guard cap with a new clamp. • Place the reaction rod into its seat. • Insert the screw. • Screw the nut fixing the reaction rod.
Page 220 Stelvio 1200 NTX ABS Chassis Bevel gears Removing • Remove the rear wheel. • Unscrew and remove the two screws. • Remove the speed sensor from the fork. • Unscrew and remove the nut fixing the reaction rod. • Remove the screw.
Page 221 Stelvio 1200 NTX ABS 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 222 Stelvio 1200 NTX ABS 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 - 222...
Page 223 Stelvio 1200 NTX ABS 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 - 223...
Page 224 Stelvio 1200 NTX ABS 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.
Page 225 Stelvio 1200 NTX ABS Chassis Insert the support group in the casing. Assemble the cap and the ring. Fit the cap on the support. Fit the clamp. Screw the clamp with the specific pliers. Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 226 Stelvio 1200 NTX ABS Chassis Apply the prescribed sealant to the casing. Fit a new sealing ring using the buffer. Lubricate the sealing ring. Assemble two centring stud bolts with M8 thread in the threaded holes of the casing as shown in the picture.
Page 227 Stelvio 1200 NTX ABS Chassis Assemble the fixing screws (7). Tighten the screws (7) to the prescribed torque. Remove excessive sealant. Assemble the ring to the casing. Tighten the fixing screws to the prescribed torque. Fit the cap with the washer.
Page 228 Stelvio 1200 NTX ABS Chassis Fit the breather with the washer. Screw the breather to the prescribed torque. Fill the transmission with the prescribed oil. Fit the cap with the washer. Screw the cap to the prescribed torque. Assemble the cap with the clamps.
Page 229 Stelvio 1200 NTX ABS Chassis REMOVAL Remove the bearing from the wheel axle with a suitable extractor. Turn the unit over. Remove the bearing from the wheel axle with a suitable extractor. FITTING Heat the bearings to 100°C (212 °F).
Page 230 Stelvio 1200 NTX ABS 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 231 Stelvio 1200 NTX ABS Chassis Assemble the sealing ring (3) to the ring nut (2) with the buffer CA715855 (see Fig.1) and a ham- mer. Lubricate the sealing ring (3). Assemble the ring nut (2). Tighten the ring nut (2) with the special spanner (s4) to the prescribe torque.
Page 232 Stelvio 1200 NTX ABS Chassis Insert the stop ring (1) in the ring nut (2) in the in- dicated direction. Assembly position of the stop ring (1). CAUTION MAKE SURE THE STOP RING IS IN ITS SEAT. Support unit Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 233 Stelvio 1200 NTX ABS Chassis REMOVAL Remove the bushing (1) with a punch. Turn the support (5) over and remove the other bushing (8). Remove the sealing rings (2) and (7) with a screw- driver. Remove the stop rings (3) and (6) from the support (5) with suitable pliers.
Page 234 Stelvio 1200 NTX ABS Chassis Remove the ball joint (4) with a suitable buffer and a rubber hammer. FITTING Fit the stop ring (6) in the support (5) with suitable pliers. Turn the support (5) over. Assemble the ball joint (4) with the buffer and a rubber hammer.
Page 235: Troubleshooting
Stelvio 1200 NTX ABS Chassis Manually assemble the new sealing rings (2) and (7). Assemble the bushing (1). Drive the bushing (1) in with a plastic hammer. Turn the support (5) over and assemble the other bushing (8). TROUBLESHOOTING Possible Cause Operation 1.
Page 236 Stelvio 1200 NTX ABS Chassis Installing • Insert the transmission casing on the swingarm making sure that the univer- sal joint engages correctly. • Tighten the four screws to the prescri- bed torque operating diagonally. • Place the reaction rod into its seat.
Page 237 Stelvio 1200 NTX ABS Chassis • Place the speed sensor and fasten the cable harness with the clamps. • Place the rear wheel on the fork. • Tighten the four screws with their spacers and the dust-protection ring. • Place the rear brake calliper on the disc and the brake pipe on the fork.
Page 238 Stelvio 1200 NTX ABS Chassis 3. Gasket 4. Flanged nut 5. Washer 6. Gasket 7. Clamp 8. Central exhaust pipe 9. TE flanged screw 10.Silent-block 11.Flanged self-locking nut 12.Lambda probe 13.Gasket 14.Clamp 15.Silencer 16.TCEI screw 17.Silencer fixing bushing 18.Muffler rubber ring 19.Spacer...
Page 239: Removing The Exhaust Manifold
Stelvio 1200 NTX ABS Chassis • Remove the exhaust end. Removing the manifold - tail pipe • Remove the exhaust end and the ex- haust manifolds. • Remove the starter motor protection in order to disconnect the lambda probe connector.
Page 240: Engine Oil Cooler
Stelvio 1200 NTX ABS Chassis • Unscrew and remove the two nuts on the head exhaust stud bolts. • Retrieve the washers. • Loosen the clamp. • Remove the exhaust manifold. Engine oil cooler Key: 1. Complete oil radiator 2. TE flanged screw...
Page 241 Stelvio 1200 NTX ABS 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 242 Stelvio 1200 NTX ABS Chassis • Undo and remove the two radiator up- per screws and collect the washer. • Remove the oil cooling radiator. Installing • Fit the oil cooling radiator on the vehi- cle following the operations described in the removal chapter but in reverse order.
Page 243: Index Of Topics
INDEX OF TOPICS BRAK SYS RAKING SYSTEM Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 244 Stelvio 1200 NTX ABS Braking system Foreword key: 1. Front brake pipe 2. Oil pipe screw 3. Aluminium gasket 4. Front brake pipe 5. Control unit/pump 6. Brake pipe 7. Rear brake pipe 8. Screw 9. Bleed valve and cover 10.
Page 245: Operating Diagram
Stelvio 1200 NTX ABS Braking system Operating diagram key: The black arrow indicates brake fluid path when the ABS system is not working. The white arrow indicates the brake fluid path when the ABS system is working. 2) ABS Control unit...
Page 246: Abs Operation
Stelvio 1200 NTX ABS Braking system 16) Front inlet valve 17) Rear inlet valve ABS OPERATION General specifications: • The front circuit is similar to the rear circuit. • The ABS inlet valve (16 - 17) is normally open and it is closed only when the system inter- venes to avoid wheel locking.
Page 247 Stelvio 1200 NTX ABS Braking system ABS SYSTEM DESCRIPTION The ABS system is a device to avoid wheels lock- ing in case of emergency braking, increasing ve- hicle braking stability when compared to a tradi- tional braking system. Sometimes when the brake is operated, the tyre locks with a consequent loss of grip, which makes it difficult to control the vehicle.
Page 248 Stelvio 1200 NTX ABS Braking system Riding with an active ABS system The warning light (7) is off. If a failure is detected, the warning light (7) turns on permanently to indi- cate the malfunction. The ABS device is automat- ically deactivated.
Page 249 Stelvio 1200 NTX ABS Braking system 10A fuse (6) Protects: the whole system safety As the ABS system operates through reading the speed of the front and rear wheels, be extremely careful when working on or near the wheels so as not to damage the tone wheels (2). A damaged tone wheel may compromise the correct operation of the whole system.
Page 250 Stelvio 1200 NTX ABS Braking system Parameter reading screen page ENGINE PARAMETER READING This screen page shows the parameters meas- ured by the several sensors (engine revs, engine temperature, etc.) or values set by the control unit (injection time, ignition advance, etc.)
Page 251 Stelvio 1200 NTX ABS Braking system 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 Deleting stored errors By pressing the 'ENTER' button, the stored errors (MEM) be- come part of the historical data (STO).
Page 252 Stelvio 1200 NTX ABS Braking system If the 10A fuse is defective, the ABS warning light remains on. Axone does not communicate with the ABS module. That is, it is not valid in case of failure of 40A or 25A fuses even if the ABS warning light is activated.
Page 253 Stelvio 1200 NTX ABS Braking system Checks: check the speed sensor signal (0.5 or 1 V) on the orange/purple cable between pin 1 of the front speed sensor connector and pin 22 of the ABS module connector. If there is not enough voltage, check cable continuity from the ABS module to the speed sensor connector and make sure that the cable is grounded insulated.
Page 254 Stelvio 1200 NTX ABS Braking system Description of the defect: the control unit detects a failure in the valve operation. Checks: make sure that the voltage in pin 25 of the ABS control unit connector is 12 V (battery voltage) and that the con- nector is not rusty.
Page 255 Stelvio 1200 NTX ABS Braking system Modulator • Remove the saddle. • Remove the battery. • Disconnect the ABS control unit con- nector. • Empty the brake fluid from the pipes into a container, disconnecting the pipes from the pumps and callipers.
Page 256 Stelvio 1200 NTX ABS Braking system WHEN THE ABS CONTROL UNIT IS REPLACED, IT IS SUPPLIED ALREADY FILLED WITH BRAKE FLUID; THEREFORE, THE CONTROL UNIT HAS TO BE ASSEMBLED ON THE VEHICLE AND THE SYSTEM FILLED AND PURGED AS ANY REGULAR SYSTEM.
Page 257: Rear Brake Calliper
Stelvio 1200 NTX ABS 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 258: Front Brake Calliper
Stelvio 1200 NTX ABS 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 259 Stelvio 1200 NTX ABS 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 260 Stelvio 1200 NTX ABS 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.
Page 261: Rear Brake Pads
Stelvio 1200 NTX ABS Braking system Rear brake pads Removal • Undo and remove the two screws. • Remove the brake calliper from the disc. • Turn the pin and pull out the split pin. • Remove the split pin.
Page 262 Stelvio 1200 NTX ABS 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.
Page 263 Stelvio 1200 NTX ABS 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.
Page 264 Stelvio 1200 NTX ABS 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 265 Stelvio 1200 NTX ABS 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 266: Index Of Topics
INDEX OF TOPICS BODYW ODYWORK Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 267: Engine Guard
Stelvio 1200 NTX ABS 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 268 Stelvio 1200 NTX ABS 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 269: Instrument Panel
Stelvio 1200 NTX ABS 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 270 Stelvio 1200 NTX ABS 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 271: Left Side
Stelvio 1200 NTX ABS 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 272: Right Side
Stelvio 1200 NTX ABS 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 273 Stelvio 1200 NTX ABS 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 274: Side Fairings
Stelvio 1200 NTX ABS 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 275 Stelvio 1200 NTX ABS 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 276 Stelvio 1200 NTX ABS 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 277 Stelvio 1200 NTX ABS 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 278 Stelvio 1200 NTX ABS 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 279: Sump Guard
Stelvio 1200 NTX ABS 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 280: Fuel Tank Cover
Stelvio 1200 NTX ABS 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...
Page 281 Stelvio 1200 NTX ABS Bodywork FUEL TANK UPPER FAIRING • Remove the fuel tank cap. • Undo and remove the four screws. • Remove the fuel tank cover. • Working from both sides, undo and re- move the screw. •...
Page 282 Stelvio 1200 NTX ABS Bodywork • Lift the rear part of the fuel tank fairing. • Disconnect the pipes. • Remove the fuel tank fairing. See also Seat FUEL TANK • Remove the tank side fairings. • Disconnect the glove-box opening control connector.
Page 283 Stelvio 1200 NTX ABS 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 284 Stelvio 1200 NTX ABS 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 - 284...
Page 285 INDEX OF TOPICS PRE DE DELIVERY Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...
Page 286 Stelvio 1200 NTX ABS Pre-delivery Carry out the listed checks before delivering the vehicle. WARNING BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL. Aesthetic inspection - Paintwork - Fitting of Plastic Parts - Scratches - Dirt Tightening torques inspection - Safety locks:...
Page 287: Road Test
Stelvio 1200 NTX ABS Pre-delivery - Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if required, program the control unit/s again: consult the technical service website to know about available upgrades and details regarding the operation.
Page 288: Static Test
Stelvio 1200 NTX ABS Pre-delivery - Response to throttle control - Stability when accelerating and braking - Front and rear brake efficiency - Front and rear suspension efficiency - Abnormal noise Static test Static check after test drive: - Restarting when warmed up...
Page 289 ABS: 244, 249 Air filter: 37 Battery: 56, 63 Brake: 257, 258, 261 Clutch: 78, 126, 129, 162 Clutch lever: 78 Display: 188, 251 Engine oil: 34, 76, 240 Fork: 192, 195, 198, 202, 208 Forks: 114 Fuel: 86, 120, 280 Fuses: 59 Gearbox oil: 36 Identification: 10...
Page 290 Tank: 86, 120, 280 Transmission: 12, 32 Tyres: 14 Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten...

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