MOTO GUZZI Stelvio 1200 NTX Specifiche

SERVICE STATION MANUAL981138Stelvio 1200 NTX ABS

IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THETIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USEA

2. Circlip3. Thickness4. Pin5. Complete desmodromic6. Ball bearing7. Spring8. Spacer9. Circlip10.Fifth wheel11.Linking pin12.Gear13.Circlip14.Thrust w

40.Index lever41.Spring42.Ball bearing43.Gear44.Gear45.Ball bearing cage46.Thrust washer47.Circlip48.Gear49.Circlip50.Gear51.Main shaft52.Transmission

•Unscrew and remove the gearbox oilfiller cap.•Place a container of suitable capacityunder it, unscrew and remove the capand then bleed all gearbox oi

•Undo and remove the two screws.•Undo and remove the screw.•Remove the gearbox.See alsoRemoving the starter motorReplacementGearbox shaftsStelvio 1200

Disassembling the gearbox•Remove the gearbox.•Unscrew and slide off the odometergear and collect the abutment washerthat is inside the gearbox.•From t

•Slide off the rod with the two bushings.•Undo and remove the five externalscrews.•Place the gearbox on the specific gearbox support tool and on a vic

•Remove the bearings from the gearboxif necessary.•Release the spring.•Pressing the selector, slide off the whole transmission lever.•Use rubber bands

•Once the transmission shaft unit is inon a bench, remove the rubber bands,being careful with the group.•Detach the shafts and label the forksbefore r

•Replace bearings if necessary and re-move the clutch shaft.See alsoRemoving the gearboxRemoving the primary shaft•Remove the main shaft.•Operate on t

•Remove the gear of the sixth gear andcollect the shoulder washer.•Remove the circlip.•Remove the gear of the third and fourthgears.•Remove the circli

This number consists of numbers and letters, as inthe example shown below.ZGULZB010YMXXXXXXKEY:ZGU: WMI (World manufacturer identifier) code;LZ: model

•Remove the gear of the fifth gear andcollect the ball bearing cage.•Heat the shaft with a specific heaterand remove the helical transmissiongear.Remo

•Remove the gear of the second gearand collect the ball bearing cage andthe shoulder washer.•Remove the circlip.•Remove the gear of the sixth gear.•Re

•Remove the gear of the fourth gear andcollect the ball bearing cage.•Remove the gear of the third gear andcollect the ball bearing cage and theshould

•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 als

Checking the desmodromic drumCheck gear drum for damage, scratches and wearand replace the desmodromic if necessary.Check the desmodromic segment «3»

Removing the primary shaftFitting the secondary shaftNOTETO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER.REMEMBER TO REPLAC

GeneratorKey:1. Alternator2. Spacer3. Screw4. Screw5. Nut6. Belt7. Generator control pulley8. Nut9. Washer10.Magneto flywheel cotter11.Screw12.NutEngi

Removing the generator•Remove the fuel tank.•Remove the control unit from its seat.•Disconnect the alternator connectors.•Undo and remove the five scr

•Loosen the nut and undo the set screwso that the alternator slides down.•Completely loosen and remove thescrew.•Remove the belt and the alternator wi

•Undo and remove the eight screws.•Undo and remove the two screws.•Undo and remove the two screws.Stelvio 1200 NTX ABS EngineENG - 119Revente Interdit

Specification Desc./QuantityBore / stroke 95 x 81.2 mm (3.74 x 3.20 in)Engine capacity 1151 cm³ (70 cu.in)Compression ratio 11: 1Electric starterIdle

•Remove the alternator frame.•Remove the sealing ring if necessary.See alsoFuel tankTensioning the belt•Operating from both sides, undo andremove the

•Undo and remove the five screws fixingthe alternator belt cover.•Remove the oil radiator lower supportbracket and the alternator belt cover.Locking t

Installing the generator•If the sealing ring has been previouslyremoved, replace it using the punch ofthe timing system cover sealing ring.Specific to

•Tighten the eight lower screws.•Operating diagonally and in stages,tighten the ten fixing screws on the al-ternator fitting.•Tighten the four screws,

•Position the screw and pre-tighten it.•Position the screw and tighten the nut.•Using the belt tensioning tool, tensionthe belt to the prescribed torq

•Tighten the alternator fixing screws.•Place the alternator belt cover.•Tighten the five screws operating diag-onally and in stages.Starter motorRemov

•Slide off the starter motor.Clutch sideDisassembling the clutch•Remove the complete gearbox.•Undo and remove the six screws.•Remove the start-up crow

•Remove the Seeger ring.•Remove the clutch pressure plate.•Undo and remove the six screws andcollect the belleville springs.•Remove the clutch disc.Se

Key:1. Complete clutch2. Clutch3. Clutch bell4. TCEI screw5. Clutch disc6. Crown7. TCEI screw8. Clutch pressure plate9. Ring10.TE flanged screw11.Coni

Checking the clutch actuatorIf the clutch is replaced, measure the length of theclutch control rod in order to use the correct rod.Measure as follows:

Specification Desc./QuantityLow/high beam headlight (halogen) 12 V - 55 W / 60 W H4Turn indicators 12V - 10 WTail light/stop light LEDInstrument panel

•Place the clutch pressure plate.•Fit the tool to centre and compress theplate.•Fully tighten the two centring toolscrews.Specific tooling020672Y Clut

•Place the clutch bell with the referencefacing upwards.•Place the start-up crown gear with thereference facing upwards.•Tighten the six screws to the

2. Stud bolt3. Cylinder head gasket4. Right rocking lever support5. Screw6. Pin7. Nut8. Right exhaust, left intake rocking lever9. Left exhaust, right

40.Rocking lever rod41.Tappet bowl42.Flanged screw43.Spacer44.Camshaft45.Pin46.Timing system gear47.Breather plate48.TE flanged screw49.O-ring50.Compl

•Unscrew and remove the four headcover fixing screws and collect thesealing O-rings.•Remove the head cover together withthe gasket.Removing the cylind

For the left head:•Unscrew and remove the screw andthe washer.•Relief oil pressure from the left chaintensioner.•Slide off the timing system gear from

•Unscrew and remove the two screws.•Remove the head.•Fit the timing system upper gear backto the chain.•Fit the chain tensioner cap temporarilyand kee

•Remove the two rocking levers fromthe cam cap.•Remove the two rods.•Undo and remove the four screws.•Remove the U-bolt.•Remove the camshaft.•Remove t

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 th

•Tighten the tool screw until fitted, andthen hit the tool head (where the uppercap works) with a mallet so that the twocotters (1) get detached from

Wheels and tyresWHEELS AND TYRES - STELVIO NTXWheel Model Wheel rim MeasurementTyre pressure withrider onlyTyre pressure, rider +passengerFront (stand

Checking the cylinder headCheck that:•the faying surfaces with the cover and the cylinder are not scored or damaged, jeopardisinga perfect sealing.•Ch

•Place the valve guide oil seal (4) in thehead.•Place the lower cap (5).•Place the valve (6) inside the head.•Place the spring (3).•Fit the upper cap

•Place the two rocking levers in the camtower seats.•Place the U-bolt on the rocking leversmaking sure the two reference pinsmatch the seats on the ca

•Place the camshaft with the gear seaton the dowel side.•Place the U-bolt on the camshaft mak-ing sure the two reference pins matchthe seats on the ca

Removing the generatorService shaft removal•Remove the tone wheel.•Remove both cylinders.•Undo and remove the two screws.•Remove the service shaft clo

•Fit the timing chains according to thereferences marked at the removalphase.•Lubricate the service shaft.•Insert the service shaft in its crankcasese

Installing sliders•Fit the crankshaft and the service shafton the crankcase.•Fit the fixed chain sliders and tightenthe fixing screws.•Tighten the cha

•Lock crankshaft rotation.•Unscrew and remove the nut fixing thecrankshaft gear.•Remove the oil pump control gear.Specific tooling12.91.18.01 Tool to

•Place a new gasket between the crank-case and the oil pump.•Place the oil pump.•Tighten the three screws fixing the oilpump.•Place the driving pin on

•Place the washer on the oil pump shaft.•Tighten the nut to the specified torque.•Place the oil pump control gear on thecrankshaft and align its refer

Name Torque in NmHead covers fixing screws (8) 8 Nm (5.9 lbf ft)Spark plug (2) 15 Nm (11.06 lbf ft) - MolykoteCRANKCASEName Torque in NmCrankcase stud

Measuring air gap•Undo and remove the two screws andremove the sensor.•Insert a suitable plain washer on thesensor and note its thickness.•Place the s

Cylinder-piston assemblyKey:1. Right cylinder2. Piston3. Screw4. Top piston ring5. Middle piston ring6. Oil scraper piston ring7. Pin8. Snap ring9. Cy

Removing the cylinderNOTETHE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLYTO BOTH HEADS.•Remove the head, the gasket betweenth

•Mark the piston crown on the exhaustside so as to remember the refitting po-sition.•Remove the piston.Fitting the pistonNOTETHE OPERATIONS DESCRIBED

•Insert the pin.•Insert the snap ring.Specific tooling020470Y Pin snap ring fitting toolInstalling the cylinderRIGHT CYLINDER•Fit the piston.•Remove t

020716Y Connecting rod locking•Remove the piston ring clamp tool andfinish positioning the cylinder.Specific tooling020674Y Piston ring clamp•Fit the

•Check that the oil in the left cylinderchain tensioner has been drained offby compressing it. If the operation isdifficult, use a pin drive to push t

Installing the cylinder head•Fit the valves in the head, if previouslyremoved.•Take the left cylinder piston to TDC andlock crankshaft rotation.•Deter

•Fix the head with the two screws.•Tighten nuts and screws to the prescri-bed torque operating diagonally and instages.•Loosen the valve set screws.•U

•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 chaintension

ALTERNATORName Torque in NmAlternator fixing screw - TCEI M8x45 (1) 22 Nm (16.23 lbf ft)Alternator fixing nut - M10x1.5 (1) 30 Nm (22.13 lbf ft)Altern

•Place the cap.•Tighten the two screws to the prescri-bed torque.•Also place the cap of the other head.•Adjust valve clearance.See alsoChecking the va

Crankcase - crankshaftRemoving the crankshaft•Remove the clutch.•Remove the tone wheel and the oilpump gear.•Working from the generator side, un-screw

•Remove the crankshaft afterwards.•Collect the shim washer from inside thecrankcase.See alsoDisassembling theclutchRemoving the phonic wheelDisassembl

Inspecting the crankshaft componentsCheck the surfaces of the main journals; if they arescored or oval-shaped, reface them (observing theundersize cha

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 connecting rods have a marked area forweight selection.The weight indicated in the chart includes screws,dowels and the bushing.CONNECTING ROD WEI

PAY ATTENTION TO CRANKSHAFT ROTATION WHEN ONLY THE CONNECTING RODS AREFITTED BECAUSE IT COULD HIT THE TWO LUBRICATION JETS INSIDE THE CRANKCASE.Instal

•Place the flywheel-side flange on thecrankshaft and check if the dowel pinwith the O-ring is correctly placed.•When fitting the flange on the crank-c

Refitting the crankcase halvesIn case the lubrication jets are removed, replacethem with two new of the same type. Check thatthe O-ring is fitted on t

1. Oil cooling radiator2. Oil delivery pipe to heads3. Oil delivery pipe to radiator4. Oil pump body5. Oil pump gasket6. Rotor for lubrication7. Rotor

Name Torque in NmFront speed sensor screws retainer 6 Nm (4.42 lbf ft) + Loc. 243ABS control unit screws retainer (2) 10 Nm (7.37 lbf ft)Rear speed se

•Remove the nipple - oil pump fitting.•Bring the left cylinder piston to the TDCin combustion phase.•Mark a reference on the oil pump con-trol gear an

•Undo and remove the three screws.•Remove the oil pump.•Remove the gasket between thecrankcase and the oil pump.See alsoReplacementRemoving the genera

•Place the driving pin on the oil pumpshaft.•Place the gear on the oil pump shaft.•Place the washer on the oil pump shaft.•Tighten the nut to the spec

•Insert the joint in the oil pump.•Fit the nipple with the gasket on thecrankcase.•Tighten the nipple to the prescribedtorque.Removing the oil sumpNOT

•Undo and remove the fourteen screwsfixing the oil sump to the engine crank-case.•Undo and remove the four screws.•Remove the flange.Engine Stelvio 12

•Undo and remove the two screws.•Remove both filters.•Unscrew and remove the plug.•Remove the thermostatic valve.•Unscrew and remove the pressure re-l

Refitting the oil sump•Place the pressure relief valve compo-nents correctly.•Screw the pressure relief valve plug.•Place the thermostatic valve.CHECK

•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.•F

•Check that the O-rings are fitted on theoil pump.•Fit the cooling oil intake filter.•Fix both filters and tighten the twoscrews to the prescribed tor

•Place the oil sump.•Tighten the fourteen screws to the pre-scribed torque.•Add engine oil up to the correct level.Stelvio 1200 NTX ABS EngineENG - 17

Name Torque in NmSilencer to chassis connecting pipe retainer 25 NmMuffler to chassis retainer - M8x45 (1) 25 Nm (18.44 lbf ft)Heat guard retainer - M

INDEX OF TOPICSPOWER SUPPLY P SUPPRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Circuit diagramKey:1. Complete fuel pump unit2. Nut3. Fuel pipe4. Pipe5. ScrewInjectionStelvio 1200 NTX ABS Power supplyP SUPP - 181Revente Interdite

DiagramKey:1 Control unit2 Ignition switch3 Battery4 Fuel pump5 Coils6 Instrument panel7 Air temperature sensor8. Throttle valve position sensor9 Inje

13 Lambda probe14 Fall sensorTHROTTLE BODY PIPES LAYINGPipes from the throttle body to the idle motorshould be laid so that the shaped part is inserte

•Make sure there are no errors in thecontrol unit; otherwise, solve them andrepeat the procedure.•Make sure the left throttle is fully in.DO NOT TOUCH

If there is a larger difference:•act on the set screw of the throttle bodyconnecting rod to reduce the pressuredifference in the two pipes.•Repeat the

Iso screen pageISOThis screen page shows general data regardingthe control unit, for example software type, map-ping, control unit programming dateISO

Specification Desc./QuantityTarget engine revs 1150 rpm (approximate values)Parameter valid at idle, setting depends especially on the en-gine tempera

Devices activation screen pageDEVICES ACTIVATIONThis screen page is used to delete errors in thecontrol unit memory and to activate some systemscontro

Specification Desc./QuantityRight injector Possible short circuit in the earth lead, battery or open circuit.If both injectors do not work, the engine

Name Torque in NmTank to chassis front retainer 10 NmENGINE COVERName Torque in NmRight cover plate retainer - M10x20 (2) 40 Nm (29.5 lbf ft)Left cove

INDEX OF TOPICSSUSPENSIONS SUSPRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

FrontRemoving the front wheel•Working from both sides, undo and re-move the two fixing screws from thefront brake callipers and remove themfrom their

•Take out the wheel bolt by inserting ascrewdriver in the bolt holes.•Upon extracting the wheel, hold it andthen remove it.•Collect the spacer from th

1. Complete front fork2. TCE screw3. Washer4. TE flanged screw5. Stem + right wheel holder6. Bushing7. Stem + left wheel holder8. Complete right pumpi

AdjustmentThe front suspension consists of a hydraulic forkconnected to the headstock by means of twoplates.To set the vehicle suspension, each fork s

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.•Remov

•Unscrew the sleeve upper cap.•Push the bushing down in order tocompress the spring and then fit a toolunder the pumping member lock nutand on the bus

•Remove the spring. Let the oil depos-ited on the spring turns fully drip intothe sleeve.•Pour the oil into the container.•Remove in order:- upper spr

Disassembling the fork•Drain out all the oil in the stem.•Block the wheel holder sleeve with avice.•Unscrew the bottom screw and removeit together wit

•Slide off the dust scraper from thesleeve using a screwdriver as a lever.•Do not damage the sleeve edge whiledoing this.•Remove the snap ring.•Take o

SERVICE STATIONMANUALStelvio 1200 NTX ABSTHE VALUE OF SERVICEOnly the mechanics of the official Moto Guzzi Service Network know this vehicle well, tha

Specification Desc./QuantityPiston diameter - selection E 94.945 - 94.955 mm (3.73798 - 3.73837 in)Cylinder diameter - selection E 95.010 - 95.020 mm

•Remove the ring and the dust guard.See alsoDraining oilChecking the componentsStemCheck the sliding surface for scorings and/or scratches.These scori

Bending limit:0.2 mm (0.00787 in)SleeveCheck that there are no damages and/or cracks; otherwise, replace it.SpringCheck the spring is in good conditio

•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-hesiv

•The sealing ring must be placed withthe stamped part facing the dust gaiter.•Fit the ring, the movable bushing and,after removing the tape, fit the f

•Get the special tool code 8140758.•Cut the tool along the longitudinal axleso as to obtain two similar half-shells tobe used on forks with inverted s

•Fit the dust guard with the specific tool.Specific toolingAP8140758 tool to fit oil seals and dust guardsfor ø 50 mm (1.97 in) stemsAP8140146 Weight•

•Measure the air gap between the oillevel and the rim.THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDERTO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVELMUST

•Fit the bushing.•Finger tight the upper cap on the pumping member stem.•Compress the spring and then fit a toolunder the pumping member lock nut toke

•Once the operations are completed,restore the spring preloading correctvalue.Installing the fork legs•Insert the fork stem in position.•Insert the wh

Steering bearingAdjusting play•Unscrew and remove the U-bolt fourfixing screws.•Remove the U-bolt.•Remove the handlebar and place itpaying attention t

Crankcase - crankshaft - connecting rodCRANKSHAFT SEAT (TIMING SYSTEM SIDE)Specification Desc./QuantityDiameter of crankshaft main journal, timing sys

•Rivet the safety washer on the head-stock.UPON REFITTING, REPLACE THE SAFETY WASHER WITHA NEW ONE•Using the suitable special tool, un-screw and remov

•Fit a new safety washer.•Screw the upper ring nut manually and then slightly tighten the clamps on the plate so as toalign notches on the ring nut.Sp

Shock absorbersAdjustingThe rear suspension consists of a spring-shockabsorber unit linked to the frame via Silent-blockand to the rear fork via a lin

Specification Desc./QuantityRebound - half -load conditions 20 clicks starting from screw (1) fully tightenedRebound - maximum load conditions 18 clic

INDEX OF TOPICSCHASSIS CHASRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Swinging armRemoving•To remove the fork, first remove the footrest holding plate and the exhaust silencer.•Slide off the rear brake calliper from the

•Unscrew and remove the nut fixing thereaction rod.•Remove the screw.•Fix the reaction rod to the chassis witha clamp.•Remove the clamp from the dust

•Loosen the ring nut.Specific tooling05.91.26.30 Tool for tightening the swingarmpin ring nut - clutch hub•Helped by a second operator, removethe pin

Installing•Spread a thin layer of lubricatinggrease all along the swingarm pin.•Fit the ring nut in the swingarm pin andscrew it manually.•Working fro

•Fit the dust guard cap in the gearbox.•Lock the dust guard cap with a newclamp.•Place the reaction rod into its seat.•Insert the screw.•Screw the nut

•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 mea

Bevel gearsRemoving•Remove the rear wheel.•Unscrew and remove the two screws.•Remove the speed sensor from thefork.•Unscrew and remove the nut fixing

•Remove the transmission casing slid-ing off the universal joint.CheckingCasing unit removalRemove the cover (20).Remove the plug (3) to drain out the

Lift the cap (10).Remove the clamps (9) and (11).Remove the cap (14).Remove the screws (16).Collect the ring (15).Chassis Stelvio 1200 NTX ABSCHAS - 2

Remove the screws (7).Remove the casing (4).Remove the clamp (12).Remove the cap (14).Collect the ring (13).Stelvio 1200 NTX ABS ChassisCHAS - 223Reve

Remove the support unit (8).Casing unit fittingAssemble the dowel pins to the casing with thebuffer and a hammer.Assemble the casing to the special fa

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

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

Assemble the fixing screws (7).Tighten the screws (7) to the prescribed torque.Remove excessive sealant.Assemble the ring to the casing.Tighten the fi

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

REMOVALRemove the bearing from the wheel axle with asuitable extractor.Turn the unit over.Remove the bearing from the wheel axle with asuitable extrac

Product Description Specificationsexceed the requirements of SAE J1703,NHTSA 116 DOT 4, ISO 4925 syntheticfluid specifications.AGIP BRAKE 4 / BRAKE 5.

Turn the unit over.Assemble the bearings to the wheel axle.Pinion unitREMOVALRemove the stop ring (1) from the ring nut.Unscrew the ring nut (2) with

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 n

Insert the stop ring (1) in the ring nut (2) in the in-dicated direction.Assembly position of the stop ring (1).CAUTIONMAKE SURE THE STOP RING IS IN I

REMOVALRemove the bushing (1) with a punch.Turn the support (5) over and remove the otherbushing (8).Remove the sealing rings (2) and (7) with a screw

Remove the ball joint (4) with a suitable buffer anda rubber hammer.FITTINGFit the stop ring (6) in the support (5) with suitablepliers.Turn the suppo

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 a

Installing•Insert the transmission casing on theswingarm making sure that the univer-sal joint engages correctly.•Tighten the four screws to the presc

•Place the speed sensor and fasten thecable harness with the clamps.•Place the rear wheel on the fork.•Tighten the four screws with theirspacers and t

3. Gasket4. Flanged nut5. Washer6. Gasket7. Clamp8. Central exhaust pipe9. TE flanged screw10.Silent-block11.Flanged self-locking nut12.Lambda probe13

•Remove the exhaust end.Removing the manifold - tail pipe•Remove the exhaust end and the ex-haust manifolds.•Remove the starter motor protection inord

INDEX OF TOPICSSPECIAL TOOLS S-TOOLSRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

•Unscrew and remove the two nuts onthe head exhaust stud bolts.•Retrieve the washers.•Loosen the clamp.•Remove the exhaust manifold.Engine oil coolerK

3. T-shaped bushing4. Rubber ring5. Radiator support6. TCEI screw7. ClipRemovingIt is necessary to remove the metal oil sump guardin order to change t

•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

INDEX OF TOPICSBRAKING SYSTEMBRAK SYSRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

ABSForewordkey:1. Front brake pipe2. Oil pipe screw3. Aluminium gasket4. Front brake pipe5. Control unit/pump6. Brake pipe7. Rear brake pipe8. Screw9.

Operating diagramkey:The black arrow indicates brake fluid path when the ABS system is not working.The white arrow indicates the brake fluid path when

16) Front inlet valve17) Rear inlet valveABS OPERATIONGeneral specifications:•The front circuit is similar to the rear circuit.•The ABS inlet valve (1

ABS SYSTEM DESCRIPTIONThe ABS system is a device to avoid wheels lock-ing in case of emergency braking, increasing ve-hicle braking stability when com

Riding with an active ABS systemThe warning light (7) is off. If a failure is detected,the warning light (7) turns on permanently to indi-cate the mal

10A fuse (6)Protects: the whole system safetyAs the ABS system operates through reading the speed of the front and rear wheels, be extremelycareful wh

ENGINEStores code Description020677Y Alternator belt tensioner, Belt tensioninglever05.91.17.30 Front cover insertion cone020716Y Connecting rod locki

Parameter reading screen pageENGINE PARAMETER READINGThis screen page shows the parameters meas-ured by the several sensors (engine revs, enginetemper

Devices activation screen pageDEVICES ACTIVATIONThis screen page is used to delete errors in thecontrol unit memory and to activate some systemscontro

If the 10A fuse is defective, the ABS warning light remains on. Axone does not communicate with theABS module. That is, it is not valid in case of fai

Checks: check the speed sensor signal (0.5 or 1 V) on the orange/purple cable between pin 1 of thefront speed sensor connector and pin 22 of the ABS m

Description of the defect: the control unit detects a failure in the valve operation. Checks: make surethat the voltage in pin 25 of the ABS control u

Modulator•Remove the saddle.•Remove the battery.•Disconnect the ABS control unit con-nector.•Empty the brake fluid from the pipesinto a container, dis

WHEN THE ABS CONTROL UNIT IS REPLACED, IT IS SUPPLIED ALREADY FILLED WITH BRAKEFLUID; THEREFORE, THE CONTROL UNIT HAS TO BE ASSEMBLED ON THE VEHICLE A

Rear brake calliperKey:1. Rear brake calliper2. Screw3. Pads4. Pin + calliper split pin5. Spring6. Gasket7. Screw8. Air bleed9. Air bleed cap10.Rear b

Front brake calliperKey:1. Front right brake calliper2. Front left brake calliper3. Pads4. Air bleed5. Air bleed cap6. Pins + Calliper springs7. Sprin

Removal•Unscrew and remove the two screws.•Slide off the brake calliper from thedisc.•Turn the pins and remove both splitpins.•Remove both pins.•Remov

Stores code Description05.90.25.30 Gearbox support19.92.96.00 Graduated dial to control ignition timing17.94.75.60 Arrow to control ignition timing12.

•Extract one pad at a time.CAUTIONAFTER REMOVING THE PADS, DO NOT OPERATE THEBRAKE CONTROL LEVER OR THE CALLIPER PLUNGERSCOULD GO OUT OF THEIR SEATS R

Rear brake padsRemoval•Undo and remove the two screws.•Remove the brake calliper from thedisc.•Turn the pin and pull out the split pin.•Remove the spl

•Extract one pad at a time.CAUTIONAFTER REMOVING THE PADS, DO NOT OPERATE THEBRAKE CONTROL LEVER OR THE CALLIPER PLUNGERSCOULD GO OUT OF THEIR SEATS R

Bleeding the braking systemFrontAny air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied bythe brake pump an

•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 obtain

then repeat the operation until air nolonger escapes.•Screw the bleed valve and remove the pipe.•Top-up the reservoir until the right brake fluid leve

INDEX OF TOPICSBODYWORK BODYWRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Seat•Rest the vehicle on its stand.•Insert the key in the saddle lock.•Turn the key clockwise and slightlypress the centre of the passenger seatrear p

•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

•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) (M8x

Stores code Description14.92.71.00 Tool to fit the sealing ring on the flywheel-side flange12.91.20.00 Tool to fit the flywheel-side flange togeth-er

•Disconnect the instrument panel con-nector.Supplementary light mountENSURE THAT THE ENGINE AND THE THERMAL PARTS OF THE VEHICLE ARE COLD BEFOREOPERAT

Additional lights•Disconnect the additional headlampsconnectors.•Slide off the cables from the openingnear the arrows between the side fair-ings and f

•Undo and remove the lower screw andcollect the two washers and thespacer.•Undo and remove the lower screw andcollect the washer and the spacer.•Disco

•Undo and remove the front lowerscrew.•Undo and remove the three screws.•Remove the right under seat fairing.•Disconnect the connectors of the rearbra

•Unscrew and remove the screw.•Detach the rear brake fluid reservoirbut keep it connected to the pipe.•Remove the right footrest plate, keeping the br

•Detach the fairing.•Disconnect the glove-box compart-ment opening cable.•Undo and remove the two front screws.•Operating from both sides, undo andrem

•Undo and remove the four screws.•Remove the headlight lower cover.•Unscrew and remove the two screws.•Operating from both sides, disconnectthe turn i

Air box•Remove the saddle.•Remove the passenger grab handle.•Undo and remove the two screws andcollect the cable guide.•Disconnect the air temperature

•Disconnect the rear light connectors•Release the clutch bleeding pipe fromthe cable guide.•Operating from both sides, undo andremove the three screws

•Remove the two breather pipes.•Operating from both sides, undo andremove the stud bolt.•Remove the filter casing.See alsoSeatSump guardENSURE THAT TH

Stores code Description020676Y Comparator support for piston positionchecking020678Y Tool for clutch rod checking05.91.25.30 Gearbox openingCHASSISSto

•Remove the four TCEI 8x40 screws (1)(two on each side)•Be careful to collect the four spacerbushings inside the sump guard.NOTEFOR REFITTING, FOLLOW

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-mo

•Lift the rear part of the fuel tank fairing.•Disconnect the pipes.•Remove the fuel tank fairing.See alsoSeatFUEL TANK•Remove the tank side fairings.•

•Lift the tank and disconnect the fuelpipe.•Disconnect the fuel pump connector.•Remove the fuel tank.See alsoSide fairingsPannier mounting•Remove the

•Remove the spacers (6) and (8).•Remove the components (11) to (16)from both supports.Bodywork Stelvio 1200 NTX ABSBODYW - 284Revente Interdite - Reve

INDEX OF TOPICSPRE-DELIVERY PRE DERevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Carry out the listed checks before delivering the vehicle.WARNINGBE EXTREMELY CAUTIOUS WHEN HANDLING FUEL.Aesthetic inspection- Paintwork- Fitting of

- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, ifrequired, program the control unit/s again:

- Response to throttle control- Stability when accelerating and braking- Front and rear brake efficiency- Front and rear suspension efficiency- Abnorm

AABS: 244, 249Air filter: 37BBattery: 56, 63Brake: 257, 258, 261CClutch: 78, 126, 129, 162Clutch lever: 78DDisplay: 188, 251EEngine oil: 34, 76, 240FF

BEVEL GEAR PAIRStores code Description05.90.27.30 Gearbox support05.90.27.31 Gearbox oil seal buffer05.90.27.32 Buffer handgrip05.90.27.33 Ball joint

TTank: 86, 120, 280Transmission: 12, 32Tyres: 14Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

SERVICE STATION MANUALStelvio 1200 NTX ABSThis manual provides the main information to carry out regular maintenance operations on your vehicle.This m

Stores code Description05.90.27.36 Bevel gear pair supportFRONT FORKStores code DescriptionAP8140146 WeightAP8140149 Protection for fitting operations

INDEX OF TOPICSMAINTENANCE MAINRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Maintenance chartNOTECARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VE-HICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS,

Check• Keep the vehicle upright with both wheels on theground.• Unscrew and remove the cap/dipstick (1).• The level is correct if the oil is close to

Engine oilCheckCAUTIONENGINE MUST BE WARM TO CHECK ENGINE OIL LEVELNOTEDO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE

•Place a container with +4,000 cm³ (244cu in) capacity under the drainage plug(3).•Unscrew and remove the drainageplug (3).•Pull out the oil filler pl

Gearbox OilInspectionCHECKING AND TOPPING UPCAUTIONENGINE MUST BE WARM TO CHECK GEARBOX OIL LEVEL.NOTEDO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT S

• Pour in new oil until it reaches the dipstick open-ing (1).• Tighten the filler cap (1).CAUTIONDO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TOTHE FLU

•Disconnect both spark plug tubes.•Unscrew and remove the four headcover fixing screws and collect thesealing O-rings.•Remove the head cover together

•For the rear brake, keep the vehicle upright so that the fluid in the reservoir is at the samelevel with the plug.•Make sure that the fluid level in

Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

WHEN USING A FUNNEL OR ANY OTHER ELEMENT,MAKE SURE IT IS PERFECTLY CLEAN.DO NOT EXCEED THE "MAX" LEVEL MARK WHEN TOP-PING UP.TOP-UP TO "

INDEX OF TOPICSELECTRICAL SYSTEM ELE SYSRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Components arrangementkey:1 Coil2 Instrument panel3 Fuel pump4 InjectorElectrical system Stelvio 1200 NTX ABSELE SYS - 42Revente Interdite - Revendita

5 Throttle valve potentiometer6 Fall sensor7 Rear light8 Main fuses9 Lambda probe10 Battery11 Starter motor12 Intake air temperature sensor13 Engine r

FRONT SECTIONTABLE A•Clamp the brake pipes with the throttlegrip transmission and right light switchproperly.•Clamp the clutch pipes with the clutchsw

•Clamp the left headlight cable (3), theleft turn indicator (4) and the TOM TOMcable (5).•Clamp the heated handgrips cable.Stelvio 1200 NTX ABS Electr

TABLE D - ABS SENSOR SYSTEM CLAMPS•Clamp in the indicated points.Central partCAUTIONONCE THE ELECTRICAL SYSTEM IS REFITTED, THE CONNECTORS RECONNECTED

TABLE B - RED CLAMP STARTING POINT INTHE ELECTRICAL SYSTEM•The red clamp must start from the pointindicated.•The cable of heated handgrips mustcome ou

•The connection must be between thechassis and the air filter.TABLE D - LAMBDA PROBE SYSTEM CLAMP-ING•Clamp the stand system with the returnpipes in s

CIAL CHECKS FOR THE CORRECT CONNECTION AND LAYING OF CABLES" IN THE "ELEC-TRICAL SYSTEM INSTALLATION" SECTION.REAR SECTIONTABLE A - COR

INDEX OF TOPICSCHARACTERISTICS CHARSPECIAL TOOLS S-TOOLSMAINTENANCE MAINELECTRICAL SYSTEM ELE SYSENGINE FROM VEHICLE ENG VEENGINE ENGPOWER SUPPLY P SU

Electrical system Stelvio 1200 NTX ABSELE SYS - 50Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

General wiring diagramkey:1. Multiple connectors2. Clutch switch3. Start-up relay4. Start-up maintenance relayStelvio 1200 NTX ABS Electrical systemEL

5. Light relay6. Fog lights relay7. Right light switch8. Left light switch9. Horn10.Instrument panel air temperature thermistor11.Instrument panel12.I

43.Left cylinder spark plug44.Right cylinder coil45.Left cylinder coil46.Right cylinder injector47.Left cylinder injector48.---49.Fall sensor50.Flywhe

Vi purpleChecks and inspectionsDashboardDiagnosisChanging the CODEIf you know the code, just enter it and then a new code that will be automatically s

Engine Temperature Error DC Gnd ECU 15Air Temperature Error DC V DC ECU 16Air Temperature Error DC Gnd ECU 17Low Battery Error ECU 20Lambda Probe Erro

Description: Oil pressure failure. Error code: DSB 08The instrument panel keeps all previous errors stored in its memory.DELETE ERRORSThis option dele

Checking the statorSingle-phase generator with regulated voltageMaximum load 40A (550W)Charging voltage 14.2 - 14.8 V (5000 rpm)Start-up system checkp

Lights listFRONT HEADLAMPSpecification Desc./QuantityFront daylight running light 12V - 5WLow/high beam headlight (halogen) 12 V - 55 W / 60 W H4REAR

FusesMAIN FUSES1 - Battery recharge (40 A).2 - Motion main fuse (30 A).NOTETHERE IS ONE SPARE FUSE.ABS MAIN FUSES3 - ABS main fuse (40 A).4 - ABS main

INDEX OF TOPICSCHARACTERISTICS CHARRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Control unitModel: Magneti Marelli IAW 5 AM2BROWN connector pin configurationPin Use1 Not used2 Not used3 Ignition potentiometer signal4 Not used5 Eng

27 Not used28 Left cylinder injector control29 Ignition potentiometer power supply30 Not used31 Not used32 Ignition potentiometer negative33 Not used3

25 Not used26 Not used27 "Engine stop" signal input28 Ignition signal input29 CAN - L line (ccm/instrument panel)30 Not used31 Not used32 Ox

23 Not used24 Not used25 ABS pump supply26 Not used27 ABS deactivation switch28 Not used29 Not used30 Not used31 Rear (ABS) speed sensor (signal / gro

Location:•Sensor: Front left side of the engine,under the generator.•Connector: Under the fuel tank.Electrical characteristics:•Winding resistance 650

Throttle position sensorFunctionIn charge of telling the control unit the position ofthe throttle valves.Operation / operating principleThe throttle v

Example value:open circuit, shorted to positive / shorted to negative.Error cause•If the circuit is open, shorted to positive: excessive voltage has b

•sensor: inside the "V"•connector: on the sensorElectrical characteristics:ENGINE TEMPERATURE SENSOR RESISTANCESpecification Desc./Quantity1

•If the circuit is open, shorted to positive: check the sensor connector and the Marelli controlunit connector. If they are not OK, restore the cable

Specification Desc./Quantity2 Resistance at 0 °C (32 °F) 9.750 kOhm3 Resistance at 10 °C (50 °F) 5.970 kOhm4 Resistance at 20 °C (68 °F) 3.750 kOhm5 R

RulesSafety rulesCarbon monoxideIf you need to keep the engine running while working on the vehicle, please ensure that you do so inan open or very we

Lambda sensorFunctionIt tells the control unit whether combustion is leanor rich.Operation / Operating principleThe Marelli injection control unit rea

Closed loop indicates that the control unit is using the lambda probe signal to keep the combustion asclose as possible to the stoichiometric value.AX

InjectorFunctionTo supply the correct amount of petrol at the righttiming.Operation / Operating principleInjector coil is excited for the petrol passa

•Shorted to positive: disconnect the injector connector, take the key to ON and check if thereis voltage on the grey/red cable: if there is voltage, r

between PIN 37 of the BROWN connector and the component PIN - and restore the cableharnessCoilFunctionIt controls the ignition spark plug in order to

•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 e

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

It this error persists, use a pressure gauge to check the pressure of the oil in the enginecircuitNeutral sensorFunctionit tells the gear position to

that the grey/black cable from PIN 1 of the sensor to PIN 23 of the BROWN connector isshorted to ground: restore the cable harness.Clutch lever sensor

the sensor. If the circuit is open, it means that the brown/purple cable from PIN 1 of thesensor to PIN 33 of the BLUE connector is shorted to ground:

BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COM-PON

Bank angle sensorFunctionit tells the vehicle position to the control unit.Operation / Operating principleWhen the sensor is inverted, the circuit is

Air temperature sensor - instrument panelFunctionIt tells the ambient air temperature to the instru-ment panel.Operation / Operating principleNTC type

If a short circuit to ground is detected at PIN 10 of the instrument panel connector, the display will showa full scale temperature indication of 60°C

27 of the BLUE connector: if not OK, restore the cable harness; if OK, replace the Marellicontrol unit.•Indication on Axone always RUN: disconnect the

19 GENERAL GROUND (OPTIONAL)20 GENERAL GROUND (OPTIONAL)The pin configuration of the BLACK-bodied connector is as follows:PIN USE21 + BATTERY22 FRONT

INDEX OF TOPICSENGINE FROM VEHICLE ENG VERevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

Vehicle preparationBefore removing the engine block, proceed as follows:•Park the vehicle on its centre stand.•From the back, secure the vehicle with

•Remove the starter motor cover.•Unscrew and remove the stud bolt.•Disconnect the ground leads.•Disconnect the starter motor connec-tors.•Disconnect t

•Disconnect the neutral sensor connec-tor.•Disconnect the horn connectors.•Operating from both sides, undo andremove the screw fixing the oil radiator

•Working on both sides disconnect theinjector connectors.•Working from both sides, undo and re-move the three inlet manifold screws.•Collect the gaske

•Keep mated parts together since they have "adjusted" to each other due to normal wear.•Some components must be used together or replaced al

•Disconnect the engine temperaturesensor connector•Disconnect the engine oil pressuresensor connector.•Disconnect the revolution sensor con-nector.•Re

•Working on both sides, unscrew andremove the front screw and collect thewasher.•Operating from both sides, undo andremove the upper engine fixing nut

Installing the engine to the vehicle•Place the vehicle chassis over the en-gine with the gear.•From the back, secure the chassis withbelts attached to

•Operating from both sides, tighten theupper engine fixing nut on the internalside of the chassis.•Fit the centre stand.•Operating from both sides, ti

•Insert the oil breather pipe and fastenit with a new clamp.•Fit the gearbox oil breather pipe.•Fit the clutch control cylinder.•Tighten the three scr

•Connect the ground leads and tightenthe stud bolt.•Fit the starter motor cover.•Tighten the screws.•Connect the neutral sensor connector.•Connect the

•Connect the revolution sensor connec-tor.•Connect the horn connectors.•Connect the engine temperature sen-sor connector.•Place the oil radiator.•Tigh

•Place the fork with cardan shaft and therear wheel.•Working on both sides, connect the in-jector connectors.•Adjust the throttle grip cable clearance

INDEX OF TOPICSENGINE ENGRevente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten

GearboxDiagramKey:1. Ball bearingStelvio 1200 NTX ABS EngineENG - 99Revente Interdite - Revendita Vietata - Resaling Forbiden - Wiederverkauf Verboten