SERVICE STATION MANUAL
B043090
Stelvio 1200 NTX MY11
SERVICE STATION
MANUAL
Stelvio 1200 NTX MY11
THE VALUE OF SERVICE
Only the mechanics of the Official Moto Guzzi Service Network know this vehicle well, thanks to constant
technical professional development and Moto Guzzi specific training programmes, and have the tools
needed to carry out maintenance and repair operations correctly.
The reliability of the vehicle also depends on its mechanical conditions. Checking the vehicle before riding
it, carrying out routine maintenance and using only Moto Guzzi Original Spare parts is fundamental!
For information about the nearest Official Dealer and/or Service Centre, consult the Yellow Pages or
search directly on the inset map in our Official Website:
www.motoguzzi.it
Only by purchasing Moto Guzzi Original Spare Parts will you get a product designed and tested during
the bike designing phase. Moto Guzzi Original Spare Parts are subject to systematic quality control
procedures so that their reliability and performance over time is guaranteed.
The descriptions and illustrations given in this publication are not binding; While the basic features as
described and illustrated in this booklet remain unchanged, Moto Guzzi reserves the right, at any time
and without being required to update this publication beforehand, to make any changes to components,
parts or accessory supplies, which it deems necessary to improve the product or which are required for
manufacturing or commercial reasons.
Not all versions/models shown in this publication are available in all countries. The availability of individual
versions should be checked with the Official Moto Guzzi sales network.
© Copyright 2011- Moto Guzzi. All rights reserved. Reproduction of this publication in whole or in part is
prohibited. Moto Guzzi - After sales service.
The Moto Guzzi brand is owned by Piaggio & C. S.p.A.
SERVICE STATION MANUAL
Stelvio 1200 NTX MY11
This manual provides the main information to carry out regular maintenance operations on your scooter.
This manual is intended to Moto Guzzi Dealers and their qualified mechanics; several concepts have
been deliberately omitted as they are considered unnecessary. As it is not possible to include complete
mechanical notions in this manual, users should have basic mechanical knowledge or minimum
knowledge about the procedures involved when repairing scooters. Without this knowledge, repairing or
checking the vehicle may be inefficient or even dangerous. As the vehicle repair and check procedures
are not described in detail, be extremely cautious so as not to damage components or injure individuals.
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. These changes will be introduced in the subsequent editions of the manual. In case of
need or further queries on repair and check procedures, consult Moto Guzzi CUSTOMER
DEPARTMENT, which will be prepared to provide any information on the subject and any further
communications on updates and technical changes related to the vehicle.
2011
NOTE Provides key information to make the procedure easier to understand and carry out.
CAUTION Refers to specific procedures to carry out for preventing damages to the vehicle.
WARNING Refers to specific procedures to carry out to prevent injuries to the repairer.
Personal safety Failure to completely observe these instructions will result in serious risk of personal
injury.
Safeguarding the environment Sections marked with this symbol indicate the correct use of the vehicle
to prevent damaging the environment.
Vehicle intactness The incomplete or non-observance of these regulations leads to the risk of serious
damage to the vehicle and sometimes even the invalidity of the guarantee
INDEX OF TOPICS
CHARACTERISTICS CHAR
SPECIAL TOOLS S-TOOLS
MAINTENANCE MAIN
ELECTRICAL SYSTEM ELE SYS
ENGINE FROM VEHICLE ENG VE
ENGINE ENG
POWER SUPPLY P SUPP
SUSPENSIONS SUSP
CHASSIS CHAS
BRAKING SYSTEM BRAK SYS
BODYWORK BODYW
PRE-DELIVERY PRE DE
INDEX OF TOPICS
CHARACTERISTICS CHAR
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.
CAUTION
EXHAUST EMISSIONS CONTAIN CARBON MONOXIDE, A POISONOUS GAS WHICH CAN CAUSE
LOSS OF CONSCIOUSNESS AND EVEN DEATH.
Fuel
CAUTION
THE FUEL USED TO POWER INTERNAL COMBUSTION ENGINES IS HIGHLY FLAMMABLE AND
MAY BE EXPLOSIVE UNDER CERTAIN CONDITIONS. IT IS THEREFORE RECOMMENDED TO
CARRY OUT REFUELLING AND MAINTENANCE PROCEDURES IN A VENTILATED AREA WITH
THE ENGINE SWITCHED OFF. DO NOT SMOKE DURING REFUELLING AND NEAR FUEL VAPOURS, AVOIDING ANY CONTACT WITH NAKED FLAMES, SPARKS OR OTHER SOURCES
WHICH MAY CAUSE THEM TO IGNITE OR EXPLODE.
DO NOT DISPERSE FUEL IN THE ENVIRONMENT.
KEEP OUT OF THE REACH OF CHILDREN
Hot components
The engine and the exhaust system components become very hot and remain hot for some time after
the engine has been switched off. When handling these components, wear insulating gloves or wait
until the engine and the exhaust system have cooled down.
Used engine oil and transmission oil
CAUTION
IT IS ADVISABLE TO WEAR PROTECTIVE IMPERMEABLE GLOVES WHEN SERVICING THE VEHICLE.
THE ENGINE OR GEARBOX OIL MAY CAUSE SERIOUS INJURIES TO THE SKIN IF HANDLED
FOR PROLONGED PERIODS OF TIME AND ON A REGULAR BASIS.
WASH YOUR HANDS CAREFULLY AFTER HANDLING OIL.
HAND THE OIL OVER TO OR HAVE IT COLLECTED BY THE NEAREST USED OIL RECYCLING
COMPANY OR THE SUPPLIER.
DO NOT DISPOSE OF OIL IN THE ENVIRONMENT
KEEP OUT OF THE REACH OF CHILDREN
Stelvio 1200 NTX MY11 Characteristics
CHAR - 7
Brake and clutch fluid
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.
WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM, PROTECT THESE COM-
PONENTS WITH A CLEAN CLOTH. ALWAYS WEAR PROTECTIVE GOGGLES WHEN SERVICING
THESE SYSTEMS. BRAKE AND CLUTCH FLUIDS ARE EXTREMELY HARMFUL FOR YOUR
EYES. IN THE EVENT OF ACCIDENTAL CONTACT WITH THE EYES, RINSE THEM IMMEDIATELY
WITH ABUNDANT COLD, CLEAN WATER AND SEEK MEDICAL ADVICE.
KEEP OUT OF THE REACH OF CHILDREN
Battery electrolyte and hydrogen gas
CAUTION
THE BATTERY ELECTROLYTE IS TOXIC, CORROSIVE AND AS IT CONTAINS SULPHURIC ACID,
IT CAN CAUSE BURNS WHEN IN CONTACT WITH THE SKIN. WHEN HANDLING BATTERY
ELECTROLYTE, WEAR TIGHT-FITTING GLOVES AND PROTECTIVE APPAREL. IN THE EVENT
OF SKIN CONTACT WITH THE ELECTROLYTIC FLUID, RINSE WELL WITH PLENTY OF CLEAN
WATER. IT IS PARTICULARLY IMPORTANT TO PROTECT YOUR EYES BECAUSE EVEN TINY
AMOUNTS OF BATTERY ACID MAY CAUSE BLINDNESS. IF THE FLUID GETS IN CONTACT WITH
YOUR EYES, WASH WITH ABUNDANT WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE
SPECIALIST IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY
FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER HEAT SOURCES. ENSURE ADE-
QUATE VENTILATION WHEN SERVICING OR RECHARGING THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN
BATTERY LIQUID IS CORROSIVE. DO NOT POUR IT OR SPILL IT, PARTICULARLY ON PLASTIC
COMPONENTS. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BAT-
TERY TO BE ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle follow the recommendations reported below
carefully.
BEFORE REMOVING COMPONENTS
•
Before dismantling components, remove dirt, mud, dust and foreign bodies from the vehicle.
Use the special tools designed for this bike, as required.
COMPONENTS REMOVAL
•
Do not loosen and/or tighten screws and nuts using pliers or any other tools than the specific
wrench.
•
Mark the positions on all connection joints (pipes, cables, etc.) before separating them, and
identify them with different distinctive symbols.
•
Each component needs to be clearly marked to enable identification during reassembly.
•
Clean and wash the dismantled components carefully using a low-flammability detergent.
•
Keep mated parts together since they have "adjusted" to each other due to normal wear.
Characteristics Stelvio 1200 NTX MY11
CHAR - 8
•
Some components must be used together or replaced altogether.
•
Keep away from heat sources.
REASSEMBLY OF COMPONENTS
CAUTION
BEARINGS MUST BE ABLE TO 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.
•
When tightening nuts and screws, start from the ones with the largest section or from the
internal ones, moving diagonally. Tighten nuts and screws in successive steps before applying the tightening torque.
•
Always replace self-locking nuts, washers, sealing rings, circlips, O-rings (OR), cotter pins
and screws with new ones if their tread is damaged.
•
When assembling the bearings, make sure to lubricate them well.
•
Check that each component is assembled correctly.
•
After a repair or routine maintenance procedure, carry out pre-ride checks and test the vehicle on private grounds or in an area with low traffic density.
•
Clean all coupling surfaces, oil guard rims and gaskets before refitting them. Smear a light
layer of lithium-based grease on the oil guard rims. Reassemble oil guards and bearings
with the brand or lot number facing outward (visible side).
ELECTRIC CONNECTORS
Electric connectors must be disconnected as described below; failure to comply with this procedure
causes irreparable damage to both the connector and the cable harness:
Press the relevant safety hooks, if any.
•
Grip the two connectors and disconnect them by pulling them in opposite directions.
•
If any signs of dirt, rust, moisture, etc. are noted, clean the inside of the connector carefully
with a jet of compressed air.
•
Ensure that the cables are correctly fastened to the internal connector terminals.
•
Then connect the two connectors, ensuring that they couple correctly (if fitted with clips, you
will hear them "click" into place).
CAUTION
TO DISCONNECT THE TWO CONNECTORS, DO NOT PULL THE CABLES.
NOTE
THE TWO CONNECTORS CONNECT ONLY FROM ONE SIDE: CONNECT THEM THE RIGHT WAY
ROUND.
TIGHTENING TORQUES
CAUTION
IF UNSCREWING A SELF-LOCKING NUT, IT MUST BE REPLACED WITH A NEW ONE.
CAUTION
DO NOT FORGET THAT THE TIGHTENING TORQUES OF ALL FASTENING ELEMENTS ON
WHEELS, BRAKES, WHEEL BOLTS AND ANY OTHER SUSPENSION COMPONENTS PLAY A
Stelvio 1200 NTX MY11 Characteristics
CHAR - 9
KEY ROLE IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES.
CHECK THE TIGHTENING TORQUES OF FASTENING PARTS ON A REGULAR BASIS AND AL-
WAYS USE A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COM-
PLY WITH THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO GET
LOOSE AND EVEN DETACHED, THUS BLOCKING A WHEEL, OR OTHERWISE COMPROMISE
VEHICLE HANDLING. THIS CAN LEAD TO FALLS, WITH THE RISK OF SERIOUS INJURY OR
DEATH.
Running-in
Engine run-in is essential to ensure engine long life and correct operation. Twisty roads and gradients
are ideal to run in engine, brakes and suspensions effectively. Vary your riding speed during the run-
in. This ensures that components operate under both "loaded" and "unloaded" conditions, allowing the
engine components to cool.
CAUTION
THE CLUTCH MAY EMIT A SLIGHT BURNING SMELL WHEN FIRST USED. THIS PHENOMENON
SHOULD BE CONSIDERED NORMAL AND WILL DISAPPEAR AS SOON AS THE CLUTCH
PLATES GET ADAPTED.
IT IS IMPORTANT TO STRAIN ENGINE COMPONENTS DURING RUN-IN, HOWEVER, MAKE SURE
NOT TO OVERDO THIS.
CAUTION
THE FULL PERFORMANCE OF THE VEHICLE IS ONLY AVAILABLE AFTER THE SERVICE AT
THE END OF THE RUNNING IN PERIOD.
Follow these guidelines:
•
Do not twist the throttle grip abruptly and completely when the engine is working at a low
revs, either during or after run-in.
•
During the first 100 Km (62 miles) use the brakes gently, avoiding sudden or prolonged
braking. 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.
Vehicle identification
SERIAL NUMBER LOCATION
These numbers are necessary for vehicle registration.
NOTE
ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PAR-
TICULAR, MODIFYING THE FRAME NUMBER IMMEDIATELY VOIDS THE WARRANTY.
Characteristics Stelvio 1200 NTX MY11
CHAR - 10
This number consists of numbers and letters, as in
the example shown below.
ZGULZG000YMXXXXXX
KEY:
ZGU: WMI (World manufacturer identifier) code;
LZ: model;
001: version variation;
0: free digit
Y year of manufacture
M: production plant (M= Mandello del Lario);
XXXXXX: serial number (6 digits);
CHASSIS NUMBER
The chassis number is stamped on the right hand
side of the headstock.
ENGINE NUMBER
The engine number is stamped on the left side,
close to the engine oil level check cap.
Dimensions and mass
WEIGHT AND DIMENSIONS
Specification
Desc./Quantity
Maximum width (without accessories) 2305 mm (90.75 in)
Maximum width at handlebar 956 mm (37.64 in)
Maximum width of vehicle with accessories 1080 mm (42.52 in)
Minimum / maximum height (adjustable windshield) 1436 / 1492 mm (56.53 / 58.74 in)
Saddle height 800 mm (31.5 in)
Minimum earth clearance 185 mm (7.3 in)
Wheelbase 1535 mm (60.43 in)
Kerb weight 281 kg (619.50 lb)
Kerb weight of full house vehicle 296 kg (652.57 lb)
Engine
ENGINE
Specification
Desc./Quantity
Type traverse-mounted twin-cylinder four-stroke V 90°
Cylinder number 2
Cylinder arrangement V 90°
Stelvio 1200 NTX MY11 Characteristics
CHAR - 11
Specification Desc./Quantity
Bore / stroke 95 x 81.2 mm (3.74 x 3.20 in)
Engine capacity 1151 cm³ (70 cu.in)
Compression ratio 11 : 1
Electric starter
Engine idle speed 1100 ± 100 rpm
Clutch hydraulically controlled single-plate dry clutch with incorpora-
ted flexible coupling
Lubrication system Pressure-fed, controlled by valves and trochoidal pump
Air filter cartridge-type dry filter
Cooling air and oil cooled with independent trochoidal pump and oil
pressure control valve
Timing system diagram single overhead camshaft with bucket tappets and rocker-op-
erated valves
Values valid with control clearance between rocker and valve intake: 0.15 mm (0.0059 in)
outlet: 0.20 mm (0.0079 in)
Transmission
TRANSMISSION
Specification Desc./Quantity
Primary drive Helical gears, ratio 26/35 = 1:1.346
Gearbox Mechanical, 6 speeds with foot lever on the left hand side of
the engine
Gear ratios, 1st gear 17/38 = 1:2.2353
Gear ratios, 2nd gear 20/34 = 1:1.7
Gear ratios, 3rd gear 23/31 = 1:1.3478
Gear ratios, 4th gear 26/29 = 1:1.1154
Gear ratios, 5th gear 31/30 = 1:0.9677
Gear ratios, 6th gear 29/25 = 1:0.8621
Final drive with U-joint
Ratio 12/44 = 1:3.6667
Capacities
CAPACITIES
Specification
Desc./Quantity
Engine oil Oil change and oil filter replacement: 3,500 cm³ (214 cu.in)
Gearbox oil 500 cm³ (30.5 cu.in)
Transmission oil 380 cm³ (23.2 cu.in)
Fork oil 650 cm³ (39.66 cu.in) (for each stem)
Fuel (reserve included) 32 l (7.04 UK gal)
Fuel reserve 7 l (1.54 UK gal)
Seats 2
Maximum weight limit 495 kg (1091.29 lb)
Electrical system
ELECTRICAL SYSTEM
Specification
Desc./Quantity
Spark plug NGK CR8EKB (long life)
Electrode gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Battery 12 V - 18 Ampere/hour
Alternator (permanent magnet type) 12 V - 550 W
Main fuses 20 (2) (1 ABS version only) - 30 (2) - 40 A
Secondary fuses 3 - 10 - 15A
Front daylight running lights 12V - 5W
Low/high beam light (halogen) 12 V - 55 W / 60 W H4
Turn indicators 12V - 10 W
Characteristics Stelvio 1200 NTX MY11
CHAR - 12
Specification Desc./Quantity
Rear daylight running light/stop light LED
Supplementary headlamps (if fitted) 12 V/55W - H3
Dashboard lighting LED
License plate light 12V - 5 W
Turn indicator warning light LED
Neutral gear warning light LED
Alarm-shift warning light LED
Side stand down warning light LED
Low fuel warning light LED
High beam warning light LED
ABS Warning Light LED
Frame and suspensions
CHASSIS
Specification Desc./Quantity
Type high strength tubular steel frame with engine as stressed ele-
ment
Trail 125 mm (4.92 in)
Headstock angle 27°
Front Upside down telescopic hydraulic fork, with 45mm (1.77 in) di-
am., stanchions and radial calliper mounting bracket with ad-
justable spring preload and hydraulic compression and re-
bound damping.
Front wheel travel 170 mm (6.69 in)
Rear single arm with progressive linkage, single shock absorber with
spring preload, hydraulic compression and rebound damping
adjustment.
Unloaded shock absorber spring length 180 mm (7.09 in)
Rear wheel travel 155 mm (6.10 in)
SIZES A AND B
Specification
Desc./Quantity
Size A 745.0 mm (29.33 in)
Size B 403.16 mm (15.87 in)
Brakes
BRAKES
Specification
Desc./Quantity
Front Ø 320-mm (12.6 in) stainless steel double floating disc, radial
callipers with 4 opposed pistons.
Rear Ø 282-mm (11.1 in) stainless steel disc, floating calliper with 2
different pins.
Stelvio 1200 NTX MY11 Characteristics
CHAR - 13
Wheels and tyres
WHEELS AND TYRES
Wheel Model Wheel rim Measure
ment
Tyre pressure with
rider only
Tyre pressure, rider +
passenger
Front (standard) H SPECIFIC Pirelli
Scorpion Trail
2.50 x 19" 110/80
R19 - 59V
2.5 bar (250 kPa) (36.3
PSI)
2.5 bar (250 kPa) (36.3
PSI)
Rear (standard) H SPECIFIC Pirelli
Scorpion Trail
4.25 x 17" 150/70
R17 - 69V
2.9 bar (290 kPa) (42.1
PSI)
2.9 bar (290 kPa) (42.1
PSI)
Front (only spoked
wheels)
Dunlop Trailmax TR91 2.50 x 19" 110/80
R19 - 59V
2.5 bar (250 kPa) (36.3
PSI)
2.5 bar (250 kPa) (36.3
PSI)
Rear (only spoked
wheels)
Dunlop Trailmax TR91 4.25 x 17" 150/70
R17 - 69V
2.9 bar (290 kPa) (42.1
PSI)
2.9 bar (290 kPa) (42.1
PSI)
THE USE OF M+S TYRES IS ALLOWED ONLY ON VEHICLES WITHOUT THE ABS SYSTEM.
WITH THIS TYRE TYPE, THE MAXIMUM SPEED ALLOWED IS 170 km/h (105.63 mi)
WHEN FITTING M+S TYRES, THE MAXIMUM SPEED WARNING LABEL (INCLUDED WITH
TYRES) MUST BE APPLIED TO THE SPEEDOMETER. USE EXTREME CAUTION WHEN RIDING
ON TARMAC ROADS WITH "OFF-ROAD / ALLROUND" TYRES AS THESE TYRES OFFER POOR
GRIP AND STABILITY ON TARMAC.
Supply
FUEL SYSTEM
Specification
Desc./Quantity
Fuel system Electronic injection (Weber . Marelli) with Stepper motor
Venturi diameter: 50 mm (1.97 in)
Fuel Premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)
Tightening Torques
Characteristics Stelvio 1200 NTX MY11
CHAR - 14
Front side
FRONT LIGHTS
pos.
Description Type Quantity Torque Notes
1 Horn fixing screw M6x20 1 15 Nm (11.06 lbf ft) 2 Viti fissaggio freccie anteriori M4 2 3 Nm (2.21 lbf ft) 3 Vite fissaggio superiore fanale a carozzeria M4 1 3 Nm (2.21 lbf ft) 4 Viti fissaggio fanale a carozzeria M4x25 2 3 Nm (2.21 lbf ft) 5 Viti TCEI fissaggio fanale a telaietto M5x25 5 6 Nm (4.42 lbf ft) -
Stelvio 1200 NTX MY11 Characteristics
CHAR - 15
INSTRUMENT PANEL
pos. Description Type Quantity Torque Notes
1 Viti TCEI fissaggio sensore velocità anteriore M5x16 2 6 Nm (4.42 lbf ft) 2 Viti TCEI fissaggio blocchetto avviamento M8x30 1 25 Nm (18.44 lbf ft) 3 Viti autofil. fissaggio supporto cruscotto 5x14 3 Manual 4 Viti autofil. fissaggio supporto cruscotto a cor-
nice
3.9x14 4 Manual -
5 Viti autofil. fissaggio cornice - 4 Manual 6 Viti TCE M5 2 6 Nm (4.42 lbf ft) -
FRONT FORK
pos.
Description Type Quantity Torque Notes
1 Viti piede forcella M8 1+1 25 Nm (18.44 lbf ft) 2 Viti chiusura mozzetti M6x30 2+2 10 Nm (7.38 lbf ft) 3 Fork cap - 1+1 - Nm (-.- lbf ft) -
Characteristics Stelvio 1200 NTX MY11
CHAR - 16
STEERING
pos.
Description Type Quantity Torque Notes
1 Viti fissaggio piastra fermatubi - 2 6 Nm (4.42 lbf ft) 2 Viti fissaggio piastre M8x30 6 20 Nm (14.75 lbf ft) 3 Headstock ring nut - 1 40 Nm (29.50 lbf ft) 4 Headstock counter-lock ring - 1 manual + 90 degrees 5 Upper yoke fixing cap - 1 100 Nm (73.76 lbf ft) -
Stelvio 1200 NTX MY11 Characteristics
CHAR - 17
CARROZZERIA ANTERIORE - CONVOGLIATORI
pos. Description Type Quantity Torque Notes
1 Viti TBEI Flang. fissaggio convogliatori M5x9 2 6 Nm (4.42 lbf ft) 2 Viti TBEI Flang. fissaggio convogliatori M5 2 6 Nm (4.42 lbf ft) 3 Viti SWP Autofil. fissaggio telaietto griglie 2.9x12 4 Manual -
CARROZZERIA ANTERIORE - CUPOLINO
pos.
Description Type Quantity Torque Notes
1 Viti fissaggio parabrezza M6 4 10 Nm (7.38 lbf ft) 2 Viti TBEI Flang. fissaggio cupolino M5x12 4 6 Nm (4.42 lbf ft) 3 Viti fissaggio deflettori superiori M5 4 6 Nm (4.42 lbf ft) 4 Colonnette fissaggio deflettori M5 2 6 Nm (4.42 lbf ft) 5 Viti TE Flang. fissaggio staffa parabrezza M6x16 4 10 Nm (7.38 lbf ft) 6 Perno filettato fissaggio supporto parabrezza M8 2 25 Nm (18.44 lbf ft) 7 Viti TBEI Flang. fissaggio deflettori inferiori M5 2 Manual -
Characteristics Stelvio 1200 NTX MY11
CHAR - 18
FRAME
pos.
Description Type Quantity Torque Notes
1 TCEI frame fixing screws M8x40 2 25 Nm (18.44 lb ft) 2 TE Screws Flang. M6x20 2 10 Nm (7.38 lb ft) -
HANDLEBAR AND CONTROLS
pos.
Description Type Quantity Torque Notes
1 TCC handlebar upper U-bolt fixing screws M8x30 4 25 Nm (18.44 lb ft) -
Stelvio 1200 NTX MY11 Characteristics
CHAR - 19
pos. Description Type Quantity Torque Notes
2 TE handlebar lower U-bolt flanged fixing
screws
M10 2 50 Nm (36.88 lb ft) Loct. 243
3 Self-tapp. screw - 1 1.5 Nm (1.11 lb ft) 4 Anti-vibration counterweight fastener connec-
tion
M18x15 2 - Nm (-.-- lb ft) -
5 TCEI anti-vibration counterweight fastener
screws
- 2 10 Nm (7.38 lb ft) Loct. 243
6 Rear-view mirror fixing connections M10 2 30 Nm (22.13 lb ft) -
FRONT BRAKE LEVER
pos.
Description Type Quantity Torque Notes
1 Viti TBEI fissaggio interruttore M4x12 1 3 Nm (2.21 lbf ft) 2 Lever pin M6 1 5-7 Nm (3.69-5.16 - lbf ft) 3 Viti fissaggio tappo serbatoio - 2 0.8-1.5 Nm (0.59-1.11 lbf
ft)
-
4 Dado perno leva M6 1 10 Nm (7.38 - lbf ft) 5 Viti fissaggio cavallotto M6 2 10 Nm (7.38 lbf ft) 6 Viti fissaggio tubo olio M10 1 23-26 Nm (16.96-19.18 lbf
ft)
-
Characteristics Stelvio 1200 NTX MY11
CHAR - 20
CLUTCH CONTROL
pos.
Description Type Quantity Torque Notes
1 Viti fissaggio tubo olio M10 3 23-26 Nm (16.96-19.18 lbf
ft)
-
2 Viti TE Flang. fissaggio cilindro comando fri-
zione
M6 3 10 Nm (7.38 lbf ft) -
3 Viti fissaggio tappo serbatoio - 2 0.8-1.5 Nm (0.59-1.11 lbf
ft)
-
4 Lever pin - 1 5-7 Nm (3.69-5.16 lbf ft) 5 Dado perno leva M6 1 10 Nm (7.38 lbf ft) 6 Viti fissaggio cavallotto - 2 10 Nm (7.38 lbf ft) -
Stelvio 1200 NTX MY11 Characteristics
CHAR - 21
FRONT MUDGUARD
pos.
Description Type Quantity Torque Notes
1 Viti TBEI Flang. fissaggio parafango anteriore M5x12 6 6 Nm (4.42 lbf ft) -
FRONT WHEEL
pos.
Description Type Quantity Torque Notes
1 Viti TE Flang. fissaggio dischi freno M8x20 12 25 Nm (18.44 lbf ft) 2 Nut fixing wheel pin - 1 80 Nm (59.00 lbf ft) 3 Vite flang. fissaggio sensore - 1 6 Nm (4.42 lbf ft) Loct. 243
Characteristics Stelvio 1200 NTX MY11
CHAR - 22
pos. Description Type Quantity Torque Notes
4 Vite TCB fissaggio passacavo M4x6 1 3 Nm (2.21 lbf ft) -
FRONT BRAKE CALLIPERS
pos.
Description Type Quantity Torque Notes
1 Viti TE Flang. fissaggio pinze M10x55 4 50 Nm (36.88 lbf ft) -
Central part
Stelvio 1200 NTX MY11 Characteristics
CHAR - 23
MAIN CABLE HARNESS
pos. Description Type Quantity Torque Notes
1 Viti TE Flang. fissaggio piastre bobine M6x20 2+2 10 Nm (7.38 lbf ft) 2 Viti TCEI fissaggio bobine - 2+2 2 Nm (1.47 lbf ft) 3 Viti TCEI fissaggio centralina - 2 10 Nm (7.38 lbf ft) 4 Viti TCEI fissaggio supporto sensore temp.
olio
M10x20 1 11 Nm (8.11 lbf ft) Loct. 243
5 Viti TCEI fissaggio sensore di fase - 2 3 Nm (2.21 lbf ft) -
CAVALLETTO CENTRALE E LATERALE
pos.
Description Type Quantity Torque Notes
1 Viti TCEI fissaggio cavalletto centrale M10x30 2 50 Nm (36.88 lbf ft) Loct. 270
2 Viti TE Flang. fissaggio piastre M8 2 25 Nm (18.44 lbf ft) 3 Screw M8x35 1 25 Nm (18.44 lbf ft) 4 Viti TBEI fissaggio piastre M12x35 4 80 Nm (59.00 lbf ft) 5 Viti TCEI fissaggio interruttore cavalletto M5 2 6 Nm (4.42 lbf ft) Loct. 243
7 Dado fissaggio cavalletto laterale M10 1 30 Nm (22.13 lbf ft) Loct. 243
Characteristics Stelvio 1200 NTX MY11
CHAR - 24
COMANDO CAMBIO
pos.
Description Type Quantity Torque Notes
1 Viti TCEI fissaggio leva rinvio cambio M6x20 1 10 Nm (7.38 lbf ft) 2 Dadi fissaggio tirante - 2 10 Nm (7.38 lbf ft) 3 Vite TCEI fissaggio piolo leva freno M6x16 1 10 Nm (7.38 lbf ft) 4 Brake lever pin M8 1 15 Nm (11.06 lbf ft) Loct. 243
Stelvio 1200 NTX MY11 Characteristics
CHAR - 25
REAR BRAKE LEVER
pos. Description Type Quantity Torque Notes
1 Viti te Flang. fissaggio pompa freno M6x20 2 10 Nm (7.38 lbf ft) Loct. 243
2 Dado bloccaggio asta pompa freno - 1 10 Nm (7.38 lbf ft) 3 Brake lever pin M8 1 15 Nm (11.06 lbf ft) Loct. 243
4 Stop switch M6 1 10 Nm (7.38 lbf ft) 5 Vite TCEI fissaggio piolo leva freno - 1 10 Nm (7.38 lbf ft) 6 Vite TE Flang. fissaggio supporto serbatoio M6x16 1 10 Nm (7.38 lbf ft) 7 Vite SWP autofil. per supporto serbatoio M5x20 1 Manual -
EXHAUST SYSTEM
pos.
Description Type Quantity Torque Notes
1 Dadi Flang. fissaggio collettori M8 4 25 Nm (18.44 lbf ft) 2 Oxygen sensor fastener - 2 38 Nm (28.03 lbf ft) 3 Vite TE Flang. fissaggio parte centrale M10x55 1 25 Nm (18.44 lbf ft) 4 Viti fissaggio protezione - 2 10 Nm (7.38 lbf ft) 5 Vite TCEI fissaggio silenziatore a telaio M8x60 1 25 Nm (18.44 lbf ft) -
Characteristics Stelvio 1200 NTX MY11
CHAR - 26
BRAKE SYSTEM
pos.
Description Type Quantity Torque Notes
1 Brake pipe slot screw on the pump M10 2 25 Nm (18.44 lbf ft) 2 Joint with brake pipes retainer bleeding on the
calliper
M10 3 25 Nm (18.44 lbf ft) -
3 Brake pipes joint on the ABS hydraulic unit - 3 25 Nm (18.44 lbf ft) 4 Brake pipes joint on the ABS hydraulic unit M12 1 30-34 Nm (22.13-25.08 lbf
ft)
-
Stelvio 1200 NTX MY11 Characteristics
CHAR - 27
SUPPORTO E PEDANE PILOTA
pos. Description Type Quantity Torque Notes
1 Viti Flang. fissaggio piastrine - 4 10 Nm (7.38 lbf ft) 2 Viti TCEI fissaggio supporto pedane M8x35 2 25 Nm (18.44 lbf ft) 3 Vite fissaggio supporto pedane - 1 25 Nm (18.44 lbf ft) 4 Vite TCEI fissaggio supporto pedane M8x25 1 25 Nm (18.44 lbf ft) 5 Vite fissaggio supporto pedane - 1 25 Nm (18.44 lbf ft) 6 Vite TCEI fissaggio supporto pedane M8x60 1 25 Nm (18.44 lbf ft) 7 Vite fissaggio supporto pedane - 1 25 Nm (18.44 lbf ft) -
PASSENGER FOOTRESTS
pos.
Description Type Quantity Torque Notes
1 Viti TE Flang. fissaggio piastrine - 4 10 Nm (7.38 lbf ft) 2 Viti TE Flang. fissaggio protezione pedana
passeggero SX
M6x12 2 10 Nm (7.38 lbf ft) -
Characteristics Stelvio 1200 NTX MY11
CHAR - 28
FUEL TANK
pos.
Description Type Quantity Torque Notes
1 Vite TCEI fissaggio anteriore M6x35 1 10 Nm (7.38 lbf ft) 2 Vite TE Flang. fissaggio posteriore M6x25 2 10 Nm (7.38 lbf ft) 3 Viti TCEI fissaggio tappo benzina M5x15 4 4 Nm (2.95 lbf ft) -
COPERTURA SERBATOIO CARBURANTE
pos.
Description Type Quantity Torque Notes
1 Vite TBEI Flang. fissaggio copertura - 4 5 Nm (3.69 lbf ft) -
Stelvio 1200 NTX MY11 Characteristics
CHAR - 29
CHASSIS
pos.
Description Type Quantity Torque Notes
1 Pin M12 1 50 Nm (36.88 lbf ft) 2 Pin M12x260 1 50 Nm (36.88 lbf ft) 3 Viti TCEI fissaggio anteriore motore a telaio M12x50 2 80 Nm (59.00 lbf ft) 4 Screws M8x14 2 25 Nm (18.44 lbf ft) 5 Viti TE Flang. M8x25 4 25 Nm (18.44 lbf ft) 6 Screws M10 2 50 Nm (36.88 lbf ft) -
Characteristics Stelvio 1200 NTX MY11
CHAR - 30
Back side
REAR BODYWORK
pos.
Description Type Quantity Torque Notes
1 Viti SWP fissaggio piastra batteria M5x20 4 Manual 2 Viti TBEI Flang. fissaggio fianchetti e para-
spruzzi
M5x9 10 6 Nm (4.42 lbf ft) -
3 Viti TE Flang. fissaggio supporti valigie M6 4 10 Nm (7.38 lbf ft) 4 Viti TBEI Flang. fissaggio paraspruzzi M5x12 2 6 Nm (4.43 lbf ft) -
Stelvio 1200 NTX MY11 Characteristics
CHAR - 31
LICENSE PLATE HOLDER
pos. Description Type Quantity Torque Notes
1 Viti TBEI Flang. fissaggio portatarga M5 2 6 Nm (4.43 lbf ft) 2 Viti TBEI speciali - 2 6 Nm (4.43 lbf ft) 3 Dado autobloc. flang. fissaggio catadiottro M5 1 6 Nm (4.43 lbf ft) -
TRANSMISSION CONNECTION - ENGINE
pos.
Description Type Quantity Torque Notes
1 Reaction rod fixing screw M10x55 2 50 Nm (36.87 lbf ft) -
Characteristics Stelvio 1200 NTX MY11
CHAR - 32
REAR SWINGARM
pos.
Description Type Quantity Torque Notes
1 Swingarm clamp fixing screw on the bushing M6x25 2 10 Nm (7.37 lbf ft) 2 2 - Swingarm fixing screw on the transmission
housing
M10x35 4 50 Nm (36.87 lbf ft) -
3 Swingarm pin on the swingarm M12 1 60 Nm (44.25 lbf ft) 4 Preloading bushing to the swingarm pin M25 1 10 Nm (7.37 lbf ft) -
Stelvio 1200 NTX MY11 Characteristics
CHAR - 33
LUCI POSTERIORI
pos. Description Type Quantity Torque Notes
1 Vite TBEI Flang. fissaggio fanale - 1 6 Nm (4.43 lbf ft) 2 Vite TCEI fissaggio fanale - 2 6 Nm (4.43 lbf ft) 3 Vite TCEI fissaggio fanale targa M5x25 1 6 Nm (4.43 lbf ft) -
MANIGLIONE E PORTAPACCHI
pos.
Description Type Quantity Torque Notes
1 Vite TCEI fissaggio maniglione passeggero M6x25 4 10 Nm (7.38 lbf ft) 2 Vite TCEI fissaggio maniglione passeggero M8 2 25 Nm (18.44 lbf ft) 3 Vite fissaggio portatarga a maniglione M5 2 6 Nm (4.42 lbf ft) 4 Vite TBEI fissaggio supporti portapacchi M8x20 2 25 Nm (18.44 lbf ft) 5 Vite TBEI fissaggio supporti portapacchi M8x30 2 25 Nm (18.44 lbf ft) 6 Vite TSPEI fissaggio coperchio portapacchi M6x35 2 10 Nm (7.38 lbf ft) 7 Vite autofil. fissaggio coperchio portapacchi 5 4 Manual -
Characteristics Stelvio 1200 NTX MY11
CHAR - 34
REAR WHEEL
pos.
Description Type Quantity Torque Notes
1 Vite TE Flang. fissaggio ruota fonica - 6 25 Nm (18.44 lbf ft) 2 Vite TE Flang. fissaggio sensore - 1 10 Nm (7.38 lbf ft) 3 Vite TE Flang. fissaggio sensore M12x65 1 110 Nm (81.13 lbf ft) -
Stelvio 1200 NTX MY11 Characteristics
CHAR - 35
REAR SUSPENSION
pos. Description Type Quantity Torque Notes
1 Vite TE Flang. fissaggio superiore ammortiz-
zatore
M10x80 1 50 Nm (36.88 lbf ft) -
2 Vite TCEI fissaggio biella doppia/forcellone M10x82 1 50 Nm (36.88 lbf ft) 3 Vite TE fissaggio biella doppia/ammortizza-
tore
M10x47 1 40 Nm (29.50 lbf ft) -
4 Vite TE flang. fissaggio biella singola/biella
doppia
M10x95 1 50 Nm (36.88 lbf ft) -
5 Vite TE flang. fissaggio biella singola al telaio M10x85 1 50 Nm (36.88 lbf ft) -
SADDLE
pos.
Description Type Quantity Torque Notes
1 Vite TBEI fissaggio piastra attacco sella M6 2 10 Nm (7.38 lbf ft) 2 Dado serratura - 1 Manual -
Characteristics Stelvio 1200 NTX MY11
CHAR - 36
Engine
LUBRICATION SYSTEM
pos.
Description Type Quantity Torque Notes
1 Pump outlet oil pipe nipple M14x1.5 1 40 Nm (29.50 lb ft) 2 Slot screw for oil pipe on the cylinder head M14x1.5 2 20 Nm (14.75 lb ft) 3 Nipple on the radiator and the oil pipe M16x1.5 2 20 Nm (14.75 lb ft) Apply Vaseline oil
4 Oil delivery pipe to radiator slot screw M14x1.5 1 35 Nm (25.81 lb ft) 5 Jets fixing screw - 3 Using a "T" spanner, close
by hand
Loctite 243
6 Minimum oil pressure sensor M12 1 25 Nm (18.44 lb ft) 7 Intake oil filter fixing screw - 2 4 Nm (2.95 lb ft) -
Stelvio 1200 NTX MY11 Characteristics
CHAR - 37
ALTERNATOR
pos.
Description Type Quantity Torque Notes
1 Generator control pulley locking nut M16 1 100 Nm (73.76 lb ft) Loctite 243
2 Generator upper fixing screw M8 1 22 Nm (16.23 lb ft) 3 Generator lower fixing screw M10x60 1 30 Nm (22.13 lb ft) -
Characteristics Stelvio 1200 NTX MY11
CHAR - 38
GEAR INTERNAL CONTROLS
pos. Description Type Quantity Torque Notes
1 Spring guide pin - 1 24 Nm (17.70 lb ft) Loctite 243
CRANKCASE AND OIL SUMP
pos.
Description Type Quantity Torque Notes
1 Stud bolt M8x75 2 10 Nm (7.37 lb ft) 2 Stud bolt M8x66 3 10 Nm (7.37 lb ft) 3 Crankshaft rear support flange fixing screw M8x25 8 26 Nm (19.18 lb ft) 4 Oil cap on the crankcase - 2 25 Nm (18.44 lb ft) 5 Flange fixing screw under the crankcase M6x60 2 10 Nm (7.37 lb ft) 6 Flange fixing screw under the crankcase - 2 10 Nm (7.37 lb ft) 7 Oil sump fixing screw (filter contour) M6x35 4 10 Nm (7.37 lb ft) 8 Oil sump fixing screw M6 14 10 Nm (7.37 lb ft) 9 Cover on the flange under the crankcase - 2 20 Nm (14.75 lb ft) 10 Magnetic oil drainage cap - 1 20 Nm (14.75 lb ft) 11 Gear to engine fixing nut M8 5 20 Nm (14.75 lb ft) 12 Gear to engine fixing screw - 1 20 Nm (14.75 lb ft) Loctite 542
Stelvio 1200 NTX MY11 Characteristics
CHAR - 39
OIL SUMP COMPONENTS
pos.
Description Type Quantity Torque Notes
1 Cover on the flange under the crankcase - 1 40 Nm (29.50 lb ft) 2 Oil filter joint - 1 10 Nm (7.37 lb ft) Loctite 243
3 Oil sump pipe - 1 20 Nm (14.75 lb ft) Loctite 648
4 Oil filter - 1 15 Nm (11.06 lb ft) Engine oil
5 Rose pipe fixing screw M6 - 10 Nm (7.37 lb ft) 6 Maximum pressure valve cover M18 1 40 Nm (29.50 lb ft) -
Characteristics Stelvio 1200 NTX MY11
CHAR - 40
CYLINDER HEAD COVERS
pos. Description Type Quantity Torque Notes
1 Special cylinder head fixing screw - 8 8 Nm (5.90 lb ft) Locked with cross
sequence
2 Spark plug cover fixing screw M5x10 2 8 Nm (5.90 lb ft) -
GENERATOR COVER
pos.
Description Type Quantity Torque Notes
1 Timing system cover cap fixing screw M6x20 2 10 Nm (7.38 lb ft) Loctite 243
2 Timing system cover fixing screw M8x55 4 25 Nm (18.44 lb ft) 3 Timing system cover fixing screw M6x30 9 12 Nm (8.85 lb ft) 4 Generator cover fixing screw M6x16 5 12 Nm (8.85 lb ft) -
Stelvio 1200 NTX MY11 Characteristics
CHAR - 41
AIR FILTER
pos.
Description Type Quantity Torque Notes
1 Air filter box fastening screw to frame - 2 10 Nm (7.38 lb ft) 2 Air filter box cover fastening screw SWP 5x20 6 3 Nm (2.21 lb ft) -
THROTTLE BODY
pos.
Description Type Quantity Torque Notes
1 Intake pipe fixing screw - 6 10 Nm (7.37 lb ft) -
Characteristics Stelvio 1200 NTX MY11
CHAR - 42
pos. Description Type Quantity Torque Notes
2 Flange fixing screw on the throttle body M5x12 2 6 Nm (4.42 lb ft) -
CLUTCH
pos.
Description Type Quantity Torque Notes
1 Clutch to crankshaft fixing screw - 6 42 Nm (30.98 lb ft) Tighten with cross
sequence
2 Clutch external flange fixing screw on flywheel M7x16 6 20 Nm (14.75 lb ft) Loctite 243
3 Start-up crown fixing screw on flywheel - 6 10 Nm (7.37 lb ft) Loctite 243
4 Clutch control cylinder fixing screw - 3 10 Nm (7.37 lb ft) Loctite 243
Stelvio 1200 NTX MY11 Characteristics
CHAR - 43
CONNECTING ROD ASSEMBLY - CYLINDERS
pos. Description Type Quantity Torque Notes
1 Thermal group fixing stud bolt M10x1.25 8 5 Nm (3.69 lb ft) Loctite 243
2 Connecting rod screws - 4 40 Nm (29.50 lb ft) Pre-tightening
2 Connecting rod screws - 4 80 Nm (59.00 lb ft) Final tightening
3 Right hydraulic tensioner cover - 1 42 Nm (30.98 lb ft) 4 Left hydraulic tensioner cover - 1 30 Nm (22.13 lb ft) -
FUEL SUPPLY SYSTEM
pos.
Description Type Quantity Torque Notes
1 Vite fissaggio protezioni corpo farfallato M6 2 10 Nm (7.38 lbf ft) -
Characteristics Stelvio 1200 NTX MY11
CHAR - 44
BLOW-BY SYSTEM
pos.
Description Type Quantity Torque Notes
1 Vite fissaggio distanziale vaso espansione
Blow - By a motore
SWP
M5x14
1 10 Nm (7.38 lbf ft) -
2 Reduction joint for oil return pipe - 1 20 Nm (14.75 lbf ft) 3 Oil return pipe (on sump) - 1 20 Nm (14.75 lbf ft) Vaseline oil
Stelvio 1200 NTX MY11 Characteristics
CHAR - 45
STARTER MOTOR
pos. Description Type Quantity Torque Notes
1 Starter motor fixing screw - 2 25 Nm (18.44 lbf ft) 2 Stud bolt - 1 10 Nm (7.37 lbf ft) 3 Starter motor cover fixing screw M6x10 2 8 Nm (5.90 lbf ft) -
OIL PUMP
pos.
Description Type Quantity Torque Notes
1 Oil pump fixing screw M6x45 3 10 Nm (7.37 lb ft) Loctite 243
2 Oil pump driven gear locking nut M6 1 8 Nm (5.90 lb ft) Loctite 243
3 Oil pressure valve cap - 1 40 Nm (29.50 lb ft) -
Characteristics Stelvio 1200 NTX MY11
CHAR - 46
OIL RADIATOR
pos.
Description Type Quantity Torque Notes
1 Screws fixing radiator to chassis M6x30 3 10 Nm (7.38 lb ft) -
RIGHT CYLINDER HEAD
pos.
Description Type Quantity Torque Notes
1 Movable chain tensioner pad fixing screw - 1 20 Nm (14.75 lb ft) Loctite 243
Stelvio 1200 NTX MY11 Characteristics
CHAR - 47
pos. Description Type Quantity Torque Notes
2 Head tightening nut M10x1.25 4 15 Nm (11.06 lb ft) Engine Oil Pre-
tightening
2 Head tightening nut M10x1.25 4 42 Nm (30.98 lb ft) Final tightening
3 Head tightening screws (chain compartment) M6x120 2 10 Nm (7.37 lb ft) 4 Plate locking screw and timing gear - 1 30 Nm (22.13 lb ft) Loctite 243
5 Timing cover fixing screw on the cylinder head M5x10 2 8 Nm (5.90 lb ft) 6 Camshaft support fixing screw - 6 18 Nm (13.28 lb ft) 7 Cup spring fixing screw - 1 18 Nm (13.28 lb ft) -
LEFT CYLINDER HEAD
pos.
Description Type Quantity Torque Notes
1 Movable chain tensioner pad fixing screw - 1 20 Nm (14.75 lb ft) Loctite 243
2 Head tightening nut M10x1.25 4 15 Nm (11.06 lb ft) Engine Oil Pre-
tightening
2 Head tightening nut M10x1.25 4 42 Nm (30.98 lb ft) Final tightening
3 Head tightening screws (chain compartment) M6x120 2 10 Nm (7.37 lb ft) 4 Plate locking screw and timing gear - 1 30 Nm (22.13 lb ft) Loctite 243
5 Timing cover fixing screw on the cylinder head M5x10 2 8 Nm (5.90 lb ft) 6 Camshaft support fixing screw - 6 18 Nm (13.28 lb ft) 7 Cup spring fixing screw - 1 18 Nm (13.28 lb ft) -
Characteristics Stelvio 1200 NTX MY11
CHAR - 48
TIMING SYSTEM CONTROL
pos.
Description Type Quantity Torque Notes
1 Control, timing system, shaft support flange
fixing screw
M6x14 2 8 Nm (5.90 lb ft) -
2 Bearing fixing screw M6x16 1 10 Nm (7.37 lb ft) Loctite 243
3 Driving gears locking nut on the crankshaft M25 1 200 Nm (147.51 lb ft) Loctite 601
4 Timing system driven gear locking nut M18 1 25 Nm (18.44 lb ft) Pre-tightening
4 Timing system driven gear locking nut M18 1 150 Nm (110.63 lb ft) Final tightening
Stelvio 1200 NTX MY11 Characteristics
CHAR - 49
GEARBOX
pos. Description Type Quantity Torque Notes
1 Clutch housing to gearbox fixing screw M6x55 14 13 Nm (9.59 lbf ft) 2 Neutral sensor - 1 10 Nm (7.37 lbf ft) 3 Breather stud bolt - 1 8 Nm (5.90 lbf ft) Loctite 243
4 Gear oil magnetic drainage cap - 1 24 Nm (17.70 lbf ft) 5 Oil filler cap M18x1.5 1 28 Nm (20.65 lbf ft) -
Overhaul data
Assembly clearances
Cylinder - piston assy.
Measurement of the cylinder diameter must be done at three heights, turning the dial gauge 90°.
Check that cylinders and pistons are of the same selection types (D, E, F).
Check clearance between cylinders and pistons on the selected diameter; if it exceeds the value specified, it is necessary to replace cylinders and pistons.
The pistons of an engine must be balanced; a weight difference of up to 1.5 g (0.0033 lb) is allowed.
PISTON - CYLINDER SELECTION TYPES
Specification
Desc./Quantity
Piston diameter - selection D 94.935 - 94.945 mm (3.73759 - 3.73798 in)
Cylinder diameter - selection D 95.000 - 95.010 mm (3.74015 - 3.74054 in)
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)
Characteristics Stelvio 1200 NTX MY11
CHAR - 50
PIN - PISTON COUPLING
Specification Desc./Quantity
Pin diameter 21.998 - 21.994 mm (0.86606 - 0.86590 in)
Pin hole diameter on piston 22.016 - 22.011 mm (0.86677 - 0.86657 in)
Clearance between pin and holes on piston 0.013 - 0.022 mm (0.00051 - 0.00087 in)
Piston rings
On each piston there are:
•
1 top piston ring;
•
1 middle piston ring;
•
1 oil scraper piston ring.
Turn the rings so that the coupling ends are 120 degrees from each other.
CLEARANCE BETWEEN PISTON RINGS AND SEATS ON PISTON
Specification Desc./Quantity
Top ring 0.030 - 0.065 mm (0.00118 - 0.00256 in)
Middle ring 0.020 - 0.055 mm (0.00079 - 0.00216 in)
Oil scraper ring 0.010 - 0.045 mm (0.00039 - 0.00177 in)
Gap between the end of the piston rings inserted in the cylinder:
•
Top and middle piston ring: 0.40 - 0.65 mm (0.00158 - 0.00255 in)
•
Oil scraper piston ring: 0.30 - 0.60 mm (0.00118 - 0.00236 in).
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)
Clearance between bushing and main journal (timing system
side)
0.025 - 0.057 mm (0.00098 - 0.00224 in)
CRANKSHAFT SEAT ( CLUTCH SIDE)
Specification
Desc./Quantity
Diameter of crankshaft main journal, clutch side 53.97 - 53.961 mm (2.12480 - 2.12444 in)
Inside diameter of crankshaft bushing on clutch-side flange 54.019 - 54.0 mm (2.12673 - 2.12598 in)
Clearance between bushing and main journal (clutch side) 0.030 - 0.058 mm (0.00118 - 0.00228 in)
Stelvio 1200 NTX MY11 Characteristics
CHAR - 51
Slot packing system
•
Fit both pistons on the connecting rods.
•
Working from both sides, fit the gasket
between the crankcase and the cylinder on the crankcase.
•
Fit both cylinders.
•
Take the left cylinder piston to TDC and
lock crankshaft rotation.
Specific tooling
020675Y Service shaft gear lock
•
Thoroughly clean the upper surface of
both cylinders.
•
Place the tool on the left cylinder to determine the "squish" (X).
•
Fasten the tool with the nuts of the stud
bolts.
Specific tooling
020676Y Dial gauge support for piston position
checking
•
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.
•
Unlock crankshaft rotation.
•
Rotate the crankshaft by 90°until the right cylinder piston reaches the TDC.
•
Lock crankshaft rotation.
•
Place the tool on the right cylinder stud bolts to determine the "squish" (X).
Specific tooling
020676Y Dial gauge support for piston position checking
Characteristics Stelvio 1200 NTX MY11
CHAR - 52
•
Repeat the same operations to determine the thickness of the left cylinder gasket between
cylinder and head also for the right cylinder.
CYLINDER GASKET THICKNESS - HEAD
Specification Desc./Quantity
Value (X) -0.56 / -0.37 mm (-0.022 / -0.0146 in) gasket thickness: 0.65 mm (0.0256 in)
Value (X) -0.37 / -0.19 mm (-0.0146 / -0.0075 in) gasket thickness: 0.85 mm (0.0335 in)
Value (X) -0.19 / 0 mm (-0.0075 / 0 in) gasket thickness: 1.05 mm (0.0413 in)
Recommended products chart
Piaggio & C. S.p.A. prescribes eni products for
the scheduled maintenance of its vehicles
RECOMMENDED PRODUCTS TABLE
Product
Description Specifications
ENI i-RIDE PG RACING 10W-60 Engine oil SAE 10W - 60. As an alternative for rec-
ommended oils, top-branded oils that
meet or exceed the requirements of
CCMC G-4 A.P.I. SG specifications can
be used.
AGIP GEAR SAE 80 W 90 Transmission oil API GL-4
AGIP GEAR MG/S SAE 85 W 90 Gearbox oil API GL-5
AGIP ARNICA SA 32 Fork oil ISO-L-HV
AGIP GREASE SM2 Lithium grease with molybdenum for
bearings and other points to lubricate
NLGI 2
Neutral grease or petroleum jelly. Battery poles
AGIP BRAKE 4 Brake fluid SAE J 1703 -FMVSS 116 - DOT 3/4 - ISO
4925 - CUNA NC 956 DOT 4 synthetic
fluid
AGIP BRAKE 5.1 Clutch fluid FMVSS 116 - DOT 5.1 Non-silicone syn-
thetic fluid
Stelvio 1200 NTX MY11 Characteristics
CHAR - 53
INDEX OF TOPICS
SPECIAL TOOLS S-TOOLS
MOTORE
Stores code Description
020677Y Generator belt tensioner, lever for belt
tensioning
05.91.17.30 Front cover insertion cone
020716Y Connecting rod locking
020470Y Pin snap ring fitting tool
05.92.72.30 Timing system cover sealing ring punch
01.92.91.00 Wrench for removing the cover on sump
and filter
Stelvio 1200 NTX MY11 Special tools
S-TOOLS - 55
Stores code Description
05.90.25.30 Gearbox support
19.92.96.00 Graduated dial to control ignition timing
12.91.18.01 Tool to lock the flywheel and the starting
ring gear
12.91.36.00 Tool to remove the flywheel-side flange
AP8140179 Support for valve fitting/removal
AP9100838 Tool for valve pressure plate
14.92.71.00 Tool to fit the sealing ring on the flywheel-
side flange
Special tools Stelvio 1200 NTX MY11
S-TOOLS - 56
Stores code Description
12.91.20.00 Tool to fit the flywheel-side flange together with seal ring on the crankshaft
19.92.71.00 Tool to fit the seal ring on the flywheel-
side flange
020673Y Graduated dial hub
020672Y Clutch spring centre and pusher
020674Y Piston ring clamp
020675Y Service shaft gear lock
020676Y Dial gauge support for piston position
checking
Stelvio 1200 NTX MY11 Special tools
S-TOOLS - 57
Stores code Description
020678Y Tool for clutch rod checking
020953Y Cam shaft lock for fixing
020954Y Centring cam shaft cup spring
05.91.25.30 Gearbox opening
CHASSIS
Stores code
Description
AP8140190 Tool for steering tightening
GU14912603 Hook spanner for fixing ring nut of the
clutch shaft internal body
Special tools Stelvio 1200 NTX MY11
S-TOOLS - 58
BEVEL GEAR SET
Stores code Description
05.90.27.30 Gearbox support
05.90.27.31 Gearbox oil seal buffer
05.90.27.32 Buffer handgrip
05.90.27.33 Ball joint sealing buffer
05.90.27.34 Wrench for pinion ring nut
05.90.27.35 Pinion oil seal buffer
Stelvio 1200 NTX MY11 Special tools
S-TOOLS - 59
FRONT FORK
Stores code Description
AP8140146 Weight
AP8140149 Protection for fitting operations
9100903 Marzocchi fork oil seal; ø 45 mm (1.77 in)
Special tools Stelvio 1200 NTX MY11
S-TOOLS - 60
INDEX OF TOPICS
MAINTENANCE MAIN
Scheduled maintenance table
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SPECIFIED IF THE VEHICLE IS USED IN PARTICULAR RAINY OR DUSTY CONDITIONS, OFF ROAD OR FOR TRACK
USE.
NOTE
THE TIMES LISTED ON THE SCHEDULED MAINTENANCE TABLE INCLUDE TIME DEDICATED
TO MANAGEMENT ACTIVITIES.
Routine maintenance table
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
(1) Check and clean and adjust or replace, if necessary, before every journey.
(2) Replace every 2 years or 20000 Km (12427 mi).
(3) Replace every 4 years.
(4) Check at each engine start.
(5) It is recommended to lubricate stands and footrests periodically with spray grease after use in particularly hard conditions (dirty with salts, dust, etc.) or after long inactivity periods.
(6) Lubricate if you are riding in the rain, on wet roads or after the vehicle has been washed.
ROUTINE MAINTENANCE TABLE
km x 1.000 (mi x 1.000)
1.5
(0.9)10(6.2)20(12.4)30(18.6)40(28.4)50(31.1)60(37.3)70(43.5)80(49.7)
Exhaust pipe flange bolts I I I I I
Spark plugs R R R R R R R R
Throttle body C C C C
Stands (5) I I I I I I I I
Transmission cables and controls I I I I I I I I I
Alternator belt A A R A A
Steering bearings and steering clearance I I I I I I I I I
Wheel bearings I I I I I I I I
Diagnosis by tool I I I I I I I I I
Brake discs I I I I I I I I I
Air filter I R I R I R I R
Engine oil filter R R R R R R R R R
Fork I I I I I
Vehicle general operation I I I I I I I I I
Braking systems I I I I I I I I I
Light circuit I I I I I I I I I
Safety switches I I I I I
Brake fluid (2) I I R I R I R I R
Clutch fluid (2) I I I I I I I I I
Gearbox oil R R R R R R R R R
Engine oil R R R R R R R R R
Fork oil / oil seals R R R R
Final drive oil R R R R R R R R R
Clutch lever pin (6) L L L L L L L L L
Tyres - pressure / wear (1) I I I I I I I I I
Engine idle speed A A A A A A A A A
Valve clearance adjustment A A A A A A A A A
Wheels I I I I I I I I I
Bolts and nuts tightening I I I I I I I I I
Battery terminals tightening I I I I I
Wheel nipple tightening (1) I I I I I I I I I
Cylinder synchronisation I I I I I I I I I
Maintenance Stelvio 1200 NTX MY11
MAIN - 62
km x 1.000 (mi x 1.000) 1.5
(0.9)10(6.2)20(12.4)30(18.6)40(28.4)50(31.1)60(37.3)70(43.5)80(49.7)
Footrests joint (5) I I I I I I I I
Suspension and setting I I I I I
Engine oil pressure warning light (4)
Empty oil drain pipe from the filter housing C C C C C C C C
Fuel lines (3) I I I I I I I I
Brake lines (3) I I I I I I I I
Clutch wear I I I I I I I I
Brake pad wear (1) I I I I I I I I I
Labour time (minutes) 150 230 210 230 210 240 210 230 210
NOTE
AT EACH SCHEDULED MAINTENANCE MUST BE VERIFIED WITH THE DIAGNOSTIC TOOL IF
THERE ARE ERRORS AND THE IF THE PARAMETERS ARE CORRECT.
Transmission fluid
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).
• If the oil is lower than specified, top-up until it
reaches the cap/dipstick hole (1).
CAUTION
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO
THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Replacement
CAUTION
THE UNIT MUST BE HOT WHEN THE OIL IS CHANGED AS UNDER SUCH CONDITIONS OIL IS
FLUID AND THEREFORE EASY TO DRAIN.
NOTE
RIDE SOME km (miles) TO WARM UP ENGINE OIL
•
Place a container with + 400 cm³ (25 cu in) capacity under the drainage plug (3).
•
Unscrew and remove the drainage plug (3).
•
Unscrew and remove the breather cap (2).
•
Drain the oil into the container; allow several minutes for oil to drain out completely.
•
Check and if necessary, replace the sealing washer of drainage plug (3).
•
Remove any metal scrap attached to the drainage plug (3) magnet.
•
Screw and tighten the drainage plug (3).
•
Pour new oil through the fill opening (1) until it reaches the cap/dipstick hole (1).
Stelvio 1200 NTX MY11 Maintenance
MAIN - 63
CAUTION
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL
OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
•
Screw and tighten the caps (1 - 2).
Engine oil
Check
CAUTION
ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL.
NOTE
DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE
OIL AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED
AFTER RUNNING FOR ABOUT 15 KM (10 miles).
•
Shut off the engine.
•
Keep the vehicle upright with both wheels on the ground.
•
Pull the filler plug / oil level dipstick (1)
straight out.
•
Wipe the oil level dipstick (1) clean and
reinsert it.
•
Pull it out again and check the oil level.
•
The oil level is correct when it is close
to the "MAX" mark. Otherwise, top-up
with engine oil.
CAUTION
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO THE FLUID. WHEN USING A FUNNEL
OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Replacement
NOTE
HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
It is necessary to remove the metal oil sump guard in order to change the engine oil and replace the oil
filter:
Maintenance Stelvio 1200 NTX MY11
MAIN - 64
•
Operating from both sides, unscrew and remove both screws (1).
•
Remove the oil sump guard.
•
Place a container with +4,000 cm³ (244
cu in) capacity under the drainage plug
(3).
•
Unscrew and remove the drainage
plug (3).
•
Pull out the oil filler plug / engine oil
level dipstick (4).
•
Drain the oil into the container; allow
several minutes for oil to drain out completely.
•
Insert the oil filler plug / engine oil level
dipstick (4).
•
Check and if necessary, replace the
drainage plug (3) sealing washers.
•
Remove any metal deposits attached
to the drainage plug (3) magnet.
•
Screw and tighten the drainage plug
(3).
DO NOT DISPOSE OF OIL INTO THE ENVIRONMENT.
DISPOSE OF ENGINE OIL IN A SEALED CONTAINER AND
TAKE IT TO YOUR SUPPLIER OR TO THE NEAREST USED
OIL COLLECTION CENTRE.
Stelvio 1200 NTX MY11 Maintenance
MAIN - 65
Engine oil filter
Replace the engine oil filter each time you
change the engine oil.
•
Drain the engine oil completely.
•
Unscrew and remove the engine oil filter from its seat.
NOTE
NEVER REUSE AN OLD FILTER.
•
Spread a thin layer of oil on the sealing ring of the new engine oil filter.
•
Fit and screw the new oil filter in its seat.
Gearbox Oil
Inspection
CHECK AND TOPPING-UP
CAUTION
GEARBOX OIL LEVEL MUST BE CHECKED WHEN THE ENGINE IS WARM.
NOTE
DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE
OIL AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED
AFTER RUNNING FOR ABOUT 15 KM (10 miles).
•
Shut off the engine.
•
Keep the vehicle upright with both
wheels on the ground.
•
Undo and remove the dipstick opening
(1) located on the right side of the gearbox.
•
The level is correct if the oil is close to
the hole of the dipstick (1).
If necessary:
•
Top-up with oil until it reaches the dipstick opening (1).
CAUTION
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO
THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Maintenance Stelvio 1200 NTX MY11
MAIN - 66
Replacement
NOTE
HOT OIL IS MORE FLUID AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
•
Place a container with suitable capacity under the drainage plug (2).
•
Unscrew and remove the drainage
plug (2).
•
Unscrew and remove the filler plug (1).
•
Drain the oil into the container; allow
several minutes for oil to drain out completely.
•
Check and if necessary, replace the
sealing washers of drainage plug (2).
•
Remove any metal scrap attached to
the drainage plug (2) magnet.
•
Screw and tighten the drainage plug
(2).
•
Pour in new oil until it reaches the cap/
dipstick opening (1).
•
Tighten the filler cap (1).
CAUTION
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO
THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Stelvio 1200 NTX MY11 Maintenance
MAIN - 67
Air filter
AIR FILTER
pos.
Description Type Quantity Torque Notes
1 Air filter box fastening screw to frame - 2 10 Nm (7.38 lb ft) 2 Air filter box cover fastening screw SWP 5x20 6 3 Nm (2.21 lb ft) -
•
Undo and remove the six screws.
•
Lift the filter housing cover.
Maintenance Stelvio 1200 NTX MY11
MAIN - 68
•
Remove the air filter.
•
Plug the intake duct with a clean cloth to prevent any foreign objects from entering the intake
manifold.
DO NOT START THE ENGINE WITHOUT THE AIR FILTER.
TO CLEAN THE FILTERING ELEMENT, USE A PRESSURE AIR JET FROM THE INSIDE TO THE
OUTSIDE.
Checking the valve clearance
If the timing system is very noisy, check the clearance between the valves and the rocking levers.
NOTE
ADJUST WITH COLD ENGINE, WITH PISTON AT TOP DEAD CENTRE (TDC) IN COMPRESSION
STROKE (VALVES CLOSED).
•
Disconnect the spark plug by leveraging a screwdriver through the slot.
CAUTION
PAY ATTENTION TO APPLY LEVERAGE ON THE RUBBER
OF THE SPARK PLUG CAP ITSELF IN ORDER TO AVOID
DAMAGES
•
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).
•
Use a screwdriver to act on set screw
(2) until the following clearances are
obtained:
Technical specifications
Values valid with control clearance between
rockers and valve
Inlet valve: 0.15 mm (0.0059 in)
Exhaust valve: 0.20 mm (0.0079 in)
Stelvio 1200 NTX MY11 Maintenance
MAIN - 69
•
The measurement must be taken using
a special thickness gauge.
CAUTION
IF CLEARANCE IS LARGER THAN RECOMMENDED, THE
TAPPETS WILL BE NOISY. OTHERWISE, THE VALVES DO
NOT CLOSE CORRECTLY, WHICH CAN LEAD TO PROBLEMS SUCH AS:
•
PRESSURE DROP;
•
ENGINE OVERHEAT;
•
VALVE BURN OUT, ETC.
Braking system
Level check
Brake fluid check
•
Rest the vehicle on its stand.
•
For the front brake, turn the handlebar fully to the right.
•
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:
MIN = minimum level
MAX = maximum level
If the fluid does not reach at least the "MIN" reference mark:
•
Check brake pads and disc for wear.
•
If the pads and/or the disc do not need replacing, top-up the fluid.
Top-up
Front brake:
•
Unscrew the two screws (1) of the
brake fluid reservoir (2) using a Phillips
screwdriver.
•
Lift and remove the cover (3) and
screws (1) as well.
•
Remove the gasket (4).
Rear brake:
•
Unscrew and remove the cap (5).
•
Remove the gasket (6).
Maintenance Stelvio 1200 NTX MY11
MAIN - 70
•
Top-up the reservoir with brake fluid to
the correct level, which is between the
two "MIN" and "MAX" reference marks.
RISK OF BRAKE FLUID SPILLING. DO NOT OPERATE THE
BRAKE LEVER IF THE BRAKE FLUID RESERVOIR CAP IS
LOOSE OR HAS BEEN REMOVED.
CAUTION
AVOID PROLONGED AIR EXPOSURE OF THE BRAKE
FLUID. BRAKE FLUID IS HYGROSCOPIC AND ABSORBS
MOISTURE WHEN IN CONTACT WITH AIR. LEAVE THE
BRAKE FLUID RESERVOIR OPEN ONLY FOR THE TIME
NEEDED TO COMPLETE THE TOPPING-UP PROCEDURE.
TO AVOID SPILLING FLUID WHILE TOPPING-UP, KEEP
THE TANK PARALLEL TO THE RESERVOIR EDGE (IN
HORIZONTAL POSITION).
DO NOT ADD ADDITIVES OR OTHER SUBSTANCES TO
THE FLUID.
WHEN USING A FUNNEL OR ANY OTHER ELEMENT,
MAKE SURE IT IS PERFECTLY CLEAN.
DO NOT EXCEED THE "MAX" LEVEL MARK WHEN TOPPING UP.
TOP-UP TO "MAX" LEVEL MARK ONLY WHEN BRAKE
PADS ARE NEW. WHEN TOPPING UP DO NOT EXCEED
THE "MAX" LEVEL MARK WHEN BRAKE PADS ARE
WORN AS YOU RISK SPILLING FLUID WHEN CHANGING
THE BRAKE PADS.
CHECK BRAKING EFFICIENCY. IN CASE OF EXCESSIVE
TRAVEL OF THE BRAKE LEVER OR POOR PERFORMANCE OF THE BRAKING SYSTEM, TAKE YOUR VEHICLE
TO AN Official Moto Guzzi Dealer, AS IT MAY BE NECESSARY TO PURGE THE AIR IN THE SYSTEM.
Stelvio 1200 NTX MY11 Maintenance
MAIN - 71
INDEX OF TOPICS
ELECTRICAL SYSTEM ELE SYS
MAIN CABLE HARNESS
pos.
Description Type Quantity Torque Notes
1 Viti TE Flang. fissaggio piastre bobine M6x20 2+2 10 Nm (7.38 lbf ft) 2 Viti TCEI fissaggio bobine - 2+2 2 Nm (1.47 lbf ft) 3 Viti TCEI fissaggio centralina - 2 10 Nm (7.38 lbf ft) 4 Viti TCEI fissaggio supporto sensore temp.
olio
M10x20 1 11 Nm (8.11 lbf ft) Loct. 243
5 Viti TCEI fissaggio sensore di fase - 2 3 Nm (2.21 lbf ft) -
Stelvio 1200 NTX MY11 Electrical system
ELE SYS - 73
Components arrangement
key:
1 Coil
2 Instrument panel
3 Fuel pump
4 Injector
5 Throttle valve potentiometer
Electrical system Stelvio 1200 NTX MY11
ELE SYS - 74
6 Fall sensor (optional equipment)
7 Rear light
8 Main fuses
9 Oxygen sensor
10 Battery
11 Starter motor
12 Intake air temperature sensor
13 Engine revolution sensor
14 Head temperature sensor
15 Engine control unit
16 Instrument panel air temperature sensor
17 Front headlamp
18 Alternator
19 Oil pressure sensor
20 Front ABS sensor
21 Auxiliary fuses
22 Relay
23 Additional headlamps
24 ABS Control unit
25 Rear ABS sensor
26 ABS Fuses
Electrical system installation
INTRODUCTION
Scope and applicability
This document aims at defining the cable harness routing in order to achieve the vehicle reliability
targets.
Materials used and corresponding quantities
The electrical system consists of the following cable harnesses and parts:
•
1 Main cable harness
•
1 Ground lead
•
1 Headlamp cable harness
•
1 Fall sensor connector
•
1 Antitheft cable harness (optional equipment)
•
8 Small clamps
•
18 Medium clamps
•
1 Big clamp
Stelvio 1200 NTX MY11 Electrical system
ELE SYS - 75
•
4 Reused clamps
•
7 Cable grommets
•
5 Rubber clamps
•
7 Cable grommets
•
1 Adhesive cable grommet
•
1 Cable grommet with clip
Motorcycle division
The wiring timing is subdivided in three essential
sections, as indicated in the figure.
1. Front section
2. Central section
3. Rear section
Special checks for the correct connection and laying of cables
It is extremely important that any security-locks for the following connectors are properly connected and
correctly tightened to ensure proper engine, and therefore proper vehicle, operation.
•
Instrument panel connector
•
Pick Up connector and alternator
•
Side Stand Switch Connector
•
Coils connectors
•
Control unit connectors
•
Fuel pump connector
•
Key Connector
•
Right Light Switch Connectors
•
Left Light Switch Connectors
•
ABS connector and correct positioning of the cap
•
Front and rear speed sensor connector
•
Auxiliary Fuses (rubber housing correct positioning and closing)
•
Intake air temperature sensor
•
Fuel injector connectors
The connectors in the list are circled in the different pictures. The listed connectors are considered more critical than the others because their disconnection could cause the vehicle to
stop or malfunction. Obviously, the correct connection of the other connectors is also important
and essential for proper vehicle operation.
It is also important and essential that the instructions regarding the routing and fixing of the cable harness in the various areas are followed meticulously in order to guarantee functionality and reliability.
Electrical system Stelvio 1200 NTX MY11
ELE SYS - 76
Front side
TABLE A
1. Front headlamp
2. Small clamps
3. Cable grommet
4. Headlamp cable harness
TABLE B
1. Rubber clamps
TABLE C
1. Front brake switch
2. Faston
•
Check the faston are connected up to
the end.
TABLE D
1. Cable grommets
2. Pipe tightening clamp
3. Front ABS sensor
Stelvio 1200 NTX MY11 Electrical system
ELE SYS - 77
TABLE E
1. Main cable harness
2. Small clamp
3. Middle clamp
TABLE F
1. Middle clamp
2. Clamp already present on the cable harness
Electrical system Stelvio 1200 NTX MY11
ELE SYS - 78
TABLE G
1. Medium clamp
TABLE H
•
No part of the cable harness must protrude to the inside of the support so as
not to obstruct the forks
TABLE I
1. Clamp that groups the cable harness of the right
light switch, the front stop switch, the front ABS
sensor and the key
TABLE L
1. Medium clamps
2. Small clamps
Stelvio 1200 NTX MY11 Electrical system
ELE SYS - 79
TABLE M
•
Check correct closure of the secondary
fuses housing cover
TABLE N
1. Middle clamp
2. Ground lead oriented as in the photo
3. Small clamp
4. Cable grommet
TABLE O
1. Medium clamps
TABLE P
1. Clamp that has the cable harness of the left light
switch and the key on the metal relay
2. Clamp that has the cable harness of the left light
switch on the pipe
3. Middle clamp
Electrical system Stelvio 1200 NTX MY11
ELE SYS - 80
TABLE Q
1. Keep the cable harness outside according to the
relays
2. Clamp
TABLE R
1. Middle clamp
TABLE S
1. Hook the clamp on the specific hole present in
the support.
2. Middle clamp
TABLE T
1. Front plug socket
2. Plug socket connector.
3. Correct alignment
4. Medium clamp to be placed after fitting the cap
so as to avoid it can remove
Stelvio 1200 NTX MY11 Electrical system
ELE SYS - 81
TABLE U
1. Instrument panel
2. Instrument panel connector correctly connected
Central part
TABLE A
1. Main cable harness
2 Motor main cable harness
3. Grey taping as reference that must remain between the two covers
TABLE B
1. Engine oil pressure sensor
2. Small clamp
TABLE C
1. Generator
2. Sensor
3. Alternator positive
Electrical system Stelvio 1200 NTX MY11
ELE SYS - 82
TABLE D
1. Pick up cable harness
2. Medium clamp that fastens the right pick-Up cable to the chassis
TABLE E
1. Reused clamp
TABLE F
1. Cable guide
2. Plastic cable guides
TABLE G
1. Neutral switch
•
Correctly fit the hood on the gear
switch
Stelvio 1200 NTX MY11 Electrical system
ELE SYS - 83
TABLE H
•
Correct laying of cables for the injectors
TABLE I
1. Left injector
2. Right injector
•
Check that the steel clip is correctly placed after the connection
TABLE L
1. Middle clamp
2. Big clamp
3. Right light switch, key and front ABS sensor connections
4. Heated hand grips connectors
5. Small clamp that blocks the heated hand grips connectors to the brake pipe.
Electrical system Stelvio 1200 NTX MY11
ELE SYS - 84
TABLE M
1. Ground cable harness
2. Battery ground lead
3. Left lambda sensor.
4. Clamp to keep the starter motor cable harness
far from the throttle bodies control pin
TABLE N
1. Starter motor
•
Make sure that the end is oriented to
the inside to avoid touching the protection of the starter motor.
Stelvio 1200 NTX MY11 Electrical system
ELE SYS - 85
TABLE O
1. Starter motor cover
2. Cable grommet
•
If the cable grommet is correctly fitted,
it will be hidden by the cover.
TABLE P
1. Oxygen sensor cable harness
2. Cable grommet
•
Hook the cable grommet with the internal cable harness of the oxygen sensor
TABLE Q
1. Fuel pump
2. Fuel pump connector
3. Small clamp
TABLE R
1. Horn
2. Horn cable harness
3. Middle clamp
TABLE S
1. ABS control unit connector
•
The initial position of the connector fastener lever must be as shown in the figure
Electrical system Stelvio 1200 NTX MY11
ELE SYS - 86
TABLE T
•
Place the connector on the opposite
side of the control unit and lower the
driving lever until the "click" that signals
the end of the stroke is heard.
TABLE U
•
When the connector is fully inserted,
the distance between the connector
and the ABS control unit must be 7.5
mm (0.29 in)
TABLE V
•
If the initial position of the connector
and the pulling level is not as the one
in "TABLE S", the connector will not
hook correctly and the distance measured will be higher than approximately
12 mm (0.47 in). In this case, repeat the
operation as described in "TABLE T"
and "TABLE U".
It is advisable to create a jig in order to check
the correct connector insertion.
Stelvio 1200 NTX MY11 Electrical system
ELE SYS - 87
Back side
TABLE A
1. Main fuses
2. Filter box air temperature sensor
3. Filter box
4. Secondary fuse protection injection system.
TABLE B
1. Medium clamp
2. Main cable harness
TABLE C
1. Rear plug socket
2. Cable grommet
3. ECU diagnosis connector
TABLE D
1. Adhesive cable grommet
Electrical system Stelvio 1200 NTX MY11
ELE SYS - 88
TABLE E
1. Plastic cable guides
TABLE F
1. Medium clamp that groups the oxygen sensor
leads, the rear stop and the rear taillight cable harness
TABLE G
1. Fall sensor connector with cover
TABLE H
1. Cable grommets
Stelvio 1200 NTX MY11 Electrical system
ELE SYS - 89
TABLE I
1. Cable grommet
2. Lambda leads
TABLE L
1. Reused clamps
2. Small clamp that has the lambda and the rear
stop cable together with the pipes group
General wiring diagram
OPTION 01
Electrical system Stelvio 1200 NTX MY11
ELE SYS - 90
key:
1. MULTIPLE CONNECTORS
2. CLUTCH SWITCH
3. START-UP RELAY
4. MAINTENANCE RELAY
5. LIGHT LOGIC RELAY
6. FOG LAMP RELAY
Stelvio 1200 NTX MY11 Electrical system
ELE SYS - 91
7. RIGHT LIGHT SWITCH
8. LEFT LIGHT SWITCH
9. HORN
10.AMBIENT AIR TEMPERATURE SENSOR
11.INSTRUMENT PANEL
12.IMMOBILIZER AERIAL
13.IGNITION KEY
14.HEATED HANDGRIPS
15.GPS COUPLING
16.-
17.-
18.REAR RIGHT TURN INDICATOR
19.TAILLIGHT ASSEMBLY
20.REAR LEFT TURN INDICATOR
21.LICENSE PLATE LIGHT BULB
22.REAR STOP SWITCH
23.FRONT STOP SWITCH
24.ABS CONTROL UNIT
25.FRONT WHEEL SPEED SENSOR
26.REAR WHEEL SPEED SENSOR
27.ANTITHEFT CONTROL UNIT (OPTIONAL EQUIPMENT)
28.-
29.SECONDARY FUSES
30.STARTER MOTOR
31.MAIN FUSES 2
32.MAIN FUSES 1
33.BATTERY
34.PLUG SOCKET "1"
35.GENERATOR
36.MAIN INJECTION RELAY
37.AUXILIARY INJECTION RELAY
38.OIL PRESSURE SENSOR
39.NEUTRAL SENSOR
40.OXYGEN SENSOR
41.SIDE STAND SWITCH
42.FUEL RESERVE SENSOR
43.FUEL PUMP
44.INTAKE AIR TEMPERATURE SENSOR
Electrical system Stelvio 1200 NTX MY11
ELE SYS - 92
45.ENGINE TEMPERATURE SENSOR
46.IDLE MOTOR
47.THROTTLE POSITION SENSOR
48.RIGHT CYLINDER COIL
49.LEFT CYLINDER COIL
50.RIGHT SPARK PLUG
51.LEFT SPARK PLUG
52.RIGHT CYLINDER INJECTOR
53.LEFT CYLINDER INJECTOR
54.FALL SENSOR (OPTIONAL EQUIPMENT)
55.PICK-UP
56.ECU
57.FOG LIGHTS
58.FRONT LEFT TURN INDICATOR
59.COMPLETE HEADLAMP
60.TAIL LIGHT BULB
61.HIGH - LOW BEAM BULB
62.FRONT RIGHT TURN INDICATOR
63.INSTRUMENT PANEL DIAGNOSIS
64.ECU DIAGNOSIS
65.HIGH BEAM LIGHT RELAY
66.PLUG SOCKET "2"
67.OXYGEN SENSOR RH
Cable colour:
Ar orange
Az sky blue
B blue
Bi white
G yellow
Gr grey
M brown
N black
R red
Ro pink
V green
Vi purple
OPTION 02
Stelvio 1200 NTX MY11 Electrical system
ELE SYS - 93
key:
1. MULTIPLE CONNECTORS
2. CLUTCH SWITCH
3. START-UP RELAY
4. MAINTENANCE RELAY
5. LIGHT LOGIC RELAY
6. FOG LAMP RELAY
Electrical system Stelvio 1200 NTX MY11
ELE SYS - 94
7. RIGHT LIGHT SWITCH
8. LEFT LIGHT SWITCH
9. HORN
10.AMBIENT AIR TEMPERATURE SENSOR
11.INSTRUMENT PANEL
12.IMMOBILIZER AERIAL
13.IGNITION SWITCH
14.HEATED HANDGRIPS
15.GPS COUPLING
16.-
17.-
18.REAR RIGHT TURN INDICATOR
19.TAILLIGHT ASSEMBLY
20.REAR LEFT TURN INDICATOR
21.LICENSE PLATE LIGHT BULB
22.REAR STOP SWITCH
23.FRONT STOP SWITCH
24.ABS CONTROL UNIT
25.FRONT WHEEL SPEED SENSOR
26.REAR WHEEL SPEED SENSOR
27.ANTITHEFT CONTROL UNIT (OPTIONAL EQUIPMENT)
28.MAIN FUSE 3
29.AUXILIARY FUSES
30.STARTER MOTOR
31.MAIN FUSES 2
32.MAIN FUSES 1
33.BATTERY
34.PLUG SOCKET "1"
35.ALTERNATOR
36.MAIN INJECTION RELAY
37.AUXILIARY INJECTION RELAY
38.OIL PRESSURE SENSOR
39.NEUTRAL SENSOR
40.LAMBDA PROBE LEFT
41.SIDE STAND SWITCH
42.FUEL RESERVE SENSOR
43.FUEL PUMP
44.INTAKE AIR TEMPERATURE SENSOR
Stelvio 1200 NTX MY11 Electrical system
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45.ENGINE TEMPERATURE SENSOR
46.IDLE MOTOR
47.THROTTLE POSITION SENSOR
48.RIGHT CYLINDER COIL
49.LEFT CYLINDER COIL
50.RIGHT SPARK PLUG
51.LEFT SPARK PLUG
52.RIGHT CYLINDER INJECTOR
53.LEFT CYLINDER INJECTOR
54.FALL SENSOR (OPTIONAL EQUIPMENT)
55.PICK-UP
56.ECU
57.FOG LIGHTS
58.FRONT LEFT TURN INDICATOR
59.COMPLETE HEADLAMP
60.TAIL LIGHT BULB
61.HIGH - LOW BEAM BULB
62.RIGHT FRONT TURN INDICATOR
63.INSTRUMENT PANEL DIAGNOSIS
64.ECU DIAGNOSIS
65.HIGH BEAM LIGHT RELAY
66.PLUG SOCKET "2"
67.LAMBDA PROBE RIGHT
Cable colour:
Ar orange
Az sky blue
B blue
Bi white
G yellow
Gr grey
M brown
N black
R red
Ro pink
V green
Vi purple
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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; in this case, at least two of
the programmed keys have to be inserted in the ignition lock.
After the first key has been inserted, the second one is requested with the following message:
INSERT KEY II
If the second key is not inserted within 20 seconds, the operation is finished.
After recognising the second key, the new code is required with the message:
ENTER NEW CODE
Once the operation is finished, the instrument panel goes back to the SET-UP menu.
DIAGNOSIS
Access to this menu (diagnosis functions), for the technical service only, after requesting a service code.
It will read: ENTER THE SERVICE CODE This vehicle code is: 10695
The functions in this menu are:
•
Exit
•
ECU diagnosis
•
Instrument Panel Errors
•
Error Clearing
•
Reset Service
•
Update
•
Change Keys
•
km / Miles
ECU ERRORS
The instrument panel receives only the current errors from the control unit.
Description Error code
Throttle Valve Error DC V DC ECU 10
Throttle Valve Error DC Gnd ECU 11
Engine Temperature Error DC V DC ECU 14
Engine Temperature Error DC Gnd ECU 15
Air Temperature Error DC V DC ECU 16
Stelvio 1200 NTX MY11 Electrical system
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Air Temperature Error DC Gnd ECU 17
Low Battery Error ECU 20
Lambda Probe Error ECU 21
Coil 1 Error DC V DC ECU 22
Coil 1 Error DC Gnd ECU 23
Coil 2 Error DC V DC ECU 24
Coil 2 Error DC Gnd ECU 25
Injector 1 Error DC V DC ECU 26
Injector 1 Error DC Gnd ECU 27
Injector 2 Error DC V DC ECU 30
Pump Relay Error ECU 36
Local Loopback Error ECU 37
Start-up Remote Error DC V DC ECU 44
Remote Error Start-up DC Gnd ECU 45
Canister Error DC V DC ECU 46
Canister Error DC Gnd ECU 47
Battery Error Hig ECU 50
Generic ECU Error ECU 51
Signal Panel Error ECU 54
Self-adaptability Value Error ECU 55
Vehicle Speed Error ECU 56
Stepper Error AC ECU 60
Stepper Error DC V DC ECU 61
Stepper Error DC Gnd ECU 62
Not recognised error ECU 00
INSTRUMENT PANEL ERRORS
In this mode a chart is displayed showing potential errors in the immobilizer and its sensors.
This is the error decoding chart:
Description: Immobilizer failure: Key code read but not recognised. Error code: DSB 01
Description: Immobilizer failure: Key code not read (Key not inserted or transponder broken) Error code:
DSB 02
Description: Immobilizer failure: Aerial not working (Open or short-circuited). Error code: DSB 03
Description: Immobilizer failure: Internal controller failure. Error code: DSB 04
Description: - Error code: DSB 05
Description: Air temperature sensor failure. Error code: DSB 06
Description: Oil sensor failure. Error code: DSB 07
Description: Oil pressure failure. Error code: DSB 08
The instrument panel keeps all previous errors stored in its memory.
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DELETE ERRORS
This option deletes instrument panel errors only, a further confirmation is requested.
INSTRUMENT PANEL SOFTWARE UPGRADE
This function is used to program the instrument
panel again with a new software through Navigator.
The Display reads: "Instrument panel disconnected. Now connect the diagnosis instrument"; the
instrument panel will connect normally after the
key is extracted-inserted.
The white connector is placed under the saddle,
beside the fuse box, close to the diagnosis connector for the injection system.
Use the Ditech connector in the Navigator Aprilia-
Moto Guzzi package to connect to the Navigator
cable.
KEY CHANGE FUNCTION
This function can be used:
1) if one key is lost; the dealer can disable this key;
2) to activate up to 4 keys;
3) should a new key lock be necessary and thus program the new set of keys.
In the first phase the user code must be entered and, after confirming the inserted key (key I) has been
programmed, the other keys must be entered too.
The procedure finishes once the 4 keys have been programmed or after 20 seconds.
Should a new key lock be necessary, the procedure is: once the key is set to ON but the instrument
panel does not recognise it, the user code is requested: enter the user code.
Now enter MENU, DIAGNOSIS (entering the service code), KEY CHANGE and program the new keys.
Battery recharge circuit
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Checking the stator
Single-phase generator with regulated voltage
Maximum load 40A (550W)
Charging voltage 14.2 - 14.8 V (5000 rpm)
Start-up system check
pick-up input about 100 A
level indicators
Petrol pump:
Input: 3.5 A (to be measured between pins 1 and
2 with 12V voltage)
Fuel level sensor:
Resistance (to be measured between pins 3 and
4)
250-300 Ohm with fuel level equal to 0 litre
100 Ohm with fuel level equal to 11.25 litres (20.43
pt)
10-20 Ohm with fuel level equal to 22.5 litres
(40.86 pt)
The low fuel warning light turns on with values over
230 Ohm.
In case there is anomaly on the fuel probe, the low fuel warning light flashes on the instrument panel.
The alarm warning light on the instrument panel does not light up and the word Service is not displayed.
Electrical system Stelvio 1200 NTX MY11
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