MOTO GUZZI Stelvio 4V-1200 ABS Specifications

SERVICE STATION MANUAL
895790
STELVIO 4V - 1200 ABS
SERVICE STATION
MANUAL
STELVIO 4V - 1200 ABS
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
setting off, 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 manual 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 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 2010 - 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.
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SERVICE STATION MANUAL
STELVIO 4V - 1200 ABS
This manual provides the main information to carry out regular maintenance operations on your vehicle.
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.
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.
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INDEX OF TOPICS
CHARACTERISTICS
CHAR
SPECIAL TOOLS
S-TOOLS
MAINTENANCE
MAIN
ELECTRICAL SYSTEM
ELE SYS
ENGINE FROM VEHICLE
ENG VE
ENGINE
POWER SUPPLY
ENG
P SUPP
SUSPENSIONS
SUSP
CHASSIS
CHAS
BRAKING SYSTEM
BRAK SYS
BODYWORK
BODYW
PRE-DELIVERY
PRE DE
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INDEX OF TOPICS
CHARACTERISTICS
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CHAR
STELVIO 4V - 1200 ABS
Characteristics
Rules
Safety rules
Carbon monoxide
If you need to keep the engine running while working on the vehicle, please ensure that you do so in
an open or very well ventilated area. Never run the engine in an enclosed area. If you do work in an
enclosed area, make sure to use a fume extraction system.
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 OR NEAR FUEL VAPOUR.
AVOID ANY CONTACT WITH NAKED FLAME, SPARKS OR OTHER HEAT SOURCES WHICH MAY
CAUSE IGNITION OR EXPLOSION.
DO NOT ALLOW FUEL TO DISPERSE INTO 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 LATEX 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
Brake and clutch fluid
CHAR - 7
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STELVIO 4V - 1200 ABS
Characteristics
BRAKE AND CLUTCH FLUIDS CAN DAMAGE THE PLASTIC OR RUBBER PAINTED SURFACES.
WHEN SERVICING THE BRAKING SYSTEM OR THE CLUTCH SYSTEM PROTECT THESE COMPONENTS 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 YOUR 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, MAY CAUSE BURNING IF IT COMES INTO 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. IN THE EVENT OF CONTACT WITH THE EYES, RINSE WITH PLENTY OF WATER FOR FIFTEEN MINUTES AND CONSULT AN EYE SPECIALIST IMMEDIATELY. IF THE FLUID IS ACCIDENTALLY SWALLOWED,
DRINK LARGE QUANTITIES OF WATER OR MILK, FOLLOWED BY MILK OF MAGNESIA OR
VEGETABLE OIL AND SEEK MEDICAL ADVICE IMMEDIATELY. THE BATTERY RELEASES EXPLOSIVE GASES; KEEP IT AWAY FROM FLAMES, SPARKS, CIGARETTES OR ANY OTHER
HEAT SOURCES. ENSURE ADEQUATE VENTILATION WHEN SERVICING OR RECHARGING
THE BATTERY.
KEEP OUT OF THE REACH OF CHILDREN
BATTERY LIQUID IS CORROSIVE. DO NOT POUR OR SPILL ON PLASTIC COMPONENTS IN
PARTICULAR. ENSURE THAT THE ELECTROLYTIC ACID IS COMPATIBLE WITH THE BATTERY
BEING ACTIVATED.
Maintenance rules
GENERAL PRECAUTIONS AND INFORMATION
When repairing, dismantling and reassembling the vehicle, follow the recommendations given below
carefully.
BEFORE DISASSEMBLING 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.
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STELVIO 4V - 1200 ABS
Characteristics
•
Keep mated parts together since they have "adjusted" to each other due to normal wear.
•
Some components must be used together or replaced altogether.
•
Keep away from heat sources.
REASSEMBLING COMPONENTS
CAUTION
BEARINGS MUST ROTATE FREELY, WITHOUT JAMMING AND/OR NOISE, OTHERWISE, THEY
NEED TO BE REPLACED.
•
Only use ORIGINAL Moto Guzzi SPARE PARTS.
•
Comply with lubricant and consumables use guidelines.
•
Lubricate parts (whenever possible) before reassembling them.
•
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), split 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 wiring harness:
Press the relative safety clips, if applicable.
•
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
DO NOT DISCONNECT CONNECTORS BY PULLING THE CABLES.
NOTE
THE TWO CONNECTORS CAN ONLY BE CONNECTED IN ONE DIRECTION: CONNECT THEM
THE RIGHT WAY ROUND.
TIGHTENING TORQUES
CAUTION
REMEMBER THAT THE TIGHTENING TORQUES FOR ALL FASTENING ELEMENTS ON WHEELS,
BRAKES, WHEEL AXLES AND ANY OTHER SUSPENSION COMPONENTS PLAY A KEY ROLE
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STELVIO 4V - 1200 ABS
Characteristics
IN ENSURING VEHICLE SAFETY AND MUST COMPLY WITH SPECIFIED VALUES. CHECK THE
TIGHTENING TORQUES OF FASTENING ELEMENTS ON A REGULAR BASIS AND ALWAYS USE
A TORQUE WRENCH TO REASSEMBLE THESE COMPONENTS. FAILURE TO COMPLY WITH
THESE RECOMMENDATIONS MAY CAUSE ONE OF THESE COMPONENTS TO LOOSEN OR
EVEN DETACH, CAUSING A WHEEL TO LOCK OR COMPROMISING VEHICLE HANDLING. THIS
MAY 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 runin. 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 DISCS
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 RUN-IN PERIOD.
Follow the guidelines detailed below:
•
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 MAINTENANCE SECTION TO AVOID INJURING YOURSELF, OTHERS AND /OR DAMAGING THE VEHICLE.
Vehicle identification
SERIAL NUMBER LOCATION
These numbers are necessary for vehicle registration.
NOTE
ALTERING IDENTIFICATION NUMBERS MAY BE SERIOUSLY PUNISHABLE BY LAW. IN PARTICULAR, MODIFYING THE CHASSIS NUMBER IMMEDIATELY VOIDS THE WARRANTY.
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STELVIO 4V - 1200 ABS
Characteristics
This number consists of numbers and letters, as in
the example shown below.
ZGULZA000YMXXXXXX
KEY:
ZGU: WMI (World manufacturer identifier) code;
LZ: model;
A00: 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
Maximum width (without accessories)
Maximum width at handlebar
Maximum width of vehicle with accessories
Minimum / maximum height (adjustable windshield)
Saddle height
Minimum ground clearance
Wheelbase
Kerb weight
Kerb weight of full house vehicle
Desc./Quantity
2305 mm (90.75 in)
910 mm (35.83 in)
1080 mm (42.52 in)
1395 / 1440 mm (54.92 / 56.69 in)
800 mm (31.5 in)
185 mm (7.3 in)
1535 mm (60.43 in)
251 kg (553 lb)
278 kg (613 lb)
Engine
ENGINE
Specification
Type
Number of cylinders
Cylinder layout
Desc./Quantity
four stroke 90° transverse V-twin
2
90° V
CHAR - 11
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STELVIO 4V - 1200 ABS
Characteristics
Specification
Bore / stroke
Engine capacity
Compression ratio
Ignition
Idle speed
Clutch
Lubrication system
Air filter
Cooling
Desc./Quantity
95 x 81.2 mm (3.74 x 3.20 in)
1151 cm³ (70 cu.in)
11: 1
electric
1100 ± 100 rpm
hydraulic single plate dry clutch with integrated flexible coupling
Pressurised circuit with regulator valves and trochoidal pump
dry cartridge air filter
air/oil system with independent trochoidal pump and pressure
regulator valve for oil cooling circuit
Timing system diagram
Single overhead camshaft with bucket tappets and rockers
Values valid with control clearance between rocker and valve
inlet: 0.10 mm (0.0039 in)
exhaust: 0.20 mm (0.0079 in)
Transmission
TRANSMISSION
Specification
Primary drive
Gearbox
Desc./Quantity
Helical gear, ratio 26/35 = 1:1.346
6 speed mechanical gearbox with foot gearshift lever on left
hand side of engine
17/38 = 1:2.2353
20/34 = 1:1.7
23/31 = 1:1.3478
26/29 = 1:1.1154
31/30 = 1:0.9677
29/25 = 1:0.8621
cardan shaft
12/44 = 1:3.6667
1st gear ratio
2nd gear ratio
3rd gear ratio
4th gear ratio
5th gear ratio
6th gear ratio
Final drive
Ratio
Capacities
CAPACITIES
Specification
Engine oil
Gearbox oil
Transmission oil
Fuel (reserve included)
Fuel reserve
Seats
Maximum weight allowed - standard version
Maximum weight allowed - NTX version
Desc./Quantity
Oil change and oil filter replacement: 3,500 cm³ (214 cu.in)
500 cm³ (30.5 cu.in)
380 cm³ (23.2 cu.in)
18 ± 1.5 l (3.96 ± 0.33 UK gal)
4 l (0.88 UK gal)
2
475 kg (1047 lb)
495 kg (1091 lb)
Electrical system
ELECTRICAL SYSTEM
Specification
Spark plug
Alternatively:
Spark plug
Electrode gap
Battery
Alternator (permanent magnet type)
Main fuses
Secondary fuses
Front daylight running light
Low/high beam headlight (halogen)
Turn indicators
Desc./Quantity
NGK PMR8B (long life)
NGK CR8EKB (long life)
0.6 - 0.7 mm (0.024 - 0.028 in)
12 V - 18 Ampere/hour
12 V - 550 W
20 (two for version with ABS) - 30 - 40 A
3 - 15 A (10A for ABS only)
12V - 5W
12 V - 55 W / 60 W H4
12V - 10 W
CHAR - 12
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STELVIO 4V - 1200 ABS
Characteristics
Specification
Rear daylight running lights /stop light
Supplementary headlamps (if fitted)
Instrument panel lighting
License plate light
Turn indicator warning light
Neutral gear warning light
Alarm warning light - Shift indicator
Side stand down warning light
Low fuel warning light
High beam warning light
ABS warning light
Desc./Quantity
LED
12 V/55W - H3
LED
12V - 5 W
LED
LED
LED
LED
LED
LED
LED
Frame and suspensions
CHASSIS
Specification
Type
Trail
Headstock
Front
Front wheel travel
Rear
Unloaded shock absorber spring length
Rear wheel travel
Desc./Quantity
high strength tubular steel frame with engine as stressed element
125 mm (4.92 in)
27°
Upside down telescopic hydraulic fork, with 45mm (1.77 in) diam., stanchions and radial calliper mounting bracket with adjustable spring preload and hydraulic compression and rebound damping.
170 mm (6.69 in)
single sided swingarm with progressive linkage and monoshock with adjustable hydraulic rebound and compression
damping and spring preloading adjustment.
180 mm (7.09 in)
155 mm (6.10 in)
SIZES A AND B
Specification
Size A
Size B
Desc./Quantity
745.0 mm (29.33 in)
403.16 mm (15.87 in)
Brakes
BRAKES
Specification
Front
Rear
Desc./Quantity
Dual 320 mm (12.6 in) diam. stainless steel floating wavy disc
with radial callipers with 4 differentiated, horizontally opposed
pistons.
282 mm (11.1 in) diam. stainless steel disc
CHAR - 13
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STELVIO 4V - 1200 ABS
Characteristics
Wheels and tyres
WHEELS AND TYRES - STELVIO (STANDARD)
Wheel
Model
Rim
Size
Front (standard)
Pirelli Scorpion Sync
2.50 x 19"
Rear (standard)
Pirelli Scorpion Sync
5.50 x 17
110/80
R19 - 59V
180/55
R17 - 73V
Tyre pressure with
Tyre pressure, rider +
rider only
passenger
2.5 bar (250 kPa) (36.3 2.5 bar (250 kPa) (36.3
PSI)
PSI)
2.9 bar (290 kPa) (42.1 2.9 bar (290 kPa) (42.1
PSI)
PSI)
WHEELS AND TYRES - STELVIO (ALTERNATIVE EQUIPMENT)
Wheel
Model
Rim
Front (alternatively)
Pirelli Scorpion Trail
2.50 x 19"
Front (alternatively)
Metzeler Karoo (*) (***)
2.50 x 19"
Rear (alternatively)
Pirelli Scorpion Trail
4.25 x 17"
Rear (alternatively)
Metzeler Karoo (*) (***)
4.25 x 17"
Size
Tyre pressure with
Tyre pressure, rider +
rider only
passenger
110/80
2.5 bar (250 kPa) (36.3 2.5 bar (250 kPa) (36.3
R19 - 59V
PSI)
PSI)
110/80
2.5 bar (250 kPa) (36.3 2.5 bar (250 kPa) (36.3
R19 - 59R
PSI) (**)
PSI) (**)
M+S
150/70
2.9 bar (290 kPa) (42.1 2.9 bar (290 kPa) (42.1
R17 - 69V
PSI)
PSI)
150/70
2.7 bar (270 kPa) (36.1 2.9 bar (290 kPa) (42.1
R17 - 69R
PSI) (**)
PSI) (**)
M+S
Supply
FUEL SYSTEM
Specification
Fuel system
Diffuser
Fuel
Desc./Quantity
Electronic injection (Weber. Marelli) with Stepper motor
diameter: 50 mm (1.97 in)
Premium unleaded petrol, minimum octane rating 95 (NORM)
and 85 (NOMM)
Tightening Torques
HEADS
Name
Oil cap (2)
Rocking lever support nut - M10x1.5 (8)
Camshaft - rocking levers support fixing screws (12)
Head fixing screw (4) - pre-tightening
Head fixing screw (4) - final tightening
Screw fixing head to chain compartment - M6x120 (4)
Oil temperature sensor
Oil temperature sensor container
Head covers fixing screws (8)
Spark plug (2)
Torque in Nm
25 Nm (18.44 lbf ft)
15 Nm (11.06 lbf ft) + 42 Nm (30.98 lbf ft)
17 Nm (12.54 lbf ft)
15 Nm (11.06 lbf ft)
42 Nm (31 lbf ft)
10 Nm (7.38 lbf ft)
11 Nm (8.11 lbf ft) - Loctite 243
11 Nm (8.11 lbf ft) - Loctite 601
8 Nm (5.9 lbf ft)
15 Nm (11.06 lbf ft) - Molykote
CRANKCASE
Name
Crankcase stud bolt - cylinder (8)
Transmission side flange stud bolt - M8x66 (3)
Transmission side flange stud bolt - M8x75 (2)
Gear side crankshaft flange screw - TE M8x25 (8)
Timing system cover screw - TCEI M8x55 (4)
Timing system cover screw - TCEI M6x30 (10)
Oil vapour union screw - TCEI M6x20 (2)
TCEI M6x40 Screw (2)
Torque in Nm
25 Nm (18.44 lbf ft)
35 Nm (25.81 lbf ft)
35 Nm (25.81 lbf ft)
26 Nm (19.18 lbf ft)
25 Nm (18.44 lbf ft)
10 Nm (7.38 lbf ft)
10 Nm (7.38 lbf ft)
10 Nm (7.38 lbf ft)
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STELVIO 4V - 1200 ABS
Characteristics
Name
Timing sensor - TCEI M5x12 (2)
Service shaft bearing locking screw (2)
Oil pressure sensor (1)
Screw fixing oil pressure sensor support - TCEI M10x20 (1)
Oil cap (2)
Torque in Nm
6 Nm (4.42 lbf ft)
10 Nm (7.38 lbf ft)
25 Nm (18.44 lbf ft)
18 Nm (13.28 lbf ft)
25 Nm (18.44 lbf ft)
OIL SUMP
Name
Oil pipe on sump reduction (1)
Oil pipe on sump
Oil sump lower screw - TCEI M6x30 (4)
Oil sump screw - TCEI M6x55 (14)
Oil sump screw - TCEI M6x60 (2)
Oil drainage plug - M10x1 (1)
Oil filter (1)
Oil filter fitting (1)
Oil pipe in sump
Pressure-relief plug
Cap on oil sump flange (2)
Cap (1)
Torque in Nm
20 Nm (14.75 lbf ft)
20 Nm (14.75 lbf ft)
10 Nm (7.38 lbf ft)
10 Nm (7.38 lbf ft)
10 Nm (7.38 lbf ft)
20 Nm (14.75 lbf ft)
15 Nm (11.06 lbf ft)
40 Nm (29.5 lbf ft) - Loctite 243
20 Nm (14.75 lbf ft) - Loctite 648
40 Nm (29.5 lbf ft)
20 Nm (14.75 lbf ft)
40 Nm (29.5 lbf ft)
CRANKSHAFT - FLYWHEEL
Name
Connecting rod screw (4) - pre-tightening
Connecting rod screw (4) - final tightening
Screw fixing clutch disc on crankshaft - M8x25 (6)
Screw fixing clutch bell on disc - M7x16 (6)
Start-up crown gear fixing screw (6)
Torque in Nm
40 Nm (29.5 lbf ft)
80 Nm (59 lbf ft)
42 Nm (30.98 lbf ft) - Loctite 243
20 Nm (14.75 lbf ft)
10 Nm (7.38 lbf ft)
OIL PUMP
Name
Oil pump fixing screws - M6x45 (3)
Oil pump gear nut - M10x1.25 (1)
Pressure-relief plug
Cooling oil intake filter fixing screw (5)
Lubrication oil intake filter fixing screw (2)
Torque in Nm
10 Nm (7.38 lbf ft)
20 Nm (14.75 lbf ft)
40 Nm (29.5 lbf ft)
10 Nm (7.38 lbf ft)
10 Nm (7.38 lbf ft)
TIMING SYSTEM
Name
Service shaft flange screw - TBEI M6x14 (2)
Timing system gear nut on service shaft - M18 (1)
Timing system gear nut on crankshaft - M25 (1)
Timing system upper gear TE screw (2)
Screw fixing timing system upper gear closing cap - TBEI
M5x10 (4)
Cylinder chain tensioner cap (2)
Screw fixing movable chain slider (2)
Torque in Nm
8 Nm (5.9 lbf ft)
150 Nm (110.6 lbf ft)
200 Nm (147.51 lbf ft)
30 Nm (22.13 lbf ft)
7 Nm (5.16 lbf ft)
30 Nm (22.13 lbf ft)
25 Nm (18.44 lbf ft)
ALTERNATOR
Name
Alternator fixing screw - TCEI M8x45 (1)
Alternator fixing nut - M10x1.5 (1)
Alternator pulley nut on crankshaft - M16 (1)
Belt tension
Alternator belt cover screw - TCEI M6x16 (4)
Alternator belt cover screw (radiator bracket retainer) TCEI
M6x40 (2)
Torque in Nm
22 Nm (16.23 lbf ft)
30 Nm (22.13 lbf ft)
80 Nm (59 lbf ft) - Loctite 243
50 Nm (36.88 lbf ft)
10 Nm (7.38 lbf ft)
10 Nm (7.38 lbf ft)
GEAR
Name
Gear shift cable lever nut
Gear shift tie rod lever nut on gear pre-selector
Torque in Nm
10 Nm (7.38 lbf ft)
10 Nm (7.38 lbf ft)
CHAR - 15
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STELVIO 4V - 1200 ABS
Characteristics
Name
Gearbox to crankcase fixing nut - M8 (5)
TE flanged screw fixing gearbox to crankcase - M8x45 (1)
Oil cap M18x1.5 (1)
Breather cap (1)
Gear in neutral sensor (1)
Oil drainage plug - M10x1 (1)
Transmission shaft ring nut (1)
Torque in Nm
20 Nm (14.75 lbf ft)
20 Nm (14.75 lbf ft)
28 Nm (20.65 lbf ft)
8 Nm (5.9 lbf ft)
10 Nm (7.38 lbf ft)
24 Nm (17.7 lbf ft)
100 Nm (73.76 lbf ft)
OIL RADIATOR
Name
Radiator to chassis retainer M6x30 (3)
Nipples to radiator retainer M16x1.5 (2)
Oil pipes to radiator and engine retainer M16x1.5 (2 + 2)
Torque in Nm
10 Nm (7.38 lbf ft)
20 Nm (14.75 lbf ft)
20 Nm (14.75 lbf ft)
CHASSIS TO ENGINE UNIT
Name
M6x40 TCEI DA screw
Reduction
Torque in Nm
8 -12 Nm
20 Nm
FUEL SUPPLY CONTROL UNIT
Name
M5x12 TCEI screw
Stainless M5x16 TBEI flanged screw
M6x25 TCEI DA screw
Torque in Nm
6 -7 Nm
6 -7 Nm
8 -12 Nm
CHASSIS
Name
Front engine to chassis retainer
Transmission to chassis retainer (M12x250 + M12x230)
Right fixing plate - transmission retainer
Plate clamp - Blow-by retainer
Coil plate retainer
Electronic control unit retainer
Bushings to electronic control unit retainer - M6x35 (1)
Tank support rubber rings to chassis retainer (2)
Filter casing fixing bolts
Left and right footrest plate to chassis upper retainer M8x30 (2
+2)
Left and right footrest plate to chassis lower retainer M8x75 (2
+2)
Brake switch on plate retainer
Chrome-plated ring to plate retainer M5x10 (6)
Retainer for cable guide on right footrest plate
Front speed sensor screws retainer
ABS control unit screws retainer (2)
Rear speed sensor screws retainer
Torque in Nm
80 Nm
50 Nm
25 Nm
10 Nm
10 Nm
10 Nm
10 Nm (7.38 lbf ft) - Loct 243
Manual - Loct 243
10 Nm
20 Nm (14.75 lbf ft)
20 Nm (14.75 lbf ft)
Manual
6 Nm (4.42 lbf ft)
6 Nm
6 Nm (4.42 lbf ft) + Loc. 243
10 Nm (7.37 lbf ft)
10 Nm (7.37 lbf ft)
FOOTRESTS AND LEVERS
Name
Footrest rubber retainer
Rider footrest sliding pin - M8
Passenger footrest support to lateral plates retainer
Rider heelrest to plates retainer
Passenger heelrest retainer
Rod retainer (nut)
Gear shift lever / brake pin retainer
Gear shift lever / pre-selector retainer
Gear shift lever pin - brake retainer M8 (1+1)
Torque in Nm
10 Nm
25 Nm
38 Nm
6 Nm
3 Nm
10 Nm
10 Nm
10 Nm
15 Nm (11.06 lbf ft) - Loct 243
SIDE STAND
Name
Stand plate to engine upper retainer
Torque in Nm
50 Nm
CHAR - 16
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STELVIO 4V - 1200 ABS
Characteristics
Name
Stand plate to engine lower retainer
Side stand retainer pin
Switch fixing screw - M6x20 (1)
Lock nut
Stand cable guide to engine retainer M8 (1)
Side lever arm retainer - M6x16 (2)
Torque in Nm
25 Nm
10 Nm
10 Nm (7.38 lbf ft) - Loct 243
30 Nm
25 Nm (18.44 lbf ft)
10 Nm (7.38 lbf ft) - Loct 243
SWINGARM
Name
Swingarm on bushing clamp retainer
Swingarm on bevel gear pair retainer
Reaction rod to bevel gear pair retainer
Reaction rod to chassis retainer
Swingarm bolt to swingarm retainer
Preloading bushing to swingarm bolt retainer
Torque in Nm
10 Nm
50 Nm
50 Nm
50 Nm
60 Nm
10 Nm
FRONT SUSPENSION
Name
Tube lock plate to steering base retainer
Fork stem on upper plate retainer - M8x30 (2)
Fork stem on lower plate retainer - M8x30 (4)
Headstock ring nut
Headstock counter ring nut
Upper yoke fixing cap
Fork hub closing - M6x30 (2+2)
Torque in Nm
6 Nm
20 Nm (14.75 lbf ft)
20 Nm (14.75 lbf ft)
40 Nm
manual + 90 degrees
100 Nm
10 Nm (7.38 lbf ft)
REAR SUSPENSION
Name
Shock absorber to chassis retainer - 8.8
Double connecting rod/shock absorber retainer - 10.9
Single connecting rod/double connecting rod retainer - 10.9
Single connecting rod to chassis retainer - 8.8
Double connecting rod/swingarm retainer - 10.9
Torque in Nm
50 Nm
40 Nm
50 Nm
50 Nm
50 Nm
AIR FILTER CASING - BLOW-BY
Name
Blow-by expansion tank spacer to engine retainer
Filter housing to chassis retainer
Torque in Nm
10 Nm
10 Nm
EXHAUST
Name
Exhaust pipe to engine retainer
Silencer to chassis connecting pipe retainer
Muffler to chassis retainer - M8x45 (1)
Heat guard retainer - M6 (3)
Lambda probe retainer
Clamps retainer - M8 (3)
Torque in Nm
25 Nm
25 Nm
25 Nm (18.44 lbf ft)
10 Nm (7.38 lbf ft)
38 Nm
20 Nm (14.75 lbf ft)
FRONT WHEEL
Name
Wheel pin nut
Torque in Nm
80 Nm
REAR WHEEL
Name
Disc retainer
Rear wheel retainer 10.9
Torque in Nm
25 Nm
110 Nm
FRONT BRAKING SYSTEM
Name
Front brake right and left calliper retainer
Torque in Nm
50 Nm
CHAR - 17
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STELVIO 4V - 1200 ABS
Characteristics
REAR BRAKING SYSTEM
Name
Rear brake calliper retainer
Rear brake fluid reservoir retainer
Rear brake fluid reservoir support to plate retainer
Rear brake rod lock nut
Brake pump retainer - M6x20 (2)
Torque in Nm
50 Nm
3 Nm
10 Nm
manual
10 Nm (7.38 lbf ft) - Loctite 243
HANDLEBAR AND CONTROLS
Name
Retainer for handlebar lower U-bolts on steering upper plate
Retainer for handlebar upper U-bolts
Anti-vibration counterweight fastener
Brake pump and clutch U-bolts retainer
Right and left light switch retainer
Clutch control cylinder to gear retainer
Rear-view mirror
Torque in Nm
50 Nm
25 Nm
10 Nm
10 Nm
1.5 Nm
10 Nm
Manual
ELECTRICAL SYSTEM
Name
Coil retainer
Horn retainer
Odometer sensor on bevel gear pair retainer
Torque in Nm
2 Nm
15 Nm
3 Nm
INSTRUMENT PANEL AND LIGHTS
Name
Instrument panel retainer
Front arrows retainer - M4 (2)
Front headlamp retainer - M6x30 (6)
Rear light to license plate retainer - M5x16 (4)
Torque in Nm
3 Nm
3 Nm (2.21 lbf ft)
10 Nm (7.38 lbf ft)
6 Nm (4.42 lbf ft)
FUEL PUMP FLANGE
Name
Pump support to tank retainer
Torque in Nm
6 Nm
FUEL TANK
Name
Filler to tank retainer
Screws on cap ring nut (aesthetic)
Tank to chassis front retainer
Torque in Nm
5 Nm
5 Nm
10 Nm
ENGINE COVER
Name
Right cover plate retainer - M10x20 (2)
Left cover plate retainer - M10 (1)
Front oil sump guard retainer - M8x25 (4)
Torque in Nm
40 Nm (29.5 lbf ft)
40 Nm (29.5 lbf ft)
20 Nm (14.75 lbf ft)
FRONT BODYWORK
Name
Front mudguard retainer
Air deflector self-tapping retainer (4+4)
Fairing junction - M5 (2+2)
Glove-box - self-tapping (4)
Compartment lock - M6 (2)
Hinge locking bracket - self-tapping (2)
Rear tank cover - M5 (2)
Rear tank cover - M6 (2)
Left - right fairing - M5 (2)
Left - right fairing - M6 (2)
Torque in Nm
6 Nm
Manual
Manual
Manual
Manual
Manual
4 Nm (2.95 lbf ft)
10 Nm (7.38 lbf ft)
4 Nm (2.95 lbf ft)
10 Nm (7.38 lbf ft)
CHAR - 18
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STELVIO 4V - 1200 ABS
Characteristics
REAR BODYWORK
Name
Left - right fairings retainer - M6 (3+3)
Retroreflector to support retainer
Retroreflector support to license plate holder retainer
License plate holder and light reinforcing retainer - M5 (1)
Cases support retainer - M6 (2)
Cases support retainer - M8 (2+2)
Passenger grab handle to chassis retainer - M8 (2)
Passenger grab handle to chassis retainer - M6 (4)
License plate holder to chassis retainer - M5 (4)
Luggage carrier brackets retainer - M8 (2+2)
Torque in Nm
10 Nm (7.38 lbf ft)
4 Nm
4 Nm
4 Nm (2.95 lbf ft)
10 Nm (7.38 lbf ft)
25 Nm (18.44 lbf ft)
25 Nm (18.44 lbf ft)
10 Nm (7.38 lbf ft)
4 Nm (2.95 lbf ft)
25 Nm (18.44 lbf ft)
FINISHINGS
Name
Ignition lock retainer - shear head screw
Torque in Nm
- Nm
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
Piston diameter - selection D
Cylinder diameter - selection D
Piston diameter - selection E
Cylinder diameter - selection E
Piston diameter - selection F
Cylinder diameter - selection F
Desc./Quantity
94.935 - 94.945 mm (3.73759 - 3.73798 in)
95.000 - 95.010 mm (3.74015 - 3.74054 in)
94.945 - 94.955 mm (3.73798 - 3.73837 in)
95.010 - 95.020 mm (3.74054 - 3.74093 in)
94.955 - 94.965 mm (3.73837 - 3.73877 in)
95.020 - 95.030 mm (3.74093 - 3.74133 in)
CHAR - 19
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STELVIO 4V - 1200 ABS
Characteristics
PIN - PISTON COUPLING
Specification
Pin diameter
Pin hole diameter on piston
Clearance between pin and holes on piston
Desc./Quantity
21.998 - 21.994 mm (0.86606 - 0.86590 in)
22.016 - 22.011 mm (0.86677 - 0.86657 in)
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
Top ring
Middle ring
Oil scraper ring
Desc./Quantity
0.030 - 0.065 mm (0.00118 - 0.00256 in)
0.020 - 0.055 mm (0.00079 - 0.00216 in)
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
Diameter of crankshaft main journal, timing system side
Inside diameter of crankshaft bushing, timing system side
Clearance between bushing and main journal (timing system
side)
Desc./Quantity
37.975 - 37.959 mm (1.49507 - 1.49444 in)
38.016 - 38.0 mm (1.49669 - 1.49606 in)
0.025 - 0.057 mm (0.00098 - 0.00224 in)
CRANKSHAFT SEAT ( CLUTCH SIDE)
Specification
Diameter of crankshaft main journal, clutch side
Inside diameter of crankshaft bushing on clutch-side flange
Clearance between bushing and main journal (clutch side)
Desc./Quantity
53.97 - 53.961 mm (2.12480 - 2.12444 in)
54.019 - 54.0 mm (2.12673 - 2.12598 in)
0.030 - 0.058 mm (0.00118 - 0.00228 in)
CHAR - 20
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STELVIO 4V - 1200 ABS
Characteristics
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 Comparator 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 Comparator support for piston position checking
CHAR - 21
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STELVIO 4V - 1200 ABS
Characteristics
•
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
Value (X) -0.56 / -0.37 mm (-0.022 / -0.0146 in)
Value (X) -0.37 / -0.19 mm (-0.0146 / -0.0075 in)
Value (X) -0.19 / 0 mm (-0.0075 / 0 in)
Desc./Quantity
gasket thickness: 0.65 mm (0.0256 in)
gasket thickness: 0.85 mm (0.0335 in)
gasket thickness: 1.05 mm (0.0413 in)
Recommended products chart
RECOMMENDED PRODUCTS
Product
AGIP RACING 4T 10W-60
AGIP GEAR SAE 80 W 90
AGIP GEAR MG/S SAE 85 W 90
AGIP ARNICA SA 32
AGIP GREASE SM2
Neutral grease or petroleum jelly.
AGIP BRAKE 4 / BRAKE 5.1
AGIP BRAKE 4 / BRAKE 5.1
Description
Engine oil
Specifications
SAE 10W - 60. As an alternative to the
suggested oils, one may use brand name
oils with performances matching or higher than CCMC G-<metricconverter productid="4 A" w:st="on" />4 A</metricconverter />.P.I. SG specifications.
SAE 0W - ISO VG 32
NLGI 2
Transmission oil
Gearbox oil
Fork oil
Lithium grease with molybdenum for
bearings and other points needing lubrication
BATTERY POLES
Brake fluid
As an alternative for recommended fluids
use top-branded fluids that meet or exceed the requirements of SAE J1703,
NHTSA 116 DOT 4, ISO 4925 Synthetic
fluid specifications.
Clutch fluid
As an alternative for recommended fluids
use top-branded fluids that meet or exceed the requirements of SAE J1703,
NHTSA 116 DOT 4, ISO 4925 Synthetic
fluid specifications.
CHAR - 22
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INDEX OF TOPICS
SPECIAL TOOLS
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S-TOOLS
STELVIO 4V - 1200 ABS
Special tools
MOTORE
Stores code
020677Y
Description
Alternator belt tensioner, Belt tensioning
lever
05.91.17.30
Front cover insertion cone
020716Y
Connecting rod locking
020470Y
Pin snap ring fitting tool
05.92.72.30
Timing system cover sealing ring punch
01.92.91.00
Wrench for removing the cover on sump
and filter
S-TOOLS - 24
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STELVIO 4V - 1200 ABS
Special tools
Stores code
05.90.25.30
Description
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 flywheelside flange
S-TOOLS - 25
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STELVIO 4V - 1200 ABS
Special tools
Stores code
12.91.20.00
Description
Tool to fit the flywheel-side flange together with sealing ring on the crankshaft
19.92.71.00
Tool to fit the sealing ring on the flywheelside flange
020673Y
Graduated dial hub
020672Y
Clutch spring centre and pusher
020674Y
Piston ring clamp
020675Y
Service shaft gear lock
020676Y
Comparator support for piston position
checking
S-TOOLS - 26
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STELVIO 4V - 1200 ABS
Special tools
Stores code
020678Y
Description
Tool for clutch rod checking
05.91.25.30
Gearbox opening
CHASSIS
Stores code
14.91.26.03
Description
Hook spanner for fixing ring nut of the
clutch shaft internal body
AP8140190
Tool for steering tightening
BEVEL GEAR SET
Stores code
05.90.27.30
Description
Gearbox support
S-TOOLS - 27
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STELVIO 4V - 1200 ABS
Special tools
Stores code
05.90.27.31
Description
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
FRONT FORK
Stores code
AP8140146
Description
Weight
S-TOOLS - 28
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STELVIO 4V - 1200 ABS
Special tools
Stores code
AP8140149
Description
Protection for fitting operations
9100903
Marzocchi fork oil seal; ø 45 mm (1.77 in)
020886Y
Spacer / pumping member pin splitting
plate
S-TOOLS - 29
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INDEX OF TOPICS
MAINTENANCE
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MAIN
STELVIO 4V - 1200 ABS
Maintenance
Maintenance chart
NOTE
CARRY OUT MAINTENANCE OPERATIONS AT HALF THE INTERVALS SHOWN IF THE VEHICLE
IS USED IN WET OR DUSTY AREAS, OFF ROAD OR FOR SPORTING APPLICATIONS.
ROUTINE MAINTENANCE TABLE
I: INSPECT AND CLEAN, ADJUST, LUBRICATE OR REPLACE IF NECESSARY
C: CLEAN, R: REPLACE, A: ADJUST, L: LUBRICATE
* Check and clean, adjust or replace if necessary before every ride.
** Replace every 2 years or 20000 km (12427 miles).
*** Replace every 4 years
**** Check at every start-up.
***** 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.
km x 1,000
Exhaust pipe flange fixing bolts
Spark plugs
Idle mixture (CO)
Throttle body
Stands*****
Transmission cables and controls
Generator belt
Steering bearings and steering clearance
Wheel bearings
Brake discs
Air filter
Engine oil filter
Fork
Vehicle general operation
Braking systems
Light circuit
Safety switches
Brake fluid **
Clutch fluid **
Gearbox oil
Engine oil
Fork oil / oil seals
Final drive oil
Tyres - pressure / wear*
Engine revs at idle speed
Valve clearance adjustment
Wheels
Bolts and nuts tightening
Battery terminals - tightening
Tightening wheel nipples*
Cylinder synchronisation
Footrest joint *****
Suspensions and setting
Engine oil pressure warning light ****
Empty oil drain pipe from the filter housing
Fuel pipes ***
Brake pipes ***
Clutch wear
Brake pad wear *
1.5
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20
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50
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60
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70
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80
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Transmission fluid
MAIN - 31
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STELVIO 4V - 1200 ABS
Maintenance
Check
• Keep the vehicle upright with both wheels on the
ground.
• Unscrew and remove the cap/dipstick (1).
• The level is correct if the oil is close to the hole
of the cap/dipstick (1).
• If the oil is lower than specified, top-up until it
reaches the cap/dipstick hole (1).
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE 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).
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO THE FLUID. WHEN USING A FUNNEL
OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
•
Screw and tighten the caps (1 - 2).
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STELVIO 4V - 1200 ABS
Maintenance
Engine oil
Check
CAUTION
ENGINE MUST BE WARM TO CHECK ENGINE OIL LEVEL
NOTE
DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE
AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER
RUNNING FOR ABOUT 15 KM (10 miles).
•
Stop 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 OIL. WHEN USING A FUNNEL OR
ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Replacement
NOTE
HOT OIL IS LESS VISCOUS AND WILL DRAIN OUT MORE EASILY AND COMPLETELY.
To change the engine oil and to replace the oil filter, remove the oil sump guard.
•
Operating from both sides, unscrew
and remove the two front screws (1).
•
Operating from both sides, unscrew
and remove the rear screw (2).
•
Remove the oil sump guard.
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STELVIO 4V - 1200 ABS
Maintenance
•
Place a container with +4,000 cm³ (244
cu in) capacity under the drainage plug
(3).
•
Unscrew and remove the drainage
plug (3).
•
Pull out the oil filler plug / engine oil
level dipstick (4).
•
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.
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.
See also
Replacement
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STELVIO 4V - 1200 ABS
Maintenance
Gearbox Oil
Inspection
CHECKING AND TOPPING UP
CAUTION
ENGINE MUST BE WARM TO CHECK GEARBOX OIL LEVEL.
NOTE
DO NOT LET THE ENGINE IDLE WITH THE VEHICLE AT STANDSTILL TO WARM UP THE ENGINE
AND REACH THE OPERATING TEMPERATURE OF ENGINE OIL. OIL IS BEST CHECKED AFTER
RUNNING FOR ABOUT 15 KM (10 miles).
•
Shut off the engine.
•
Keep the vehicle upright with both
wheels on the ground.
•
Unscrew and remove the cap/dipstick
(1) placed on the gearbox right side.
•
• The level is correct if the oil is on the
rim of the hole of the cap/dipstick (1).
If necessary:
•
Top-up with oil until it reaches the dipstick opening (1).
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE 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.
• Place a container with suitable capacity under the
drainage plug (2).
• Unscrew and remove the drainage plug (2).
• Unscrew and remove the filler cap (1).
• Drain the oil into the container; allow several minutes for oil to drain out completely.
• Check and replace, if necessary, 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).
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STELVIO 4V - 1200 ABS
Maintenance
• Pour in new oil until it reaches the dipstick opening (1).
• Tighten the filler cap (1).
CAUTION
DO NOT ADD ADDITIVES OR ANY OTHER SUBSTANCE TO
THE FLUID. WHEN USING A FUNNEL OR ANY OTHER ELEMENT, MAKE SURE IT IS PERFECTLY CLEAN.
Air filter
•
Undo and remove the six screws.
•
Lift the filter housing cover.
•
Remove the air filter.
•
Cover the inlet duct with a clean cloth so that no foreign bodies get into the inlet ducts.
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).
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STELVIO 4V - 1200 ABS
•
Disconnect both spark plug tubes.
•
Unscrew and remove the four head
Maintenance
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:
Characteristic
Values valid with control clearance between
rocker and valve
inlet: 0.10 mm (0.0039 in)
exhaust: 0.20 mm (0.0079 in)
•
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.
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STELVIO 4V - 1200 ABS
Maintenance
•
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).
•
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).
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STELVIO 4V - 1200 ABS
Maintenance
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.
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INDEX OF TOPICS
ELECTRICAL SYSTEM
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ELE SYS
STELVIO 4V - 1200 ABS
Electrical system
Components arrangement
Key:
1 Coil
2 Instrument panel
3 Fuel pump
4 Injector
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STELVIO 4V - 1200 ABS
5 Throttle valve potentiometer
6 Fall sensor
7 Rear light
8 Main fuses
9 Lambda probe
10 Battery
11 Starter motor
12 Intake air temperature sensor
13 Engine revolution sensor
14 Head temperature sensor
15 Engine control unit
16 Instrument panel air temperature sensor
17 Front headlamp
18 Alternator
19 Oil pressure sensor
20 Speed sensor
21 Auxiliary fuses
22 Relay
23 ABS Control unit
24 Rear speed sensor
25 ABS Fuses
Electrical system installation
INTRODUCTION
Scope and applicability
The purpose of this document is to define cables laying, their fastening on the motorcycle and possible
criticalities, special checks on connections and layouts, all this with the aim of obtaining vehicle reliability.
Special checks for the correct connection and laying of cables
The indicated connectors are considered critical in comparison with the others because the vehicle will
stop if they are accidentally disconnected. Undoubtedly the connection of the rest of connectors is also
important and essential for the correct operation of the vehicle.
Vehicle sections
The wiring distribution is subdivided in three essential sections, as indicated in the figure.
1. Front section
2. Central section
3. Rear section
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STELVIO 4V - 1200 ABS
Electrical system
Front side
TABLE A
1 - Check that the ground terminals are placed on
the coils
TABLE B
2 - Clamps.
3 - Auxiliary fuses.
4 - Instrument panel cable harness.
5 - Relays.
6 - Right coil.
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Electrical system
STELVIO 4V - 1200 ABS
TABLE C
7 - Marelli control unit.
8 - Left coil.
TABLE D
9 - Clamp.
10 - Horn.
TABLE E
11 - Clamps.
12 - Pick-Up.
13 - Antitheft.
TABLE F
14 - Left fog light.
15 - GPS Connector.
TABLE G
16 - Rubber clamps.
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STELVIO 4V - 1200 ABS
Electrical system
TABLE H
17 - Clamps.
18 - Instrument panel air temperature thermistor.
TABLE I
19 - Clamp not completely pulled.
20 - Left light switch cable harness.
21 - Key switch cable harness.
22 - Clutch switch cable harness.
TABLE J
23 - Clamps.
24 - Instrument panel cable harness.
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Electrical system
STELVIO 4V - 1200 ABS
TABLE J1
A - Black cable grommet.
B - Pipe lock clamp.
C - Front ABS sensor.
TABLE J2
D - Black cable grommet.
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STELVIO 4V - 1200 ABS
Electrical system
Central part
TABLE K
25 - Main cable harness.
TABLE L
Main cable harness passage with output: left coil,
horn, pick up, antitheft, control unit, left turn indicator, GPS connector and compartment lock.
TABLE M
Main cable harness passage with output: right coil,
key, right light switch, instrument panel, secondary
fuses, relay, lights and right turn indicator.
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Electrical system
STELVIO 4V - 1200 ABS
TABLE N
26 - Clamp.
27 - Heated hand grips connectors.
TABLE O
28 - Clamps.
TABLE O1
- Connect the ABS connector by fully inserting the
cap in its housing.
- Slide out the cables and connectors of: speed
sensor, light switch and ignition switch assembly.
E - ABS Control unit.
F - Clamp.
TABLE O2
- Set the connectors as in figure.
TABLE O3
- The initial position of the connector fastener lever must be as shown in the figure.
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STELVIO 4V - 1200 ABS
Electrical system
TABLE O4
- Place the connector in the control unit counter
part and lower the pulling lever until you hear the
"click" of end of stroke.
TABLE O5 CORRECT ASSEMBLY
- When the connector is fully inserted, the distance
measured between this and the ABS control unit
must be of 7.5 mm (0.29 in).
TABLE O6 WRONG ASSEMBLY
- If the initial position of the connector and the pulling level is not as the one previously shown, 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 connection
operations.
TABLE P
29 - Injectors.
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Electrical system
STELVIO 4V - 1200 ABS
TABLE O
28 - Clamps.
TABLE P
29 - Injectors.
TABLE Q
30 - Clamp.
31 - Fall sensor.
32 - Main cable harness.
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STELVIO 4V - 1200 ABS
Electrical system
TABLE R
33 - Starter motor.
34 - Positive battery cable.
Back side
TABLE S
35 - Adhesive cable guides.
TABLE T
36 - Adhesive cable guides.
37 - U-bolt.
TABLE U
38 - Clamps.
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Electrical system
STELVIO 4V - 1200 ABS
TABLE V
39 - Negative battery cable.
TABLE W
40 - Black cable grommet.
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STELVIO 4V - 1200 ABS
Electrical system
General wiring diagram
key:
1. MULTIPLE CONNECTORS
2. CLUTCH SWITCH
3. START-UP RELAY
4. MAINTENANCE RELAY
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Electrical system
STELVIO 4V - 1200 ABS
5. LIGHT LOGIC RELAY
6. FOG LIGHTS RELAY (OPTIONAL EQUIPMENT)
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.GLOVE-BOX COMPARTMENT OPENING RELAY
17.ELECTRIC LOCK
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.UNDER SADDLE SWITCH
29.Secondary fuses
30.STARTER MOTOR
31.MAIN FUSES 2
32.MAIN FUSES 1
33.Battery
34.PLUG SOCKET
35.ALTERNATOR
36.MAIN INJECTION RELAY
37.AUXILIARY INJECTION RELAY
38.OIL PRESSURE SENSOR
39.NEUTRAL SENSOR
40.LAMBDA PROBE
41.SIDE STAND SWITCH
42.FUEL RESERVE SENSOR
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STELVIO 4V - 1200 ABS
Electrical system
43.FUEL PUMP
44.INTAKE AIR TEMPERATURE SENSOR
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
55.PICK-UP
56.ECU
57.FOG LIGHT (OPTIONAL EQUIPMENT)
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
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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Electrical system
STELVIO 4V - 1200 ABS
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
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STELVIO 4V - 1200 ABS
Electrical system
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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Electrical system
STELVIO 4V - 1200 ABS
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 ApriliaMoto 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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STELVIO 4V - 1200 ABS
Electrical system
Checking the stator
Single-phase generator with regulated voltage
Maximum load 40A (550W)
Charging voltage 14.2 - 14.8 V (5000 rpm)
Start-up system check
pick-up input about 100 A
level indicators
Petrol pump:
Input: 3.5 A (to be measured between pins 1 and
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.
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STELVIO 4V - 1200 ABS
Electrical system
Lights list
FRONT HEADLAMP
Specification
Front daylight running light
Low/high beam headlight (halogen)
Desc./Quantity
12V - 5W
12 V - 55 W / 60 W H4
REAR LIGHT
Specification
Rear daylight running lights /stop light
License plate light
Desc./Quantity
LED
12V - 5 W
Fuses
AUXILIARY FUSES
A - Stop, horn, coil, GPS, hazard button lighting,
coils, light relay, passing, heated grips (15 A).
B - Daylight running lights, license plate light, starter motor, accessory storage compartment relay
(15 A).
C - Live positive, ABS control unit power supply
(10 A) (where foreseen)
D - Fuel pump, coils, injectors (15 A).
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STELVIO 4V - 1200 ABS
Electrical system
D - Lambda burner, secondary injection relay coil,
start-up relay coil (15 A).
F- Permanent positive, ECU power supply (3A).
NOTE
THERE ARE TWO SPARE FUSES.
MAIN FUSES
1 - Battery recharge (40 A).
2 - Motion main fuse (30 A).
3 - High beam fuse (20 A).
4 - Primary ABS fuse (20 A) (where foreseen).
NOTE
THERE IS ONE SPARE FUSE.
Control unit
Model: Magneti Marelli IAW 5 AM2
Battery
12 V - 18 Ampere/hour
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Electrical system
STELVIO 4V - 1200 ABS
Speed sensor
FRONT
FUNCTION:To indicate the vehicle speed by reading the front wheel turning speed.
OPERATION / OPERATING PRINCIPLE:Magnetoresistive sensor: a square-wave pulse is generated with voltage approx. between 11.55 V and
11.25 V
WIRING DIAGRAM Level in wiring diagram: ABS.
REMOVAL
LOCATION ON THE VEHICLE:on the fork, right
stem, next to the brake calliper support.
CONNECTOR LOCATION (if available): under
the fuel tank, front position.
PINS
•
PIN 1- Ground connection (white)
•
PIN 2 - Power supply voltage/Output
signal (white/brown)
NAVIGATOR: PARAMETERS
Speed sensor
Vehicle speed: km/h
FRONT SPEED SENSOR, ELECTRICAL ERRORS
5D90 electric malfunction: Electrical fault in sensor or cable harness.
Troubleshooting: Check the sensor connector and the ABS control unit connector. If it is not OK,
restore the connectors; if it is OK, check continuity of the cable between sensor PIN 2 on the cable
harness side and PIN 14 ABS control unit connector. If there is no continuity, restore them. If there is,
PIN 2 of the sensor on the cable harness side, with the sensor disconnected and key set to ON, must
have 12V voltage approximately: if there is no voltage, check PIN 2 for continuity with the vehicle ground
connection: if it is grounded, restore the cable harness. If OK, replace the control unit. If PIN 2 has
approx. 12 V, check continuity of the cable between PIN 1 of the sensor on the cable harness side and
PIN 13 of the ABS control unit connector. If this is not OK, restore the cable harness. If it is OK, replace
the sensor.
LOGIC ERRORS
Speed sensor
5D91 the signal works irregularly: faulty sensor or signal interference.
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Electrical system
Troubleshooting: Check speed sensor retainer. If it is not OK, restore it. If it is OK, check if the tone
wheel is dirty, deformed or wrongly fixed. If any of this happens, replace the tone wheel. Otherwise,
replace the speed sensor.
5D92 the signal decreases periodically: Possible tone wheel fault due to deformations or dirt; possible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel vibrations.
Troubleshooting: Check if the tone wheel is dirty, deformed or wrongly fixed. If the tone wheel is not
OK, replace it. If it is OK, check for possible faults in the wheel bearings and if it is not OK, replace the
bearings.
5D93 missing signal or speed measured too low in relation to the rear wheel: faulty sensor or
missing sensor/tone wheel. Or excessive distance between the sensor and the tone wheel or tone wheel
with wrong number of teeth.
Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install
them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace
the tone wheel and if it is OK, replace the speed sensor.
5D94 no acceleration after pressure reduction: Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone wheel.
Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install
them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace
the tone wheel and if it is OK, replace the speed sensor.
5D95 excessive speed measured: Faulty sensor or tone wheel, or tone wheel with wrong number of
teeth or wrong tyre size.
Troubleshooting: Check that the speed sensor and the tone wheel are installed. If they are not, install
them. If they are, check the speed sensor retainer. If it is not OK, restore it. If it is, check if the tone
wheel has the correct number of teeth or if it is dirty, deformed or wrongly fixed. If it is not OK, replace
the tone wheel and if it is OK, check that the tyre size is the correct one. If it is not OK, replace it. If it is
OK, check that the tyre pressure is the correct one. If it is not OK, restore it; if it is OK, replace the speed
sensor.
REAR
FUNCTION: It is used by the ABS module, and
then by the ECU and the instrument panel.
OPERATION / OPERATING PRINCIPLE:Differential Hall effect sensor.
ELECTRICAL CIRCUIT DIAGRAM- Level in wiring diagram: ABS.
REMOVAL
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LOCATION ON THE VEHICLE:Under the bevel
gear set box, right side.
CONNECTOR LOCATION (if available):Under
the saddle, right side.
PIN-OUT:
•
PIN1 - Ground
•
PIN2 - Signal
NAVIGATOR: PARAMETERS
Speed sensor
Vehicle speed: km/h
REAR SPEED SENSOR OPEN CIRCUIT OR SHORT CIRCUIT NAVIGATOR ERROR
Description of the defect: the control unit detects abnormal voltage in the rear speed sensor signal.
Checks:check battery voltage on the cable between pin 2 of the rear speed sensor connector and pin
11 of the ABS module connector. If there is not enough voltage, check cable continuity from the ABS
module to the speed sensor connector and make sure that the cable is ground insulated.
Solution:restore wiring. It is normal that when the speed sensor connector is disconnected, no voltage
is detected.
If functioning is correct, proceed to the next check
Checks: check the speed sensor signal (0.5 or 1 V) on the cable between pin 1 of the rear speed sensor
connector and pin 12 of the ABS module connector. If there is not enough voltage, check cable continuity
from the ABS module to the speed sensor connector and make sure that the cable is grounded insulated.
Solution:if the cable is interrupted or grounded, restore wiring.
If the cable harness is not damaged, it means that the speed sensor is defective or the circuit between
sensor and connector is interrupted: replace the speed sensor.
FRONT / REAR SPEED SENSOR COHERENCE NAVIGATOR ERROR
Description of the defect: the control unit detects an abnormal condition in the signals coming from
the speed sensors: for example, disturbances, signal intensity reduced, speed difference between the
two wheels for a certain period of time, etc.
Checks:check the correct distance between speed sensor and tone wheel.
Solution:restore the correct distance between speed sensor and tone wheel.
If functioning is correct, proceed to the next check
Checks:check the tone wheel is not distorted (it should not be deformed or damaged).
Solution:replace tone wheel
If functioning is correct, proceed to the next check
Checks: check the speed sensor position and integrity.
Solution:position the speed sensor correctly or replace it.
If functioning is correct, proceed to the next check.
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Electrical system
Checks:check tyres for wear (there should not be much difference between front and rear) and for
correct pressure.
Solution:use tyres with the specified tyre wear condition and pressure.
If functioning is correct, proceed to the next check
Checks:make sure that "the failure" has not been caused by using the vehicle in sport competitions.
Solution:for example, avoid prolonged rearing up on the back wheel
Engine rpm sensor
Function
Informs crankshaft position and speed to the Marelli control unit.
Operation / Operating principle
Inductive sensor: sinusoidal-type generated voltage; two teeth are missing on the flywheel for the
reference position.
Level in electrical circuit diagram:
Engine speed sensor
Location:
•
Sensor: Front left side of the engine,
under the generator.
•
Connector: Under the fuel tank.
Electrical characteristics:
•
Winding resistance 650 Ohm +/- 15%
•
Output alternating voltage, value
range: minimum: 0.5 V - maximum: 5 V
PIN:
1. Engine revolution sensor positive signal.
2. Engine revolution sensor negative signal.
3. Revolution sensor anti-jamming cable.
NAVIGATOR: PARAMETERS
Target engine revs
Example value:1100 +/- 100 rpm
Parameter valid at idle, setting depends especially on engine temperature: the ECU unit will try to keep
the engine running at this revs, acting on the ignition advance.
NAVIGATOR: STATUSES
Synchronisation
Example value:Synchronised / Not synchronised
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Indicates if the control unit detects the revolution sensor signal correctly
DIAGNOSIS
Engine revolution sensor
An interruption in the sensor circuit has been detected, from PIN 25 to PIN 35 of connector A (BROWN)
Check the sensor connector and the injection control unit connector A (BROWN): it they are not OK,
restore. If OK, check continuity of the two cables leading to PINS 25 and 35 of the control unit connector:
if there is not continuity, restore the cable harness; if there is continuity, check the interruption on the
sensor and replace it.
WARNING If the electric circuit is short-circuited, no error is displayed. Check the sensor electrical
specifications: If they are not correct, replace the sensor. If correct, check supply insulation and ground
connection insulation of both cables. Perform the tests from the sensor connector towards the sensor.
If they are not OK, restore the cable harness or replace the sensor. If OK, perform the tests for pins 25
and 35 of the Marelli control unit connector A (BROWN) towards the cable harness.
Air gap value:
Place the sensor plus the corresponding spacers; the air gap should be between 0.7 and 0.9 mm.
Throttle position sensor
Function
In charge of telling the control unit the position of
the throttle valves.
Operation / Operating principle
The throttle valve position sensor works as a variable resistance according to the throttle rotation.
Level in electrical circuit diagram:Throttle and
idle motor
Location:
•
sensor: on the right cylinder throttle
body
•
connector: on the potentiometer
Electrical characteristics:
•
PINS A-C: throttle closed approx. 2.5
kOhm; throttle open approx. 1.5 kOhm.
•
PINS A-B: approx. 1.1 kOhm
Pin-out:
•
PIN A: ground connection
•
PIN B: supply voltage +5V
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•
Electrical system
PIN C: potentiometer signal
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
NAVIGATOR: FUEL INJECTION SYSTEM
NAVIGATOR: PARAMETERS
Throttle
Example value: 4.9°
NAVIGATOR: STATUSES
Throttle position
Example value:Released/Pressed/Full load
Indicates if the throttle potentiometer is open or closed in the released position.
NAVIGATOR: ERRORS
Throttle actuator position sensor P0120
Example value:open circuit, shorted to positive / shorted to negative.
Error cause
•
If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 3 of
connector A (BROWN).
•
If shorted to negative: voltage equal to zero has been detected.
Troubleshooting
•
Circuit is open, shorted to positive: check the injection control unit connector and the sensor
connector: if they are not OK, restore; if they are OK, check continuity between PIN 3 of
connector A (BROWN) and PIN C of the sensor (red cable): if there is not continuity, restore
the cable harness; if there is continuity, check continuity of the sensor between PIN A and
PIN C: if there is not continuity, replace the potentiometer; if there is continuity, check the
resistance. If resistance is over 2.5 kOhm, it means the red cable is shorted to positive and
the cable harness should be restored
•
shorted to negative: disconnect the sensor connector and check the ground insulation of the
red cable (from throttle sensor connector or control unit connector): if there is continuity to
ground, restore the cable harness; if it is ground insulated, the resistance between PIN A
and PIN C is below 1.3 kOhm; therefore, the throttle body should be replaced
NAVIGATOR: ADJUSTMENT
Throttle position autodetection: It allows the control unit to detect the closed throttle position; just
press the Enter key.
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Electrical system
Self-adjustable parameters reset: Lambda probe self-adaptability parameters reset: operation to be
carried out after the throttle body is cleaned or in the case a new engine, a new lambda probe or a new
injector is fitted, or the correct operation of the injection system or the valves is restored.
NAVIGATOR: RESET PROCEDURE
Once the throttle body or the injection control unit is replaced, it is necessary to connect to the diagnosis
instrument selecting FUEL INJECTION and carry out the operation: Throttle position autodetection.
Engine temperature sensor
Function
tells the engine temperature to the control unit so
as to optimise its operation.
Operation / Operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in electrical circuit diagram:Temperature
sensors
Location:
•
sensor: inside the "V"
•
Connector: on the sensor
Electrical characteristics:
ENGINE TEMPERATURE SENSOR RESISTANCE
Specification
Resistance at -40 °C (-40 °F)
Resistance at -30 °C (-22 °F)
Resistance at -20 °C (-4 °F)
Resistance at -10 °C (14 °F)
Resistance at 0 °C (32 °F)
Resistance at +10 °C (50 °F)
Resistance at +20 °C (68 °F)
Resistance at +30 °C (86 °F)
Resistance at +40 °C (104 °F)
Resistance at +50 °C (122 °F)
Resistance at +60 °C (140 °F)
Resistance at +70 °C (158 °F)
Resistance at +80 °C (176 °F)
Resistance at +90 °C (194 °F)
Resistance at +100 °C (212 °F)
Resistance at +110 °C (230 °F)
Resistance at +120 °C (257 °F)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Desc./Quantity
100.950 kOhm
53.100 kOhm
29.120 kOhm
16.600 kOhm
9.750 kOhm
5.970 kOhm
3.750 kOhm
2.420 kOhm
1.600 kOhm
1.080 kOhm
0.750 kOhm
0.530 kOhm
0.380 kOhm
0.280 kOhm
0.204 kOhm
0.153 kOhm
0.102 kOhm
Pin-out:
•
PIN 1: Ground connection
•
PIN 2:0-5 V signal
THE CONNECTION DIAGRAMS ARE IN THE ELECTRICAL SYSTEM SECTIONS; PAY ATTENTION
TO THESE DIAGRAMS AS THEY SHOW THE CONNECTOR/COMPONENT AS VIEWED FROM
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THE CABLE HARNESS SIDE, THAT IS LOOKING AT THE CABLES WHEN GOING OUT OF THE
"MAIN" CABLE HARNESS AND INTO THE CONNECTOR/COMPONENT.
CAUTION
BEFORE CARRYING OUT ANY TROUBLESHOOTING, CAREFULLY READ THE GENERAL TROUBLESHOOTING CONCEPTS FOR ELECTRICAL DEVICES AT THE BEGINNING OF THE CHECK
AND CONTROL SECTION IN THE ELECTRICAL SYSTEM CHAPTER.
NAVIGATOR: FUEL INJECTION SYSTEM
NAVIGATOR: PARAMETERS
Engine temperature
In case of recovery, this value is set by the control unit.
NAVIGATOR: ERRORS
engine temperature sensor P0115 - open circuit, shorted to positive / shorted to negative.
Error cause
•
If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 5 of
connector A (BROWN).
•
If shorted to negative: voltage equal to zero has been detected at PIN 5 of the BROWN
connector.
Troubleshooting
•
If the circuit is open, shorted to positive: check the sensor connector and the Marelli control
unit connector. If they are not OK, restore the cable harness; if OK, check the continuity of
the sensor; if it is not OK, replace the sensor; if it is OK, check continuity between PIN 5 of
the BROWN connector and PIN 2 of sensor: restore cable harness if there is not continuity;
if it is OK, reconnect the control unit connector and, with key set to key ON, check the
continuity between the sensor connector PIN 1 and the vehicle ground connection: if there
is not continuity, restore the cable harness; if there is continuity, it means that the cause of
the error is that the cable is shorted to positive and now the cable harness between the
BROWN PIN 5 and PIN 2 of the sensor should be restored. If the air temperature sensor
error is displayed at the same time, this means that the grey cable common for both sensors
is shorted to positive.
•
If shorted to negative, check sensor correct resistance: if resistance is null, replace the sensor; if resistance is correct, it means that the orange cable has ground connection: restore
the cable harness.
NOTES No error is detected if the sensor does not work correctly or the control unit connector
or sensor terminals are rusty: then check through Navigator if the temperature indicated is the
same as the engine temperature. Check also that the sensor electrical characteristics are observed: replace the sensor if not OK; if it is OK, check the sensor connector and the Marelli
control unit connector
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Electrical system
Air temperature sensor
Function
It tells the control unit the intake air temperature in
order to calculate oxygen presence so as to optimise the petrol quantity necessary for correct combustion.
Operation / Operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in electrical circuit diagram:Temperature
sensors
Location:
•
sensor: on filter casing
•
connector: on the sensor
Electrical characteristics:
AIR TEMPERATURE SENSOR RESISTANCE
Specification
Resistance at -40 °C (-40 °F)
Resistance at 0 °C (32 °F)
Resistance at 10 °C (50 °F)
Resistance at 20 °C (68 °F)
Resistance at 30 °C (86 °F)
Resistance at 40 °C (104 °F)
Resistance at 90 °C (194 °F)
1
2
3
4
5
6
7
Desc./Quantity
100.950 kOhm
9.750 kOhm
5.970 kOhm
3.750 kOhm
2.420 kOhm
1.600 kOhm
0.280 kOhm
Pin-out:
•
PIN 1: Ground connection
•
PIN 2: 0-5 V signal
NAVIGATOR: PARAMETERS
Air temperature
In case of failure, temperature is set at 25 °C (77 °F)
NAVIGATOR: ERRORS
air temperature sensor P0110 - open circuit, shorted to positive / shorted to negative.
Error cause
•
If the circuit is open, shorted to positive: excessive voltage has been detected at PIN 14 of
the BROWN connector. If shorted to negative: voltage equal to zero has been detected at
PIN 14 of the BROWN connector
Troubleshooting
•
If the circuit is open, shorted to positive: check the sensor connector and the Marelli control
unit connector. If they are not OK, restore the cable harness; if OK, check the continuity of
the sensor; if it is not OK, replace the sensor; if it is OK, check continuity between PIN 14
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Electrical system
of the BROWN connector and PIN 2 of sensor: restore cable harness if there is not continuity;
if it is OK, reconnect the control unit connector and, with key set to key ON, check the
continuity between the sensor connector PIN 1 and the vehicle ground connection: if there
is not continuity, restore the cable harness; if there is continuity, it means that the cause of
the error is that the cable is shorted to positive and now the cable harness between the
BROWN PIN 14 and PIN 2 of the sensor should be restored. If the engine temperature
sensor error is displayed at the same time, this means that the grey cable common for both
sensors is shorted to positive.
•
If shorted to negative, check sensor correct resistance: if resistance = 0, replace the sensor;
if resistance is correct, it means that the pink/black cable has ground connection: restore
the cable harness
NOTES No error is detected if the sensor does not work correctly or the control unit connector
or sensor terminals are rusty: then check through Navigator if the temperature indicated is
plausible in relation to the ambient temperature. Check also that the sensor electrical characteristics are observed: replace the sensor if not OK; if it is OK, check the sensor connector and
the Marelli control unit connector
Lambda sensor
Function
In charge of telling the control unit whether the
mixture is lean or rich.
Operation / Operating principle
The Marelli injection control unit reads and interprets a voltage generated by the difference in oxygen content between the exhaust fumes and the
ambient. It does not require an external supply
source but, in order to work properly, it should
reach a high operating temperature: that is why
there is a heating circuit inside.
Level in electrical circuit diagram:Lambda
probe
Location:
•
sensor: exhaust pipe
•
Connector: near the probe
Electrical characteristics:
Heater circuit: 12 -14 Ω at 20 °C (68 °F)
Pin-out:
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STELVIO 4V - 1200 ABS
1. Sensor signal + (black wire)
2. Sensor signal - (grey wire)
3. Heater ground connection (white)
4. Heater power supply (white)
NAVIGATOR: PARAMETERS
Lambda probe
Example value: 0 - 1000 mV
If there is a short circuit at + 5 V or above, the value read is approx. 5,000 mV. If there is a short circuit
to ground instead, the value read is equal to 0 mV and the Lambda Sensor Correction parameter shows
25%: no error is displayed, though.
Lambda sensor correction
example value: 1.00
In closed loop, the value must be close to 0 % (values not within the +10 % and -10 % range may
indicate a fault): In an open circuit, the lambda probe signal is too low. Therefore, the control unit takes
it as a lean mixture condition and will try to enrich it. The value read will be +25%.
NAVIGATOR: STATUSES
Lambda check
Example value: Open loop / Closed loop
Closed loop indicates that the control unit is using the lambda probe signal to keep the combustion as
close as possible to the stoichiometric value.
NAVIGATOR: ERRORS
Lambda probe P0130 - Shorted to positive.
Error cause
•
Excessive voltage (battery voltage) has been detected at PINS 32 and 22 of the BLUE
connector.
Troubleshooting
•
shorted to positive: with the key set to ON, disconnect the sensor connector and measure
voltage at PIN 1 on the cable harness side (white/yellow cable): if there is voltage (5 or 12
V), restore the cable harness; it there is no voltage, measure voltage at PIN 2, cable harness
side, (green/white cable) and if there is voltage, restore the cable harness; if there is no
voltage, replace the lambda probe
Lambda probe heating P0135 - shorted to positive / open circuit, shorted to negative.
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 11 of the BLUE connector.
•
If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 11
of the BLUE connector.
Troubleshooting
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•
Electrical system
shorted to positive: disconnect the probe connector and check the sensor correct resistance:
replace the sensor if not OK; if it is OK, restore the cable harness.
•
circuit is open, shorted to negative: check the continuity from probe connector (PIN 3 and
4) towards the probe: if not OK, replace the probe; if it is correct, check the sensor connector
and the Marelli control unit connector. If not OK, restore. If OK, and with key set to ON and
sensor connector disconnected, check if there is battery voltage at PIN 4: if not OK, check
the red/black cable (cable harness side) between the probe connector and the auxiliary
injection relay (No. 37 in the wiring diagram, placed on the front right side of the motorcycle,
in the auxiliary fuses/relays box, first relay to the left starting from the front; CHECK, however, the identification of the relay with the colour of the cables). If there are also coil and
injector errors, check that relay and its excitation and power line; if there is voltage at PIN
4, check the white cable ground insulation, cable harness side (PIN 3): if it is not OK, restore
the cable harness. If OK, check continuity of the white cable, cable harness side (between
PIN 3 of the sensor connector PIN 3 and PIN 11 of the BLUE connector) and restore the
cable harness.
Injector
Function
To supply the correct amount of petrol at the right
timing.
Operation / Operating principle
Injector coil is excited for the petrol passage to
open.
Level in electrical circuit diagram:Coils and injectors
Location:
•
on the intake manifold
•
connector: on injector
Electrical characteristics:14.8 Ohm +/- 5% (at
20 °C)
Pin-out:
"+": Supply:
" ": Ground connection
NAVIGATOR:FUEL INJECTION SYSTEM
NAVIGATOR: PARAMETERS
Injection time
NAVIGATOR: ACTIVATION
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STELVIO 4V - 1200 ABS
Left injector: operation for 4 ms, 5 times
The auxiliary injection relay (No. 37 in the electrical circuit diagram, placed on the front right side of the
motorcycle, in the auxiliary fuses/relays box, first relay to the left starting from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the grey/
red cable of the injector is closed to ground for 4 ms per second. Disconnect the 4-way connector of
the fuel pump to be able to hear the relay and injector activation. The continuity of the cable harness is
necessary for correct activation: no error indications are displayed in case of lack of activation.
NAVIGATOR: ERRORS
Left injector P0201 - shorted to positive / shorted to negative / open circuit.
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 28 of the BROWN connector.
•
If shorted to negative: no voltage has been detected.
•
If the circuit is open: an interruption has been detected
Troubleshooting
•
Shorted to positive: disconnect the injector connector, take the key to ON and check if there
is voltage on the grey/red cable: if there is voltage, restore the cable harness. If there is no
voltage, replace the injector.
•
If shorted to negative: disconnect the injector connector, take the key to ON and check if the
grey/red cable has continuity to the ground connection: if there is continuity to ground, restore the cable harness; if there is not continuity, replace the injector
•
The circuit is open: check the component correct electrical characteristic: if it is not the correct one, replace the component; if it is correct, check the connector on the component and
the Marelli control unit connector: If they are not OK, restore. If OK, check cable continuity
between PIN 28 of the BROWN connector and the component PIN - and restore the cable
harness.
NAVIGATOR: ACTIVATION
Right injector: Operation for 4 ms, 5 times
The auxiliary injection relay (No. 37 in the electrical circuit diagram, placed on the front right side of the
motorcycle, in the auxiliary fuses/relays box, first relay to the left starting from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the blue/
red cable of the injector is closed to ground for 4 ms per second. Disconnect the 4-way connector of
the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is necessary
for correct activation: no error indications are displayed in case of lack of activation.
NAVIGATOR: ERRORS
Right injector P0202 - shorted to positive / shorted to negative / open circuit.
Error cause
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•
Electrical system
If shorted to positive: excessive voltage has been detected at PIN 37 of the BROWN connector.
•
If shorted to negative: no voltage has been detected.
•
If the circuit is open: an interruption has been detected
Troubleshooting
•
If shorted to positive: disconnect the injector connector, take the key to ON and check if
there is voltage on the blue/red cable: if there is voltage, restore the cable harness. If there
is no voltage, replace the injector.
•
If shorted to negative: disconnect the injector connector, take the key to ON and check if the
blue/red cable has continuity to the ground connection: if there is continuity to ground, restore the cable harness; if there is not continuity, replace the injector
•
The circuit is open: check the component correct electrical characteristic: if it is not the correct one, replace the component; if it is correct, check the connector on the component and
the Marelli control unit connector: If they are not OK, restore. If OK, check cable continuity
between PIN 37 of the BROWN connector and the component PIN - and restore the cable
harness
Coil
Function
It controls the ignition spark plug in order to generate the fuel ignition spark.
Operation / Operating principle
Inductive discharge system
Level in electrical circuit diagram:Coils and injectors
Location:
•
In front of the fuel tank, left and right
side
•
Connector: on the coils
Electrical characteristics:
•
Primary winding resistance: 550 mΩ ±
10%, at approx. 23 °C (73.4 °F).
•
Secondary winding resistance: 3 mΩ
± 10%, at approx. 23 °C (73.4 °F).
•
Tube resistance: 5 kΩ.
Pin-out:
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Electrical system
STELVIO 4V - 1200 ABS
1. Power supply + Vbatt
2. Circuit ground
NAVIGATOR: PARAMETERS
Left coil ignition advance.
NAVIGATOR: ACTIVATION
Left coil:
The auxiliary injection relay (No. 37 in the electrical circuit diagram, placed on the front right side of the
motorcycle, in the auxiliary fuses/relays box, first relay to the left starting from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the
green/orange cable of the coil is closed to ground for 2 ms per second. Disconnect the 4-way connector
of the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is
necessary for correct activation: no error indications are displayed in case of lack of activation
NAVIGATOR: ERRORS
Left coil P0351- shorted to positive / open circuit, shorted to negative
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 38 of the BROWN connector.
•
If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 38
of the BROWN connector
Troubleshooting
•
Shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with
Navigator and check voltage at connector PIN 2: if there is voltage, restore the cable harness; if voltage = 0, replace the coil.
•
If the circuit is open, shorted to negative: check the coil connector and the Marelli control
unit connector. If they are not OK, restore; if everything is OK, check cable continuity between PIN 2 of the coil connector and PIN 38 of the BROWN connector. If there is not
continuity, restore the cable harness; if there is cable continuity, with the key set to KEY ON,
check the cable ground insulation (from coil connector or control unit connector). If this is
not OK, restore the cable harness.
NAVIGATOR: PARAMETERS
Right coil ignition advance.
NAVIGATOR: ACTIVATION
Right coil:
The auxiliary injection relay (No. 37 in the electrical circuit diagram, placed on the front right side of the
motorcycle, in the auxiliary fuses/relays box, first relay to the left starting from the front; CHECK, however, the identification of the relay with the colour of the cables) is energised for 5 seconds and the sky
blue/green cable of the coil is closed to ground for 2 ms per second. Disconnect the 4-way connector
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STELVIO 4V - 1200 ABS
Electrical system
of the fuel pump to be able to hear the relay and injector activation. The continuity of the wiring is
necessary for correct activation: no error indications are displayed in case of lack of activation
NAVIGATOR: ERRORS
Right coil P0352 - shorted to positive / open circuit, shorted to negative.
Error cause
•
If shorted to positive: excessive voltage has been detected at PIN 10 of the BROWN connector.
•
If the circuit is open, shorted to negative: voltage equal to zero has been detected at PIN 10
of the BROWN connector
Troubleshooting
•
shorted to positive: disconnect the coil connector, set the key to ON, activate the coil with
Navigator and check voltage at connector PIN 2: if there is voltage, restore the cable harness; if voltage = 0, replace the coil
•
if the circuit is open, shorted to negative: check the coil connector and the Marelli control
unit connector. If they are not OK, restore; if everything is OK, check cable continuity between PIN 2 of the coil connector and PIN 10 of the BROWN connector. If there is not
continuity, restore the cable harness; if there is cable continuity, with the key set to KEY ON,
check the cable ground insulation (from coil connector or control unit connector). If this is
not OK, restore the cable harness.
Engine oil pressure sensor
Function:Indicates the instrument panel if there is
enough oil pressure (0.35 +/- 0.15 bar) (5.1 +/2.18 PSI) in the engine.
Operation / Operating principle: normally closed
switch. With oil pressure above 0.35 +/-0.15 bar
(5.1 +/- 2.18 PSI), open circuit.
Level in wiring diagram:fuel reserve and oil pressure.
Location:
•
Sensor: in between the engine "V", a
little to the left, under the generator
•
Connector: on the sensor.
Pin-out: Voltage 12V
Instrument panel
Oil sensor failure DSB 07
Error cause
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Electrical system
•
STELVIO 4V - 1200 ABS
An oil sensor failure is signalled when, with engine off, it is detected that the sensor circuit
is open. The test is performed only once when the key is set to ON. This error is signalled
by the bulb icon and the general warning light turns on as well.
Troubleshooting
•
Check the sensor connector and the instrument panel connector (PIN 17): If not OK, restore.
If OK, check the continuity of the purple cable between the sensor connector and the instrument panel connector PIN 17: if not OK, restore the cable harness; if OK, replace the
sensor.
Oil pressure failure DSB 08
Error cause
•
An oil sensor failure is signalled when, with engine running, it is detected that the sensor
circuit is closed. This error is signalled by the bulb icon and the general warning light turns
on as well.
Troubleshooting
•
Detach the sensor connector and check the purple cable is ground insulated: if there is
continuity to ground, restore the cable harness; if it is ground insulated, replace the switch.
It this error persists, use a pressure gauge to check the pressure of the oil in the engine
circuit
Neutral sensor
Function
it tells the gear position to the control unit: in neutral or in gear.
Operation / Operating principle
for gear in neutral, the circuit is closed to ground connection: then, via CAN, the control unit sends the
signal to the instrument panel which turns on the neutral speed warning light.
Level in electrical circuit diagram:start-up enabling switches
Location:
•
Sensor: rear / upper side of the gearbox
•
Connector: on the sensor
Electrical characteristics:
•
Gear in neutral: closed circuit (0 V on wire from control unit to sensor / switch in continuity).
•
Gearshift engaged: open circuit (12 V on wire from control unit to sensor / open switch,
infinite resistance)
Pin-out:
•
PIN 1: Voltage 12V
NAVIGATOR: STATUSES
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STELVIO 4V - 1200 ABS
Electrical system
Gear in neutral
Example value:yes/no
DIAGNOSIS
•
Indication on the instrument panel always gear engaged: check the control unit connector
and the sensor connector: if they are not OK, restore the cable harness; if OK, disconnect
the connector and, with gear in neutral, check continuity to ground of the terminal, sensor
side: if there is not continuity, replace the sensor (after checking cable harness continuity
on the sensor side and the correct mechanical position); if there is, check cable continuity
between the sensor connector and PIN 23 of the BROWN connector: if there is no continuity,
restore the cable harness. If there is, replace the instrument panel if the vehicle performance
is correct (the engine starts with gear in neutral but the neutral warning light is off) or replace
the control unit if the vehicle performance is not correct (the engine does not start with gear
in neutral).
•
Indication on the instrument panel always gear in neutral: disconnect the terminals from the
sensor and check if there is continuity with ground connection at PIN toward the sensor, with
gear engaged: if there is continuity, replace the sensor. If it is ground insulated, it means
that the grey/black cable from PIN 1 of the sensor to PIN 23 of the BROWN connector is
shorted to ground: restore the cable harness.
Clutch lever sensor
Function
It tells the clutch lever position to the control unit.
Operation / Operating principle
If the gear is engaged but the clutch is pulled, i.e. circuit closed to ground, vehicle start-up is enabled
anyway.
Level in electrical circuit diagram:Start-up enabling switches.
Location:
•
sensor: under clutch lever
•
Connector: on the sensor
Electrical characteristics:
•
Clutch pulled: closed circuit (continuity)
•
Clutch released: open circuit (infinite resistance)
Pin-out:
1. Voltage 12V
2. Ground connection
NAVIGATOR: STATUSES
Clutch
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Electrical system
STELVIO 4V - 1200 ABS
Example value:Yes/No
The statuses regularly viewed are YES / NO
DIAGNOSIS
Troubleshooting:
•
Indication on Navigator always No: check the correct position of the cable terminals on the
sensor and the correct connection of the cables on the terminals. If they are not correct,
restore the cable harness; if correct, disconnect the two terminals from the sensor and check
continuity to ground of PIN 2 (cable harness side): if there is no continuity, restore the cable
harness; if there is, replace the sensor. Check continuity of the brown/purple cable between
PIN 1 of the sensor and PIN 33 of the BLUE connector, cable harness side: if there is no
continuity, restore the cable harness; if there is, replace the sensor. With the key set to ON,
check that 12 Volt is fed to PIN 33 of the BLUE connector
•
Indication on Navigator always Yes: disconnect the terminals from the sensor and check if
there is continuity between the two PINS, with clutch released: if there is continuity, replace
the sensor. If the circuit is open, it means that the brown/purple cable from PIN 1 of the
sensor to PIN 33 of the BLUE connector is shorted to ground: restore the cable harness
Side stand sensor
Function
It tells the side stand position to the control unit.
Operation / Operating principle
If the gear is engaged and the side stand is unfolded, and therefore the circuit is open, the control unit
does not enable vehicle start-up or shuts off the engine if it is rotating.
Level in electrical circuit diagram:Start-up enabling switches
Location:
•
Sensor: on side stand supporting plate
•
Connector: left side, near the starter motor
Electrical characteristics:
•
Side Stand Up: closed circuit (continuity)
•
Side Stand Down: open circuit (infinite resistance)
Pin-out:
1. Ground connection
2. Voltage 12 V (brown, sensor side)
NAVIGATOR: STATUSES
Side stand
Example value:retracted / extended
DIAGNOSIS
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STELVIO 4V - 1200 ABS
•
Electrical system
Indication on Navigator always EXTENDED: check the side stand sensor connector and the
ECU connector: if they are not OK, restore; if OK, disconnect both terminals from the sensor
and check continuity to ground of PIN 1 (blue/green, cable harness side): if there is not
continuity, restore the cable harness; if there is, check continuity of the green/brown cable:
if it is not OK, restore; if OK, replace the sensor.
•
Indication on Navigator always RETRACTED: disconnect the terminals from the sensor and
check if there is continuity between the two PINS, with stand down: if there is continuity,
replace the sensor; if the circuit is open, it means that the brown/green cable (cable harness
side) from PIN 2 of the sensor to PIN 38 of the BLUE connector is shorted to ground: restore
the cable harness.
Bank angle sensor
Function
it tells the vehicle position to the control unit.
Operation / Operating principle
When the sensor is inverted, the circuit is closed
to ground: when the Marelli control unit detects this
earthing, it disables the fuel pump circuit and the
engine start-up circuit via the injection relay.
Level in electrical circuit diagram:Start-up enabling switches.
Location:
•
Sensor: under the saddle, right side
•
Connector: near the sensor
Electrical characteristics:
•
Sensor in vertical position: open circuit
(resistance: 62 kOhm)
•
Sensor inverted: closed circuit (resistance below 0.5 kOhm)
Pin-out:
1. Voltage 12V
2. Ground connection
NAVIGATOR: STATUSES
Fall sensor
Example value: Normal / Tip over
DIAGNOSIS
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Electrical system
•
STELVIO 4V - 1200 ABS
Indication on Navigator always Normal, even when the sensor is inverted: disconnect the
connector and, with sensor inverted, check if there is continuity between the two PINS of
the sensor: if there is no continuity, replace the sensor; if there is, check the connector. If
not OK, restore the cable harness; if OK, check continuity to ground of PIN 2: if there is no
continuity, restore the cable harness; if there is, with key set to KEY ON, check if there is
12V voltage at PIN 1. If there is not, check the Marelli control unit connector (PIN 35 of the
BLUE connector)
•
Indication on Navigator always Tip over: disconnect the connector and check if there is
continuity between the two PINS when the sensor is in vertical position: if there is continuity,
replace the sensor; if there is not, it means that, with key set to KEY ON, there is no 12V
voltage at PIN 1: restore the cable harness whose pink/yellow cable will be shorted to ground
Air temperature sensor - instrument panel
Function
It tells the ambient air temperature to the instrument panel.
Operation / Operating principle
NTC type sensor (resistance sensor, inversely
variable with temperature).
Level in electrical circuit diagram:Temperature
sensors
Location:
•
Sensor: under the instrument panel
•
Connector: under the instrument panel
Electrical characteristics:
•
Resistance at 0 °C (32 °F): 32.5 kOhm
+/- 5%
•
Resistance at 25 °C (77 °F): 10.0
kOhm +/- 5%
Pin-out:
1. Voltage 5V
2. Ground connection
Instrument panel
Air temperature sensor failure DSB 06
Error cause
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STELVIO 4V - 1200 ABS
•
Electrical system
An oil sensor failure is signalled when it is detected that the sensor circuit is open or shorted
to positive
Troubleshooting
•
Check the sensor connector and the instrument panel connector (PINS 10 and 18): If they
are not OK, restore. If OK, check continuity of the pink cable between the sensor connector
and the instrument panel connector PIN 10: if it is not OK, restore the cable harness; if OK,
check the correct sensor resistance: if it is not OK, replace the sensor; if it is OK, check
continuity of the brown cable between the sensor connector and PIN 18 of the instrument
panel connector: If not OK, restore the cable harness; if OK, with key set to ON, check if
there is voltage at the sensor connector PIN 1: if there is no voltage, replace the instrument
panel; if there is approximately 12V, restore the cable harness (there is a short circuit in the
battery). If there is 5V voltage, connect a 10 kOhm resistance to PIN 1 of the sensor connector and to the vehicle ground connection: if, with key set to ON, the voltage measured
upstream the resistance decreases, replace the instrument panel. If voltage continues to be
approximately 5V, restore the pink cable (there is a short circuit at + 5V).
Notes
If a short circuit to ground is detected at PIN 10 of the instrument panel connector, the display will show
a full scale air temperature indication of 60 °C (140 °F)
Check the ground insulation of the sensor connector pink cable: if there is a connection, restore the
cable harness; if it is earth insulated, check that sensor resistance is correct: if it is not OK, replace the
sensor; if it is OK, replace the instrument panel.
RUN/STOP switch
Function
It tells the control unit if the driver wishes to enable engine start-up or to keep the engine running.
Operation / Operating principle
If the driver wants to shut off the engine or to disable engine start-up, the switch should be open, i.e.
the Marelli control unit should not detect voltage at PIN 27 of the BLUE connector.
Level in electrical circuit diagram:start-up enabling switches.
Location:
•
right light switch.
•
connector: right side, near the coil.
Electrical characteristics:
•
STOP position: the circuit is open
•
RUN position: closed circuit (continuity)
PIN:
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Electrical system
STELVIO 4V - 1200 ABS
•
sky blue/orange cable: 0V if engine kill in STOP; 12V if engine kill in RUN
•
red/black cable: Voltage 12V
NAVIGATOR: STATUSES
Run / stop switch
Example value:Run/Stop
DIAGNOSIS
•
Indication on Navigator always STOP: disconnect the connector and, with the switch set to
RUN, check if there is continuity towards the switch of both the green/orange and the grey/
yellow cables (sensor side): if there is not continuity, replace the sensor; if there is, check
the connector. If it is not OK, restore the cable harness; if it is OK, with the key set to ON,
check if there is voltage on the red/black cable (cable harness side): if there is no voltage,
restore the cable harness; if there is, check the ground insulation of the sky blue/orange
cable (cable harness side): if there is continuity to ground, restore the cable harness; if it is
OK, take the key to OFF and check that the BLUE connector is in good conditions and if
there is continuity of the sky blue/orange cable between the connector in question and PIN
27 of the BLUE connector: if not OK, restore the cable harness; if OK, replace the Marelli
control unit.
•
Indication on Navigator always RUN: disconnect the connector and, with the switch set to
STOP, check if there is continuity between the two cables of the switch (sensor side): if there
is continuity, replace the switch; if there is not, it means that, with the key set to KEY ON,
the sky blue/orange cable is shorted to positive: restore the cable harness.
Connectors
ECU
BROWN connector pin configuration
Pin Use
1 Not used
2 Not used
3 Ignition potentiometer signal
4 Not used
5 Engine temperature signal
6 Not used
7 Not used
8 Not used
9 Stepper motor (+)
10 Right cylinder coil control
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STELVIO 4V - 1200 ABS
Electrical system
11 Not used
12 Not used
13 Not used
14 Air temperature signal
15 Not used
16 Not used
17 Stepper motor (+)
18 Stepper motor (-)
19 Stepper motor (-)
20 5V power supply (NTC sensors)
21 Not used
22 Not used
23 Neutral sensor signal
24 Not used
25 Engine revolution sensor signal
26 Not used
27 Not used
28 Left cylinder injector control
29 Ignition potentiometer negative
30 Not used
31 Not used
32 Ignition potentiometer power supply
33 Not used
34 Revolution sensor anti-jamming cable
35 Engine revolution sensor signal
36 Not used
37 Right cylinder injector control
38 Left cylinder coil control
BLUE connector pin configuration
Pin Use
1 Pin 85 ignition relay control
2 Not used
3 Not used
4 Power supply protected from instrument panel
5 Not used
6 Pin 86 auxiliary relay control
7 Immobilizer line
8 Not used
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STELVIO 4V - 1200 ABS
9 Not used
10 Not used
11 Oxygen probe negative control
12 Not used
13 Not used
14 Not used
15 Not used
16 K line (diagnosis)
17 Power supply from main relay
18 Not used
19 Not used
20 CAN - H line (ccm/instrument panel)
21 Not used
22 Oxygen probe signal
23 Not used
24 Vehicle speed signal input
25 Not used
26 Not used
27 "Engine stop" signal input
28 Ignition signal input
29 CAN - L line (ccm/instrument panel)
30 Not used
31 Not used
32 Oxygen probe power supply
33 Clutch sensor signal
34 Not used
35 Fall sensor signal
36 Not used
37 Not used
38 Side stand sensor signal
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STELVIO 4V - 1200 ABS
Electrical system
Dashboard
The pin configuration of the GREY-bodied connector is as follows:
PIN USE
1 + KEY
2 RIGHT TURN INDICATOR CONTROL
3 HIGH-BEAM LIGHT INPUT
45 FOG LIGHTS ON (OPT)
6 K LINE
78 CONTROL - SET
9 FUEL LEVEL SENSOR
10 AIR TEMPERATURE SENSOR
11 + BATTERY
12 LEFT TURN INDICATOR CONTROL
13 14 15 16 GENERAL EARTH CONNECTION
17 OIL PRESSURE SENSOR INTAKE
18 SENSORS EARTH CONNECTION
19 GENERAL GROUND (OPTIONAL)
20 GENERAL GROUND (OPTIONAL)
The pin configuration of the BLACK-bodied connector is as follows:
PIN USE
21 + BATTERY
22 FRONT LEFT TURN INDICATOR ACTIVATION
23 REAR LEFT TURN INDICATOR ACTIVATION
24 AERIAL 1
25 LEFT HEATED HANDGRIPS ACTUATOR (OPT)
26 CAN H
27 CONTROL - RESET
28 LIGHTS RELAY ACTIVATION
29 ANTITHEFT DEVICE LED (+12v)
30 CONTROL - DOWN
31 + BATTERY
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STELVIO 4V - 1200 ABS
32 FRONT RIGHT TURN INDICATOR ACTIVATION
33 REAR RIGHT TURN INDICATOR ACTIVATION
34 AERIAL 2
35 RIGHT HEATED HANDGRIPS ACTUATOR (OPT)
36 CAN L
37 HAZARD CONTROL
38 39 ABS
40 CONTROL - UP
ABS Modulator
Pin Use
1. Ground connection
2. Not used
3. Speed signal for injection ECU
4. ABS control unit power supply
5. Not used
6. Not used
7. ABS deactivation switch
8. ABS warning light
9. Not used
10.Not used
11.Rear (ABS) speed sensor (supply)
12.Rear (ABS) speed sensor (signal / ground)
13.Front (ABS) speed sensor (signal / ground)
14.Front (ABS) speed sensor (supply)
15.Ground connection
16.Diagnosis
17.Not used
18.ABS pump supply
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INDEX OF TOPICS
ENGINE FROM VEHICLE
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ENG VE
Engine from vehicle
STELVIO 4V - 1200 ABS
Vehicle preparation
Before removing the engine block, proceed as follows:
•
Rest the vehicle on its centre stand.
•
From the back, secure the vehicle with belts attached to a hoist.
•
From the front, secure the vehicle with belts attached to the handlebar and fixed to the work
bench.
•
Remove the exhaust system, the fork with cardan shaft, the fuel tank and the rear shock
absorber.
See also
Exhaust
Removing
Fuel tank
Removing
Removing the engine from the vehicle
•
Disconnect the spark plug tubes.
•
Unscrew and remove the three screws
and remove the clutch control cylinder.
•
Lock the cylinder using a clamp to prevent oil leaks.
•
Remove the starter motor cover.
•
Unscrew and remove the stud bolt.
•
Disconnect the ground leads.
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STELVIO 4V - 1200 ABS
•
Engine from vehicle
Disconnect the starter motor connectors.
•
Disconnect the stand sensor connector and release it from the clamps.
•
Slide off the gearbox oil breather pipe.
•
Disconnect the neutral sensor connector.
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Engine from vehicle
•
Disconnect the horn connectors.
•
Operating from both sides, undo and
STELVIO 4V - 1200 ABS
remove the screw fixing the oil radiator
to the chassis.
•
Loosen the clamp and slide off the oil pipe from the blow-by tank.
•
Working on both sides, release the
clamp and slide off the engine oil
breather pipe.
•
Working on both sides disconnect the
injector connectors.
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STELVIO 4V - 1200 ABS
•
Engine from vehicle
Working from both sides, undo and remove the three inlet manifold screws.
•
Collect the gasket.
•
Disconnect the alternator connectors.
•
Disconnect the engine temperature
sensor connector
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Engine from vehicle
•
STELVIO 4V - 1200 ABS
Disconnect the engine oil pressure
sensor connector.
•
Disconnect the revolution sensor connector.
•
Remove the fairing under the oil sump.
•
Support the vehicle with the engine
service stand.
•
Undo and remove the screws fixing the
centre stand plates.
•
Remove the centre stand.
•
Working on both sides, unscrew and
remove the front screw and collect the
washer.
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STELVIO 4V - 1200 ABS
•
Engine from vehicle
Operating from both sides, undo and
remove the upper engine fixing nut on
the internal side of the chassis.
•
Unscrew and remove the engine lower
fixing nut and collect the washer.
•
Remove the lower bolt and collect the
washer.
•
Unscrew and remove the upper nut fixing the engine and collect the washer.
•
Remove the upper pin and collect the
washer.
•
Lower the engine completely.
•
Lift the rear part of the vehicle.
•
Release the front belts.
•
Hold the rear part of the vehicle, remove the chassis from the engine.
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Engine from vehicle
STELVIO 4V - 1200 ABS
Installing the engine to the vehicle
•
Place the vehicle chassis over the engine with the gear.
•
From the back, secure the chassis with
belts attached to a hoist.
•
From the front, secure the vehicle with
belts attached to the handlebar and
fixed to the work bench.
•
Lift the engine placing it in position.
•
Connect the oil pressure sensor connector.
•
Working from the left side, fit the engine upper bolt with the washer.
•
From the opposite side, fit the washer
and screw the nut.
•
Working on both sides, insert the
washer and screw the screw without
tighten it.
•
Working from the left side, fit the engine lower bolt with the washer.
•
From the opposite side, fit the washer
and tighten the nut.
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STELVIO 4V - 1200 ABS
•
Engine from vehicle
Operating from both sides, tighten the
upper engine fixing nut on the internal
side of the chassis.
•
Fit the centre stand.
•
Operating from both sides, tighten the
screws fixing the centre stand plates.
•
Remove the engine service stand from
under the oil sump.
•
Working from both sides, place the inlet manifold fitting a new gasket between the manifold and head.
•
Fasten the inlet manifold with the three
screws.
•
Connect the stand sensor connector
and fix it to the chassis with new
clamps.
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Engine from vehicle
•
STELVIO 4V - 1200 ABS
Insert the oil breather pipe and fasten
it with a new clamp.
•
Fit the gearbox oil breather pipe.
•
Fit the clutch control cylinder.
•
Tighten the three screws.
•
Connect the starter motor connectors.
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STELVIO 4V - 1200 ABS
•
Engine from vehicle
Connect the ground leads and tighten
the stud bolt.
•
Fit the starter motor cover.
•
Tighten the screws.
•
Connect the neutral sensor connector.
•
Connect the alternator connectors.
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Engine from vehicle
•
STELVIO 4V - 1200 ABS
Connect the revolution sensor connector.
•
Connect the horn connectors.
•
Connect the engine temperature sensor connector.
•
Place the oil radiator.
•
Tighten the two screws.
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STELVIO 4V - 1200 ABS
•
Engine from vehicle
Place the fork with cardan shaft and the
rear wheel.
•
Working on both sides, connect the injector connectors.
•
Adjust the throttle grip cable clearance.
•
Working from both sides, connect the
spark plug tube.
•
Install the fuel tank.
•
Fit the saddle.
•
Install the complete exhaust.
ENG VE - 101
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INDEX OF TOPICS
ENGINE
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ENG
STELVIO 4V - 1200 ABS
Engine
Gearbox
Diagram
Key:
1. Ball bearing
ENG - 103
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STELVIO 4V - 1200 ABS
Engine
2. Circlip
3. Thickness
4. Pin
5. Complete desmodromic
6. Ball bearing
7. Spring
8. Spacer
9. Circlip
10.Fifth wheel
11.Linking pin
12.Gear
13.Circlip
14.Thrust washer
15.Ball bearing cage
16.Gear
17.Sealing ring
18.Ball bearing
19.Gear
20.Circlip
21.Clutch shaft
22.Ball bearing
23.Oil plug
24.Washer
25.Gearbox
26.Aluminium washer
27.Breather cap
28.Neutral sensor
29.Gasket
30.Sealing ring
31.Bushing
32.Gasket
33.Oil drainage plug
34.Sealing ring
35.Thrust bearing
36.Roller bearing
37.Spring
38.Complete pre-selector
39.Bushing
ENG - 104
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40.Index lever
41.Spring
42.Ball bearing
43.Gear
44.Gear
45.Ball bearing cage
46.Thrust washer
47.Circlip
48.Gear
49.Circlip
50.Gear
51.Main shaft
52.Transmission gear
53.Fork (5th - 1st)
54.Fork shaft
55.Fork (3rd - 4th)
56.Fork (2nd - 4th)
57.Gear
58.Gear
59.Ball bearing
60.Transmission shaft
61.Gear
62.Spacer
Gearbox
Removing the gearbox
•
Remove the starter motor.
•
Make sure the transmission is in idle.
•
Undo and remove the screw and remove the gearbox lever.
ENG - 105
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STELVIO 4V - 1200 ABS
Engine
•
Unscrew and remove the gearbox oil
filler cap.
•
Place a container of suitable capacity
under it, unscrew and remove the cap
and then bleed all gearbox oil.
•
Loosen and turn the oil pipe fitting on
the sump.
•
Undo and remove the three screws.
ENG - 106
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STELVIO 4V - 1200 ABS
•
Undo and remove the two screws.
•
Undo and remove the screw.
•
Remove the gearbox.
Engine
See also
Removing the starter motor
Replacement
Gearbox shafts
ENG - 107
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STELVIO 4V - 1200 ABS
Engine
Disassembling the gearbox
•
Remove the gearbox.
•
Unscrew and slide off the odometer
gear and collect the abutment washer
that is inside the gearbox.
•
From the outside, slide off the thrust
cylinder and collect the O-Ring and the
washer.
•
Remove the thrust bearing and the
washer.
ENG - 108
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STELVIO 4V - 1200 ABS
•
Slide off the rod with the two bushings.
•
Undo and remove the five external
Engine
screws.
•
Place the gearbox on the specific gearbox support tool and on a vice.
Specific tooling
05.90.25.30 Gearbox support
•
Undo and remove the nine internal
screws.
•
Open the gearbox using the specific
tool.
Specific tooling
05.91.25.30 Gearbox opening
ENG - 109
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STELVIO 4V - 1200 ABS
Engine
•
Remove the bearings from the gearbox
if necessary.
•
Release the spring.
•
Pressing the selector, slide off the whole transmission lever.
•
Use rubber bands to tie down the transmission shaft unit and extract it.
ENG - 110
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•
Engine
Once the transmission shaft unit is in
on a bench, remove the rubber bands,
being careful with the group.
•
Detach the shafts and label the forks
before removal.
•
Remove the forks and collect the shaft.
ENG - 111
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STELVIO 4V - 1200 ABS
Engine
•
Replace bearings if necessary and remove the clutch shaft.
See also
Removing the gearbox
Removing the primary shaft
•
Remove the main shaft.
•
Operate on the main shaft from the
second gear side.
•
Remove the gear of the second gear
and collect the ball bearing cage.
ENG - 112
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•
Engine
Remove the gear of the sixth gear and
collect the shoulder washer.
•
Remove the circlip.
•
Remove the gear of the third and fourth
gears.
•
Remove the circlip and collect the
shoulder washer.
ENG - 113
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Engine
•
Remove the gear of the fifth gear and
collect the ball bearing cage.
•
Heat the shaft with a specific heater
and remove the helical transmission
gear.
Removing the secondary shaft
•
Remove the transmission shaft.
•
Operate on the shaft from the grooved
side.
•
Remove the shoulder washer.
ENG - 114
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STELVIO 4V - 1200 ABS
•
Engine
Remove the gear of the second gear
and collect the ball bearing cage and
the shoulder washer.
•
Remove the circlip.
•
Remove the gear of the sixth gear.
•
Remove the circlip and collect the
shoulder washer.
ENG - 115
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STELVIO 4V - 1200 ABS
Engine
•
Remove the gear of the fourth gear and
collect the ball bearing cage.
•
Remove the gear of the third gear and
collect the ball bearing cage and the
shoulder washer.
•
Remove the circlip.
•
Remove the gear of the fifth gear.
ENG - 116
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STELVIO 4V - 1200 ABS
•
Engine
Remove the circlip, the shoulder washer and remove the gear of the first gear,
collect the ball bearing cage.
•
Remove the bearing if necessary.
See also
Disassembling the gearbox
Checking the primary shaft
Measure coaxiality of the main shaft with a dial
gauge and a centring device and replace it if not
complying with specifications.
Characteristic
Shaft coaxiality limit
0.08 mm (0.0031 in)
Check transmission gears for signs of pitting and wear and replace damaged gears if necessary.
Check the gear fitting teeth for cracks, damage and wear and replace those damaged if necessary.
Check the transmission gears movement and, if it is not regular, replace the damaged part.
Checking the secondary shaft
Measure the coaxiality of the transmission shaft
with a dial gauge and a centring device and replace it if not complying with specifications.
Characteristic
Shaft coaxiality limit
0.08 mm (0.0031 in)
Check transmission gears for signs of pitting and wear and replace damaged gears if necessary.
Check the gear fitting teeth for cracks, damage and wear and replace those damaged if necessary.
Check the transmission gears movement and, if it is not regular, replace the damaged part.
ENG - 117
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STELVIO 4V - 1200 ABS
Engine
Checking the desmodromic drum
Check gear drum for damage, scratches and wear
and replace the desmodromic if necessary.
Check the desmodromic segment «3» for damage
and wear and replace it if necessary.
Check the desmodromic bearing «4» for damage
and cracks and replace it if necessary.
Checking the forks
NOTE
THE FOLLOWING PROCEDURE IS VALID FOR ALL GEARBOX FORKS.
•
Check the transmission fork cam roller
«1» and the transmission fork tooth
«2» for damage, deformation and
wear.
•
Replace the transmission fork if necessary.
•
Check the transmission fork movement and if it is not regular, replace the
transmission forks.
See also
Disassembling the gearbox
Fitting the primary shaft
NOTE
TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER.
REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY
REMOVED.
See also
ENG - 118
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STELVIO 4V - 1200 ABS
Engine
Removing the primary shaft
Fitting the secondary shaft
NOTE
TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER.
REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY
REMOVED.
See also
Removing the secondary shaft
Assembling the gearbox
NOTE
TO REFIT, FOLLOW THE SAME INSTRUCTIONS AS FOR REMOVAL BUT IN REVERSE ORDER.
REMEMBER TO REPLACE ALL SEALING RINGS, CIRCLIPS AND SAFETY RINGS PREVIOUSLY
REMOVED.
If the clutch is replaced, measure the length of the
clutch control rod in order to use the correct rod.
Measure as follows:
•
Fit the new clutch on the crankshaft.
•
Fit the clutch control bowl in the gearbox.
•
Fit the gearbox on the engine block.
•
Fit the tool in the gearbox to determine
the clutch control rod length.
•
Measure rod protrusion using a depth
gauge (see picture).
•
According to the value found, select
the correct rod based on the following
table:
Specific tooling
020678Y Tool for clutch rod checking
CLUTCH CONTROL ROD SELECTION
Specification
Protrusion: 9.8 - 11.2 mm (0.386 - 0.441 in)
Protrusion: 8.3 - 9.7 mm (0.327 - 0.382 in)
Protrusion: 6.8 - 8.2 mm (0.268 - 0.323 in)
Protrusion: 5.3 - 6.7 mm (0.209 - 0.264 in)
Desc./Quantity
Clutch control rod length (code 976593) = 183 mm (7.205 in)
Clutch control rod length (code 976594) = 184.5 mm (7.264 in)
Clutch control rod length (code 976595) = 186 mm (7.323 in)
Clutch control rod length (code 976596) = 187.5 mm (7.382 in)
See also
Disassembling the gearbox
ENG - 119
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Engine
Generator
Key:
1. Alternator
2. Spacer
3. Screw
4. Screw
5. Nut
6. Belt
7. Generator control pulley
8. Nut
9. Washer
10.Magneto flywheel cotter
11.Screw
12.Nut
ENG - 120
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Engine
Removing the generator
•
Remove the fuel tank.
•
Remove the control unit from its seat.
•
Disconnect the alternator connectors.
•
Undo and remove the five screws and
collect the bushings.
•
Remove the cover.
•
Unscrew the nut and collect the screw.
•
Loosen the screw.
ENG - 121
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STELVIO 4V - 1200 ABS
Engine
•
Loosen the nut and undo the set screw
so that the alternator slides down.
•
Completely loosen and remove the
screw.
•
Remove the belt and the alternator with
pulley.
•
Using a compressed air gun, unscrew
and remove the nut and collect the
spacer.
•
Remove the lower pulley.
ENG - 122
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•
Undo and remove the eight screws.
•
Undo and remove the two screws.
•
Undo and remove the two screws.
Engine
ENG - 123
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STELVIO 4V - 1200 ABS
Engine
•
Remove the alternator frame.
•
Remove the sealing ring if necessary.
See also
Fuel tank
Tensioning the belt
•
Operating from both sides, undo and
remove the screw fixing the oil radiator
to the chassis.
•
Undo and remove the radiator lower
screw and collect the washer.
•
Undo and remove the horn fixing
screw.
ENG - 124
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STELVIO 4V - 1200 ABS
•
Engine
Undo and remove the five screws fixing
the alternator belt cover.
•
Remove the oil radiator lower support
bracket and the alternator belt cover.
Locking torques (N*m)
Alternator belt cover screw (radiator bracket
retainer) TCEI M6x40 (2) 10 Nm (7.38 lbf ft) Alternator belt cover screw - TCEI M6x16 (4) 10 Nm
(7.38 lbf ft)
•
Loosen the screw.
•
Loosen the nut and undo the set screw
so that the alternator slides down.
•
Using the belt tensioning tool, tension
the belt to the prescribed torque.
•
Tighten the set screw.
•
Tighten the lock nut.
Specific tooling
020677Y Alternator belt tensioner, Belt tensioning lever
Locking torques (N*m)
Belt tension 50 Nm (36.88 lbf ft)
ENG - 125
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STELVIO 4V - 1200 ABS
Engine
Installing the generator
•
If the sealing ring has been previously
removed, replace it using the punch of
the timing system cover sealing ring.
Specific tooling
05.92.72.30 Timing system cover sealing ring
punch
•
Place the bolt and the pin in the generator cover.
•
Replace the gasket and place the alternator frame using the front cover insertion cone.
•
Remove the insertion cone afterwards.
Specific tooling
05.91.17.30 Front cover insertion cone
•
Tighten the two screws.
ENG - 126
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STELVIO 4V - 1200 ABS
•
Tighten the eight lower screws.
•
Operating diagonally and in stages,
Engine
tighten the ten fixing screws on the alternator fitting.
•
Tighten the four screws, operating diagonally and in stages.
•
Position the lower pulley and the
spacer.
•
Tighten the nut to the prescribed torque.
•
Position the alternator and the timing
system belt.
ENG - 127
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Engine
•
Position the screw and pre-tighten it.
•
Position the screw and tighten the nut.
•
Using the belt tensioning tool, tension
the belt to the prescribed torque and
tighten the set screw.
•
Remove the belt tensioning tool.
•
Lock the set screw in position by
screwing the lock nut.
Specific tooling
020677Y Alternator belt tensioner, Belt tensioning lever
ENG - 128
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STELVIO 4V - 1200 ABS
•
Tighten the alternator fixing screws.
•
Place the alternator belt cover.
•
Tighten the five screws operating diag-
Engine
onally and in stages.
Starter motor
Removing the starter motor
•
Undo and remove the two screws and
collect the washers.
ENG - 129
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STELVIO 4V - 1200 ABS
Engine
•
Slide off the starter motor.
Clutch side
Disassembling the clutch
•
Remove the complete gearbox.
•
Undo and remove the six screws.
•
Remove the start-up crown gear.
•
Remove the clutch bell and the friction
disc.
ENG - 130
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STELVIO 4V - 1200 ABS
•
Remove the Seeger ring.
•
Remove the clutch pressure plate.
•
Undo and remove the six screws and
Engine
collect the belleville springs.
•
Remove the clutch disc.
See also
Removing the gearbox
ENG - 131
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Engine
Key:
1. Complete clutch
2. Clutch
3. Clutch bell
4. TCEI screw
5. Clutch disc
6. Crown
7. TCEI screw
8. Clutch pressure plate
9. Ring
10.TE flanged screw
11.Conical washer
12.Bushing
13.Rod
14.Bushing
15.Intermediate body
16.Thrust bearing
17.Clutch control bowl
18.Thrust cylinder
19.Clutch control cylinder
20.TE flanged screw
ENG - 132
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STELVIO 4V - 1200 ABS
Engine
Checking the clutch actuator
If the clutch is replaced, measure the length of the
clutch control rod in order to use the correct rod.
Measure as follows:
•
Fit the new clutch on the crankshaft.
•
Fit the clutch control bowl in the gearbox.
•
Fit the gearbox on the engine block.
•
Fit the tool in the gearbox to determine
the clutch control rod length.
•
Measure rod protrusion using a depth
gauge (see picture).
•
According to the value found, select
the correct rod based on the following
table:
Specific tooling
020678Y Tool for clutch rod checking
CLUTCH CONTROL ROD SELECTION
Specification
Protrusion: 9.8 - 11.2 mm (0.386 - 0.441 in)
Protrusion: 8.3 - 9.7 mm (0.327 - 0.382 in)
Protrusion: 6.8 - 8.2 mm (0.268 - 0.323 in)
Protrusion: 5.3 - 6.7 mm (0.209 - 0.264 in)
Desc./Quantity
Clutch control rod length (code 976593) = 183 mm (7.205 in)
Clutch control rod length (code 976594) = 184.5 mm (7.264 in)
Clutch control rod length (code 976595) = 186 mm (7.323 in)
Clutch control rod length (code 976596) = 187.5 mm (7.382 in)
Assembling the clutch
•
Lock crankshaft rotation with the
crankpin facing upwards.
•
Place the clutch disc with the reference
facing upwards.
•
Fasten the clutch disc on the crankshaft with the six screws, Loctite 243
and the belleville springs.
ENG - 133
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STELVIO 4V - 1200 ABS
Engine
•
Place the clutch pressure plate.
•
Fit the tool to centre and compress the
plate.
•
Fully tighten the two centring tool
screws.
Specific tooling
020672Y Clutch spring centre and pusher
•
Once the centring tool is fitted, lock the
plate with the snap ring.
•
Undo and remove the two screws fixing
the tool.
•
Remove the special tool.
•
Place the friction disc; centre it.
ENG - 134
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STELVIO 4V - 1200 ABS
•
Engine
Place the clutch bell with the reference
facing upwards.
•
Place the start-up crown gear with the
reference facing upwards.
•
Tighten the six screws to the prescribed torque operating diagonally and in
stages.
Head and timing
Key:
1. Right cylinder head
ENG - 135
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STELVIO 4V - 1200 ABS
Engine
2. Stud bolt
3. Cylinder head gasket
4. Right rocking lever support
5. Screw
6. Pin
7. Nut
8. Right exhaust, left intake rocking lever
9. Left exhaust, right intake rocking lever
10.Set screw
11.Nut
12.Rocking lever rod
13.Tappet bowl
14.Flanged screw
15.Spacer
16.Camshaft
17.Pin
18.Timing system gear
19.Breather plate
20.TE flanged screw
21.O-ring
22.Complete breather cover
23.TBEI screw
24.Timing system chain
25.Chain guide slider
26.Chain tensioner pad
27.Chain tensioner screw
28.Right chain tensioner
29.Left cylinder head
30.Stud bolt
31.Cylinder head gasket
32.Left rocking lever support
33.Screw
34.Pin
35.Nut
36.Right exhaust, left intake rocking lever
37.Left exhaust, right intake rocking lever
38.Set screw
39.Nut
ENG - 136
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Engine
40.Rocking lever rod
41.Tappet bowl
42.Flanged screw
43.Spacer
44.Camshaft
45.Pin
46.Timing system gear
47.Breather plate
48.TE flanged screw
49.O-ring
50.Complete breather cover
51.TBEI screw
52.Timing system chain
53.Chain guide slider
54.Chain tensioner pad
55.Chain tensioner screw
56.Left chain tensioner
57.Spacer
Removing the head cover
NOTE
THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY
TO BOTH HEADS.
•
Disconnect the spark plug tube.
ENG - 137
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STELVIO 4V - 1200 ABS
Engine
•
Unscrew and remove the four head
cover fixing screws and collect the
sealing O-rings.
•
Remove the head cover together with
the gasket.
Removing the cylinder head
CAUTION
WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CAREFULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
•
Remove the head cover.
•
Unscrew and remove the two screws
•
Remove the cap.
•
Unscrew and remove the screw.
•
Remove the timing system upper gear
bulkhead.
For the right head:
•
Unscrew and remove the chain tensioner cap.
•
Remove the right chain tensioner.
ENG - 138
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STELVIO 4V - 1200 ABS
Engine
For the left head:
•
Unscrew and remove the screw and
the washer.
•
Relief oil pressure from the left chain
tensioner.
•
Slide off the timing system gear from
the chain to remove it from the camshaft.
•
Unscrew and remove the four nuts on
the stud bolts.
•
Remove the complete cam cap.
ENG - 139
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STELVIO 4V - 1200 ABS
Engine
•
Unscrew and remove the two screws.
•
Remove the head.
•
Fit the timing system upper gear back
to the chain.
•
Fit the chain tensioner cap temporarily
and keep the chain taut on the service
shaft.
•
Collect the two head dowel pins.
•
Collect the gasket between the head
and the cylinder.
See also
Removing the head cover
Cylinder head
Removing the overhead camshaft
CAUTION
WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CAREFULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
ENG - 140
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STELVIO 4V - 1200 ABS
•
Engine
Remove the two rocking levers from
the cam cap.
•
Remove the two rods.
•
Undo and remove the four screws.
•
Remove the U-bolt.
•
Remove the camshaft.
•
Remove the bowls from the cam cap,
and mark their position so as not interchange them when refitting.
See also
Removing the rocker arms
Removing the rocker arms
CAUTION
ENG - 141
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STELVIO 4V - 1200 ABS
Engine
WHEN REMOVING THE COMPONENTS, MARK THE POSITION OF EACH PART VERY CAREFULLY IN ORDER TO PLACE THEM IN THEIR ORIGINAL POSITION UPON FITTING.
•
Remove the cam cap from the stud
bolts.
•
Undo and remove the two screws.
•
Remove the U-bolt.
•
Remove the two rocking levers from
the cam cap.
See also
Removing the cylinder head
Removing the valves
•
Remove the head.
•
Place the special tool on the upper cap
and at the centre of the head of the
valve to be removed.
Specific tooling
10.90.72.00 Tool for valve removal and refitting
AP9100838 Tool for valve pressure plate
ENG - 142
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STELVIO 4V - 1200 ABS
•
Engine
Tighten the tool screw until fitted, and
then hit the tool head (where the upper
cap works) with a mallet so that the two
cotters (1) get detached from the upper
cap (2).
•
Once the two cotters (1) are detached,
screw these cotters until they can be
slid off the valve seats; unscrew the
tool and remove it from the head.
•
Slide off the upper cap (2).
•
Remove the spring (3).
•
Remove the lower cap (5) and the
valve guide oil seal (4), if necessary.
•
Remove the valve (6) from inside the
head.
Checking the valve guides
Use a punch to extract the valve guides from the heads.
The valve guides should be replaced only if the clearance between them and the stem cannot be eliminated by simply replacing the valves.
To refit the valve guides on the head, follow this procedure:
•
Heat the head in an oven at about 60°C (140°F).
•
Lubricate the valve guide.
•
Fit the circlips.
•
Press the valve guide with a punch.
•
Use a reamer to bore the holes the valve stems slide through so that the inside diameter is
at the prescribed value. The interference between the seat on the head and the valve guide
must be 0.046 - 0.075 mm (0.0018 - 0.0030 in)
VALVE GUIDE COUPLING - VALVES (INLET)
Specification
Valve guide inside diameter
Valve stem diameter
Fitting clearance
Desc./Quantity
5.0 ÷ 5.012 mm (0.19685 ÷ 0.19732 in)
4.972 ÷ 4.987 mm (0.19574 ÷ 0.19633 in)
0.013 ÷ 0.040 mm (0.00051 ÷ 0.00157 in)
VALVE GUIDE COUPLING - VALVES (OUTLET)
Specification
Valve guide inside diameter
Valve stem diameter
Fitting clearance
Desc./Quantity
5.0 ÷ 5.012 mm (0.19685 ÷ 0.19732 in)
4.960 ÷ 4.975 mm (0.19527 ÷ 0.19587 in)
0.025 ÷ 0.052 mm (0.00098 ÷ 0.00205 in)
ENG - 143
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Engine
Checking the cylinder head
Check that:
•
the faying surfaces with the cover and the cylinder are not scored or damaged, jeopardising
a perfect sealing.
•
Check that the tolerance between the valve guide holes and the valve stems is within the
prescribed limits.
•
Check the valve seats are in good conditions.
INLET VALVE SEAT DETAIL DRAWING
OUTLET VALVE SEAT DETAIL DRAWING
- If the width of the mark on the valve seat is larger than the prescribed limits, true the seats with a 45°
milling cutter and then grind.
- Replace the head in case of excessive wear or damage.
Installing the valves
NOTE
THE FOLLOWING OPERATIONS REFER TO REMOVING ONLY ONE HEAD BUT APPLY TO BOTH
HEADS.
ENG - 144
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•
Engine
Place the valve guide oil seal (4) in the
head.
•
Place the lower cap (5).
•
Place the valve (6) inside the head.
•
Place the spring (3).
•
Fit the upper cap (2).
•
Place the two cotters (1) on the seats
in the valves.
•
By compressing the spring (3) with the
special tool, fit the valve cotters.
Specific tooling
10.90.72.00 Tool for valve removal and refitting
AP9100838 Tool for valve pressure plate
•
Remove the special tool
Installing the rocker arms
•
Fit the camshaft.
•
Fit the two rods.
WARNING
MAKE SURE THAT THE NOTCH ON THE DIPSTICK BODY
FACES THE ROCKING LEVER.
ENG - 145
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•
Place the two rocking levers in the cam
tower seats.
•
Place the U-bolt on the rocking levers
making sure the two reference pins
match the seats on the cam tower.
•
Tighten the two screws operating diagonally and in stages.
See also
Installing the overhead camshaft
Installing the overhead camshaft
•
Place the bowls in the cam tower, if
those previously removed are refitted
be careful not to interchange them.
ENG - 146
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•
Engine
Place the camshaft with the gear seat
on the dowel side.
•
Place the U-bolt on the camshaft making sure the two reference pins match
the seats on the cam tower.
•
Tighten the four screws operating diagonally and in stages.
Timing
Removing the phonic wheel
•
Remove the generator and the timing
system cover.
•
Unscrew and remove the nut and collect the washer.
•
Remove the timing system gear on the
service shaft.
•
Remove the timing sensor and any
shim washers.
•
Remove the tone wheel.
•
Remove the cotter and shim washer
from the service shaft.
See also
ENG - 147
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Removing the generator
Service shaft removal
•
Remove the tone wheel.
•
Remove both cylinders.
•
Undo and remove the two screws.
•
Remove the service shaft closing cap.
•
Mark the timing chains so as not to invert the direction of rotation upon fitting.
•
Slide off the service shaft from the
chains.
•
Remove both chains.
See also
Removing the phonic wheel
Installing the service shaft
•
Place the service shaft bearing (if previously removed) on the crankcase.
•
Fix it to the seat with the lock washer
and screw.
ENG - 148
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•
Engine
Fit the timing chains according to the
references marked at the removal
phase.
•
Lubricate the service shaft.
•
Insert the service shaft in its crankcase
seat by sliding it through the two
chains.
•
Fit each chain to the corresponding
service shaft gear.
•
Fit the roller cage and a new O-ring on
the service shaft closing cap.
•
Partially fit the service shaft closing
cap.
•
To screw the cap until it stops, use two
M6 flanged screws larger than the original screws.
•
Tighten the two M6 flanged screws operating in stages until the cap stops
against the crankcase.
•
Undo and remove the two M6 flanged
screws.
•
Tighten the cap with the two original
TBEI screws.
ENG - 149
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Installing sliders
•
Fit the crankshaft and the service shaft
on the crankcase.
•
Fit the fixed chain sliders and tighten
the fixing screws.
•
Tighten the chain caps with O-rings.
•
The operations related to the movable
chain sliders are described in the cylinder fitting section.
See also
Installing the crankshaft
Installing the service shaft
Cam timing
•
Fit the crankshaft and the service shaft
on the crankcase.
•
Fit the cylinders.
•
Turn the crankshaft until the left cylinder piston reaches the top dead centre
(TDC).
•
Fit the cotter and the shim washer on
the service shaft.
•
Fit the tone wheel with the chamfered
side facing the crankcase on the service shaft.
ENG - 150
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•
Lock crankshaft rotation.
•
Unscrew and remove the nut fixing the
Engine
crankshaft gear.
•
Remove the oil pump control gear.
Specific tooling
12.91.18.01 Tool to lock the flywheel and the
starting ring gear
•
Fit the timing system gear and align the
reference with that on the crankshaft
gear. Turn the crankshaft to align the
two gears.
•
After shimming the timing sensor properly, proceed to fit it.
•
Fit the washer and tighten the timing
system gear fixing nut of the service
shaft.
ENG - 151
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Engine
•
Place a new gasket between the crankcase and the oil pump.
•
Place the oil pump.
•
Tighten the three screws fixing the oil
pump.
•
Place the driving pin on the oil pump
shaft.
•
Place the gear on the oil pump shaft.
ENG - 152
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STELVIO 4V - 1200 ABS
•
Place the washer on the oil pump shaft.
•
Tighten the nut to the specified torque.
•
Place the oil pump control gear on the
Engine
crankshaft and align its reference with
that marked during the removal phase
on the oil pump driven gear.
•
Tighten the nut to the specified torque.
•
Tighten the screw with the washer to
the prescribed torque.
See also
Installing the crankshaft
Installing the service shaft
Measuring air gap
ENG - 153
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Engine
Measuring air gap
•
Undo and remove the two screws and
remove the sensor.
•
Insert a suitable plain washer on the
sensor and note its thickness.
•
Place the sensor on the crankcase and move it until it makes contact with the tone wheel.
•
Measure the clearance between the fixing plate and the crankcase with a thickness gauge.
Subtract the plain washer value from this measurement to obtain the clearance between the
sensor and the tone wheel.
•
Remove the washer and fit the sensor after applying adequate sealing paste on the fixing
plate, then tighten the screws to the prescribed torque.
ENG - 154
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Cylinder-piston assembly
Key:
1. Right cylinder
2. Piston
3. Screw
4. Top piston ring
5. Middle piston ring
6. Oil scraper piston ring
7. Pin
8. Snap ring
9. Cylinder base gasket
10.Stud bolt
11.Pin
12.Cylinder head gasket
13.Left cylinder
14.Washer
15.Chain tensioner cap
16.Washer
17.Left chain tensioner
18.Right chain tensioner
ENG - 155
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Removing the cylinder
NOTE
THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY
TO BOTH HEADS.
•
Remove the head, the gasket between
the head and the cylinder and the two
dowel pins.
•
Slide off the movable chain slider.
•
Remove the cylinder from the stud
bolts.
•
Remove the two dowel pins on the stud
bolts.
•
Remove the two gaskets between the
crankcase and the cylinder.
•
Cover the crankcase opening with a
clean cloth.
See also
Removing the cylinder head
Disassembling the piston
NOTE
THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY
TO BOTH HEADS.
•
Remove the cylinder.
•
Cover the crankcase opening with a
clean cloth.
•
Disengage the pin clip.
•
Remove the pin.
ENG - 156
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•
Engine
Mark the piston crown on the exhaust
side so as to remember the refitting position.
•
Remove the piston.
Fitting the piston
NOTE
THE OPERATIONS DESCRIBED BELOW REFER TO REMOVING ONLY ONE HEAD BUT APPLY
TO BOTH HEADS.
•
The reference on the piston ring must
be facing the piston crown.
•
Fit the piston rings on the piston: - the
oil scraper in the lower slot; - the thicker
smooth ring in the intermediate slot; the less thick smooth ring in the upper
slot.
•
The piston rings must be offset at 120°
one from the other.
•
Fit one of the two pin snap rings on the
piston.
•
Lock crankshaft rotation.
Specific tooling
12.91.18.01 Tool to lock the flywheel and the
starting ring gear
•
Fit the piston.
NOTE
CHECK THE PISTON DIRECTION ACCORDING TO THE REFERENCES MARKED ON THE PISTON
CROWN. DO NOT ASSEMBLE PISTONS AND CYLINDERS OF DIFFERENT SELECTOR TYPES.
ENG - 157
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Engine
•
Insert the pin.
•
Insert the snap ring.
Specific tooling
020470Y Pin snap ring fitting tool
Installing the cylinder
RIGHT CYLINDER
•
Fit the piston.
•
Remove the cloth used to prevent foreign bodies from getting into the crankcase.
•
Turn the rings so that the coupling ends
are 120 degrees from each other.
•
Place a new metal gasket between the
crankcase and the cylinder. Place the
two dowel pins on the stud bolts. Lubricate the piston and the cylinder.
Lock connecting rod motion with the
fork tool. Using the suitable piston ring
clamp tool, place the cylinder and fit the
chain in the timing system plate.
CAUTION
DURING THIS OPERATION, PAY ATTENTION NOT TO
DAMAGE THE PISTON.
Specific tooling
020674Y Piston ring clamp
ENG - 158
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Engine
020716Y Connecting rod locking
•
Remove the piston ring clamp tool and
finish positioning the cylinder.
Specific tooling
020674Y Piston ring clamp
•
Fit the movable chain slider.
•
Fit the upper gear.
•
Fit the chain tensioner and the chain
tensioner cap temporarily and keep the
chain taut on the service shaft.
LEFT CYLINDER
•
Fit the piston.
•
Remove the cloth used to prevent foreign bodies from getting into the crankcase.
•
Turn the rings so that the coupling ends
are 120 degrees from each other.
•
Place a new metal gasket between the
crankcase and the cylinder.
•
Place the two dowel pins on the stud
bolts.
•
Undo the screw which will be used to
time the upper gear.
ENG - 159
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•
Check that the oil in the left cylinder
chain tensioner has been drained off
by compressing it. If the operation is
difficult, use a pin drive to push the
central hole so that the oil is drained off
from the circuit.
•
Fit the chain tensioner in the cylinder.
•
Lubricate the piston and the cylinder.
•
Lock connecting rod motion with the fork tool.
•
Using the suitable piston ring clamp tool, place the cylinder and fit the chain in the timing
system plate.
CAUTION
DURING THIS OPERATION, PAY ATTENTION NOT TO DAMAGE THE PISTON.
Specific tooling
020674Y Piston ring clamp
020716Y Connecting rod locking
•
Fit the movable chain slider.
•
Fit the upper gear.
•
Fit the chain tensioner cap temporarily
and keep the chain taut on the service
shaft.
ENG - 160
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Installing the cylinder head
•
Fit the valves in the head, if previously
removed.
•
Take the left cylinder piston to TDC and
lock crankshaft rotation.
•
Determine the thickness of the gasket
to be fitted between the head and the
cylinder as described in the section:
Shimming system.
•
Place the two dowel pins.
•
Fit the gasket with the correct thickness between the head and the cylinder.
•
Fit the left cylinder head.
•
Fit a new O-ring in the spark plug hole.
•
Fit the complete cam cap.
•
Fix the cam cap with the four nuts on
the stud bolts.
ENG - 161
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•
Fix the head with the two screws.
•
Tighten nuts and screws to the prescribed torque operating diagonally and in
stages.
•
Loosen the valve set screws.
•
Using a thin screwdriver relief oil pressure from the left cylinder chain tensioner.
•
Screw two screws in the threaded
holes of the timing system upper gear.
•
Rotate the camshaft so that its pin is
aimed towards the hole in the timing
system chain.
•
Place the gear in the chain.
•
On the left camshaft pin, fit the hole
marked with the letter "L" of the timing
system gear.
•
Block the left chain tensioner hole with
screw and washer.
•
Rotate the crankshaft by 90°so that the
right cylinder piston reaches the TDC;
lock crankshaft rotation.
•
Also determine the thickness of the
gasket for the right cylinder, to be fitted
between the head and the cylinder as
described in the section: Shimming
system.
•
Place the two dowel pins.
ENG - 162
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•
Engine
Fit the gasket with the correct thickness between the head and the cylinder.
•
Fit the right cylinder head.
•
Unscrew and remove the right chain
tensioner cap.
•
Screw two screws in the threaded
holes of the timing system upper gear.
•
Rotate the camshaft so that its pin is
aimed towards the hole in the timing
system chain.
•
Place the gear in the chain.
•
On the right camshaft pin, fit the hole
marked with the letter "R" of the timing
system gear.
•
Screw the cap of the right chain tensioner.
•
Undo and remove the screws used to
place the gear on the camshaft.
•
Place the bulkhead and align the holes
with the timing system gear.
•
Fix the bulkhead on the timing system
gear using a screw with Loctite on the
thread.
•
Tighten the screw to the prescribed torque.
•
Also place the bulkhead of the other
head.
ENG - 163
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•
Place the cap.
•
Tighten the two screws to the prescribed torque.
•
Also place the cap of the other head.
•
Adjust valve clearance.
See also
Checking the valve clearance
Installing the head cover
•
Replace the gasket and install the
head cover.
•
Place the plastic half-cover.
•
Replace the four rubber rings.
•
Tighten the four screws to the prescribed torque.
•
Place the spark plug tube.
ENG - 164
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Crankcase - crankshaft
Removing the crankshaft
•
Remove the clutch.
•
Remove the tone wheel and the oil
pump gear.
•
Working from the generator side, unscrew and remove the nut.
•
Remove both gears.
•
Remove the connecting rods.
•
Undo and remove the eight fixing
screws and collect the washers.
•
Hold the crankshaft during flange removal.
•
Using the suitable special tool, remove
the crankshaft flange.
•
Remove the sealing ring from the
flange, if necessary.
Specific tooling
12.91.36.00 Tool to remove the flywheel-side
flange
ENG - 165
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•
Remove the crankshaft afterwards.
•
Collect the shim washer from inside the
crankcase.
See also
Disassembling the
clutch
Removing the phonic wheel
Disassembling the connecting rod
•
Remove both heads.
•
Remove the cylinders and the pistons.
•
Remove the oil sump.
•
Undo the coupling screws (A) inside
the crankcase and remove the connecting rods (B).
See also
Removing the flywheel
Disassembling the piston
Removing the cylinder
Removing the cylinder head
ENG - 166
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Inspecting the crankshaft components
Check the surfaces of the main journals; if they are
scored or oval-shaped, reface them (observing the
undersize charts), and replace the main bushing/
s.
Reference (1) indicates the position where the coloured reference is applied to select diameter (B).
Reference (2) indicates the position where the coloured reference is applied to select balancing.
CRANKSHAFT SEAT (TIMING SYSTEM SIDE)
Specification
Diameter of crankshaft main journal, timing system side
Inside diameter of crankshaft bushing, timing system side
Clearance between bushing and main journal (timing system
side)
Desc./Quantity
37.975 - 37.959 mm (1.49507 - 1.49444 in)
38.016 - 38.0 mm (1.49669 - 1.49606 in)
0.025 - 0.057 mm (0.00098 - 0.00224 in)
CRANKSHAFT SEAT ( CLUTCH SIDE)
Specification
Diameter of crankshaft main journal, clutch side
Inside diameter of crankshaft bushing on clutch-side flange
Clearance between bushing and main journal (clutch side)
Desc./Quantity
53.97 - 53.961 mm (2.12480 - 2.12444 in)
54.019 - 54.0 mm (2.12673 - 2.12598 in)
0.030 - 0.058 mm (0.00118 - 0.00228 in)
CRANKPIN DIAMETER (B)
Specification
'Blue' bushing half-shell regular production
'Red' bushing half-shell regular production
Desc./Quantity
44.008 ÷ 44.014 mm (1.73259 ÷ 1.73283 in)
44.014 ÷ 44.020 mm (1.73283 ÷ 1.73307 in)
BALANCING SELECTION COLOURS (2)
Specification
Crankshaft selection colour (2) brown
Crankshaft selection colour (2) green
Crankshaft selection colour (2) black
Desc./Quantity
Type 1 to be used with brown connecting rods.
Balance with a 1558 g (54.96 oz) +/- 0.25% weight fitted on the
crankpin (B). Maximum imbalance allowed for each shoulder:
2 g (0.07 oz).
Type 2 to be used with green connecting rods.
Balance with a 1575 g (55.56 oz) +/- 0.25% weight fitted on the
crankpin (B). Maximum imbalance allowed for each shoulder:
2 g (0.07 oz).
Type 2 to be used with black connecting rods.
Balance with a 1592 g (56.16 oz) +/- 0.25% weight fitted on the
crankpin (B). Maximum imbalance allowed for each shoulder:
2 g (0.07 oz).
Checking the connecting rod
When examining the connecting rods, check that:
•
Bushing conditions and bushings-pins clearance;
•
Shaft parallelism;
•
Connecting rod bearings.
These are thin shell bearings, anti-friction alloy that does not allow for any adaptation; replace them
immediately if seizing or wear marks are found.
ENG - 167
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Upon replacing the bearings it may be necessary to ream the crankshaft pin.
Before reaming the crankpin, measure the pin diameter (B) comparing it with the maximum wear allowed, as indicated in the figure; this defines what kind of undersizing the bearing should have and to
which diameter the pin (B) should be reamed.
Checking shaft parallelism
Check shafts for squaring before fitting them.
It is therefore necessary to check that the head holes and the rod small end are parallel and on the
same plane.
The maximum parallelism and plane error of the two head shafts and connecting rod small end should
be +/- 0.10 mm (0.00393 inch).
CONNECTING ROD BEARING THICKNESS
Specification
Regular 'Blue' connecting rod bearing (production)
Regular 'Red' connecting rod bearing (production)
Desc./Quantity
1.539 - 1.544 mm (0.06059 - 0.06079 in)
1.535 - 1.540 mm (0.06043 - 0.06063 in)
CRANKPIN DIAMETER (B)
Specification
'Blue' bushing half-shell regular production
'Red' bushing half-shell regular production
Desc./Quantity
44.008 ÷ 44.014 mm (1.73259 ÷ 1.73283 in)
44.014 ÷ 44.020 mm (1.73283 ÷ 1.73307 in)
PIN-BUSHING COUPLING DATA
Specification
Fitted and machined bushing - inside Ø
Pin diameter
Clearance between pin and bushing
Desc./Quantity
22.003 - 22.020 mm (0.86626 - 0.86692 in)
21.998 - 21.994 mm (0.86606 - 0.86590 in)
0.005 - 0.026 mm (0.000197 - 0.001024 in)
ENG - 168
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The connecting rods have a marked area for
weight selection.
The weight indicated in the chart includes screws,
dowels and the bushing.
CONNECTING ROD WEIGHT SELECTION
Specification
Connecting rod - brown
Connecting rod - green
Connecting rod - black
Desc./Quantity
0.588 - 0.598 mm (0.02074 - 0.02109 in)
0.598 - 0.608 mm (0.02109 - 0.02145 in)
0.608 - 0.618 mm (0.02145 - 0.02180 in)
Assembling the connecting rod
•
Lubricate the crankpin on which the
connecting rods are to be fixed.
•
If the connecting rods are not replaced,
be careful not to interchange the right
connecting rod with the left one and
vice versa.
To place the connecting rods: the two pins must
be facing the crankcase internal side.
•
Place the connecting rods and the
caps (B) on the crankshaft and fasten
them with new screws (A).
•
Remember these recommendations:
•
The screws fixing the connecting rods to the crankshaft must be replaced with new ones at
the following refitting as they are subject to high loads and stress;
•
The fitting clearance between bearing and connecting rod pin is 0.028 mm (0.0011 inch)
minimum and 0.052 mm (0.0020 inch) maximum;
•
The clearance between the shim washers of the connecting rod and those of the crankshaft
is comprised between 0.30 mm (0.01181 in) and 0.50 mm (0.01968 in);
•
Lock the screws (A) on the caps (B) with a torque wrench at the prescribed torque.
ENG - 169
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PAY ATTENTION TO CRANKSHAFT ROTATION WHEN ONLY THE CONNECTING RODS ARE
FITTED BECAUSE IT COULD HIT THE TWO LUBRICATION JETS INSIDE THE CRANKCASE.
Installing the crankshaft
•
Fit the shim washer inside the crankcase with the chamfered side facing
the generator side.
•
Lubricate the crankshaft bushing on
the crankcase, generator side.
•
Use the sealing ring fitting tool on the flywheel-side flange to fit the sealing ring on the flange.
Specific tooling
19.92.71.00 Tool to fit the sealing ring on the flywheel-side flange
•
Fit a new gasket between the crankcase and the crankshaft flange, flywheel side.
•
Fit the crankshaft on the crankcase,
flywheel side.
•
Mark the crankshaft on the flywheel
side with the crankpin facing upwards.
•
Place the suitable sealing ring centring
tool on the crankshaft.
Specific tooling
12.91.20.00 Tool to fit the flywheel-side flange
together with sealing ring on the crankshaft
ENG - 170
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•
Engine
Place the flywheel-side flange on the
crankshaft and check if the dowel pin
with the O-ring is correctly placed.
•
When fitting the flange on the crankcase, make sure that the three dowel
pins match the seats on the crankcase.
•
Apply Teflon tape on the two lower fixing screws at the back in order to prevent oil leaks.
•
Screw the eight flange screws on the
flywheel side proceeding diagonally.
•
Remove the sealing ring centring tool from the crankshaft.
Specific tooling
12.91.20.00 Tool to fit the flywheel-side flange together with sealing ring on the crankshaft
•
To avoid that the shim washer inside
the crankcase moves out of its seat, fit
the two gears and the nut on the crankshaft on the generator side.
ENG - 171
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STELVIO 4V - 1200 ABS
Engine
Refitting the crankcase halves
In case the lubrication jets are removed, replace
them with two new of the same type. Check that
the O-ring is fitted on the jets.
Do not interchange them upon refitting because
they have a different length.
Lubrication
Conceptual diagrams
Key:
ENG - 172
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STELVIO 4V - 1200 ABS
Engine
1. Oil cooling radiator
2. Oil delivery pipe to heads
3. Oil delivery pipe to radiator
4. Oil pump body
5. Oil pump gasket
6. Rotor for lubrication
7. Rotor for cooling
8. Rotor control shaft
9. Oil pump cover
10.Oil pump control gear
11.Lubrication oil intake filter
12.Cooling oil intake filter
The oil pump is operated by the gear (10) which receives the motion directly from the crankshaft. The
gear (10) is mounted on the shaft (8), on which two rotors are fitted: one for engine cooling (7) and
another for lubrication (6).
Cooling:
The rotor (7) takes in oil from the sump through the filter (12); the oil is sent to the radiator (1) through
the hoses (3). Oil passes through the radiator (1) dispersing part of the heat and reaches the heads
through the hoses (2). Oil goes down to the sump again and joins the oil used for lubrication.
Lubrication:
The rotor (6) takes in oil from the sump through the filter (11); the oil is sent through special ducts in
the crankcase to all the parts to be lubricated. Oil goes down to the sump again and joins the oil used
for cooling.
Oil pump
Removing
•
Drain off the engine oil.
•
Remove the generator and the timing
system cover.
•
Unscrew and remove the nipple.
•
Collect the gasket.
ENG - 173
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STELVIO 4V - 1200 ABS
Engine
•
Remove the nipple - oil pump fitting.
•
Bring the left cylinder piston to the TDC
in combustion phase.
•
Mark a reference on the oil pump control gear and another on the driven
gear so as to place them correctly
again upon refitting.
•
Unscrew and remove the nut on the
crankshaft.
•
Remove the oil pump control gear.
•
Screw the nut again so that the internal
shim washer does not fall in the crankshaft crankcase.
•
Unscrew and remove the driven gear
nut.
•
Collect the washer.
•
Remove the oil pump driven gear.
•
Remove the driving pin.
ENG - 174
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STELVIO 4V - 1200 ABS
•
Undo and remove the three screws.
•
Remove the oil pump.
•
Remove the gasket between the
Engine
crankcase and the oil pump.
See also
Replacement
Removing the generator
Installing
•
Place a new gasket between the crankcase and the oil pump.
•
Place the oil pump.
•
Tighten the three screws fixing the oil
pump.
ENG - 175
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STELVIO 4V - 1200 ABS
Engine
•
Place the driving pin on the oil pump
shaft.
•
Place the gear on the oil pump shaft.
•
Place the washer on the oil pump shaft.
•
Tighten the nut to the specified torque.
•
Place the oil pump control gear on the
crankshaft and align its reference with
that marked during the removal phase
on the oil pump driven gear.
•
Tighten the nut to the specified torque.
ENG - 176
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STELVIO 4V - 1200 ABS
•
Insert the joint in the oil pump.
•
Fit the nipple with the gasket on the
Engine
crankcase.
•
Tighten the nipple to the prescribed
torque.
Removing the oil sump
NOTE
TO REMOVE THE OIL SUMP, PLACE A SUITABLE CONTAINER UNDER IT TO COLLECT THE
USED OIL AND DRAIN OUT ALL OIL.
•
If necessary, the filter can be removed with the suitable special tool.
Specific tooling
01.92.91.00 Wrench for removing the cover on sump and filter
•
Unscrew and remove the oil level plug
and collect the O-Ring.
ENG - 177
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STELVIO 4V - 1200 ABS
Engine
•
Undo and remove the fourteen screws
fixing the oil sump to the engine crankcase.
•
Undo and remove the four screws.
•
Remove the flange.
ENG - 178
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STELVIO 4V - 1200 ABS
•
Undo and remove the two screws.
•
Remove both filters.
•
Unscrew and remove the plug.
•
Remove the thermostatic valve.
•
Unscrew and remove the pressure re-
Engine
lief valve plug.
•
Remove the pressure relief valve components
ENG - 179
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STELVIO 4V - 1200 ABS
Engine
Refitting the oil sump
•
Place the pressure relief valve components correctly.
•
Screw the pressure relief valve plug.
•
Place the thermostatic valve.
CHECK THAT THE ENGINE OIL PASSAGE HOLE IS NOT
CLOGGED.
ENG - 180
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STELVIO 4V - 1200 ABS
•
Tighten the thermostatic valve plug.
•
Place a new gasket between the crank-
Engine
case and the flange.
•
Fit the flange.
•
Fix the flange with the four screws.
•
Fit the lubrication oil intake filter.
ENG - 181
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STELVIO 4V - 1200 ABS
Engine
•
Check that the O-rings are fitted on the
oil pump.
•
Fit the cooling oil intake filter.
•
Fix both filters and tighten the two
screws to the prescribed torque.
•
Fit a new oil filter and tighten it to the
prescribed torque.
•
Place a new gasket between the flange
and the sump.
ENG - 182
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STELVIO 4V - 1200 ABS
•
Place the oil sump.
•
Tighten the fourteen screws to the pre-
Engine
scribed torque.
•
Add engine oil up to the correct level.
ENG - 183
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INDEX OF TOPICS
POWER SUPPLY
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P SUPP
STELVIO 4V - 1200 ABS
Power supply
Circuit diagram
Key:
1. Complete fuel pump unit
2. Nut
3. Fuel pipe
4. Pipe
5. Screw
Injection
P SUPP - 185
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STELVIO 4V - 1200 ABS
Power supply
Diagram
Key:
1 Control unit
2 Ignition switch
3 Battery
4 Fuel pump
5 Coils
6 Instrument panel
7 Air temperature sensor
8. Throttle valve position sensor
9 Injectors
10 Engine temperature sensor
11 Crankshaft position sensor
12. Side stand
P SUPP - 186
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STELVIO 4V - 1200 ABS
Power supply
13 Lambda probe
14 Fall sensor
THROTTLE BODY PIPES LAYING
Pipes from the throttle body to the idle motor
should be laid so that the shaped part is inserted
in the air filter casing.
The shortest part of the fuel pipe connected to the
throttle bodies should be placed on the right.
Cylinders synchronisation
•
With engine off, connect the Navigator
tool to the diagnosis connector and to
the vehicle battery.
•
Turn on the scanner.
•
Screw the joints connecting the vacuometer pipes on the inlet pipe holes.
•
Connect the vacuometer pipes to the
relative joints.
•
Set the key to ON.
P SUPP - 187
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STELVIO 4V - 1200 ABS
Power supply
•
Make sure there are no errors in the
control unit; otherwise, solve them and
repeat the procedure.
•
Make sure the left throttle is fully in.
DO NOT TOUCH THE THROTTLE ABUTMENT SCREW OR
THE THROTTLE BODY MUST BE REPLACED. CHECK
THAT THE THROTTLE RETURN CABLE IS NOT TAUT.
•
The instrument should display the adjustable parameters screen page.
•
Autodetect the throttle position.
•
Turn the key to "OFF" and leave it for
at least 30 seconds.
•
Turn the key back to "ON" and restore
the instrument session.
•
Check that the "Throttle" value reading
is 4.7 +/- 0.2°. If the value is incorrect,
replace the control unit and repeat the
procedure from the start.
•
Completely close the two by-pass
screws on the throttle bodies.
•
Start the engine.
•
Take the engine to the prescribed temperature: 60 °C (140 °F).
•
Make the engine rev at 2000/3000 rpm
and with the vacuometer check that the
difference between the two pressures
is 1 cm Hg (1.33 kPa) maximum.
If this condition is detected:
•
take the engine back to idle and check
the depression values so that they are
aligned between the two cylinders.
Otherwise, open only the screw with
higher depression, using the by-pass
screws, to compensate.
P SUPP - 188
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STELVIO 4V - 1200 ABS
Power supply
If there is a larger difference:
•
act on the set screw of the throttle body
connecting rod to reduce the pressure
difference in the two pipes.
•
Repeat the procedure "Throttle position self-acquisition" as explained
above.
•
Take the engine back to idle and check
the depression values so that they are
aligned between the two cylinders.
•
Otherwise, open only the screw with
higher depression, using the by-pass
screws, to compensate.
Recovery function
If the signal of the following sensors is interrupted, the control unit determines some values to keep the
engine running or it uses a different parameter. The instrument panel and the Navigator also signal the
problem.
RECOVERY FUNCTION
Specification
air temperature
engine temperature
barometric pressure
throttle valve potentiometer
idle motor
Desc./Quantity
25 °C (77 °F)
30 °C (86 °F)
with linear increase from the air temperature at ignition
1010 hPa
2.9° at idle, otherwise variable.
fixed value variable depending on the vehicle
Using Navigator for injection system
Injection system
P SUPP - 189
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STELVIO 4V - 1200 ABS
Power supply
ECU INFO screen page
This screen page shows general data regarding
the control unit, for example software type, mapping, control unit programming date
INFO ECU SCREEN PAGE
Specification
Mapping
Desc./Quantity
-
PARAMETERS screen page
This screen page shows the parameters measured by the several sensors (engine revs, engine
temperature, etc.) or values set by the control unit
(injection time, ignition advance, etc.)
PARAMETERS SCREEN PAGE
Specification
Engine rpm
Injection time
Ignition advance
Air temperature
Engine temperature
Battery voltage
Throttle
Atmospheric pressure
Lambda probe
Lambda integrator
Vehicle speed
Desc./Quantity
Engine revolutions per minute: the minimum value is set by the
control unit cannot be adjusted
- ms
-°
°C
Temperature of the air taken in by the engine, measured by the
sensor in the filter casing. This is not the temperature indicated
by the instrument panel
°C
V
Value corresponding to the throttle when closed (approximate
value between 4.5 and 4.9°) (left throttle supported by the end
of stroke screw). If a different value is read, it is necessary to
activate the parameter "Throttle positioner autodetection" and
obtain this value.
1015 mPa (approximate values)
The sensor is inside the instrument panel
100 - 900 mV (approximate values)
Signal when energised that the control unit receives from the
lambda probe: inversely proportional to the presence of oxygen
When the control unit uses the lambda probe signal (see the
'Lambda' parameter on the 'Statuses' screen page) this value
should be close to 0%.
- km/h
P SUPP - 190
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STELVIO 4V - 1200 ABS
Power supply
Specification
Target engine revs
Desc./Quantity
1150 rpm (approximate values)
Parameter valid at idle, setting depends especially on the engine temperature: the control unit will try to keep the engine
running at this revs, acting on the ignition advance and the
Stepper motor
70 - 100 (approximate values)
Steps corresponding to the Stepper motor reference position
70 - 150 (approximate values)
Steps set by the control unit for the Stepper motor. At idle, steps
so that the engine keeps the target engine revs set by the control unit
Difference between current steps of motor at idle and those at
the reference position
0°
With engine not at idle speed, this value indicates the throttle
degrees corresponding to the Stepper motor air flow
Stepper base
CL Stepper
Stepper regulator
Virtual throttle angle from Stepper
STATUS screen page
This screen page shows the status (usually ON/
OFF) of the vehicle devices or the operation condition of some vehicle systems (for example, lambda probe functioning status).
STATUSES
Specification
Engine status
Throttle position
Stand
Ignition
RUN / STOP switch
Clutch
Gear engaged
fall sensor
Lambda
Synchronisation
Desc./Quantity
ON/run/power-latch/stopped
operation conditions
Released / pressed
indicates if the throttle potentiometer is open or closed
Retracted / extended
indicates the position of the side stand (only with gear engaged)
Enabled / disabled
indicates if the control unit consents engine start-up
Run / stop
indicates the position of the safety switch
No / Yes
indicates the clutch sensor status
No / Yes
indicates the gear sensor status
Normal / Tip over
indicates the vehicle fall sensor status
Open loop / Closed loop
Indicates if the control unit is using (CLOSED) the lambda
probe signal to keep the stoichiometric combustion. At idle
CLOSED only if: Air T over 20°C (68°F) and engine T over 30°
C (86°F) and engine on for at least 2-3 minutes
Synchronised / Not synchronised
Indicates if the control unit detects the revolution sensor signal
correctly
P SUPP - 191
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STELVIO 4V - 1200 ABS
Power supply
ACTIVATION screen page
This screen page is used to delete errors in the
control unit memory and to activate some systems
controlled by the control unit.
ACTIVATION
Specification
Left coil
Right coil
Left injector
Right injector
Error clearing
Desc./Quantity
operation for 2.5 m, 5 times
operation for 2.5 m, 5 times
Operation for 4 m, 5 times
Operation for 4 m, 5 times
By pressing the 'enter' button, the stored errors (MEM) become
part of the historical data (STO). In the next connection between the Navigator and the control unit, the historical errors
(STO) are no longer shown
Operation for 30''
<span style="FONT-SIZE: 12pt; FONT-FAMILY: "Times New
Roman"; mso-fareast-font-family: "Times New Roman"; msoansi-language: IT; mso-fareast-language: IT; mso-bidi-language: AR-SA">For 4'' advancement command of 32 steps, for
the next 4'' retrocession command of 32 steps and so on for
30''
Fuel pump
Stepper control
ERRORS screen page
This screen page shows potential errors detected
in the vehicle (ATT) or stored in the control unit
(MEM) and it allows to check error clearing (STO).
ERRORS
Specification
Pressure sensor
Air temperature
Engine temperature
Throttle actuator position sensor
Desc./Quantity
Possible short circuit in the earth lead, battery or open circuit:
recovery function noticeable for customer. Careful with the air
pressure sensor in the instrument panel
Possible short circuit in the earth lead, battery or open circuit:
recovery function hardly noticeable for customer.
Possible short circuit in the earth lead, battery or open circuit:
recovery function.
Possible short circuit in the earth lead, battery or open circuit:
recovery function noticeable for customer.
P SUPP - 192
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STELVIO 4V - 1200 ABS
Power supply
Specification
Lambda probe
Desc./Quantity
Possible short circuit on the earth lead, battery or open circuit
or plausibility: recovery function hardly noticeable for customer.
Possible short circuit in the earth lead, battery or open circuit.
If both injectors do not work, the engine does not work
Possible short circuit in the earth lead, battery or open circuit.
If both injectors do not work, the engine does not work
Possible short circuit in the earth lead, battery or open circuit:
the engine does not start.
Possible short circuit in the earth lead, battery or open circuit.
If both coils do not work, the engine does not work.
Possible short circuit in the earth lead, battery or open circuit.
If both coils do not work, the engine does not work.
Possible short circuit in the earth lead, battery or open circuit:
recovery function noticeable for the customer due to no idle
management
Battery voltage detected is too low (7V) or too high (16V) for a
certain period
Possible short circuit in the earth lead, battery or open circuit.
Possible open circuit.
Possible short circuit in the earth lead, battery or lambda probe
heating circuit open.
Left injector
Right injector
Fuel pump relay
Left coil
Right coil
Idle regulator
Battery voltage
Starter diagnosis
Engine revolution sensor
Lambda heater
SPEED SENSOR
CAN line diagnosis
<span style="FONT-SIZE: 12pt; FONT-FAMILY: "Times New
Roman"; mso-fareast-font-family: "Times New Roman"; msoansi-language: IT; mso-fareast-language: IT; mso-bidi-language: AR-SA">Possible error on line CAN: short circuit or line
break or no signal or plausibility error detected.
Possible internal control unit error. Also check the control unit
supply and earth connections
Possible internal control unit error. Also check the control unit
supply and earth connections
Possible internal control unit error. Also check the control unit
supply and earth connections
Possible internal control unit error. Also check the control unit
supply and earth connections
RAM memory
ROM memory
Microprocessor
Checksum EPROM
SETTINGS screen page
This screen page is used to adjust some control
unit parameters.
ADJUSTMENTS
Specification
Throttle positioner autodetection
Desc./Quantity
Allows the control unit to detect the closed throttle position: just
press the enter button
P SUPP - 193
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INDEX OF TOPICS
SUSPENSIONS
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SUSP
STELVIO 4V - 1200 ABS
Suspensions
Front
Removing the front wheel
•
Working from both sides, undo and remove the two fixing screws from the
front brake callipers and remove them
from their seats.
•
Hold the vehicle front part.
•
Unscrew and remove the wheel axle
fixing nut and collect the sealing washer.
•
Working from both sides, loosen the
screws on the wheel bolt clamps.
•
Tap the wheel axle slightly with a rubber mallet so that the hole on the opposite side is
exposed.
SUSP - 195
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STELVIO 4V - 1200 ABS
Suspensions
•
Remove the wheel axle by inserting a
screwdriver in the holes on the pin.
•
During extraction, support the wheel
and then remove it.
•
Collect the spacer from the front wheel
right side.
Front fork
Diagram
Key:
SUSP - 196
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STELVIO 4V - 1200 ABS
Suspensions
1. Complete front fork
2. TCE screw
3. Washer
4. TE flanged screw
5. Stem + right wheel holder
6. Bushing
7. Stem + left wheel holder
8. Complete right pumping member
9. Nut
10.Complete left pumping member
11.Fork upper plate
12.TCE screw
13.Base with headstock
14.Right sleeve cap
15.Left sleeve cap
16.O-ring
17.O-ring
18.Washer
19.Snap ring
20.O-ring
21.Complete sleeve
22.Spring holder cap
23.Spring guide
24.Preloading pipe
25.Spring guide
26.Spring
27.Bushing
28.Dust guard
29.Snap ring
30.Sealing ring
31.Cap
32.Bushing
SUSP - 197
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STELVIO 4V - 1200 ABS
Suspensions
Adjustment
The front suspension consists of a hydraulic fork
connected to the headstock by means of two
plates.
To set the vehicle suspension, each fork stem features an upper nut (1), to adjust spring preloading,
and an upper set screw (2):
•
act on the right stem set screw to adjust
hydraulic rebound damping;
•
act on the left stem set screw to adjust
hydraulic compression damping.
ADJUSTMENTS
Regular adjustment (standard):
- only rider.
Medium load setting:
- (for example, rider with passenger or with luggage).
Maximum load adjustment:
- (for example, rider, passenger and luggage).
FORK SETTING
Regular load adjustments are the standard settings by the manufacturer:
FORK ADJUSTMENT (1) (2)
Specification
Spring preloading, nut (1) - regular load conditions
Spring preloading, nut (1) - half-load conditions
Spring preloading, nut (1) - maximum load conditions
Rebound damping, right stem set screw (2) - regular load conditions
Rebound damping, right stem set screw (2) - half-load conditions
Rebound damping, right stem set screw (2) - maximum load
conditions
Compression damping, left stem set screw (2) - regular load
conditions
Compression damping, left stem set screw (2) - half-load conditions
Compression damping, left stem set screw (2) - maximum load
conditions
Desc./Quantity
tighten (clockwise) 6 turns from fully open
tighten (clockwise) 7 turns from fully open
tighten (clockwise) 7 turns from fully open
unscrew (anticlockwise) 2 turns from fully closed
unscrew (anticlockwise) 2 turns from fully closed
unscrew (anticlockwise) 2 turns from fully closed
unscrew (anticlockwise) 2 turns from fully closed
unscrew (anticlockwise) 2 turns from fully closed
unscrew (anticlockwise) 1.5 turns from fully closed
(1) THE SETTING SHOWN IN THE TABLE MAY NEED TO BE MODIFIED ACCORDING TO THE
TYRE AND ROAD TYPE.
NOTE
(2) IF FITTED.
SUSP - 198
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STELVIO 4V - 1200 ABS
Suspensions
Removing the fork legs
•
Rest the vehicle on its centre stand.
•
Secure the rear part of the vehicle through belts in order to lift the front wheel.
•
Remove the mudguard.
•
Remove the front wheel.
•
Support the fork stem and loosen the
screws on the upper and then the lower
plate.
•
Remove the ABS sensor.
•
Remove the fork stem.
See also
Removing the front wheel
Draining oil
•
Lock the sleeve in the vice with the
specified tool.
•
Set the minimum spring preloading.
Specific tooling
AP8140149 Protection for fitting operations
SUSP - 199
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STELVIO 4V - 1200 ABS
Suspensions
•
Unscrew the sleeve top cap.
•
Push the bushing down in order to
compress the spring and then fit the
appropriate tool under the pumping
member pin lock nut and on the bushing to keep the spring compressed.
Specific tooling
020886Y Spacer / pumping member pin splitting plate
•
Remove the complete cap.
•
Press down and force the spring to
compress. Remove the tool.
SUSP - 200
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STELVIO 4V - 1200 ABS
•
Suspensions
Remove the spring. Let the oil deposited on the spring turns fully drip into
the sleeve.
•
Pour the oil into the container.
•
Remove the preload pipe and the
spring holder cap.
SUSP - 201
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STELVIO 4V - 1200 ABS
Suspensions
•
Push the bushing down in order to
compress the spring and then fit the
appropriate tool under the pumping
member pin lock nut and on the bushing to keep the spring compressed.
Specific tooling
020886Y Spacer / pumping member pin splitting plate
•
Remove the complete cap.
•
Press down and force the spring to
compress. Remove the tool.
•
Remove the spring. Let the oil deposited on the spring turns fully drip into
the sleeve.
SUSP - 202
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STELVIO 4V - 1200 ABS
•
Pour the oil into the container.
•
Remove the preload pipe and the
Suspensions
spring holder cap.
Disassembling the fork
•
Drain all the oil from the stem.
•
Tighten the wheel holder sleeve in a
vice.
•
Undo the fork end bottom screw and
remove it with the corresponding gasket.
SUSP - 203
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STELVIO 4V - 1200 ABS
Suspensions
•
Remove the pumping member pin.
•
Slide off the dust scraper from the
sleeve using a screwdriver as a lever.
•
During this operation, pay attention not
to damage the sleeve rim.
•
Remove the retainer ring.
•
Take out the sleeve from the stem using the stem as a hammer puller.
SUSP - 204
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STELVIO 4V - 1200 ABS
•
Suspensions
From the stem remove the fixed fitted
bushing, the movable bushing, the ring
and the oil seal.
•
Remove the ring and the dust guard.
See also
Draining oil
Checking the components
Stem
SUSP - 205
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STELVIO 4V - 1200 ABS
Suspensions
Check the sliding surface for scorings and/or scratches.
These scorings can be eliminated by rubbing them with wet sandpaper (grain 1).
If the scorings are deep, replace the stem.
Use a dial gauge to check that the stem bending is below the limit value.
If over the value, replace the stem.
CAUTION
A BENT STEM SHOULD NEVER BE STRAIGHTENED BECAUSE ITS STRUCTURE WOULD BE
WEAKENED AND USING THE VEHICLE MAY BECOME DANGEROUS.
Characteristic
Bending limit:
0.2 mm (0.00787 in)
Sleeve
Check that there are no damages and/or cracks; otherwise, replace it.
Spring
Check the spring is in good conditions.
Check that the following components are in good
conditions:
•
upper bushing;
•
lower bushing;
•
pumping member pin.
If there are signs of excessive wear or damage, replace the affected component.
CAUTION
REMOVE ANY IMPURITY IN THE BUSHINGS, TAKING CARE NOT TO SCRATCH THEIR SURFACE.
SUSP - 206
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STELVIO 4V - 1200 ABS
Suspensions
Replace the following components with new ones:
•
sealing ring;
•
dust guard;
•
O-Ring on the cap.
Reassembling the fork
•
Lock the stem in a vice without damaging the surface.
•
Protect the bearing tube end with adhesive tape.
•
Lubricate the sliding edges with fork oil
or sealing grease.
•
Fit on the slider the dust scraper, the
retainer ring and the seal ring.
SUSP - 207
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STELVIO 4V - 1200 ABS
Suspensions
•
The sealing ring must be placed with
the stamped part facing the dust gaiter.
•
Fit the ring, the movable bushing and,
after removing the tape, fit the fixed
bushing.
SUSP - 208
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STELVIO 4V - 1200 ABS
•
Suspensions
Fit the dust gaiter with the specific tool.
Specific tooling
9100903 Marzocchi fork oil seal; ø 45 mm (1.77
in)
•
Fit the pumping member pin with the
cap in the spring holder sleeve and in
the preload pipe.
SUSP - 209
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STELVIO 4V - 1200 ABS
Suspensions
•
Tighten the screw fixing the pumping
member on the fork end to the prescribed torque.
•
Fit the sleeve on the stem and set the
oil seal into position with the aid of the
specific tool.
Specific tooling
9100903 Marzocchi fork oil seal; ø 45 mm (1.77
in)
•
Insert the retainer ring in its position.
Filling oil
•
Place the sleeve upright in a vice fitted
with protection shoes.
•
Compress the sleeve in the stem.
Place a support under the stem in order
to leave it compressed.
•
Pour part of the fork oil into the sleeve.
•
Wait some minutes until the oil fills all
the ducts.
•
Pour the remaining oil.
•
Pump out oil a few times.
SUSP - 210
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STELVIO 4V - 1200 ABS
•
Suspensions
Measure the air gap between the oil
level and the rim.
THE SLEEVE MUST BE PERFECTLY UPRIGHT IN ORDER
TO MEASURE THE CORRECT OIL LEVEL. THE OIL LEVEL
MUST BE THE SAME IN BOTH STEMS.
Specific tooling
AP8140149 Protection for fitting operations
Characteristic
Oil level (from sleeve rim, without the spring
and preloading pipe)
110 mm (4.33 in).
•
Fit the spring.
•
Finger tight the upper cap on the pumping member stem.
•
Compress the spring and then fit the
appropriate tool under the pumping
member pin nut and on the bushing to
keep the spring compressed.
Specific tooling
020886Y Spacer / pumping member pin splitting plate
SUSP - 211
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STELVIO 4V - 1200 ABS
Suspensions
•
Screw the upper cap on the pumping
member pin.
•
Remove the tool to compress the
spring.
•
Place the sleeve in the vice using the
specified tool.
•
Screw the upper cover, tightening it to
the prescribed torque.
Specific tooling
AP8140149 Protection for fitting operations
•
Once the operations are completed,
restore the spring preloading correct
value.
Installing the fork legs
•
Insert the fork stem in position.
•
Insert the wheel pin so that the stems
are aligned.
SUSP - 212
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STELVIO 4V - 1200 ABS
•
Suspensions
Tighten the screws on the fork plates
to the prescribed torque.
Steering bearing
Adjusting play
•
Unscrew and remove the U-bolt four
fixing screws.
•
Remove the U-bolt.
•
Remove the handlebar and place it
paying attention that oil in the clutch
and front brake tanks does not spill out.
•
Working on both sides, unscrew and
remove the upper plate fixing screw on
the fork stems.
SUSP - 213
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STELVIO 4V - 1200 ABS
Suspensions
•
Unscrew and remove the fork upper
plate cover; collect the shim.
•
Lift the fork upper plate sliding it off
from the stems.
•
Rivet the safety washer on the headstock.
UPON REFITTING, REPLACE THE SAFETY WASHER WITH
A NEW ONE
•
Using the suitable special tool, unscrew and remove the upper ring nut.
Specific tooling
AP8140190 Tool for steering tightening
SUSP - 214
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STELVIO 4V - 1200 ABS
•
Remove the safety washer.
•
Using the suitable special tool, set the
Suspensions
preloading of the steering bearings.
Specific tooling
AP8140190 Tool for steering tightening
•
Fit a new safety washer.
•
Screw the upper ring nut manually and then slightly tighten the clamps on the plate so as to
align notches on the ring nut.
Specific tooling
AP8140190 Tool for steering tightening
•
Rivet the tongues of the new safety washer.
•
Fit the fork upper plate on the stems.
Rear
SUSP - 215
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STELVIO 4V - 1200 ABS
Suspensions
Removing the rear wheel
•
Support the vehicle rear part using a
suitable stand.
•
Engage the first gear.
•
Undo and remove the four screws, collect the spacers and the dust-protection ring.
•
Remove rear wheel.
Shock absorbers
Adjusting
The rear suspension consists of a spring-shock
absorber unit linked to the frame via Silent-block
and to the rear fork via a linkage system.
To set vehicle suspension, the shock absorber
has:
- a set screw (1) to adjust the hydraulic rebound
damping;
- a set knob (2) to adjust spring (3) preloading.
SUSP - 216
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STELVIO 4V - 1200 ABS
Suspensions
Standard rear shock absorber setting is adjusted
to suit most high and low speed riding conditions,
to transport the rider plus luggage.
However, this set can be modified for specific
needs according to vehicle use.
ALLOW ENGINE AND EXHAUST SILENCER TO COOL OFF
BEFORE OPERATING THE SET SCREWS.
ADJUSTMENTS
Regular adjustment (standard):
- only rider.
Half load adjustment:
- (for example, rider with passenger or with luggage).
Maximum load adjustment:
- (for example, rider, passenger and luggage).
CAUTION
SET SPRING PRELOADING AND SHOCK ABSORBER REBOUND DAMPING ACCORDING TO
THE VEHICLE USE CONDITIONS. IF THE SPRING PRELOADING IS INCREASED, IT IS NECESSARY TO INCREASE THE REBOUND DAMPING ACCORDINGLY TO AVOID SUDDEN JERKS
WHEN RIDING. IF NECESSARY, CONTACT AN Official Moto Guzzi Dealer. TRY RIDING THE VEHICLE ON THE STREET UNTIL THE OPTIMUM ADJUSTMENT IS OBTAINED.
SHOCK ABSORBER SETTING TABLE
Regular load adjustments are the standard settings by manufacturer
REAR SHOCK ABSORBER ADJUSTMENT (1)
Specification
Preload - regular load conditions
Preload - half-load conditions
Preload - maximum load conditions
Rebound - regular load conditions
Rebound - half -load conditions
Rebound - maximum load conditions
Desc./Quantity
15 clicks starting from knob (2) fully loosened
28 clicks starting from knob (2) fully loosened
33 clicks starting from knob (2) fully loosened
24 clicks starting from screw (1) fully tightened
20 clicks starting from screw (1) fully tightened
18 clicks starting from screw (1) fully tightened
(1) THE SETTING SHOWN IN THE TABLE MAY NEED TO BE MODIFIED ACCORDING TO THE
TYRE AND ROAD TYPE.
NOTE
(2) IF FITTED.
SUSP - 217
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STELVIO 4V - 1200 ABS
Suspensions
Removing
•
Park the vehicle on its centre stand.
•
Lock the vehicle handlebar so that the
rear wheel is off the ground.
•
Remove the fork.
•
Undo and remove the shock absorber
upper screw.
•
Remove the shock absorber.
SUSP - 218
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INDEX OF TOPICS
CHASSIS
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CHAS
STELVIO 4V - 1200 ABS
Chassis
Swinging arm
Removing
•
To remove the fork, first remove the footrest holding plate and the exhaust silencer.
•
Slide off the rear brake calliper from the disc and release the brake pipe.
•
Engage the first gear.
•
Unscrew and remove the four screws,
collecting the spacers and the dust protection ring.
•
Remove the rear wheel.
•
Unscrew and remove the two screws.
•
Remove the speed sensor from the
fork.
CHAS - 220
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STELVIO 4V - 1200 ABS
•
Chassis
Unscrew and remove the nut fixing the
reaction rod.
•
Remove the screw.
•
Fix the reaction rod to the chassis with
a clamp.
•
Remove the clamp from the dust guard
cap.
•
Loosen the two swingarm terminal
screws.
•
Unscrew and remove the fixing nut of
the connecting rod assembly and collect the screw.
CHAS - 221
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STELVIO 4V - 1200 ABS
Chassis
•
Loosen the ring nut.
Specific tooling
14.91.26.03 Hook spanner for fixing ring nut of
the clutch shaft internal body
•
Helped by a second operator, remove
the pin and remove the swingarm together with the cardan shaft.
Checking
•
Check that the universal joint is not
damaged, the gear teeth inserting in
the sleeve grooves and the grooves on
the joint are not deformed or damaged;
otherwise, replace the joint.
•
Check that the rubber bellows are not
cut or pierced; otherwise, replace it.
•
Check that the fork pin threads and the
fork fixing nuts are not damaged, deformed or flattened; otherwise, replace
them.
•
Check that the sleeve grooves are not
damaged, deformed or deteriorated;
otherwise, replace the sleeve.
•
Check that the sleeve outer toothing
and grooves are not damaged.
CHAS - 222
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STELVIO 4V - 1200 ABS
Chassis
Installing
•
Spread a thin layer of lubricating
grease all along the swingarm pin.
•
Fit the ring nut in the swingarm pin and
screw it manually.
•
Working from both sides, grease the
cardan shaft cables with the recommended product from the recommended products table.
•
Block the swingarm, insert the universal joint, align the holes and, at the
same time, helped by a second operator, insert the pin completely.
•
Tighten the swingarm pin.
•
Use the suitable box-spanner to tighten the ring nut.
Specific tooling
05.91.26.30 Tool for tightening the swingarm
pin ring nut - clutch hub
•
Tighten the two swingarm terminal
screws.
CHAS - 223
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STELVIO 4V - 1200 ABS
Chassis
•
Fit the dust guard cap in the gearbox.
•
Lock the dust guard cap with a new
clamp.
•
Place the reaction rod into its seat.
•
Insert the screw.
•
Screw the nut fixing the reaction rod.
•
Place the connecting rod assembly on
the swingarm.
•
Insert the screw.
•
Tighten the fixing nut of the connecting
rod assembly.
•
Place the speed sensor on the fork and
screw the two screws.
•
Fit the rear wheel.
•
Place the rear brake calliper on the disc
and the brake pipe on the fork.
See also
Recommended products chart
CHAS - 224
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STELVIO 4V - 1200 ABS
Chassis
Bevel gears
Removing
•
Remove the rear wheel.
•
Unscrew and remove the two screws.
•
Remove the speed sensor from the
fork.
•
Unscrew and remove the nut fixing the
reaction rod.
•
Remove the screw.
•
Fasten the reaction rod to the chassis
with a clamp.
•
Undo and remove the four screws.
CHAS - 225
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STELVIO 4V - 1200 ABS
Chassis
•
Remove the transmission casing sliding off the universal joint.
Checking
Smontaggio gruppo scatola
Remove the cover (20).
Remove the plug (3) to drain out the oil.
CHAS - 226
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STELVIO 4V - 1200 ABS
Chassis
Lift the cap (10).
Remove the clamps (9) and (11).
Remove the cap (14).
Remove the screws (16).
Collect the ring (15).
CHAS - 227
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STELVIO 4V - 1200 ABS
Chassis
Remove the screws (7).
Remove the casing (4).
Remove the clamp (12).
Remove the cap (14).
Collect the ring (13).
CHAS - 228
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STELVIO 4V - 1200 ABS
Chassis
Remove the support unit (8).
Montaggio gruppo scatola
Assemble the dowel pins to the casing with the
buffer and a hammer.
Assemble the casing to the special fastening tool.
Clean the casing faying surfaces carefully.
Heat the casing.
CHAS - 229
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STELVIO 4V - 1200 ABS
Chassis
Insert the support group in the casing.
Assemble the cap and the ring.
Fit the cap on the support.
Fit the clamp.
Screw the clamp with the specific pliers.
CHAS - 230
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STELVIO 4V - 1200 ABS
Chassis
Apply the prescribed sealant to the casing.
Fit a new sealing ring using the buffer.
Lubricate the sealing ring.
Assemble two centring stud bolts with M8 thread
in the threaded holes of the casing as shown in the
picture.
Fit the casing.
Remove the two dowel pins.
CHAS - 231
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STELVIO 4V - 1200 ABS
Chassis
Assemble the fixing screws (7).
Tighten the screws (7) to the prescribed torque.
Remove excessive sealant.
Assemble the ring to the casing.
Tighten the fixing screws to the prescribed torque.
Fit the cap with the washer.
Screw the cap to the prescribed torque.
CHAS - 232
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STELVIO 4V - 1200 ABS
Chassis
Fit the breather with the washer.
Screw the breather to the prescribed torque.
Fill the transmission with the prescribed oil.
Fit the cap with the washer.
Screw the cap to the prescribed torque.
Assemble the cap with the clamps.
Fit the cap in its seat.
Gruppo asse ruota
CHAS - 233
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STELVIO 4V - 1200 ABS
Chassis
REMOVAL
Remove the bearing from the wheel axle with a
suitable extractor.
Turn the unit over.
Remove the bearing from the wheel axle with a
suitable extractor.
FITTING
Heat the bearings to 100°C (212 °F).
Assemble the bearings to the wheel axle.
CHAS - 234
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STELVIO 4V - 1200 ABS
Chassis
Turn the unit over.
Assemble the bearings to the wheel axle.
Gruppo pignone
REMOVAL
Remove the stop ring (1) from the ring nut.
Unscrew the ring nut (2) with the special spanner
(s4).
Remove the ring nut (2) and remove the sealing
ring from the ring nut.
NOTE
THIS OPERATION DESTROYS THE SEALING RING.
CHAS - 235
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STELVIO 4V - 1200 ABS
Chassis
Assemble the sealing ring (3) to the ring nut (2)
with the buffer CA715855 (see Fig.1) and a hammer.
Lubricate the sealing ring (3).
Assemble the ring nut (2).
Tighten the ring nut (2) with the special spanner
(s4) to the prescribe torque.
CHAS - 236
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STELVIO 4V - 1200 ABS
Chassis
Insert the stop ring (1) in the ring nut (2) in the indicated direction.
Assembly position of the stop ring (1).
CAUTION
MAKE SURE THE STOP RING IS IN ITS SEAT.
Gruppo supporto
CHAS - 237
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STELVIO 4V - 1200 ABS
Chassis
REMOVAL
Remove the bushing (1) with a punch.
Turn the support (5) over and remove the other
bushing (8).
Remove the sealing rings (2) and (7) with a screwdriver.
Remove the stop rings (3) and (6) from the support
(5) with suitable pliers.
NOTE
THIS OPERATION DESTROYS THE SEALING RING.
CHAS - 238
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STELVIO 4V - 1200 ABS
Chassis
Remove the ball joint (4) with a suitable buffer and
a rubber hammer.
FITTING
Fit the stop ring (6) in the support (5) with suitable
pliers.
Turn the support (5) over.
Assemble the ball joint (4) with the buffer and a
rubber hammer.
Fit the stop ring (3) in the support (5) with suitable
pliers.
CHAS - 239
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STELVIO 4V - 1200 ABS
Chassis
Manually assemble the new sealing rings (2) and
(7).
Assemble the bushing (1).
Drive the bushing (1) in with a plastic hammer.
Turn the support (5) over and assemble the other
bushing (8).
TROUBLESHOOTING
Possible Cause
1. Fitting error of the radial seal or seal damaged 2. Sliding
surface of the wheel axle seal spoiled or damaged
1. Casing not sealed 2. Closing screws of the casing shells not
tightened to the prescribed torque
1. Dirt between the sealing ring and the casing 2. A used sealing ring has been fitted 3. Plug not tightened to the prescribed
torque
1. Cap damaged 2. Retaining clamp or closing cover loose 3.
Fitting error of the radial seal or seal damaged 4. Sliding surface of the wheel spacer spoiled or damaged
1. Cap damaged 2. Internal retaining clamp or external closing
clamp loose
1. Bevel gear pair fitting error 2. Bevel gear pair toothing spoiled
or damaged
1. Ball bearings on the wheel axle damaged
Operation
1. Replace the sealing ring and fit it correctly with the suitable
tool
2. Replace the wheel axle
1. Open the casing shells, clean the surfaces, seal and reassemble the casing shells
2. Tighten the closing screws to the correct torque
1. Clean and tighten to the correct torque
2. Replace the sealing ring
3. Tighten the plug to the correct torque
1. Replace the cap
2. Screw the clamp with suitable pliers
3. Replace the sealing ring and fit it correctly with the suitable
tool
4. Replace the spacer
1. Replace the cap
2. Screw the internal or external clamp with suitable pliers
1. Replace the bevel gear pair
1. Replace the wheel bearings
CHAS - 240
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STELVIO 4V - 1200 ABS
Chassis
Installing
•
Insert the transmission casing on the
swingarm making sure that the universal joint engages correctly.
•
Tighten the four screws to the prescribed torque operating diagonally.
•
Place the reaction rod into its seat.
•
Insert the screw.
•
Screw the nut fixing the reaction rod.
•
Place the dust-protection ring between
the rim and the cardan shaft taking
care to mount it with the collar facing
the transmission unit.
CHAS - 241
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STELVIO 4V - 1200 ABS
Chassis
•
Place the speed sensor and fasten the
cable harness with the clamps.
•
Place the rear wheel on the fork.
•
Tighten the four screws with their
spacers and the dust-protection ring.
•
Place the rear brake calliper on the disc
and the brake pipe on the fork.
Exhaust
key:
1. Right exhaust pipe
2. Left exhaust pipe
CHAS - 242
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STELVIO 4V - 1200 ABS
Chassis
3. Gasket
4. Flanged nut
5. Washer
6. Gasket
7. Clamp
8. Central exhaust pipe
9. TE flanged screw
10.Silent-block
11.Flanged self-locking nut
12.Lambda probe
13.Gasket
14.Clamp
15.Silencer
16.TCEI screw
17.Silencer fixing bushing
18.Muffler rubber ring
19.Spacer
20.Washer
21.Nut
Removing the tail pipe
•
Loosen the sealing clamp between the
exhaust and the central manifold.
•
Undo and remove the screw and collect the nut and the washer.
CHAS - 243
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STELVIO 4V - 1200 ABS
Chassis
•
Remove the exhaust end.
Removing the manifold - tail pipe
•
Remove the exhaust end and the exhaust manifolds.
•
Remove the starter motor protection in
order to disconnect the lambda probe
connector.
•
Unscrew and remove the nut and remove the fixing screw.
•
Remove the manifold - exhaust end
coupling together with the lambda
probe.
See also
Removing the exhaust manifold
Removing the tail pipe
Removing the exhaust manifold
The engine and the exhaust system components get very hot and remain in this condition for a certain
time interval after the engine has been switched off. Before handling these components, make sure that
you are wearing insulating gloves or wait until the engine and the exhaust system have cooled down.
CHAS - 244
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STELVIO 4V - 1200 ABS
•
Chassis
Unscrew and remove the two nuts on
the head exhaust stud bolts.
•
Retrieve the washers.
•
Loosen the clamp.
•
Remove the exhaust manifold.
Engine oil cooler
Key:
1. Complete oil radiator
2. TE flanged screw
CHAS - 245
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STELVIO 4V - 1200 ABS
Chassis
3. T-shaped bushing
4. Rubber ring
5. Radiator support
6. TCEI screw
7. Clip
Removing
To change the engine oil and to replace the oil filter, remove the oil sump guard.
•
Operating from both sides, unscrew
and remove the two front screws (1).
•
Operating from both sides, unscrew
and remove the rear screw (2).
•
Remove the oil sump guard.
•
Place a collecting container and empty the lubrication system.
•
Unscrew and remove the two oil pipes
on the radiator.
•
Undo and remove the radiator lower
screw and collect the washer.
CHAS - 246
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STELVIO 4V - 1200 ABS
•
Chassis
Undo and remove the two radiator upper screws and collect the washer.
•
Remove the oil cooling radiator.
Installing
•
Fit the oil cooling radiator on the vehicle following the operations described
in the removal chapter but in reverse
order.
•
Pull out the oil filler plug / oil level dipstick (1).
•
Pour new oil until it goes over the minimum level marked "MIN" on the dipstick (1).
•
Insert the oil filler plug / oil level dipstick
(1).
•
Start the vehicle and let the engine run
for a few minutes so that the oil circulates and fills the radiator internal
ducts.
•
Stop the engine and check the oil level
with the dipstick (1).
•
Fill with engine oil as required.
CHAS - 247
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INDEX OF TOPICS
BRAKING SYSTEM
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BRAK SYS
STELVIO 4V - 1200 ABS
Braking system
Interventions rules
CAUTION
THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE
SPECIFICATIONS OF THE SYSTEM.
ABS
key:
1. ABS ECU control unit
2. Front ABS sensor
3. Rear ABS sensor
4. Battery
5. Main relay
6. ECU
7. Instrument panel
8. K line (diagnosis)
9. Key
10.Fuses
BRAK SYS - 249
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STELVIO 4V - 1200 ABS
Braking system
Operating diagram
ABS functional diagram key
1. Front system circuit
2. Front brake pump
3. Front brake lever control
4. Rear system circuit
BRAK SYS - 250
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STELVIO 4V - 1200 ABS
Braking system
5. Rear brake pump
6. Rear brake pedal control
7. ABS CONTROL UNIT
8. Rear brake calliper
9. Front calliper (2 callipers)
10.Front brake circuit intake solenoid valve (normally open)
11.Humidifier
12.Rear brake circuit intake solenoid valve (normally open)
13.Rear brake exhaust circuit solenoid valve (normally closed)
14.Rear/front brake circuit low pressure accumulator
15.Front brake exhaust circuit solenoid valve (normally closed)
16.DC electric motor
17.Double circuit hydraulic pump (ABS)
18.Rear brake reservoir
19.Front brake reservoir
ABS OPERATION
General specifications:
The front circuit is similar to the rear circuit.
•
The ABS inlet valve (10 - 12) is normally open and it is closed only when the system intervenes to avoid wheel locking.
•
The outlet valve (13 - 15) is normally closed and it is opened only when the system intervenes
to avoid wheel locking.
•
When the system is standby, the ABS processor never stops monitoring the speed of the
wheels in order to assess potential wheel slippage.
•
When in standby, the system does not intervene at all when the rider brakes; the braking
system is the same as the one without ABS.
Stages in ABS cycle (the following operations refer to the front circuit but are also applicable to
the rear one):
A - Brake activation: the rider starts braking as he would usually do.
B - Pressure reduction: it coincides with danger recognition (wheel slippage above threshold): the
system closes the inlet valve (10-12) and opens the outlet valve (13-15) temporarily.
At this stage the rider cannot increase the pressure on the callipers (8-9) and the system reduces the
pressure on the callipers partially. The excess fluid temporarily fills the front reservoir (18-19) until the
ABS pump (17) self-activates and delivers the fluid back to the brake pump (2-5).
C - Pressure maintained: the pressure in the callipers (8-9) remains low until total recovery of speed /
wheel grip.
The system restores the fluid taken from the calliper (8-9) in the section of the system between the
brake pump (2-5) and the ABS inlet valve (10-12).
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D - Pressure restored: by opening the inlet valve (10-12) momentarily, the pressure of the callipers
(8-9) is increased until maximum deceleration is reached. Then, the system gives the control over the
braking back to the rider.
E - If the wheel does not reach complete grip, the system continues operating as before until complete
grip is obtained or until the vehicle stops. An error can be detected if the duration of the pressure
reduction phase exceeds the pre-set time limit.
ABS SYSTEM DESCRIPTION
The ABS system is a device to avoid wheels locking in case of emergency braking, increasing vehicle
braking stability when compared to a traditional braking system.
Sometimes when the brake is operated, the tyre locks with a consequent loss of grip, which makes it
difficult to control the vehicle. A position sensor (3) on the tone wheel (2), forming an integral unit with
the vehicle wheel, "reads" the status of the vehicle wheel spotting any possible lock.
A control unit (1) signals this out and adjusts the pressure in the braking circuit accordingly.
NOTE
WHEN THE ABS SYSTEM STARTS WORKING, A VIBRATION IS FELT ON THE BRAKE LEVER.
THE WHEEL ANTILOCK BRAKING SYSTEM DOES NOT PREVENT FALLS WHILE ON A BEND.
AN EMERGENCY BRAKING WITH THE VEHICLE INCLINED, HANDLE BAR TURNED, ON UNEVEN OR SLIPPERY ROADS, OR WITH POOR GRIP CREATES LACK OF STABILITY DIFFICULT
TO HANDLE. THEREFORE, RIDE CAREFULLY AND SENSIBLY AND ALWAYS BRAKE GRADUALLY. BRAKING WHILE TURNING A CORNER IS SUBJECT TO LAWS OF PHYSICS WHICH NOT
EVEN ABS CAN ELIMINATE.
When the sensors (3) detect a significant speed difference between the rear and the front wheels (for
example, when rearing up on the back wheel), the ABS system could take this as a dangerous situation.
In this case, two things may occur:
•
The ABS system intervenes by releasing pressure from the calliper until the wheel turns
again at the same speed of the other wheel. It is not possible to brake for an instant.
•
if the speed difference lasts long, the system may detect an error and deactivate the ABS
system. As a consequence, the system works like any regular braking system.
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Riding with an active ABS system
•
At engine starter, the ABS warning light
(5) on the instrument panel (4) flashes
until the vehicle exceeds 5 km/h (3.1
mph).
If the ABS warning light remains on when the
vehicle is running, it means that a fault has
been detected and the ABS system has been
automatically deactivated.
Riding with a disabled ABS system
The warning light (5) turns on permanently, the system was deactivated.
ABS device deactivation
To deactivate the system, proceed as follows:
•
Start the engine.
•
With the vehicle at a standstill, press
and hold the button. After roughly three
seconds, the indicator light ABS (5) on
the instrument panel (4) becomes
steadily on.
•
Release the button immediately.
•
Now the ABS warning light (5) on the
instrument panel (4) continues to be
on; the ABS system is then completely
deactivated.
ABS system reactivation
•
With the vehicle at a standstill, press
and hold the button. After roughly three
seconds, the indicator light ABS (5) on
the instrument panel (4) will start to
flash.
•
Release the button immediately.
•
Once riding, the ABS system will be reactivated only after riding faster than 5
km/h (3.1 mi/h) and the ABS warning
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light (5) on the instrument panel (4)
turns off.
IF THE ABS SWITCH IS PRESSED FOR MORE THAN TEN
SECONDS, THE SYSTEM DETECTS A FAILURE. TO ACTIVATE THE ABS SYSTEM AGAIN TURN THE IGNITION
SWITCH TO "OFF" AND THEN TO "ON".
IN CASE OF FAILURE OR WITH ABS DISCONNECTED,
THE VEHICLE OPERATES AS IF IT DID NOT HAVE THIS
SYSTEM.
20 A fuse (ABS Main fuse) (6)
Protects: ABS Control unit.
Guide to diagnosis
PREMISE
Each time the key is ON, if, at least one current or
stored* error is detected, the ABS warning light
turns on permanently.
The ABS system is deactivated!
The system operates perfectly just as any other
braking system without ABS
* The diagnosis requires exceeding the 5 km/h
(3.1 mph).
Each time the key is ON, if at least one current or stored* error of the ABS system is not detected:
•
the ABS warning light flashes.
When the 5 km/h (3.1 mph) are exceeded:
- if errors are not detected: the ABS warning light turns off
- if at least one malfunction is detected: the ABS warning light turns on permanently.
The ABS system is deactivated!
The system operates perfectly just as any other braking system without ABS.
The detection of malfunctions may require more or less time according to the type of failure.
Error detection logic foresees that for the errors to be diagnosed one or more conditions must persist
within a given time.
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If during this given time one of the conditions is missing but then it comes back, the timer is reset and
the system is no longer able to diagnose the error.
The ABS system is still inactive.
Example:
- error code 5D93 requires some minutes before it is diagnosed during the given time: the ABS warning
light ABS keeps flashing.
ABS FAULTS - GUIDE TO THE DIAGNOSIS
1. ABS WARNING LIGHT ON
2- CONNECT NAVIGATOR
DOES NAVIGATOR COMMUNICATE? (NO, go to 3; YES, go to 4)
3.PERFORM THESE CHECKS:
•
A. PIN 1 Ground connection
•
B. +12V at PIN 18
•
C. +12V at PIN 4 with key ON
4. ARE THERE ANY ERRORS? (YES, go to 5; NO, go to 6)
5. CONSULT THE ERRORS TABLE
6. ABS WARNING LIGHT ACTIVATION
ACTIVE?(YES, go to 7; NO, go to 8)
7. CONTACT TECHNICAL SERVICE
8. CHECK:
•
A. Cable continuity between PIN 8 of the ABS control unit connector and PIN 39 of the
instrument panel.
•
B. Check connectors - refer to the operations described in the chapter
If the previous checks are OK, the causes might be:
•
C. ABS control unit malfunction
•
D. Instrument panel malfunction
Using Navigator for the abs
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ECU INFO screen page
This screen page shows general data regarding
the control unit, for example software type, mapping, control unit programming date
INFO ECU SCREEN PAGE
Characteristic
Value/example
Vehicle manufacturing date
Chassis number
Software version
Vehicle code
Vehicle identification according to
the status of Pin 2 and 15 of the ABS
control unit connector
Unit of
measure
ment
Stelvio / Norge
Stelvio / Norge
Notes
The vehicle code stored in the control unit is read.
Depending on the detected connection of PIN 2
and PIN 15 of the ABS control unit connector corresponds to a different type of vehicle: see the
following table
NOTE: the "X" in the table identifies the connector pin is grounded.
ABS CONNECTOR IS GROUNDED
Vehicle
PIN 2
Stelvio 1200 4V ABS
Norge 1200 4V ABS
PIN 15
X
X
PARAMETERS screen page
This screen page shows the parameters measured by the several sensors (engine revs, engine
temperature, etc.) or values set by the control unit
(injection time, ignition advance, etc.)
PARAMETERS
Characteristic
Front wheel speed
Rear wheel speed
Battery voltage
Value/example
0
0
11.9
Unit of
measure
ment
km/h
km/h
V
Notes
With stopped wheel, 0 Km/h is displayed
With stopped wheel, 0 Km/h is displayed
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ACTIVATION screen page
This screen page is used to delete errors in the
control unit memory and to activate some systems
controlled by the control unit.
ACTIVATION
Characteristic
Value/example
Front brake bleeding procedure
Rear brake bleeding procedure
ABS warning light
Ambient parameter error reading (1)
Ambient parameter error reading (2)
Ambient parameter error reading (3)
Ambient parameter error reading (4)
Ambient parameter error reading (5)
Error clearing (1)
Error clearing (2)
Unit of
measure
ment
Notes
Useful in case of lever sponginess although the
bleeding has been done as in a regular braking
system
Useful in case of lever sponginess although the
bleeding has been done as in a regular braking
system
During the test the warning light stays on
The ambient parameters are 4: Number of error
detections, Operation cycles from the last detection, Battery voltage, Speed.
Number of error detections: number of times the
error has been detected by the control unit;
for example, if it indicates 2, it means that the error
has been detected (ATT), then it has not been detected for a while (sent to the MEM) and then it
has been detected again.
Operation cycles from the last reading: a cycle is
counted if the following occurs: key ON and speed
over 20 km/h.
If for example 5 is shown, it means that the last
time the error has been measured was 5 cycles
ago.
Press "enter" to transfer errors from the memory
(MEM) to the historical record (STO).
In the next connection between Navigator and the
control unit, the historical errors (STO) are no longer shown.
ERRORS screen page
This screen page shows potential errors detected
in the vehicle (ATT) or stored in the control unit
(MEM) and it allows to check error clearing (STO).
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ERRORS
Characteristic
Front speed sensor: 5D90 electric
malfunction
Front speed sensor: 5D91 the signal
works irregularly
Front speed sensor: 5D92 the signal
decreases periodically
Front speed sensor: no signal or
speed measured too low in relation
to the rear wheel 5D93
Front speed sensor: 5D94 no acceleration after pressure reduction
Front speed sensor: 5D95 excessive
measured speed
Rear speed sensor: 5DA0 electric
malfunction
Rear speed sensor: 5DA1 the signal
works irregularly
Rear speed sensor: 5DA2 the signal
decreases periodically
Rear speed sensor: 5DA3 no signal
or speed measured too low in relation to the front wheel
Rear speed sensor: 5DA4 no acceleration after pressure reduction
Rear speed sensor: excessive measured speed 5DA5
Control unit: missing valve calibration 5DD2
Control unit 5DD3
Recirculation pump 5DF0
Recirculation pump 5DF1
Control unit 5DF2
Low electric voltage - long period
measurement 5DF3
Control unit 5DF5
High electric voltage 5DF7
Vehicle code 5E59
Control unit F000
CAN line: D347 electric malfunction
CAN line: 5E11 electric malfunction
0xF01F control unit
5E5A ABS switch
Value/example
Unit of
measure
ment
Notes
Electrical fault in sensor or cable harness
Faulty sensor or signal interference
Possible tone wheel fault due to deformations or
dirt; possible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel
vibrations
Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone
wheel or tone wheel with wrong number of teeth
Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone
wheel
Faulty sensor/tone wheel, or tone wheel with
wrong number of teeth or wrong tyre size
Electrical fault in sensor or cable harness
Faulty sensor or signal interference
Possible tone wheel fault due to deformations or
dirt; possible alterations on the wheel bearing surface. In very rare cases, abnormal tone wheel
vibrations
Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone
wheel or tone wheel with wrong number of teeth
Faulty sensor or missing sensor/tone wheel or excessive distance between the sensor and the tone
wheel
Faulty sensor or tone wheel with wrong number of
teeth or wrong tyre size
Possible control unit fault
Possible control unit fault
Possible control unit fault
Possible control unit fault
Possible control unit fault
Voltage too low measured for 30 seconds at PIN
18 of the ABS control unit:
Possible control unit fault
Excessive voltage measured at PIN 18 of the ABS
control unit
Inconsistency detected between memory coding
(INFO ECU/Vehicle code) and what is measured
at cable harness identification PIN (INFO ECU
screen page, Vehicle identification line - Pins 2-15
of ABS control unit)
Possible control unit fault
Open circuit, short circuit in the ground lead or to
battery of one or both wires of CAN line. Possible
short circuit between the two cables.
Open circuit, short circuit in the ground lead or to
battery of one or both wires of CAN line. Possible
short circuit between the two cables.
Possible control unit fault
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SETTINGS screen page
This screen page is used to adjust some control
unit parameters.
ADJUSTMENTS
Characteristic
Value/example
Coding (1)
Unit of
measure
ment
Notes
Used for re-coding the control unit or coding a new
one.
Vehicle identification is done according to the connection of PINS 2 and 15 of the ABS control unit
connector and is stored in the control unit memory.
The identification can be read in the INFO ECU
screen page in the line: Vehicle code.
Coding (2)
Coding (3)
NOTE: the "X" in the table identifies the connector pin is grounded.
ABS CONNECTOR IS GROUNDED
Vehicle
Stelvio 1200 4V ABS
Norge 1200 4V ABS
PIN 2
PIN 15
X
X
Abs screen pages
Modulator
•
Remove the fuel tank.
•
Cut the cable harness clamp.
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•
With a felt-tip pen, mark a reference on
the pipes and on the ABS control unit
to avoid inverting them when refitting.
•
Protect with a clean cloth the plastic
materials near the ABS control unit.
•
Loosen the nuts and remove the pipes.
•
Cover the pipes to prevent brake fluid
spilling.
See also
Fuel tank
•
Unscrew and remove the two screws.
•
Disconnect the ABS control unit connector.
•
Remove the ABS control unit.
INSERTION PROCEDURE OF ABS CONTROL UNIT CONNECTOR
•
Check the initial position of the lever that couples the connector.
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•
Braking system
When the connector is fully inserted,
the distance between the connector
and the ABS control unit must be 7.5
mm (0.29 in).
•
If the initial position of the connector
and the driving lever is not that shown
in fig. 1, the connector will not be properly coupled and the distance measured will be greater (12 mm approx.
(0.47 in)). In this case repeat the operation as described in the two previous
points.
It is advisable to create a template to check the
correct connector insertion.
•
Fit the protection casing.
Component maintenance
The vehicle is fitted with a two-channel ABS system, i.e. it works on both the front and the rear
wheel.
Check periodically and each time the wheels are
refitted, the tone wheel (2) or the sensor (1) replaced, that the wheel distance is constant at each
360°. Use a thickness gauge to check the distance
between sensor (1) and tone wheel (2) at three
points at a 120° span. The values should be between:
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2.10 - 2.25 mm (0.083 - 0.088 in) for the front one;
1.90 - 2.30 mm (0.075 - 0.090 in) for the rear one;
CAUTION
IF A VALUE BEYOND THE TOLERANCE RANGE IS MEASURED, REPLACE THE SENSOR (1) AND/OR THE TONE
WHEEL (2) AND REPEAT THE CHECKS; MAKE SURE
THAT THE VALUES ARE WITHIN THE TOLERANCE LIMITS.
TONE WHEELS (2) CLEANING
It is important to check that all the tone wheels (2) are always clean. Otherwise,: gently remove any
possible dirt deposits with a cloth or metal brush. Avoid using solvents, abrasives and air or water jets
directly on the tone wheel (2).
TONE WHEEL SENSOR REPLACEMENT
Disconnect the tone wheel sensor connector (1) from the main wire. Unscrew and remove the screw
and remove the tone wheel sensor (1).
CAUTION
BEFORE REFITTING, MAKE SURE THAT THE FAYING SURFACES BETWEEN THE SENSOR (1)
AND THE SEAT ITSELF DO NOT SHOW SIGNS OF DAMAGE AND ARE COMPLETELY CLEAN.
ALWAYS CHECK THE DISTANCE BETWEEN THE SENSOR (1) AND THE TONE WHEEL (2).
Rear brake calliper
Key:
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1. Rear brake calliper
2. Screw
3. Pads
4. Pin + calliper split pin
5. Spring
6. Gasket
7. Screw
8. Air bleed
9. Air bleed cap
10.Rear brake pipe
11.Oil pipe screw
Front brake calliper
Key:
1. Front right brake calliper
2. Front left brake calliper
3. Pads
4. Air bleed
5. Air bleed cap
6. Pins + Calliper springs
7. Spring
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8. Aluminium gasket
9. Screw
Rear brake disc
Disc Inspection
CAUTION
THE BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE SPECIFICATIONS OF THE SYSTEM.
•
The following operations are to be carried out with brake disc fitted on the
wheel.
•
Check the disc for wear by measuring
the minimum thickness with a micrometer in different points. If the minimum thickness, even in a single point
of the disc, is less than the minimum
value, replace the disc.
Disc thickness minimum value: 4.5 mm (0.18
in)
Front brake disc
Disc Inspection
CAUTION
THE FRONT BRAKE DISC SHAPE DOES NOT CHANGE THE OPERATING AND MAINTENANCE
SPECIFICATIONS OF THE SYSTEM.
•
The following operations must be carried out with the brake discs fitted on
the wheel; they refer to a single disc,
but are valid for both.
•
Check the disc for wear by measuring
the minimum thickness with a micrometer in different points. If the minimum thickness, even in a single point
of the disc, is less than the minimum
value, replace the disc.
Disc thickness minimum value: 4 mm (0.16 in)
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•
Braking system
Using a dial gauge, check that the maximum oscillation of the disc does not
exceed the tolerance; otherwise, replace it.
Disc oscillation tolerance: 0.15 mm (0.0059 in)
Front brake pads
Removal
•
Unscrew and remove the two screws.
•
Slide off the brake calliper from the
disc.
•
Turn the pins and remove both split
pins.
•
Remove both pins.
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•
Remove the vibration-damping plate.
•
Extract one pad at a time.
CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE
BRAKE LEVER OR THE CALLIPER PLUNGERS COULD
GO OUT OF THEIR SEATS RESULTING IN BRAKE FLUID
LEAKS.
Installing
•
Insert two new pads, placing them so
that the holes are aligned with the calliper holes.
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY
ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
•
Position the anti-vibration plate.
•
Insert both pins.
•
Position both split pins.
•
Abut the plungers against the pads,
acting on the brake pump lever several
times.
•
Check the brake fluid level in the reservoir.
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Rear brake pads
Removal
•
Undo and remove the two screws.
•
Remove the brake calliper from the
disc.
•
Turn the pin and pull out the split pin.
•
Remove the split pin.
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•
Remove the pin.
•
Extract one pad at a time.
CAUTION
AFTER REMOVING THE PADS, DO NOT OPERATE THE
BRAKE CONTROL LEVER OR THE CALLIPER PLUNGERS
COULD GO OUT OF THEIR SEATS RESULTING IN BRAKE
FLUID LEAKS.
Installing
•
Insert two new pads, placing them so
that the holes are aligned with the calliper holes.
CAUTION
ALWAYS REPLACE BOTH PADS AND MAKE SURE THEY
ARE CORRECTLY POSITIONED INSIDE THE CALLIPER.
•
Insert the pin.
•
Position the split pin.
•
Abut the plungers against the pads,
acting on the brake pump pedal several times.
•
Check the brake fluid level in the reservoir.
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Bleeding the braking system
VEHICLE PREPARATION
•
It is important to check that there is always enough brake fluid in the reservoir.
•
Using a bleed device facilitates these operations while, in the meantime, the "Brake fluid
replacement" operations are performed.
•
In this case, the bleed process must be accompanied by further pedal strokes and with the
bleed device connected (about 5 for each wheel circuit).
BRAKE PUMP REPLACEMENT
PRELIMINARY OPERATIONS
•
Replace the damaged brake pump with a new one.
•
Connect the brake pipe to the new brake pump.
•
Fill the reservoir with new brake fluid.
CAUTION
PERFORM THE REGULAR BRAKING SYSTEM BLEEDING, AS DESCRIBED AT THE END OF THE
CHAPTER.
•
Always fill the reservoir up to the reference "MAX" and refit the cap.
•
Check the stroke and the sensitivity of both the lever and the brake pedal.
•
If, after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in
the braking system and if everything is ok, continue bleeding operations using Navigator as
described.
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Braking system
•
Detach the bleed hoses and close the bleed screws again to the correct tightening torque.
See also
Front
Rear
REPLACE THE ABS CONTROL UNIT
VEHICLE PREPARATION
•
Connect the bleed bottle to the bleed
screws of the front and rear callipers
and open it.
•
Fully press down the lever and the
brake pedal and fix them into position
with the respective locking devices.
•
Close the bleed screws of the front and
rear callipers and remove the bleed
bottle.
•
Remove the damaged ABS control
unit.
Note: First of all, detach the brake pipes that
go from the ABS control unit to the brake pump
(1-4) and immediately seal the opened unions
of the ABS control unit with protective caps.
Afterwards, remove pipes (2-3) that go from the
ABS control unit to the brakes and also seal
these unions with protective caps.
•
Install the new ABS control unit, previously filled up.
•
So that the brake fluid remains in the
ABS control unit, first remove the protective caps of the braking circuit unions and connect the respective pipes.
Once all the braking circuits have been connected, remove the protective caps from the
braking pump unions and connect the braking
pump pipes to the ABS control unit.
•
Unlock the lever and the brake pedal.
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•
Braking system
Remove the reservoir cap and fill it with
new brake fluid up to the reference
"MAX".
CAUTION
PERFORM THE REGULAR BRAKING SYSTEM BLEEDING,
AS DESCRIBED AT THE END OF THE CHAPTER.
•
Always fill the reservoir up to the reference "MAX" and refit the cap.
•
Check the stroke and the sensitivity of both the lever and the brake pedal.
•
If, after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in
the braking system and if everything is ok, continue bleeding operations using Navigator as
described.
•
Detach the bleed hoses and close the bleed screws again to the correct tightening torque.
See also
Front
Rear
CALLIPERS REPLACEMENT
VEHICLE PREPARATION - The operations are
described for the front system, but they are also valid for both braking systems.
•
Connect the bleed bottles to the bleed
screw of the front calliper and open it.
•
Fully press down the brake lever and
fasten it into position with a locking device so as to avoid fluid flowing out from
the open system.
•
Close the bleed screws of the front calliper and remove the bleed bottle.
•
Replace the damaged calliper with a
new one.
•
Unlock the brake lever.
•
Remove the reservoir cap and fill it with
new brake fluid up to the reference
"MAX".
CAUTION
PERFORM THE REGULAR BRAKING SYSTEM BLEEDING,
AS DESCRIBED AT THE END OF THE CHAPTER.
•
Always fill the reservoir up to the reference "MAX" and refit the cap.
•
Check the stroke and the sensitivity of both the lever and the brake pedal.
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•
If, after bleeding, the pedal or the lever stroke is too long, check that there are no leaks in
the braking system and if everything is ok, continue bleeding operations using Navigator as
described.
•
Detach the bleed hoses and close the bleed screws again to the correct tightening torque.
See also
Front
Rear
BLEEDING SYSTEM WITH NAVIGATOR
This type of bleeding has to be carried out if after all the checks the brake lever and the pedal
are still spongy.
The operations described here are valid for both systems even though the description refers to
the front system.
FRONT
•
With Navigator properly connected, select the function "FRONT BRAKE BLEEDING PROCEDURE".
•
The pump starts rotating.
•
While the pump is performing a rotation cycle, operate and release the front brake lever until
the message Navigator cycle completion is received.
•
This procedure allows the air to turn and to accumulate.
•
Once the procedure with Navigator is finished, perform the REGULAR BLEEDING to remove
the air from the system completely.
CAUTION
PERFORM THE REGULAR BRAKING SYSTEM BLEEDING, AS DESCRIBED AT THE END OF THE
CHAPTER.
See also
Front
Rear
Front
Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by
the brake pump and minimising the braking power of the calliper.
The presence of air is signalled by the "sponginess" of the brake control and by poor braking efficiency.
CAUTION
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER
REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CONDITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED.
NOTE
THE FOLLOWING OPERATIONS REFER TO ONLY ONE FRONT BRAKE CALLIPER BUT APPLY
TO BOTH CALLIPERS. THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE
PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY
BRAK SYS - 272
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STELVIO 4V - 1200 ABS
Braking system
OF BRAKE FLUID. CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID
IN THE RESERVOIR.
REGULAR AIR BLEEDING SYSTEM
•
Remove the rubber protection cover
from the bleed valve.
•
Insert the transparent plastic pipe in
the front brake calliper bleed valve and
slide the other end of this pipe in a container to collect the fluid.
•
Remove the front brake fluid reservoir
cap.
•
Operate the brake lever and then open
the bleed valve on the calliper by a 1/4
turn to let the air escape.
•
Close the bleed valve before reaching
the end of travel of the brake lever,
then repeat the operation until air no
longer escapes.
•
Repeat the procedure for both callipers.
•
Screw the bleed valve and remove the pipe.
•
Top-up the reservoir until the right brake fluid level is obtained.
•
Refit and block the front brake fluid reservoir cap.
•
Refit the protective rubber cap.
Rear
Any air trapped in the hydraulic circuit acts as a cushion, absorbing much of the pressure applied by
the brake pump and minimising the braking power of the calliper.
The presence of air is signalled by the "sponginess" of the brake control and by poor braking efficiency.
CAUTION
CONSIDERING THE DANGER FOR VEHICLE AND RIDER, IT IS STRICTLY NECESSARY, AFTER
REFITTING BRAKES AND RESTORING THE BRAKING SYSTEM TO THE REGULAR USE CONDITIONS, THAT THE HYDRAULIC CIRCUIT BE AIR PURGED.
NOTE
THE VEHICLE MUST BE ON LEVEL GROUND TO BE PURGED. WHILE PURGING THE HYDRAULIC SYSTEM, FILL THE RESERVOIR WITH THE NECESSARY QUANTITY OF BRAKE FLUID.
CHECK THAT, DURING THE OPERATION, THERE IS ALWAYS BRAKE FLUID IN THE RESERVOIR.
REGULAR AIR BLEEDING SYSTEM
BRAK SYS - 273
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STELVIO 4V - 1200 ABS
Braking system
•
Remove the rubber protection cover
from the bleed valve.
•
Insert the transparent plastic pipe in
the rear brake calliper bleed valve and
insert the other end of this pipe into a
container to collect the fluid.
•
Remove the rear brake fluid reservoir
cap.
•
Operate the brake lever and then open
the bleed valve on the calliper by a 1/4
turn to let the air escape.
•
Close the bleed valve before reaching
the end of travel of the brake lever,
then repeat the operation until air no
longer escapes.
•
Screw the bleed valve and remove the pipe.
•
Top-up the reservoir until the right brake fluid level is obtained.
•
Refit and lock the rear brake fluid reservoir cap.
•
Refit the protective rubber cap.
BRAK SYS - 274
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INDEX OF TOPICS
BODYWORK
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BODYW
STELVIO 4V - 1200 ABS
Bodywork
Seat
•
Rest the vehicle on its stand.
•
Insert the key in the saddle lock.
•
Turn the key clockwise, pressing lightly in the middle of the rear passenger saddle seat to
help pin release.
•
Lift the passenger seat and slide it off from behind.
•
Remove the rider saddle.
CAUTION
BEFORE LOWERING AND LOCKING THE SADDLE, CHECK THAT THE KEY HAS NOT BEEN
LEFT INSIDE THE GLOVE-BOX / TOOLKIT COMPARTMENT.
Instrument panel
•
Undo and remove the four screws.
•
Disconnect the instrument panel connector.
BODYW - 276
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STELVIO 4V - 1200 ABS
Bodywork
Rider footrest plate
LEFT SIDE
•
Undo and remove the upper screw and
collect the washer and the nut.
•
Undo and remove the lower screw and
collect the two washers and the
spacer.
•
Undo and remove the lower screw and
collect the washer and the spacer.
•
Disconnect the gearbox rod and release the spring.
•
Remove the left footrest holding plate.
BODYW - 277
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STELVIO 4V - 1200 ABS
Bodywork
RIGHT SIDE
•
Undo and remove the upper screw and
collect the washer and the nut.
•
Undo and remove the front lower
screw.
•
Undo and remove the three screws.
•
Remove the right under seat fairing.
•
Disconnect the connectors of the rear
brake lever switch and the speed sensor.
•
Release the cable harness from the
clamps.
BODYW - 278
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STELVIO 4V - 1200 ABS
•
Bodywork
Undo and remove the two rear lower
screws; collect the washers and the
spacer.
•
Unscrew and remove the screw.
•
Detach the rear brake fluid reservoir
but keep it connected to the pipe.
•
Remove the right footrest plate, keeping the brake fluid reservoir in vertical position.
Side fairings
•
Remove the fuel tank upper fairing.
•
Unscrew and remove the two screws.
BODYW - 279
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STELVIO 4V - 1200 ABS
Bodywork
•
Working from both sides, undo and remove the screw.
•
Working from both sides, undo and remove the screw.
•
Detach the fairing.
•
Disconnect the glove-box compartment opening cable.
•
Undo and remove the two front screws.
BODYW - 280
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STELVIO 4V - 1200 ABS
•
Bodywork
Operating from both sides, undo and
remove the internal screw and collect
the washer and the nut.
•
Unscrew and remove the two screws.
•
Undo and remove the four screws.
•
Remove the headlight lower cover.
•
Unscrew and remove the two screws.
BODYW - 281
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STELVIO 4V - 1200 ABS
Bodywork
•
Operating from both sides, disconnect
the turn indicator connector.
•
Slightly detach the fairing.
•
Disconnect the front headlight connectors releasing the cable harness from
the clamps.
•
Remove the fairing together with the
front headlight.
Air box
•
Remove the saddle.
•
Remove the passenger grab handle.
•
Undo and remove the two screws and
collect the cable guide.
BODYW - 282
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STELVIO 4V - 1200 ABS
•
Bodywork
Disconnect the air temperature sensor
connector.
•
Slide off and remove the main fuse box
from its holder.
•
Disconnect the rear light connectors
•
Release the clutch bleeding pipe from
the cable guide.
BODYW - 283
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STELVIO 4V - 1200 ABS
Bodywork
•
Operating from both sides, undo and
remove the three screws.
•
Remove the mudflap.
•
Release from its and remove the
breather pipe placed on the right side
of the filter casing.
•
Operating on both sides, loosen the
clamp.
•
Remove the two breather pipes.
BODYW - 284
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STELVIO 4V - 1200 ABS
•
Bodywork
Operating from both sides, undo and
remove the stud bolt.
•
Remove the filter casing.
See also
Seat
Fuel tank
FUEL TANK CAP REMOVAL
•
Open the fuel tank cap.
•
Cover the tank fill opening with a clean
cloth so that no foreign bodies can
come in.
•
Undo and remove the four screws.
•
Remove the cap.
FUEL TANK COVER
•
Remove the rider saddle.
•
Operating from both sides, undo and
remove the three screws.
•
Collect the rubber rings of the rear
screws.
•
Remove the fuel tank cover.
See also
Seat
BODYW - 285
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STELVIO 4V - 1200 ABS
Bodywork
FUEL TANK UPPER FAIRING
•
Remove the fuel tank cap.
•
Undo and remove the four screws.
•
Remove the fuel tank cover.
•
Working from both sides, undo and remove the screw.
•
Unscrew and remove the front screw
fixing the tank.
•
Operating from both sides, undo and
remove the two screws.
BODYW - 286
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STELVIO 4V - 1200 ABS
•
Lift the rear part of the fuel tank fairing.
•
Disconnect the pipes.
•
Remove the fuel tank fairing.
Bodywork
See also
Seat
FUEL TANK
•
Remove the tank side fairings.
•
Disconnect the glove-box opening
control connector.
•
Undo and remove the two rear screws
and collect the washers.
•
Undo and remove the two front screws.
BODYW - 287
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STELVIO 4V - 1200 ABS
Bodywork
•
Lift the tank and disconnect the fuel
pipe.
•
Disconnect the fuel pump connector.
•
Remove the fuel tank.
See also
Side fairings
Adjustable windscreen
•
Remove the windscreen glass.
•
Working from both sides, undo and remove the windscreen top set screw
and remove the knob.
•
Working from both sides, unscrew and
remove the lower screw.
BODYW - 288
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STELVIO 4V - 1200 ABS
•
Bodywork
Working from both sides, remove the
windscreen support from the bracket.
•
Remove the four bushings from the
brackets
If replacing the bushings remember to place them
with the larger diameter inside the brackets.
BODYW - 289
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INDEX OF TOPICS
PRE-DELIVERY
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PRE DE
STELVIO 4V - 1200 ABS
Pre-delivery
Carry out the listed checks before delivering the vehicle.
WARNING
BE EXTREMELY CAUTIOUS WHEN HANDLING FUEL.
Aesthetic inspection
- Paintwork
- Fitting of Plastic Parts
- Scratches
- Dirt
Tightening torques inspection
- Safety locks:
front and rear suspension unit
front and rear brake calliper retainer unit
front and rear wheel unit
engine - chassis retainers
steering assembly
- Plastic parts fixing screws
Electrical system
- Main switch
- Headlamps: high-beam lights, low-beam lights, tail lights (front and rear) and their warning lights
- Headlight adjustment according to regulations in force
- Front and rear stop light switches and their bulbs
- Turn indicators and their warning lights
- Instrument panel lights
- Instrument panel: fuel and temperature indicator (if present)
- Instrument panel warning lights
- Horn
- Electric start-up
- Engine stop via emergency stop switch and side stand
- Helmet compartment electrical opening switch (if present)
PRE DE - 291
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STELVIO 4V - 1200 ABS
Pre-delivery
- Through the diagnosis tool, check that the last mapping version is present in the control unit/s and, if
required, program the control unit/s again: consult the technical service website to know about available
upgrades and details regarding the operation.
CAUTION
TO ENSURE MAXIMUM PERFORMANCE, THE BATTERY MUST BE CHARGED BEFORE USE.
INADEQUATE CHARGING OF THE BATTERY WITH A LOW LEVEL OF ELECTROLYTE BEFORE
IT IS FIRST USED SHORTENS BATTERY LIFE.
CAUTION
UPON INSTALLING THE BATTERY, ATTACH THE POSITIVE LEAD FIRST AND THEN THE NEGATIVE ONE, AND PERFORM THE REVERSE OPERATION UPON REMOVAL.
WARNING
THE BATTERY ELECTROLYTE IS POISONOUS AS IT MAY CAUSE SERIOUS BURNS. IT CONTAINS SULPHURIC ACID. AVOID CONTACT WITH YOUR EYES, SKIN AND CLOTHING.
IN CASE OF CONTACT WITH YOUR EYES OR SKIN, WASH WITH ABUNDANT WATER FOR APPROX. 15 MIN. AND SEEK MEDICAL ATTENTION IMMEDIATELY.
IF ACCIDENTALLY SWALLOWED, IMMEDIATELY DRINK LARGE QUANTITIES OF WATER OR
VEGETABLE OIL. SEEK MEDICAL ATTENTION IMMEDIATELY.
BATTERIES PRODUCE EXPLOSIVE GASES; KEEP CLEAR OF NAKED FLAMES, SPARKS OR
CIGARETTES. VENTILATE THE AREA WHEN RECHARGING INDOORS. ALWAYS WEAR EYE
PROTECTION WHEN WORKING IN THE PROXIMITY OF BATTERIES.
KEEP OUT OF THE REACH OF CHILDREN
CAUTION
NEVER USE FUSES WITH A CAPACITY HIGHER THAN THE RECOMMENDED CAPACITY. USING
A FUSE OF UNSUITABLE RATING MAY SERIOUSLY DAMAGE THE VEHICLE OR EVEN CAUSE
A FIRE.
Levels check
- Hydraulic braking system fluid level
- Clutch system fluid level (if present)
- Gearbox oil level (if present)
- Transmission oil level (if present)
- Engine coolant level (if present)
- Engine oil level
- Mixer oil level (if present)
Road test
- Cold start
- Instrument panel operation
PRE DE - 292
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STELVIO 4V - 1200 ABS
Pre-delivery
- Response to throttle control
- Stability when accelerating and braking
- Front and rear brake efficiency
- Front and rear suspension efficiency
- Abnormal noise
Static test
Static check after test drive:
- Restarting when warmed up
- Starter operation (if present)
- Minimum holding (turning the handlebar)
- Uniform turning of the steering
- Possible leaks
- Radiator electric fan operation (if present)
Functional inspection
- Hydraulic braking system
- Stroke of brake and clutch levers (if present)
- Clutch - Check for correct operation
- Engine - Check for correct general operation and absence of abnormal noise
- Other
- Documentation check:
- Chassis and engine numbers check
- Supplied tools check
- License plate fitting
- Locks checking
- Tyre pressure check
- Installation of mirrors and any possible accessories
NEVER EXCEED THE RECOMMENDED INFLATION PRESSURES AS TYRES MAY BURST.
CAUTION
CHECK AND ADJUST TYRE PRESSURE WITH TYRES AT AMBIENT TEMPERATURE.
PRE DE - 293
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A
ABS: 88, 249, 255, 259
Air filter: 36
B
Battery: 58, 61
Brake: 262–265, 267
C
Clutch: 79, 130, 133, 166
Clutch lever: 79
E
Engine oil: 33, 77, 245
F
Fork: 196, 199, 203, 207, 212
Forks: 118
Fuel: 90, 124, 260, 285
Fuses: 60
G
Gearbox oil: 35
I
Identification: 10
Instrument panel: 82, 276
M
Maintenance: 8, 31, 261
O
Oil filter: 34
R
Recommended products: 22, 224
S
Shock absorber:
Shock absorbers: 216
Stand: 80
Start-up: 59
T
Tank: 90, 124, 260, 285
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Transmission: 12, 31
Tyres: 14
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